ACKNOWLEDGEMENT

“An engineer with theoretical knowledge is not complete

engineer. Practical knowledge is very important for an engineer to
develop and apply engineering skills”. It gives me a great pleasure to
have an opportunity to acknowledge and to express gratitude to those
who were associated with my training art BHEL.

First of all I am thankful to training coordinate Mr.B.C. SHARMA

for providing me with an opportunity to undergo my training at BHEL
(Haridwar). I am great full to our training and placement officer Mr. S.K.
SOOD .

I express my sincere thanks and gratitude to BHEL authorities'

for allowing me to undergo my training in this prestigious organization.
My most thanks to Mr. A.K.GOAL (DY. MGR. Rotor wdg.), Mr.R.
Sharma (EME Rotor winding), Mr.S.K.MEENA
(Exciter),Mr.V.K.Sharma .without whose kind and best benedictions my
project work would have been impossible. I shall always remain indebted
to them for their constant interest & excellent guidance in my project
work. More over for providing me with an opportunity to work & gain
experience.

Special thanks to Mr. K.C. BHATIA (project coordinator) who has

guided me at every step & my discussion with them was truly
enlightening. Their dedication & sincerity towards the project helped me
a lot in the completion of project report & gave it the present attractive
look.
Last but not the least I would again like to express my sincere
thanks to all project guides for there constant friendly guidance during the
entire stretch of this report. Every new step I took was due to their
persistent enthusiastic backing and I acknowledge that with a deep sense
of gratitude.

JOHAR SINGH MANN

1
 CONTENTS

 PREFACE

 INTRODUCTION

 COMPANY PROFILE

 BLOCKS

 INSULATION

 GENERATORS

 CONSTRUCTIONA FEATURE OF TURBO

GENERATORS

 BRUSHLESS EXCITER

 STUDY OF AC MACHINES

 CONCLUSION

 BIBLIOGRAPHY

2
 PREFACE

It is a matter of great pleasure for me to present the following

report on my industrial implant training at B.H.E.L. (HARIDWAR). It
outlines the whole course of my training in a specific and oriented
manner.
The basic aim of this report is to study the organizational set-up of
B.H.E.L., HARDWAR, the division of the plant (BHEL Plant) into
various Blocks, Department, Auxiliary units & Laboratories as well as the
latest manufacturing techniques employed to produce quality product. It
gives a wholesome picture of how work is carried out at BHEL in the
different blocks present there & an overview of the coordinated & well
planned, systematic manner in which these blocks feed each other to
make a desired product.
From the Electrical point of view the main stress is given on the
manufacture and maintenance of Turbo generators and Hydro generators
in BLOCK-1 as well as the latest manufacturing techniques being
employed for their production
It presents a detailed analysis on the manufacture of Turbo generators
bars and various insulating materials used in BLOCK-4.

3
All in all I have tried my best to present this report in a very precise and
profitable manner.

INTRODUCTION

In1956 India took a major step towards the establishment of its heavy
engineering industry when BHEL, the first heavy electrical
manufacturing unit of the country was set up 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. BHEL appeared on power map of
India in 1969 when the first unit supplied by it was commissioned at the
Basin Bridge Thermal Power Station in Tamilnadu. Within a decade,
BHEL had commissioned the 100th unit at Santaldih, West Bengal.
BHEL has 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 power generating equipment that was commissioned
in India during 1979-80. BHEL has already supplied generating
equipment to various utilities capable of generating 18000 MW power.
Today BHEL can produce annually; equipment capable of generating
6000 MW. This will grow further to enable BHEL to meet all of India's
projected power equipment requirements, as well as sizeable portion of
export targets...

4
 In the world power scene, BHEL ranks among the top ten
manufacturers of power plant equipment and in terms of the
spectrum of 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
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
include a network of regional branch offices throughout India.

5
 BHEL UNITS
PLACE FACTORIES
BHOPAL Heavy Electrical Equipment Plant
BANGALORE Control Equipment Division
Electro-Porcelain Division
HARDWAR Heavy Electrical Equipment Plant
Central Foundry Forge Plant
GOINDWAL Industrial Valves Plant
JAGDISHPUR High Tension Ceramic
insulation plant
JHANSI Transformer Plant
HYDERABAD Heavy Power Equipment Plant
TIRUCHIRAPALLI High Pressure Boiler Plant

The 200/120 MW set of BHEL forms the backbone of the

thermal generating capacity in the country .It has manufacturing
500 MW generating sets and has acquired the technology to
produce even 1000 MW sets Considering the fact that the first
200MW set was taken up for manufacture only in 1972, the
progress achieved by BHEL is spectacular. The just set was tested
in 1973 and commissioned in 1977. Till the end of
March 1983, BHEL manufactured power equipment totaling about
22000 MW.

6
BHEL-BRIEF HISTORY:
The first plant of what is today known as BHEL was established nearly
40 years ago at Bhopal and was the genesis of the heavy electrical
equipment industry in India. BHEL is today the largest engineering
enterprise of its kind in India. With a well recognized track record of
performance making profit continuously since 1971-72. It achieved sales
turn over of Rs. 1022 crores in 1997-98 BHEL caters to core sectors of
the Indian economy viz power, industry, transportation, transmission,
defense etc.
The wide network of bhel's14 manufacturing devisions9 service
centers & 4 power sector regional centers & about 150 project sites
enables the company to be closer to its customers & provide them with
suitable products, systems & services at competitive prices. Having
attained ISO 9000 certification, BHEL is now embarking upon the TQM.
The company's Inherent potential coupled with its strong performance
over the years, has resulted in it being chosen as one of the
"NAVRATNA"PSEs, which are to be supported by the government in
their endeavor to become future global players.

