INDEX

S.No.
NO.

CONTENTS

PAGE

1.

INTRODUCTION

2.

BHEL-A Brief Profile

3.

BHEL - AN OVERVIEW

4.

HEEP: AN OVERVIEW

5.

TURBO GENERATOR

12

6.

CONSTRUCTIONAL FEATURES OF

15

10

TURBO GENERATOR
7.

CONSTRUCTION OF STATOR

20

8.

INSULATION PROCESS

27

9.

CONSTRUCTION OF ROTOR

29

10.

COOLING SYSTEM

33

11.

EXCITATION SYSTEM

37

CHAPTER 1

INTRODUCTION

In 1956, India took a major step towards the establishment of its heavy
engineering industry when Bharat Heavy Electrical Ltd., the first heavy
electrical manufacturing unit of the country was setup at Bhopal. It
progressed rapidly and three more factories went into production in 1965.
The main aim of establishing BHEL was to meet the growing power
requirement of the country.

B.H.E.L appeared on the power map of India in 1969 when the first
unit supplied by it was commissioned at the Basin Bridge Thermal Power
Station in Tamil Nadu. Within a decade, BHEL had commissioned the
100th unit at Santaldih, West Bengal. BHEL had taken India from a near
total dependence on imports to complete self-reliance in this vital area of
power plant equipment BHEL has supplied 97% of the power generating
equipment. BHEL has already supplied generating equipment to various
utilities capable of generating over 18000 MW power. Today BHEL can
produce annually; equipment capable of generating 6000MW. This will
grow further to enable BHEL to meet all of Indias projected power
equipment requirements. As well as sizeable portion of export targets.

Probably the most significant aspect of BHEL.s growth has been its

diversification. The constant reorientation of the organization to meet the

varied needs in time with time a philosophy that has led to the
development of a total capability from concepts to commissioning not
only in the field of energy but also in industry and transportation.

In the world power scene, BHEL ranks among the top ten
manufactures of power plant equipment and in terms of the spectrum o0f
products and services offered, it is right on top. BHEL.s technological
excellence and turnkey capabilities have won it worldwide recognition.
Over 40 countries in the world over have placed orders with BHEL
covering individual equipment to complete power stations on a turnkey
basis.

In 1978-79 export earnings reached Rs. 122 crores, the highest for
any one-year. BHEL has its headquarters at New Delhi. Its operations are
spread over 11 manufacturing plants and number of engineering and
service divisions located across the country/ the service divisions includes
a network of regional branch offices throughout India.

CHAPTER 2

BHEL-A Brief Profile

BHEL is the largest engineering and manufacturing enterprise in
India in the energy-related/infrastructure sector, today. BHEL is ushering
in the indigenous Heavy Electrical Equipment industry in India-a dream
that has been more than realized with a well-recognized track record of
Performance.

A widespread network comprising of 14 manufacturing companies,

which have international recognition for its commitment towards quality.
With an export presence in more than 60 countries, BHEL is truly India.s
industrial ambassador to the world. BHEL.s vision is to become a world
class engineering enterprise, committed to enhancing stakeholder value.

BHEL has:-

Installed equipment for over 90,000MW of power generation.for

Utilities, captive and Industrial users.
Supplied over 25000 Motors with Drive Control System to power
projects, Petrochemicals Refineries, Steel, Aluminum, Fertilizer,
Cement plant, etc.
Supplied Traction electrics and AC/DC locos over 12000 kms
Railway network.
Supplied over one million Values to Power Plants and other
Industries.

CHAPTER 3

BHEL - AN OVERVIEW

The first plant of what is today known as BHEL was established nearly
40 years ago at Bhopal & was the genesis of the Heavy Electrical
Equipment industry in India.

BHEL is today the largest Engineering Enterprise of its kind in

India with excellent track record of performance, making profits
continuously since 1971-72.

BHEL business operations cater to core sectors of the Indian Economy

like.
Power
Industry
Transportation
Transmission
Defenses etc..
Today BHEL has
14 Manufacturing Divisions
9 Service Centers
4 Power Sector Regional Centers
150 Project sites

BHEL. vision is to world-class engineering enterprise, committed to

enhancing stakeholder value. The greatest strength of BHEL is its highly
skilled and committed 44,000 employees.
Spread all over India & abroad to provide prompt and effective service to
customers.

