Manufacturing of Turbo Generators in BHEL

CONTENT 

Introduction  History  Working principle  Step by designing of turbo

generators  Manufacturing of rotor winding  Applications of turbo
generators  Advantages of turbo generators  Disadvantages of turbo
generators  Conclusion  Future Scope  Queries

INTRODUCTION .

Turbo generator is a turbine directly connected to electrical generators for the

generation of electric power. These machines are the largest energy
converters found in the world. They can also be used as auxiliary power units.
They are of 3 types namely: 1)Steam turbine generators 2)Gas turbine
generators 3)Hydro turbine generators

HISTORY 

The turbo generator is invented by Blathy Otto a electrical engineer of

Hungary ,central Europe in the year 1912. Later it was developed by
Michael Faraday a British scientist by using a theory of Induction” “Electro
Magnetic

WORKING PRINCIPLE

An emf is induced in a conductor when it is cut by magnetic flux is known as

electromagnetic induction.

STEP BY DESIGNING PROCESS OF TURBO GENERATOR

There are 12 designing steps to construct the turbo generator they are: 1)Press
shop 2)Light machine shop 3)Heavy machine shop 4)Copper shop 5)Coil
shop 6)Insulation shop 7)Rotor windings 8)Stator windings 9)Balancing
10)VPI plant 11)Assembly 12)Testing

MANUFACTURING OF ROTOR WINDINGS:

The rotor in turbo generators is the magnetic field. these are of 2 types: 1)
Solid rotor 2) Laminated rotor.

THE MAIN PARTS OF ROTOR

1)Rotor shaft 2) Rotor Slot wedges 3) Damper holes 4) Rotor retaining rings
5) Fans
CONSTRUCTION OF ROTOR WINDINGS

Several series connected coils inserted into the longitudinal slots of rotor body
*conductor material *Insulation

BLOCK DIAGRAM OF ROTOR

APPLICATIONS OF TURBO GENERATORS

1. Gas Turbines drive the smallest class of turbogenerators. The motive force
for these turbines is the burning of gaseous fuels. Because they can be started
and stopped easily, they are used for a variety of intermittent applications
including emergency power

2. Steam Turbines drive much bigger turbogenerators. The steam is generated

by a variety of methods including burning coal, nuclear power and geothermal
energy. These types of turbogenerators supply the bulk of the electrical power
in the US and other countries.

3. The third class of Turbo-generator are powered by water turbines. Invented

in the 19th century water turbines are very efficient devices for extracting
energy for moving water. They are used in virtually all hydro-electric power
plants worldwide.

ADVANTAGES OF TURBO GENERATORS 

Turbo generator concept is simple and time testing. It can be generated from
the renewable energy sources which are environmental friendly. The life
span of the machine is long. Economic in cost compare to other generators,
hence in US 90% of electrical generation is done by turbo generators.

DIS- ADVANTAGES OF TURBO GENERATORS 

As the turbo generator is high voltage machine the possibility of causing a

spark in air and the danger of electric shock by contact may occur. 
Repairing cost is high. Maintenance cost is high

CONCLUSION

As turbo generators are high voltage machines which are ranging from less
than 1500volts, hence the machine efficiency is accurate. Turbo generators
are also more reliable in nature. As the production of sources are taken from
the non- renewable energy sources the cost is economic.

FUTURE SCOPE
 The scientists are investigating the technical and logistical merit of
performing offline quadratic rate partial discharges test on the stator winding
insulation besides VPI technique of turbo generators. A series of laboratory
based insulation research studies on stator bars have been conducted to gain
a better understanding of the various parts discharge phenomenon involved.

Bharat Heavy Electrical Limited (BHEL) is the largest Engineering and manufacturing
Enterprise of it kind in the Public Sector in India. It ranks among the top twelve
organizations in the world, engaged in the manufacture of power generation equipment.

BHEL, Hyderabad manufactures turbo generators of ratings upto 200MW for industrial
applications and for power generation. These turbo generators are supplied together
with the turbines and matching excitation systems, and are used mostly in paper, sugar,
cement, petrochemical, fertilizers, rayon industries etc, and thermal power stations.