POWER SECTOR
Power sector comprises thermal, nuclear, gas and hydro power plant
business. Today, BHEL supplied sets account for nearly 56318MW or

7
65% of the total installed capacity of 86636MW in as against nil till
1969-70.
BHEL has proven turnkey capabilities for executing power project
from concept to commissioning; it possesses the technology and
capability to produce thermal power plant equipments up to 1000MW
rating and gas turbine generator sets up to a unit rating of 240MW.
Cogeneration and combined cycle plants have been introduced to achieve
higher plant efficiencies. To make efficient use of the high ash content
coal available in India, bhel manufactures 235MW nuclear turbine
generator sets and has commenced production of 500MW nuclear turbine
generator sets, custom made hydro sets of Frances, Pelton &Kaplan types
for different head discharge combinations or also engineer and
manufactured by BHEL is based on contemporary technology
comparable to the best in the world and is also internationally
competitive.

TRANSMISSION
BHEL also supplies a wide range of transmission products and systems
up to 400 KV. These include high voltage power and distribution
transformers, instrument transformers, dry type transformers, SF6
switchgear, capacitors and insulators etc. For economic transmission of
bulk power over long distances. High Voltage Direct Current systems are
supplied series and shunt compensation systems have also have been
developed and introduced to minimize transmission losses.

8
9
TRANSPORTATION
A high percentage of trains operated by Indian railways are equipped
with BHEL's traction and traction control equipment including the Metro
at Calcutta. The company supplies broad gauge electric locomotives to
Indian railways and diesel shunting locomotives to various industries.
5000/6000 hp AC/DC locomotives developed and manufactured by
BHEL have been leased to Indian railways. Battery powered road
vehicles are also manufactured by the company.

INTERNATIONAL OPERATIONS
BHEL's products, services and projects have been exported over 50
countries ranging from United State in the west to New Zealand in the far
east. The cumulative capacity of power generating equipment supplied by
BHEL outside India is over 3000 MW. The company's overseas presence
includes projects in various countries. A few notable ones are: 150 MW
(ISO) Gas turbines to Germany. Utility boilers and Open Cycle Gas
Turbine Power Plants to Malaysia, Tripoli-West, and power station in
Libya executed on turnkey basis, Thermal Power Plant equipment to
Malta and Cyprus. Hydro Generators to New Zealand and Hydro Power
Plant equipment to Thailand. BHEL has recently executed major Gas
based Power Projects in Saudi Arabia and Oman, a boiler contract in
Egypt and several Transformers contracts in Malaysia and Greece.

10
THE VARIOUS COLLABORATORS ARE

• Combustion Engineering Inc. U.S.A.

• Air preheats Co. Inc. U.S.A.
• Suljew Brothers Switzerland
• International General Electrical Co. Inc. U.S.A.
• Creuset Loire France
• Nuoveo pignore S.P.A. Italy
• Svenska Flaktabrites Sweden
• Siemens Ag. W. Germany
• English Electric Co. U.K.
• Pronum Ashen port U.S.S.R.
• Hitachi Japan
• Weir Pumps Ltd. U.K.

BHEL is aware that both its national and international commitments

will increase greatly in the years to come and it faces the
challenges and the tasks ahead with the confidence acquired through
the wealth of experience in the world market it serves.

11
 PRODUCT PROFILE OF HEEP
PRODUCT
Thermal Set/ Nuclear Set
Hydro Set
Generator
Gas Turbines
Combined Cycle Power Plant
Heat Exchanger/ Condenser
AC electrical machines
DC electrical machines
Control Gear Equipment
Light Air Craft
Medical Equipment
Micro-electronic devices
RATING
210 MW -1000 MW
115 MW
For different power stations
60 MW - 200 MW
For different types
Upto 800 MW rating
250 KW - 1600 KW
7 KW - 1000 KW
According to energy equipments
Two Seated
For Cancer Treatment
Various Combinations

At present nearly 37% of the country's electrical energy is

generated from the sets manufactured by BHEL, HARDWAR.
Immediately to the south of HEEP a relatively new unit Central
Foundry Forging Plant(CFFP) is located.
Much before the manufacturing of the first electrical machine at
HEEP, BHEL, HARDWAR, the HRD Center was established in the
year 1963. Known as Technical Training School .The center was

12
utilized for large scale fabrication activity, which helped the erection
of Heavy Electrical Equipment Plant.

13
BLOCK-1
Bay-1: HYDROGENERATORS
The unique combination of lead discharge and water conduit system
at any Hydroelectric site makes the design of the turbine and
generator custom built for each other.
Based on the unit rating and speed selected for the turbine, the
generator is designed to suit the specific requirements of rational
inertia over speed, the system requirements, special design technique
have to be used taking into account the transport limitations to site.
The expertise and experience accumulated from the manufacture of
such customs built machines have resulted in establishing
engineering & technological practices. The facilities thus provided are:

MACHINE SECTION
This section is equipped with large size vertical boring, horizontal
boring, drilling and double column planning machines. also it has
milling machines, slotting machines and a shaper for machining
small components for Hydro generators. The major components
machined in this section are stator frames, upper & lower brackets,
rotor spider, pole & plates etc.

14
ASSEMBLY SECTION:
This section has two centering columns and sets of welding
transformers for carrying out iron assembly of hydro generator
stator.

STATOR WINDING:
This section has oven for heating the bars before laying and one
trunk mounted brazing installation.

Bay-II: TURBOGENERATORS:-

Facilities available in this bay are:

MACHINE SECTION:
This section is equipped with large sized machine tools such as
lathes, vertical boring and radial drilling machining stator body, rotor
shaft, end shields, bearing etc. For turbogen. Also it has a special
rotor slot - milling machine for cutting slots in rotor shafts.