3.1 BUSINESS SECTOR

BHEL operations are organized around business sectors to provide a

strong
market orientation. These business sectors are Power Indus and
International operations.

3.2 POWER SECTOR

Power sector comprises of thermal, nuclear, gas and hydro business.

Today BHEL supplied sets account for nearly 65% of the total installed
capacity in the country as against nil till 1969-70.

BHEL has proven turnkey capabilities for executing power

projects from concept to commissioning and manufactures boilers,
thermal turbine generator set and auxiliaries up to 500MW.
It possesses the technology and capability to procure thermal
power generation equipment up to 1000MW.
Co-generation and combined cycle plants have also been
introduced.
For efficient use of the high ash content coal-BHEL supplies
circulating fluidized boiler.
6

 BHEL manufactures 235MW nuclear sets and has also

commenced production of 500MWnuclear set.

Custom-made huge hydro sets of Francis, Elton and Kaplan types for
different headdischarge combinations are also engineered and
manufactured by BHEL.

3.3 INDUSTRY SECTOR

BHEL is a major contributor of equipment and system to important

industries like
Cement
Petrochemicals
Fertilizers
Steel paper
Refineries
Mining and Telecommunication
The range of system and equipment supplied including captive power
stations
High speed industrial drive turbines
Industrial boilers and auxiliaries
Waste heat recovery boilers
Gas turbines pump, valves, seamless steel tubes
Heat exchangers
Process control etc.

3.4 TRANSPORATION :-

BHEL supplies a wide equipment and system to Indian Railways.

Electric locomotive
Traction electric and traction control equipment

3.5 TELECOMMUNICATION:-

BHEL also caters to Telecommunication sector by way of small, medium

and large switching system.
BHEL has divided into many blocks:-

1). Block-1:In block one turbo generator, generator, exciter motors (A.C & D.C) are
manufactured & assembled.

2). Block-2:In block two large size fabricated assemblies\component for power
equipment are manufactured & assembled.

3) Block-3:In block -3 steam turbine, hydro turbines, and gas turbines, turbines blade
are manufactured & assembled.

4) Block-4:In block -4winding for turbo generator, hydro generator, insulation of

A.C&D.C motors insulating component for turbo generator, hydro
generator motors are manufactured & assembled.
8

5) Block-5:In block -5 fabricated parts of steam turbine water box, hydro turbine
turbines parts are manufactured & assembled.

6) Block-6:In block -6 fabricated oil tanks hollow guide blades, rings, stator frames
rotor spiders are manufactured & assembled.

7) Block-7:In block -7all types of dies including stamping dies, stamping for
generators
&motors are manufactured & assembled.

8) Block-8:In block -8 LP heaters, ejectors, steam coolers, oil coolers, ACG coolers,
oil tanks are manufactured & assembled.

CHAPTER 4

HEEP: AN OVERVIEW

Over the years, Bharat Heavy Electrical Limited has emerged as world
class
engineering and Industrial giant, the best of its kind in entire South East
Asia. Its business profile cuts across various sectors of engineering/power
utilities and industry. The company today enjoys national and
international presence featuring in the .fortune international-500. and is
ranked among the top 12 companies in the world, manufacturing power
generation equipment. BHEL has now 14 manufacturing division, 8
service centers and 4power power sectors regional centers besides a large
number of project sites spread over India and abroad.
The company is embarking upon an ambitious growth path through
clear vision, mission and committed values to sustain and augment its
image as a world-class enterprise.

4.1 VISION

A world-class innovating, competitive and profitable engineering

enterprise
providing total business solution.

4.2 MISSION

To be the leading Indian engineering enterprise providing quality

products system and services in the field of energy, transportation,
infrastructure and other potential areas.
10

4.3 VALUES

Meeting commitments made to external & internal customers

Foster learning creative and speed of response
Respect for dignity and potential of individual
Loyalty and pride in the company Team playing

11

CHAPTER 5
TURBO GENERATOR

General Description:
Currently BHEL Haridwar is manufacturing generators of four modulesTARI, THW, THRI, THDF
A Generator consists of the following components:
Stator
Stator Frame
End shields
Stator core
Stator winding
Hydrogen coolers
Rotor
Rotor shaft
Rotor windings
Rotor retaining rings
Field connections
Bearings
Shaft seals
The following auxiliary system is required depending upon different
modules:
Oil system
Gas system
Primary water system
Excitation system