TURBO GENERATORS

The general components of a turbo generator are

# Stator
- Stator Frame
- Stator Core
- Stator Windings
- End Covers
# Rotor
- Rotor Shaft
- Rotor Windings
- Rotor Retaining Rings
# Bearings
# Cooling System

The following auxiliaries are required for operation:

# Oil Supply system
# Excitation System

 Quality Assurance checks being followed right from procurement stage to

dispatch stage are enumerated in the following flow chart

STATOR
1.1 STATOR FRAME
The stator frame is of welded steel single piece construction. It supports the laminated
core and winding. It has radial and axial ribs having adequate strength and rigidity to
minimize core vibrations and suitably designed to ensure efficient cooling. Guide bars
are welded or bolted inside the stator frame over which the core is assembled. Footings
are provided to support the stator foundation.

1.2 STATOR CORE

The stator core is made of silicon steel with high permeability and low hysteresis and
eddy current Losses. The sheets are suspended in the stator frame from insulated guide
bars. Stator laminations are coated with synthetic varnish; are stacked and held
between sturdy steel clamping plates with non-magnetic pressing fingers which are
fastened or welded to the stator frame.

In order to minimize eddy current losses of rotating magnetic flux which interact with
the core is built of thin laminations. Each lamination layer is made of individual
segments.
The segments are punched in one operation from electrical sheet steel lamination
having a high silicon content and are carefully deburred. The stator laminations are
assembled as separate cage core without the stator frame. The segments are staggered
from layer to layer so that a core of high
mechanical strength and uniform permeability to magnetic flux is obtained. On the outer
circumference the segments are stacked on insulated rectangular bars which hold them
in position.
To obtain optimum compression and eliminate looseness during operation the
laminations are hydraulically compressed and heated during the stacking procedure. To
remove the heat, spaced segments are placed at intervals along the core length which
divide the core into sections to provide wide radial passages for cooling air to flow.

1.3 STATOR WINDING CONSTRUCTION

The stator windings consist of two layers made of individual bars. To minimize losses,
bars are composed of separately insulated strands which are transposed by 360
degrees. To minimize stray losses in end windings, strands of top and bottom bars are
separately brazed and insulated from each other.

Each bar consists of a large number of separately insulated strands to reduce the skin
effect losses. In straight slot portion, the strands are transposed by 360 degrees. The
transposition provides for mutual neutralization of voltages induced in the individual
strands due to slot cross field and ensures that no or small circulating currents exist in
the bar interior. The current flowing through the bar is thus distributed uniformly over
the entire cross section of a bar so that the current dependent losses will be reduced.
INSULATION OF BARS

High voltage insulation is provided with thermosetting system. A voltage insulation

obtained by vaccum press impregnation is particularly void free with excellent electrical,
mechanical and thermal properties. To prevent corona discharge between the insulation
and slot wall, a final layer of conductive tape is applied to the surface of all bars within
the slot range. All bars are conditionally provided with an end corona protection to
control the electric filed at the transition from slot to the end winding portion and to
prevent the formation of creepage sparks.

(A) VACCUM PRESS IMPREGNATED MICALASTIC HIGH VOLTAGE INSULATION

The high voltage insulation is provided according to the proven resin poor mica base of
thermosetting epoxy system. Several half overlapped continuous layer of resin poor
mica type are applied over the bars. The number of layers or thickness of insulation
depends on machine voltage.

The bars are inserted into the slots with very small lateral clearance and wedged with
packers. To prevent moment of end windings in circumferential direction, spacer blocks
are arranged between the bars and firmly with treated glass tapes. To minimize the
effect of radial forces, winding holders and insulated rings are used to support the
overhang.

The stator is impregnated in a tank under vaccum and pressure with low viscosity epoxy
resin that penetrates the winding thoroughly. After impregnation, the stator is cured at
at appropriate temperature in an oven.

The high voltage insulation thus obtained is characterized by its excellent electrical,
mechanical and thermal properties. Its moisture absorption is extremely low and it is
oil resistant. The behavior of the insulation is far superior to any other conventional
mica tape insulation system.