IRON ASSEMBLY:
This section has facilities for stator core assembly of turbo
generators and heavy electrical motors including transformer for
induction heating of retaining rings and armature cores of large size
electric motors.

15
HEAVY ROTOR ASSEMBLY SECTION:
It has a 250-ton horizontal press and other necessary facilities for
assembly of large size rotors.

STATOR WINDING SECTION:

It has 2 dust proof stands for stator winding of turbo generators and an
installation for heating stator bars.

ARMATURE / ROTOR SECTION:

It is equipped with installations for laying windings in turbo
generators and large size D.C. Armatures. Also it has a dynamic
balancing machining for rotors up to 16- ton weight.

ARMATURE / ROTOR IMPREGNATION SECTION:

It has impregnation and drying ovens for large D.C. Armatures.

GENERAL ASSEMBLY SECTION:

In this general section assembly of turbo generators, large size AC
and D.C. Motors are carried out.

16
TEST STANDS:
Turbo generators test stand is equipped with 6 MW drive motor and
a test pit, open circuit, sudden short circuit temperature rise,
hydraulic and hydrogen leakage tests are carried out for Turbo
generators

Bay-III: MEDIUM SIZE MOTORS:

MACHINE SECTION:
This section is equipped with medium size machine tools for
machining the components for medium size AC and D.C. Motors
and small components of Turbo generators.

17
ROTOR ASSEMBLY SECTION:
In this section double and four column presses are installed for
assembly and pressing the iron cores of medium size electrical
motors.

COMMUTATOR SECTION:
It has ovens for static and dynamic forming and installation for
boozing of risers.

POLE CORE SECTION:

It is equipped with core building installation, horizontal press and
special straightening plate for the assembly of Hydro-generators poles.

PAINTING SECTION:
It contains paint spray booths and drying ovens for painting various
components.

BUS BAR AND FITTING SECTION:

It is equipped with edge blinding machine for copper flats shearing
press for cutting copper sheaths, hydraulic and single crank open
type presses etc. The main components manufactured in
This section is bus bars, commutator segments and lubricating rings.

18
ROTOR ASSEMBLY SECTION:
It has static and dynamic balancing installations for balancing the rotor of
the medium size motors.

WINDING SECTION:
It is equipped with binding machines, brazing installations, stator rotating
machine etc. For winding stator armatures/slip ring rotors.

GENERAL ASSEMBLY SECTION:

The final assembly of medium size motors is carried out in this
section. A painting booth and a drying oven have been provided in
this section for final painting of motors.

TEST STAND:
It is equipped to test motors upto 6.6 kV and 800 A rating

Bay-IV: SMALL SIZE MOTORS:

Facilities available in this section are:
MACHINE SECTION:

19
It is equipped with small and medium size center lathes, milling,
radial, cylindrical grinding, slotting, internal grinding and surface
grinding machines.

POLE SECTION:
It is equipped with a vertical hydraulic press for building pole cores
of D.C. motors. It has pneumatic shearing machines
pole straightening installations, electric furnaces for bright annealing
of copper coils timing installation and hydraulic presses up to 800
Ton capacity for manufacturing pole coils of D.C. motors,A.C.
synchronous motors and Hydro generators.

TURBO ROTOR COILS SECTION:

It has block type hydraulic press installed for forming and drilling
half coils, installed for soldering and installed for straightening and
cutting conductors for turbo coils.

IMPREGNATION SYSTEM:
It is equipped with electric drying ovens, air-drying booths, and bath
for armature/rotor impregnation and spray painting booths. Rotors
and armatures of a.c. and D.C. motors are impregnated in varnish and
painted in this section.

MACHINE HALL

20
It is equipped with high capacity motor generator sets (10 MVA)
coupling transformer (32000 kVA), induction regulators (2050 kVA),
Auto transformer and auxiliary motor-generator sets. Main role of
this complex is to maintain the electrical supply of different nature
like a.c. Or D.C. Variations in voltage / frequency for testing.

BLOCK -II
Known as the Fabrication block, Block-II is a feeder block for
various products - steam turbines, hydro turbines and turbo
generators, Hydro generators, electrical machines and apparatus and
control gears. Block consists of four bays, namely Bay-I, Bay-II,
Bay-III and Bay-IV and is provided with overhead crane facilities
for storing of plates, gas cut blanks and furnished products. This
Block has facilities for compressed air, oxygen, acetylene and
carbondioxide gas pipelines.
All the parts prior to delivery to main blocks are given a coating
of primer for the purpose of corrosion, precaution and decoration.
Before painting the welded assemblies are cleaned in the short
blasting chambers which is cancelled out at different temperatures.

21
BLOCK-III
Known as Turbine Block, this is the major block for manufacturing
turbines. All types of Hydro, Steam, Gas and Nuclear Turbines are
manufactured and dispatched from this block. Blades of different
stages are also manufactured in this block.