12

Technical Data of TurboGeneratos:

1. THW, THRI AND THDF TYPE:
SL. TECHNICA 130
NO
L
MW
. PARAMETE
R
1. GENERATO THRI
R TYPE
93/38
2. RATED MVA 162.5
RATED MW 130.0
3.
RATED
10.5
VOLT. kV
4.
POWER
0.80
FACTOR
5.
STATOR
8935
CURRENT
6. SPEED RPM 3000
7. FREQ. HZ
50
8. HYDROGEN 3.0
PRESSURE
Kg/Cm2(g)
9. TYPE OF STATI
EXCITATION C

210 235 MW 210 250 MW 500 MW 560 MW

MW
MW

THW- THW210-2 235-2

247.1 264.1
210.0 237.7
15.75
16.5

THRI
108/44
247.1
210.0
15.75

THRI
108/44
294.1
250.0
16.5

THDF
115/59
588.2
500.0
21.0

THDF
115/59
659.0
560.0
21.0

0.85

0.90

0.85

0.85

0.85

0.85

9054

9240

9054

10291

16166

18118

3000
50
3.5

3000
50
3.5

3000
50
2.0

3000
50
3.0

3000
50
3.5

3000
50
4.0

STATI STATIC/ BLESS BLESS BLESS BLESS

C/
HFG
/
HFG
STATIC

2. TARI TYPE:
SL. TECHNICAL TROMBA KAYAMK KAYAMK FARIDAB FARIDAB
NO PARAMETER
Y
ULAM
ULAM
AD GTG AD STG
13

.
1.
2.

3.
4.
5.
6.
7.

STG
GENERATOR TARI 93/38
TYPE
BASE LOAD
100
MVA
80
MW
RATED VOLT.
10.5
kV
POWER
0.80
FACTOR
STATOR
5499
CURRENT
SPEED RPM
3000
FREQ. HZ
50

GTG
TARI
108/36
137.5
116.8

STG
TARI
108/36
154.3
131.1

TARI
108/41
170.1
144.6

TARI
108/46
188.2
160.0

10.5

10.5

10.5

15.75

0.85

0.85

0.85

0.85

7561

8484

9354

6900

3000
50

3000
50

3000
50

3000
50

CHAPTER 6
CONSTRUCTIONAL FEATURES OF TURBO-GENERATORS:

14

1.STATOR FABRICATION
The fabricated structure of stator consists of following parts :1.
2.
3.
4.

Stator Frame
End Shield
Stator Core Housing
Suspension arrangement of wound core into stator

(i)Stator Frame
Stator Frame is a split fabricated structure in two halve stator
frame (lower half) and stator frame (upper half). This constructional
feature facilitates manufacture of stator frame and stator core in
parallel reducing manufacturing cycle time.
The stator frame (lower half) is fabricated from structural
steel. There are two thick Side Walls and several Inner Walls.
Thick side walls are used because rotor load (static as well as
dynamic) are transmitted to stator through End Shields bolted
on this wall. The inside surface of the stator frame is stiffened
by means of number of radial and axial ribs joining side walls,
inner walls and casing. The arrangement and dimensioning of
the ribs are determined by the cooling air passages and the
required mechanical strength. Dimensioning is also dictated
by vibration considerations, resulting partly in greater wall
thickness than required from the point of view of mechanical
strength. These provides a rigid stator frame which is required
due to the forces and torques arising during operation and
transmitted to the foundation via the welded stator feet. The inner
frame with the electrically active parts of the stator is
supported in the stator frame (lower half) by welding plate
springs rigidly with the inner walls of stator body and
stiffening rings of core.
Openings are provided in outer casing to facilitate flow
paths for hot and cold air to Cooler Housing having 4 nos. of
coolers.
The stator frame (upper half) is fabricated from structural
steel. Thickens of side walls and inner walls are same as that
of stator frame (lower half). Axial distances of walls in upper
15

half and lower half are same. The upper casing is semicircular
in shape with a flat surface on exciter end of stator for
mounting Terminal Bushing.

Openings are provided in outer casing to facilitate flow paths for

hot and cold air to Cooler Housing having 4 nos. of coolers.
Stator frame has flanges mounted the casing and bottom plate in
lower half for drainage of oil & water and also for taking out cables
for temperature measurement, end winding vibration measurement
etc.