(B) CORONA PROTECTION

To prevent a potential difference and possible corona discharges between the insulation
and slot wall, the slot sections of bars are provided with an outer corona protection.
This protection consists of polyester fleece tape impregnated in epoxy resin with carbon
and graphite as filters.

At the transition from slot to the end winding portion of stator bars a semi-conductive
tape made of polyester fleece is impregnated with silicon carbide as filler is applied for
a specific length. This ensures uniform control of the electric field and prevents the
formation of corona discharge during operation and performance of HV tests.

1.4 END COVERS

The end covers are made of fabricated steel or aluminum alloy castings. They are
employed with guide vanes on inner side for ensuring uniform distribution of cooling air
or gas.

ROTOR

Solid rotors are manufactured from forged alloy steel with suitable alloying elements to
achieve very high mechanical and superior magnetic properties. Rectangular or
trapezoidal rotors slots are accurately machined to close tolerances on slot milling
machine. For indirectly cooled generator rotors, ventilation slots are machined in the
teeth.
For directly cooled rotors, Sub slots are provided for cooling Generators rotors of 1500
RPM are of round laminated construction. Punched and varnished laminations of high
tensile steel are mounted over machined shaft are firmly clamped by end clamping
plates.

2.1 ROTOR SHAFT

Rotor shaft is a single piece solid forming manufactured form a vaccum casting. It is
forged from a vaccum cast steel ignot. Slots for insertion or the field winding are milled
into rotor body. The longitudinal slots are disturbed over the circumference such that
two solid poles are obtained.

To ensure that only a high quality product is obtained, strength tests, material analysis
and ultrasonic tests are performed during the manufacture of rotor. The high
mechanical stresses resulting from the centrifugal forces and short circuit torque call
for a high specified mechanical and magnetic properties as well as homogeneous
forging. After completion, the rotor is balanced in various planes at different speeds and
then subjected the rotor is balanced in various planes at different speeds and then
subjected to an over speed test at 120% of the rated speed for two minutes.

The rotor consists of electrically active portion and two shaft ends. Approximately 60%
of rotor body circumference have longitudinal slots which hold the field winding. Slot
pitch is selected so that the two solid poles are displaced by 180 degrees. The rotor
wedges act as damper winding within the range of winding slots. The rotor teeth at the
ends of rotor body are provided with axial and radial holes enabling the cooling air to
be discharged into the air gap after intensive cooling of end windings

2.2 ROTOR WINDINGS

The windings consist of several coils inserted into the slots and series connected such
that two coil groups form one pole. Each coil consists of several series connected turns,
each of which consists of two half turns connected by brazing in the end section. The
rotor bearing is made of silver bearing copper ensuring an increased thermal stability.
The individual turns of coils are insulated against each other by interlayer insulation. L-
shaped strips of laminated epoxy glass fiber fabric with nomex filter are used for slot
insulation.

The slot wedges are made o high electrical conductivity material and thus act as damper
windings. At their ends the slot wedges are short circuited through the rotor body.

CONSTRUCTION
The field winding consists of several series connected coils inserted into the longitudinal
slots of 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 or cooling air. All conductors have identical copper and cooling duct cross
section. The individual bars are bent to obtain half turns. After insertion into one slot
constitute one coil. The individual coils of rotor are connected in a way that one north
and one south pole is obtained.

CONDUCTOR MATERIAL
The conductors are made of copper with a silver content of approximately 0.1%. As
compared to electrolytic copper, silver alloyed copper features high strength properties
at high temperatures so that coil deformations due to thermal stresses are eliminated.

INSULATION
The insulation between the individual turns is made of layer of glass fiber laminate. The
coils are insulated from the rotor body with L- shaped strips of glass fiber laminate with
nomex interlines. To obtain the required leakage paths between the coil and rotor body
thick top strips of glass fiber laminate are inserted below top wedges. The top strips are
provided with axial slots of the same cross section and spacing as used on the rotor
winding.