BLOCK- IV:
Known as the Apparatus and Control Gear and Insulation
Manufacture Block. Block-IV is feeder block for insulating items,
windings with class 'B' Bituminous insulation and sheet-metal
Components for all the products of Block - I i.e. Turbo generator, Hydro
generator, A.C. and D.C. motors. also control cubicles for Turbo
generators, Hydro generators, industrial drives for motors, Turbo
generators, auxiliaries, contractor, relays and master
Controllers are manufactured in this Block. Block- IV consists of three
bays namely Bay-I, Bay-II, Bay-III. Overhead crane facilities have been
provided in all the bays for air, nitrogen gas, vacuum pumps and an
air condition chamber.
The manufacturing facilities available in this block are:
ASSEMBLY SECTION:
It has the following sub-sections:

22
1. Mechanical Assembly Section : It is equipped with small size
drilling machine, welding sets and hydraulic testing equipment for
manufacturing turbo generator mechanical assemblies.
2. Close Cubical Assembly Section

STATOR BAR WINDING SECTION:

It is equipped with machines to manufacture bars for
Turbo generators up to 235 MW and Hydro generators up to 115
MW. It comprises of following sections:
•Conductor cutting, insulation spinning and transposition section are
having facilities for transposition the bar up to 9000 mm length.
Stack consolidation section, forming and lug brazing sections have
block type hydraulic press, steel former and resistance brazing
installations respectively.
• Insulation taping sections with automatic taping facilities in
air condition atmosphere covering max. Slot portion of 4800 mm and
each side overhang of 1200 mm.
• Baking and Pressing section having baking moulds for
simultaneous curving of straight and overhead portion with electrical
heating.

CONTROL PENAL ASSEMBLY SECTION

It has following sub-sections:
• Fabrication Section

23
• Assembly Section
• Relay Contractor Assembly Section

ARMATURE WINDING ROTOR BAR AND STATOR COIL

SECTION:
It is equipped to manufacture coils for:
AC MACHINES : Coils diamond pulled type with class 'B' (bitumen)
and class 'F' (Conventional or resin rich discontinuous epoxy
insulation) and class 'H' silicon insulation for machines ranging from
5 to 460 kW capacity.
This section has the following work centers:
• Conductor cutting, U-bending and trimming of conductor cutting
machines, U-bending machines and trimming baths.
• Forming and insulation of D.C. Coils.
• Main and interlope winding: It is having semi automatic winding
machine.
• Blanking, boat pulling and diamond pulling for A.C.coils :
It is equipped with winding, boat pulling and diamond pulling machine.
• Insulation and pressing of A.C. coils : It is equipped with
hydraulic presses of 608 T capacity.

24
COMPOUNDING SECTION:
It is equipped with horizontal and vertical tags for compounding
Turbo generator, Hydro generator and A.C. machine coils and bars
with class 'B' insulation.

MACHINE SECTION:
It has following sub-sections:
• Tool Maintenance Section :For carrying out the maintenance
and repairs of various machine tools installed in Block - IV
• Sheet Metal Section : It is equipped with nibbling machine,
hydraulic press, deburring machine, spot welding and power shearing
catches and lowers etc. For all the products of Block-I and Block -II are
manufactured. Spot welding and riveting of fingers to end stamping
for motors and generators is also done in this section.
• Machine Section : It is equipped with small size lathes, drilling,
milling and surface grinding machines. More components for turbo
generators auxiliaries are machined.
• Engraving Section :Used for engraving the nameplates of all
the products for the plant by a special pantograph type machine.

IMPREGNATION SECTION:

25
It is equipped with impregnation tank, ovens and calendaring
machine for impregnation of D.C. Pole coils, machined insulating
details and glass cloths.

ELECTROPLATING SECTION:
It is equipped with facilities for providing protective and decorative
coating to all parts and sub-assemblies.
Prickling, preservation, polishing, copper, nickel plating, chrome plating
and many other processes are carried out here. Cadmium plating is done
on fasteners, governor of hydro turbine and steam turbine and on
sheet metal components. Copper, nickel chromium plating is done on
governor parts, mechanical assemblies of A.C. generators and dies and
fixtures from Tool Room. Trimming is done on panel bus-bars, copper
sheets And other components and steam turbine parts for preservation.
Pickling is done on pole coils, compensating bars and other such
parts, which are rusty and dirty.
Phosphordizing is done on oil coolers and water cooler parts, motor
covers of sheet metal and other such items.

INSULATION SECTION:
It comprises of the following sub-sections:
• Insulating details: Machining is equipped with small size
lathes, milling and radial drilling machines, laminate cutting machines
and jet cutting saw.

26
• Press Molding Section :It has electrical ovens, hydraulic
presses, shearing and circular saw cutting machine for manufacturing
press moulded components of all the electrical machines.
• Plastic Moulding Section :
It is equipped with various presses for plastic moulded parts.
• Bitumen Mica Tape Manufacture:
It is equipped with mica tape manufacturing machine and lathe for
slitting mica tape to required size.

BLOCK – V
Known as the FABRICATION AND FORGE BLOCK, Block-V consists
of two bays. Fabrication work is carried out in bay-I and forgings are
made in bay-II.

FABRICATION SECTION:
Fabrication work being done in this bay is of steam turbine parts like
condenser upper part (left & right), water box (front & rear), and middle
part of LPC, storage tanks etc. and Hydro turbine parts like outlet
pipes, inlet pipes, cylindrical parts etc. Fabrication of Hydro
generator pipe, conical rotor spider and grinding of hydro turbine
fluid vanes and stray vanes is also carried out.

27
FORGE SECTION:
Forging of carbon alloy and stainless steel are manufactured in this
section. This is equipped with pneumatic hammers from 100 kg to 3 tons
capacity. Gas fixed furnaces for heating of blooms and for subsequent
heat treatment of forging, hydraulic manipulator of 2 ton capacity is
used to handle the forging on 3 tons hammer.
The blooms re-heating furnaces available in this section can
accommodate a job of 1500mm length and can be heated to a
max. Temperature of 1500 0C.

BLOCK – VI
Known as the STAMPINGS AND DIES MANUFACTURE
BLOCK, Block-VI has 3 bays. Bay-I is for manufacturing all types
of dies while bay-II is for manufacturing stampings for Turbo
generators, Hydro generators and motors. Bay-II is also known as
Engineering Works Section.