Upper half and Lower half stator frame is bolted together on parting
plane through longitudinal and Transverse flanges
ii)End Shield
End Shield is a rigid, split fabricated structure in two halves
lower half and upper half. Both halves are bolted together and are
16

mounted on each end of stator on its side wall. End Shield gives
support to rotor through bearings. Lower half has a thick plate which
supports semi circular bearing support ring which in turn supports
bearings. This support ring is bolted to end shield with an insulation
sheet in between. This insulation sheet isolates rotor from earthing
and reduces possibility of damage of bearing surface due to
circulating currents. Lower half has provision for supply and drainage
of lubricating oil.

17

Exciter Side
End Shield

Turbine Side
End Shield

18

(iii)Stator Core Housing:

Stator Core Housing consists of three spring baskets. Spring
basket consists of two rings in two halves joined together with
the help of stiffeners and three flat plates. After stacking of
the stator core, the insulated core bars are installed in the
respective slots. Thereafter, both halve of spring basket are
assembled over core, stretched with the help of fixture and
welded together. Flat plate has several threaded holes for
assembly of plate springs. The load of wound core is
transferred to stator through these springs.

(iv)Suspension arrangement of wound core

Wound core is assembled inside lower half of stator frame through
9 nos. plate springs arranged along the length at the location of spring
baskets. At each spring basket location, two springs are assembled at
3 oclock and 9 oclock position vertically and one spring at the
bottom of core (6 oclock position) horizontally. Top end of spring is
bolted to spring basket plate and lower end is welded to inner walls
of stator through brackets. These springs help transfer of load of
wound core to stator and finally to foundation through stator feet.
After this assembly, upper half of stator frame is bolted to lower half
through parting plane flanges.
19

CHAPTER 7
CONSTRUCTION OF STATOR
1. STATOR CORE:
The stator core is one of the most significant parts of turbogenerator. Apart from providing support to the stator winding it
provides a closed path for flux produced by the winding.
The stator core is stacked from insulated electrical sheet steel
(ETS) laminations with a low loss index and flexibly supported in the
lower half stator casing by means of insulated core bars and rings. The
load transfer of wound core is through springs to stator body. The
stacking of core laminations is done in the vertical position with
the exciter side downward. To obtain smooth slot walls, mandrels and
stacking guides are inserted in the stator slots as well as in the
holes meant for tension bolts. Tension bolts are insulated from the
core. Axial compression of stator core is obtained by clamping
fingers, pressure plates and tension bolts. The clamping fingers ensure a
uniform clamping pressure, especially within the range of teeth, and
provide for uniform, intensive cooling of the stator core ends.
Core diameter is constrained from vibrations, type
suspension, saturation levels, temperature rises

of core

and transportation

limits. Length of the machine is decided from output, type of

CORE
BUILDING IN

20

cooling, no .of slots, voltage, air gap flux density and permissible
behavior from vibrations and critical speed considerations. Slot width is
decided from permissible tooth density and temperature of winding.
The cooling of

the

stator

core

is achieved through the

cold air admitted to the individual frame compartments , the gas

flows through ventilating ducts in the core where it absorbs the
heat from the core.

2. STATOR WINDING ASSEMBLY:

The three phase stator winding is a fractional pitch two layer type
winding consisting of individual bars. Each stator slot accommodates two
bars. The slots are uniformly distributed on the circumference of the
stator core. The slot bottom bars and top bars are displaced from each
other by one winding pitch and connected at their ends to form coil
groups. The top and bottom bars are connected together by individual
strip-to-strip brazing. The brazed joints are also insulated against each
other. The coil groups are connected together with connecting bus bars
inside stator frame. The stator winding connections are brought out
through the connecting bus bars to six terminal bushings.
The bars offer maximum operating reliability, since each coil
consists of only one turn. This makes the turn insulation and the main
insulation same. To protect the stator winding against the magnetic bar
bouncing forces under normal load condition and sudden short circuit, top
ripple spring are placed beneath

the

slot

wedges in the slot, which

ensures permanent firm sitting of the bars in the slot during

operation.

21

WOUND STATOR
The involute shape in the overhang ensures a uniform spacing of the
bars after assembly over the entire length of the end turns and results in a
cone shaped winding, having favorable characteristics both in respect of
its electrical properties and resistance to magnetically induced forces. For
firm support in the overhang, the

end-windings are braided to the

insulated support brackets.