ROTOR SLOT WEDGES

To protect the winding against the effects of centrifugal forces, the winding is secured
in the slots with wedges. The slot wedges are made of copper alloy featuring high
strength and good electrical conductivity. They are also used as damper winding bars.
The slot wedges extend beyond the shrink seats of retaining rings. The wedge and
retaining rings act on the damper winding in the event of abnormal operations. The
rings act as a short circuit rings in the damper windings.

END WINDING BRACING

The spaces between the individual coils in the end winding are filled with insulated
members that prevent coil movement. Two insulation plates held by HGL-high glass
laminate plates separate the different cooling zones the overhangs on either sides.

2.3 ROTOR RETAINING RINGS

The centrifugal forces of the rotor end winding are contained by single piece rotor
retaining rings. Retaining rings are made of non-magnetic high strength steel in order
to reduce stray losses. Each retaining ring with its shrink fitted. Insert ring is shrunk on
the rotor in an overhang position. The retaining ring is secured in the axial position by
snap rings.

The rotor retaining rings withstand the centrifugal forces due to end windings. One end
of each ring is shrunk fitted on the rotor body while the other end overhangs the end
windings without contact on the rotor shaft. This ensures an unobstructed shaft
deflection at end winding.

The shrunk on hub on the end of the retaining ring serves to reinforce the retaining ring
and secures the end winding in the axial direction at the same time.
A snap ring is provided against axial displacement of retaining ring. The shrunk seat of
currents. To reduce the stray losses and have high strength, The rings are made of non
magnetic, cold worked materials.

2.4 ROTOR FANS

The cooling air in generator is circulated by two axial flow fans located on the rotor shaft
one at each end. To augment the cooling of the rotor winding, the pressure established
by the fan works in conjunction with the air expelled from the discharge parts along the
rotor. The blades of the fan have threaded roots for being screwed into the rotor shaft.
The blades are drop forged from aluminium alloy. Threaded root fastenings permit angle
to be changed. Each blade is secured at its root with a threaded pin.

BEARINGS
The turbo generators are provided with pressure lubricated self - aligning elliptical type
bearings to ensure higher mechanical stability and reduced vibration in operation. The
bearings are provided with suitable temperature element devices to monitor bearing
metal temperature in operation.

The temperature of each bearing is monitored with two RTDs (Resistance Thermo
Detectors) embedded in the lower bearing sleeve such that the measuring point is
located directly below the babbit. These RTDs are monitored a temperature scanner in
the control panel and annunciated if the temperature exceeds the prescribed limits. All
bearings have provisions for fitting vibration pickups to monitor shaft vibrations.
To prevent damage to the journals due to shaft currents, bearings and oil piping on
either side of the non-drive end bearings are insulated from the foundation frame.
For facilitating and monitoring the healthiness of bearing insulation, split insulation is
provided.

VENTILATION AND COOLING

Turbo generators are designed with the following ventilation systems:

 Closed circuit air cooling with water or air coolers mounted in the pit.
 Closed circuit hydrogen cooling with water or hydrogen coolers mounted axially
on the stator frame.

The fan design usually consists of two axial fans on either made of cast aluminum with
integral fan blades or forged and machined aluminum with integral fan blades or forged
and machined aluminum alloy blades screwed to the rotor. In case of 1500 RPM
generators, fabricated radial fans are provided.

EXCITER

The exciter is brushless mainly consisting of:

- Rectifier wheels
- Three phase main exciter
- Three phase pilot exciter
- Metering and supervisory equipment

The brushless exciter is an AC exciter with rotating armature and stationary field. The
armature is connected to rotating rectifier bridges for rectifying AC voltage induced in
the armature to DC voltage.

The pilot exciter is a PMG(Permanent Magnet Generator). The PMG is also an AC

machine with stationary armature and rotating field ( the permanent magnets).When
the generator rotates at the rated speed, the PMG generates 220v at 150 Hz to provides
power supply to automatic voltage regulator.

A common shaft carries the rectifier wheels the rotor of the main exciter and the
permanent magnet rotor of the pilot exciter. The shaft is rigidly coupled to the generator
rotor and exciter rotors are then supported on three bearings.