STAMPING MANUFACTURE
Press Section:

28
It is equipped with presses varying from 10 T to 500 T. Shearing
machines, segmental and radial notching machines. Shearing, blanking
and punching operations are carried out here to form stampings of various
products.
De-burring, Degreasing and De-rusting:
A contractor carries this out before feeding them to varnishing
section.
Varnishing Section, Spot Welding and Painting Section:
This section is equipped with 2 varnishing machines, 2 spot welding
machines and 1 paint-spraying booth. Here varnishing, coating, spacers
cutting, spot welding and painting operations are carried out.

BLOCK - VII
Known as the wood working block, Block-VII has got 2 bays. Bay-I
known as the pattern section is equipped with various wood
working machine tools like groove cutting machines, wood working
lathes, surface planer, pendulum saw etc. This section is making
patterns for CFFP as per their requirement of various castings. Bay-
II known as the packing section, package for packing and dispatch of
various products are manufactured here.

BLOCK - VIII

29
Known as the Thermal Power Block, Block-VIII is adjacent to the
center plant stores building and got 1 bay only. Heat exchange units
are Steam turbines, Hydro turbines, Hydrogen. Etc. Are manufactured
here.

SOME SPECIAL FEATURES OF BHEL MOTORS

Micalastic Totally Impregnated Class F Insulation

The micalastic insulation has the following advantages:

- High withstand capability for switching surges.
- High dielectric strength and better heat transfer.
- High mechanical strength and resistance to abrasion.
- High resistance to moisture and chemically aggressive atmosphere.
- Radiation withstands capability for using nuclear power station.
- Withstands extremely low temperatures.
- High reliability and long life
- Suitable for use with vacuum circuit breakers.
- Capable of withstanding 1000 nos. of starts per annum.

Rotor cage construction:

The rotor bar joints with S.C. rings are heated by induction heating
process, employing high frequency current (at 10,000 c/s). Inductive
Brazing is a clean process requiring no flux and provides a high tensile

30
strength. With induction brazing, brazing of joints is much faster and
hence unnecessary heating of S.C. rings as well as core is avoided.
In case of squirrel cage rotors, special design features are adopted to
ensure tightness of rotor bars in the slots. This also ensures better heat
transfer from bar to the core.

Balancing of rotors :
Rotors are sensitive to residual unbalance that is a major source of
vibration. All the rotors are dynamically balanced at rated speed along
With the fans. This ensures smooth running of motor, while in operation.

High quality stampings:

Stampings are manufactured on N.C. notching presses to achieve very
high quality and accuracy. Pre coated E.T.S. steel is employed.

Low noise:
To achieve low noise, following features have been incorporated:
• Magnetic slot wedges.
• Skewed rotor slots – in selected cases.
• Optimum design of fans and cooling air passages.

31
Sound absorbers/ silencers/ mufflers at inlets/ outlets/ housing inner
surface, are also employed in cases where specific noise levels are
demanded.

Quality assurance:
Established Quality Control and Quality Assurance Standards, in line
with inter national practices ensure quality product. More than 50
individual tests, covering the entire production from raw materials to
complete motors are carried out. No motor goes out of the works with
fulfilling all the quality requirements.
Tests:
Motors are subjected to routine and type tests in accordance with
national/ international standards and as demanded by the users.

32
33
INSULATION MATERIALS AND THEIR SPECIFICATIONS

CLASS TEMP MATERIAL

Y 900C
A 1050C
E 1200C
B 1300C
F 1550C- 1650C
H 1800C
C >1800C
Cotton, silk paper
Cotton, silk paper with impregnation
Synthetic material
Mica, Asbestos, Glass fiber.
Mica, glass cloth base with epoxy resin
Mica,porcelain,Quartz,glass
Mica, porcelain,glass (without bending
agent )

INSULATION TAPE
It consists of three materials:
1. BINDER (Resin or varnish e.g. epoxy resin of class-F)
2. Backing material to provide mechanical strength (e.g. glass tape or
polyester tape).
3. MICA-poor mechanical strength in paper form

Mica and glass can withstand at temperature (700-8000C). As a whole it

is class-F due to binder. There are two types of tapes

34
• RESIN RICH
• RESIN POOR

RESIN RICH: Binder of the order of 40% by weight here during curing
the resin should flow and fill the voids and oozes out. Due to curing air
voids are more and hence thickness is more in it. Life of machine is 20-25
years. It has less life as there is flexible tape over the overhang portion
and therefore more moisture enters in it.

RESIN POOR: Binder is of the order of 6-8% by weight after curing the
insulation we need 34-35% of the binder. Before curing it is impregnated
to resin to get the required %age of the resin. Life of machine is almost
100years. Here we first remove all the air & thus penetration of resin is
better & voids are less and thickness is less. Also no effect of vibration.

INSULATION SYSTEMS:
The insulation of coils and winding bars is built by applying insulation
materials in the form of tapes and sheets. These tapes consist of electrical
material (Generally mica splitting or mica paper).
Depending upon the building materials insulation systems are classified
in to two main parts.
1. Thermoplastic insulation system
2. Thermo reactive or thermosetting insulation system.

35
Thermoplastic insulation system: In this system, the nature of resin is
oil modified electrical grade bitumen varnish. This system is not suitable
beyond a temperature of 1300C. This is because the thermoplastic
insulating materials exhibit a reversible change in state with an increase
in temperature. At room temperature the thermoplastic arte hard and
solid, while at elevated temperature these get softened and will melt at
higher temperature. Generally this system is used for class-b electrical
machines. Due to this system machines run at very high speeds and when
temperature gets increase there is a risk of insulation risk out.