3. STATOR WINDING BAR

The individual stator-winding bar consists of a large number of
solid copper strands evenly distributed in the cross-section. To
minimize the stray losses, the individual conductor strands are
separately insulated and transposed in the slot portion. The
22

transposition is 360 for air-cooled generators manufactured so

far and the bar consists of two columns side by side. A vertical
separator insulates these columns against each other also.
The transposition provides for a mutual neutralization of the
voltages induced in the individual strands due to the slot cross-field and
end-winding flux leakage and ensures that the circulating current is
minimum. The current flowing through the conductor is thus uniformly
distributed over the entire bar cross section so that the current dependent
losses will be reduced. At the Roebel crossover points, the insulation is
reinforced with insulating strip inserts. Before applying the insulation, the
bars are cured in an electrically heated press and bar ends are bent with a
special device to form the involute shape. The stator winding bars are
insulated with MICALASTIC (trade name) insulation. High quality mica,
selected epoxy resins and a matching vacuum impregnation process are
the characteristic features of the Micalastic insulation system.

23

4. Transposition of Stator Bar Winding:

24

MANUFACTURING OF STATOR BARS IN PROGRESS

PROGRESS

25

In the course of manufacture, the bars are subjected to numerous

electrical tests for quality control. These include Inter-strand Short test,
the dielectric dissipation loss factor Tan measurement and High Voltage
Tests at various stages of manufacture and assembly.

26

CHAPTER 8
INSULATION PROCESS
1. MICALASTIC INSULATION
The
to

high

voltage

insulation

is

provided

according

the proven MICALASTIC SYSTEM. The main insulation is Mica

tape half overlapped. Number of layers and insulation thickness depends

on the machine voltage. The bars are manufactured by Vacuum Pressure
Impregnation (VPI) technique with resin poor tape. In this system, the
bars are dried under vacuum and impregnated with epoxy resin, which
has very good penetration properties due to low viscosity. The penetration
is still better under the application of nitrogen pressure. Then these bars
are cured at high temperature. This ensures nearly void free high quality
insulation having good electrical, mechanical and thermal properties. This
Class-F highly reliable insulation has the following additional
advantages:
Micalastic is a good conductor of heat by reason of the high
mica content and the void free synthetic resin. Efficient heat
transfer is particularly important in machines having thick
insulation and having indirect cooling.
Micalastic provides high resistance to moisture and chemical
action. Corrosive gases, vapors, lubricating oil and weak
acids, to which the winding may be subjected during
operation, do not attack the insulation.
Micalastic

has

elasticity

and

accommodates

thermo-

mechanical stresses.
Micalastic owes insensitivity to high temperatures.

27

 Micalastic does not burn. The flammability is so low that it

does not continue to burn after the arc is extinguished and
therefore CO2 fire extinguisher systems are not necessary for
this.
Micalastic retains outstanding properties even after years of
operation.

2. CORONA PROTECTION
To prevent potential differences and possible corona discharges
between the insulation and the slot wall, Outer corona protection (OCP) is
provided in the slot part. The OCP consists of a wear resistant, highly
flexible coating of conductive alkyd varnish containing graphite to which
an outer sleeve of semi conductive polyester mat is bonded.
At the transition from the slot to the end winding portion of the stator
bars, a semi conductive coating is applied. On top of this, several layers
of semi-conductive End Corona protection (ECP) coatings are applied in
varying lengths. This ensures uniform control of the electrical field and
prevents the formation of corona discharge during operation and during
performance of high voltage tests.