Thermo reactive insulation system: In this system the insulation

material gets harden when heated and maintained at elevated temperature
for sufficient period of time. This is called curing. This is a non-reversible
process meaning thereby that the insulation remains hard after cooling
and again heating. This is also called thermosetting system. The oil
bituminous bond is replaced by epoxy synthetic based resin which
hardens under the effect of heat. This system has superior thermal,
mechanical and dielectric properties. This system has main two types
depending upon the binder materials.

1. Resin rich insulation system 2. Resin poor insulation system

Resin rich insulation system:

36
Resin rich system makes use of resin saturated glass backed mica paper
tape. After taking, heating of the insulation at elevated temperature under
pressure is done fore a sufficiently long period to accelerate curing
reaction. During this process extra resin is squeezed out of the insulation.
The time, temperature and pressure require for proper consolidation
depends upon the type of resin used and wall thickness.

Resin poor insulation system: This system is employed for

manufacturing stator bars of 500MW T.G. in this system the bars are
insulated with dry and relatively porous mica paper tape. The tape
normally contains little amount of resin. The resin is introduced in the
system later during the process of impregnation.

37
 PROJECT

BASED ON

STUDYON
TURBO GENERATOR
(500MW)
38
 Technical Data
(General & Electrical data)

Rated data & Turbo

Main exciter Pilot exciter
output generator
Apparent Power 588 MVA - 65 kVA
Active Power 500 MW 3780 kW -
Current 1 6.2 kA 6300 A 195 A
Voltage 21 kV 600 V 220 V
Frequency 50 Hz 400 Hz
Power Factor 0.85 - -
Inner Connection of - -
stator winding YY
Hydrogen pressure 3.5 BAR - -
Rated field current 4040 A - -
Rated field voltage 340 V - -

39
Rectifier Wheel
Number of fusses per rectifier 30
wheel (800 V, 800 A)
Fuse Resistance Approx. 150 μ ohms
Number of diodes per rectifier 60
wheel

GENERATOR
Generators are the machines which converts mechanical energy into
electrical energy or the machine which are used to generate electricity.

The various types of generators manufactured in B.H.E.L.Hardwar are as

follows:-
1) THDF (500 MW)
2) THRI (210/250 MW) Siemens Design
3) TARI (120-160 MW)
4) THW (210/235 MW) Russian Design
The first three types are of Siemens Design and the last one is of Russian
Design. The meaning of the above nomenclature is as follows:-

T H DF
T H RI
T A R I

40
 Stator cooling
1) I Indirect cooling by H2
2) F Forced cooling by water.
Rotor cooling
1) R radial cooling of rotor
2) D direct cooling of rotor
Cooling gas in the casing
1) H Hydrogen
2) A Air
Product: Turbo generator

CONSTRUCTIONAL FEATURES OF
TURBOGENERATORS
The two pole generator uses direct hydrogen cooling for the rotor
winding and direct water cooling for the stator winding. The losses in the
remaining generator components, such as iron losses friction and windage
losses and stray losses are also dissipated through hydrogen.
The generator frame is pressure resistant, gas tight and equipped
with end-shields at each end. The hydrogen coolers are arranged
vertically inside the turbine end stator end shield.

The generator consists of following components:

• STATOR
Stator frame

41
Stator core
Stator winding
End shields
Terminal bushings
Phase connectors
Hydrogen coolers
Stator cooling system
Supervision of generator
End winding vibrations

• ROTOR
Rotor shaft
Rotor winding
Rotor retaining rings
Field connection
Fans
Rotor Cooling System

• BEARINGS
• SHAFT SEALS

The following additional auxiliaries are required for generator operation:

42
1. Gas system
2. Excitation system

43
 STATOR FRAME
The stator frame with flexible core suspension components, core and
stator winding is the heaviest component of the entire generator .A rigid
frame is required due to the forces and torque arising during operation. In
addition, the use of hydrogen for the generator cooling requires the frame
to be pressure resistant up to an internal pressure of approximately 10
bars.

44
 The welded stator frame consists of cylindrical frame housing, two
flanged rings and axial and radial ribs. Housing and ribs with in the range
of the phase connectors of the stator winding are made of non magnetic
steel to prevent eddy current losses, while the remaining frame parts are
fabricated from structural steel.
The arrangement and dimensionally of the ribs determine by the
cooling gas passages and the required mechanical strength and stiffness.
Diminishing is also dictated by vibration considerations, resulting partlly
in greater wall thickness than required, from the point of view of the
mechanical strength. The natural frequency of the frame does not
correspond to any exciting frequency.
Two lateral supports for flexible core sustention in the frame are
located directly adjacent to the points where the frame is supported on the
foundation; due to the rigid design of the supports and foot portion the
forces due to the weight and short circuits neither will nor result in any
over stressing of the frame.
Manifolds are arranged inside the stator frame at the bottom and
top for filling the generator with CO2 and H2. The connections of the
manifolds are located side by side in the lower part of the frame housing.
Additional openings in the housing, which are sealed gas tight by
pressure resistant covers, afford access to the core clamping flanges of the
flexible core suspension system and permit the lower portion of the core
to be inspected. Access to the end winding compartments is possible
through manholes in the end shields.

45
In the lower part of the frame at the exciter end an opening is provided
for bringing out the winding ends, the generator terminal box is flanged
to this opening.

STATOR FRAME

STATOR CORE
In order to minimize the hysterisis and eddy current losses of the rotating
magnetic flux which interacts with the core, the entire core is built up of
thin laminations. Each lamination layer is made up from a number of
individual segments. The segments are punched in one operation from 0.5
mm thick electrical sheet-steel laminations having high silicon content,
carefully deburred and then coated with insulating varnish on both sides.
The stator frame is turned on end while the core is stacked with
lamination segments in individual layers. The segments are staggered

46
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
dovetail bars which hold them in position. One dovetail bar is not
insulated to provide for grounding of the laminated core. Stacking guides
inserted in to the winding slots during stacking provide smooth slot walls.
To obtain the maximum compression and eliminates undue settling
during operation, the laminations are hydraulically compressed and
heated during the stacking procedure when certain heights of stacks are
reached. The complete stack is kept under pressure and located in the
frame by means of clamping bolts and pressure plates. The clamping
bolts running through the core are made of non-magnetic steel and are
insulated from the core and the pressure plates to prevent the clamping
bolts from short-circuiting the laminations and allowing the flow of eddy
currents.

The pressure is transmitted from the pressure plates to the core by

clamping fingers. The clamping fingers extend up to the ends of the teeth,
thus ensuring a firm compression in the area of the teeth. The stepped
arrangement of the laminations at the core ends provides for an efficient
support of the tooth portion and, in addition, contributes to a reduction of
a eddy current losses and local heating in this area. The clamping fingers
are made of non-magnetic steel to avoid eddy current losses.

47
 The protection against the effects of stray flux in the coil ends, the
pressure plates and the core end portions are shielded by gas cooled rings
of insulation bonded electrical sheet-steel.
To remove the heat, spacer segments, placed at intervals along the bore
length, divide the core in to sections to provide radial passages for
cooling gas flow. In the core end portions, the cooling ducts are wider
and spaced more closely to account for the higher losses and to ensure
more intensive cooling of the narrow core sections.
The revolving magnetic field exerts a pull on the core, resulting in a
revolving and nearly elliptical deformation of the core which sets up
stator vibration at twice the system frequency. To reduce the transmission
of these vibrations to the foundation, the generator core is spring mounted
in the stator frame. The core is supported in several sets of rings and two
core clamping rings. The structural members to which the insulated
dovetail bars are bolted are uniformly positioned around the supporting
ring interior to support the core and to take up the torque acting on the
core.

STATOR CORE

STATOR WINDING

48
Manufacturing the stator bar
The stator bar consists of large number of separately insulated hollow and
solid strands which are distributed over the entire bar cross-sections so
that good heat dissipation is insured. The manufacturing process contains
following operations.
1. Conductor cutting: The required size of conductor is cut by cnc
conductor cutting machine. For the lower bar length of conductors is
10.2m and for upper bar, length of conductors is 10.05m. The lower and
upper bar contains 20 conductors each. Total bar contains 20 hollow and
20 solid conductors.
2. Transposition: To minimize the stray losses, the bars are composed of
separately insulated strands which are transposed by 5400 in the slot
portion the Tran positioning 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 insures that minimum circulation currents
exists. The current flowing through the conductor is uniformly distributed
over the entire bar cross section so that the current dependent losses will
be reduced.
3. Bandaging: Between the lower and upper bar insulation is placed. The
insulating material is epoxy glass. The individual layers are insulated
from each other by a vertical separator. This process is known as
bandaging.

49
4. Pressing and calibration: After bandaging the bars are pressed under
the temperature of 1500 for settlement of insulation.
5. Inter turn testing: This testing is done at 300volt .this is done to check
whether the conductors are short or not.
6. Forming: In forming bars are bended from each end by heating at
1800c for 35 min.
7. Coil lug brazing: at the bar ends, the solid strands are jointly brazed
in to a connecting sleeve and the hollow strands in to a water box from
which the cooling water enter and exists via Teflon insulating connection
between top and bottom bars is made by a bolted connections at the
connecting sleeve.

8. Pickling: in this process, the conductors ends are dipped in acid.

Pickling solution contains sulphuric acid, phosphoric acid, water,
hydrogen peroxide in definite composition. The conductor ends are
dipped in this solution for 15 minute. Then the conductor ends cleaned
with water and brass brush. or neutralization we dipped conductor end in
ammonia solution which consist of water and liquid ammonia. After that
the ends are dipped in ethyl alcohol and after that conductors are dried by
nitrogen. This whole processes are done for four times.
9. Testing:
• Nitrogen leakage test: this is done to check the leakage in sleeves at
pressure 11kg/sqcm

50
• Helium leakage test: Helium gas is filled inside the bar at 11kg/sqcm.
And the bar is covered with polythene bag and locked on both sides. By
helium leak detector probe, if any leakage at lug point occurs, then the
meter will show and it can be confirmed for a repair of bar joint.
• Hydraulic test:
• Thermal shock test

10. Micalastic high voltage insulation: High voltage insulation is

provided according to the micalastic system. With this insulating system,
several half over lapped continuous layers of mica tape are applied to the
bars. The mica tape is build up from large area mica splitting which are
sandwiched between two polyester backed fabric layers with epoxy as an
adhesive. The number of layers, i.e. thickness of the insulation depends
on the machine voltage. In this machine the numbers of layers are 11. The
bars are dried under vacuum and impregnated with epoxy resin which has
very good penetration properties due to its low viscosity. After
impregnation under vacuums, the bars are subjected to pressure, with
nitrogen being used as pressurizing medium (VPI process). The
impregnated bars are formed to the required shape in moulds and cured in
an oven at high temperature. The high voltage insulation obtained is
nearly void free and is characterized by its excellent electrical,
mechanical and thermal properties in addition to being fully water proof
and oil resistant.