28

CHAPTER 9
CONSTRUCTION OF ROTOR
Rotor shaft:
The rotor shaft is forged from a vaccum cast steel ingot. Comprehensive
tests ensure adherence to the specified mechanical and magnetic
properties as well as a homogeneous forging.
The rotor consists of an electrically active portion and the two shaft ends.
An integrally forged flange coupling to connect the rotor to the turbine is
located outboard of the bearing.
Approximately 60% of the rotor body circumference is provided with
longitudinal slots, which hold the field windings. Slot pitch is selected so
that the two solid poles are displaced by 180 0.
Due to the non-uniform slot distribution on the circumference different
moments of inertia are obtained in the main axis of the rotor. This in turn
causes oscillating shaft deflections at twice the system frequency to
reduce this vibrations the deflection in the direction of the pole axis and
the neutral axis are compensated by transverse slotting of the poles.
The rotor teeth at the ends of the rotor body are provided with axial and
radial ducts, enabling the cooling gas to be discharged into the air gap for
intensive cooling of the end windings.
Rotor winding:
The field winding consists of several series connected coils inserted into
the longitudinal slots of the rotor body. The coils are wound so that two
poles are obtained.
The solid conductors have a rectangular cross-section and are provided
with axial slots for radial discharge of the cooling gas. All conductors
have identical copper and cooling duct cross-sections.
The individual conductors are bent to obtain half turns. After insertion
into the rotor slots, these turns are combined to form full turns, the seriesconnected turns of one slot constituting one coil. The individual coils of
the rotor windings are electrically series connected so that one north and
one south magnetic pole are obtained.

29

Rotor retaining ring:

The rotor retaining rings contain the centrifugal forces due to the end
windings. One end of each ring is shrunk on the rotor body while the
other end of the ring overhangs the end windings without contacting the
shaft. This ensures an un-obstructed shaft deflection at the end windings.
The shrunk on end ring at the free end of the retaining ring serves to
reinforce the retaining ring and secures the end windings in the axial
direction at the same time.
A snap ring is also provided for additional protection against axial
displacement of the retaining ring.
To reduce the stray losses and retain strength, the rings are made of nonmagnetic cold worked material

30

TERMINAL BUSHING
There are six terminal bushings located on the top of Exciter End stator
casing. Three are for phase and three are for neutral side. The terminal
bushings are Air-cooled. These are connected to the connecting bus bars
inside the machine by copper flexible connections.

31

BEARINGS:
The rotor shaft is supported on sleeve bearings having forced oil lubrication.
The bearings are either pedestal mounted or located in the stator end shields.
The oil required for bearing lubrication and cooling is obtained from the
turbine oil supply system and supplied to the lower bearing sleeve. The
bearing is insulated to prevent flow of shaft currents.
The inner surface of the bearing sleeve is provided with spiral dovetail
grooves, which hold the Babbitt firmly.
The lower bearing sleeve has grooves to admit the bearing oil to the bearing
surface. The upper sleeve through which the oil is distributed over the shaft
journals and fed to the lubricating gap. The oil is drained laterally from the
lubricating gap, caught by wipers, collected in the bearing compartment and
returned to turbine oil tank via pipes.
The generator bearings are provided with hydraulic shaft lift oil system to
reduce bearing friction during start up of the T.G. set. High pressure is
forced between bearing surface and the journal, lifting the rotor shaft to
allow the formation of a lubricating film. The bearing temperature is
monitored with double element thermocouples located approximately in the
place of maximum oil film pressure.

32

CHAPTER 10
COOLING SYSTEM
INTRODUCTION
The heat losses arising in the generator interior are dissipated to the
secondary coolant (raw water, condensate etc.) through hydrogen
and primary water.
Direct cooling essentially eliminates hot spots and differential
temperatures between adjacent components, which could result in
mechanical stresses particularly to the copper conductors,
insulation, rotor body and stator core.

Gas Coolers/ Air coolers for Generators:

1) Introduction:
It is mandatory that cooling of electrical machines is employed in power
plants irrespective of nature of plants, i.e., fossil, thermal power plants, and
nuclear power plants, combined cycle power plants. The reason is very clear
that the heat produced during the conversion of mechanical energy into
electrical energy is required to be dissipated to atmosphere to keep the
integrity of insulating material and the electrical conductor. It will not be out
of the way to mention that if heat is not dissipated to atmosphere then the
machine will get damaged.
Different methods of cooling are employed depending upon the size and
duty of electrical machine. It could be natural convection air-cooling for the
small machine or forced natural air-cooling for relatively medium machine.
However, in large machines the cooling is done in binary cycle as shown
below:

33

Hot

Hot water
Air/H2

Cold
Electrical
Machine

Cooler

Cold water

Cooling of Rotor windings:of electrical machine is normally done by air or

H2 Which is in turn cooled by water cooler and air/H 2 is re-circulated into
the generator in the closed circuit as described above.
Cooling of stator bars: In large capacity stator, bars are hollow and through
which H2/Air/Water is passed to dissipate the heat. In case of H 2/Air, the
system is same as shown above. However, in case of water, the water is
cooled outside the generator as shown below:

Hot
water/Air
Hot water

Cold water

Cold water/

Air
Electrical machine
Hollow stator

Cooler

34

2) Constructional details:
Air / gas coolers are plug-in type of coolers. They are inserted into the
generator housing provided at a suitable location within it as per the flow
path so that air/ gas picks up heat from windings and flows through the
cooler and gives up the heat and again cold air/gas flows through the
windings. The coolers are inserted vertically or horizontally as per the
arrangement. Basically these are surface type wherein water flows inside the
cooler and air/gas outside over the fins. The tubes are externally wound by
copper wire and duly soldered or fins wound over the tubes to enhance the
surface area. At each end of tubes water boxes are provided to guide the flow
of water. The coolers can be single pass or double pass. To prevent the
bypassing of air/ gas from the cooler, either strip or sealing rubber are
provided. Typical drawing of horizontal or vertical cooler is shown in fig. 1
& 2 respectively.

3) Factors affecting the performance of coolers:

(a) H2/Air pressure in the generator.
(b) Quantity of H2 pegged in the cooler
(c) Cooling water quantity passing through the cooler
(d) Pressure drop of H2/Air in the winding
(e) Purity of H2

35

4) Points of observations with cooler in operation

The following are the major points for observation while the cooler is in
operation:
(a) Inlet cooling water temperature.
(b) Outlet cooling water temperature.
(c) Quantity of cooling water through the cooler
(d) H2 pressure in generator.
(e) Hot gas/ air temperature.
(f) Cold gas/ air temperature.
(g) Purity of make-up H2

5) Maintenance of coolers:
It is very essential that from time to time ( as per capital maintenance of
unit ), coolers are taken out and inspected from both tube side as well as
from outside ( finned side ). If required, cleaning is carried out. Inspect the
sealing strip and its spring action by pressing with hand. Ensure spring
action is there. Replace rubber flap in case design envisages the same. In
case fins are worn out or loose, replace the cooler.

36

CHAPTER 11
EXCITATION SYSTEM
BRUSH-LESS EXCITATION SYSTEM FOR
TURBOGENERATORS:
An important characteristic of large turbo-generator is that the
excitation requirements increased sharply with the rating of the m/c.
since excitation voltage is limited from insulation considerations,
excitation current levels increase sharply.
Brush-less excitation system connected through driven revolving armature
a.c. exciter connected through shaft mounted rectifiers to the rotating field of
the turbo generator with no coupling of excitation power between the source
of generation and point of supply to the generator field. Today, leading
manufacturers offer brush-less excitation with rotating diodes as the
preferred excitation system.
MERITS:
(a)
(b)
(c)
(d)
(e)
(f)
(g)

Completely eliminates brush gear, slip rings, field breaker and excited
bus or cable.
Eliminates the hazard of changing brushes and leads.
Carbon dust is no longer produced and hence the operation is fully
dust free.
Brush losses are eliminated.
Operating costs are reduced.
The system is best suited for atmospheres contaminated with oil, salt,
chemical etc.and where sparking may be a fire hazard
The system is simple and requires practically no maintenance except
for an occasional inspection. Maintenance costs are thus reduced.
Ideally suited for locations where maintenance is likely to be rare due
to continuous demand on the m/c.

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(h)
(i)
(j)
(k)

Brush-less system with shaft mounted pilot exciter is of selfgenerating type and the excitation is unaffected by system faults and
disturbances.
Reliability is better.
Ideally suited for large sets.
Increasingly popular system the world over.

CONTRUCTIONAL FEATURES OF BRUSHLESS EXCITER:

The three phase pilot exciter is of revolving field type with permanent
magnet poles. The three-phase a.c. generated in the stator is fed to the field
of revolving armature main exciter via a stationary regulator and rectifier
unit. The three-phase a.c. induced in the rotor of the main exciter is rectified
in the rotating Rectifier Bridge, (i.e. diode wheels) and fed into the field
winding of the generator rotor through the a.c. lead in the rotor shaft.
A common shaft carries the rectifier wheels, the rotor of the main exciter and
the permanent magnet rotor of the pilot exciter, arranged one behind the
other. The shaft is rigidly coupled to the generator rotor at its driving end
and supported on a journal bearing at its non-driving end. The generator and
exciter rotors are thus supported in a total of 3 bearings.

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