51
11. Conductor varnishing coating: To prevent potential differences
and corona discharges between the insulation and slot wall, the slot
sections of the bars are provided with an outer corona protection. This
protection consists of wear resistant, highly flexible coating of conductive
alkyd varnish containing graphite.
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 coating 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.
12. Tan δ & high voltage test: To check the mechanical strength of
stator bars high voltage testing is done. After insulation and curing, the
insulation of each stator bar is subjected to high voltage test at 150% of
the winding test voltage. (UT = 2* UN +1 KV). For assessment of the
quality of the slot insulation the dielectric dissipation factor tan δ is
measured as a function of the voltage. The dissipation factor of the stator
winding is measured in the range of 0.2 to 1.4 UN.
13. Dispatch: after all the bars are dispatched to block one for
assembling in stator frame.

Locating the bars:

The three phase stator winding is a fractional pitch two layer type
consisting of individual bars. The stator windings are placed in

52
rectangular slots which are uniformly distributed around the
circumference of the stator core. Each stator slot accommodates two bars.
Total slots are 48. The slot bottom bar & top bar are displaced from each
other by one winding pitch and connected at there ends to form coil
groups. The coil groups are connected together with phase connectors
inside the stator frame shown in the connection diagram.

Tp- pole pitch

Lap type winding

Coil pitch = slots/pole = 48/2

= 24 i.e. full pitch
Short pitch = pole pitch = 24*(5/6)
= 20
Slot per pole per phase = 48/ (2*3)
=8

The bars are protected by a cemented graphitize paper

wrapper over the slot portion of the bars. The bars fit tightly in the
slots .manufacturing tolerances are compensated with semi conducting

53
filler strips along the bar sides which ensure good contact between the
outer corona protection & the slot wall.
Radial positioning of the bar is done with slot wedges. To protect the
stator winding against the effects of magnetic forces due to load and to
ensure permanent firm seating of the bars in the slots during operation,
the bars are inserted with a top ripple spring located beneath the slot
wedge. The ripple spring is made of semiconductor material performs
following functions:

• Provide mechanical strength

• Absorb vibrations
• Act as insulator
• Protect from corona

Below the longitunally divided slot wedges fiber glass fabric is arranged
between the filler and slide strip which presses the bars against the slot
bottom with the specific pre loading. An equalizing strip is inserted at the
slot bottom to compensate any unevenness in the bar shape and slot
bottom surface during bar insertion. The strip is cure after insertion of
bars. These measures prevent vibrations. The specified preloading is
checked at each slot wedge.
With the winding placed in slots, the bar ends form a cone shaped
end winding having particularly favorable characteristics both in respect
of its electrical properties and resistance to magnetically induced forces.

54
A small cone taper is used to keep the stray losses at a minimum. Any
gaps in the end winding due to the design or manufacturing are filled with
curable plastic fillers, insuring solid sport of the cone shaped top and
bottom layers.
The two bar layers are brazed with clamping bolts of high
strength fiber glass fabric against a rigid , tapered supporting rings of
insulated material. Tight sitting is insured by plastic filters on both sides
of the bars which are cured on completion of winding assembly. Each end
winding forms a compact, self supporting arch of high rigidity which
prevents bar vibrations during operation and can with stand short circuit
forces.
In addition, the end turn covering provides good protection
against external damage. The supporting rings rest on supporting brackets
which are capable of moving in the axial direction. This allows for a
differential movement between the end winding and the core as the result
of different thermal expansions. The stator winding connections are
brought out to six bushings locating in the compartment of welded non
magnetic steel below the generator at the exciter end. Current
transformers for metering and relaying purposes can be mounting on the
bushings. The bars are subjected to numerous electrical and leakage test
for quality control.

55
inding bars are laid in the stator slots in the core in two layers. The lower
layer is supported on the overhung portion by means of glass textolite
brackets and a binding ring. The upper layer of the winding bar is laid
also in slot and separated from the lower bar by means of glass textolite
acking. Both the bars are held against the short circuit forces and the
forces encountered in the service by means of impact resistant plastic
wedges. The welding is ensured to be very tight so that during the
operation of a machine the same should not get loosened. The complete
system in the overhang portion is designed to withstand the forces
encountered due to sudden short circuit. One end of the winding is
connected to two water headers, one inlet and one outlet, by means of
Teflon hoses the length of which is decided on the basis of minimum
resistance of water column to be maintained between the bar and the
header. These headers are supported on the insulator and their connectors
are brought out from the stator frame through the porcelain insulator.
During the laying of stator winding special resistance thermometer are
laid to monitor the temperature of core and winding in slots. These
resistance thermometers are of special design and are wound by means of
a fine copper wire.

56
 END SHILDS
The ends of the stator frame are closed by pressure containing end
shields. The end shields features a high stiffness and accommodate the
generator bearings, shaft seals and hydrogen coolers. The end shields are
horizontally split to allow for assembly.

TERMINAL BUSHINGS
The cylindrical bushing conductor consists of high conductivity copper
with a bore central bore for direct primary water cooling. The insulator is
wound directly over the conductor. It consists of impregnated capacitor
with conducting fillers for equalization of the electrical direct-axis and
quadrature-axis fields. The beginnings and ends of the three phase
windings are brought out from the stator frame through terminal bushings
which provide for high voltage insulation and seal against hydrogen
leakage. The bushings are bolted to the bottom plate of the generator
terminal box by the mounting flanges.

PHASE CONNECTORS
The phase connectors interconnect the coil groups and link the beginning
and ends of the winding to the bushings. They consist of thick-walled
copper tubes. The stator bars are coupled to the phase connectors. The
phase connectors are provided with micalastic insulation.

HYDROGEN COOLER

57
The hydrogen cooler is a shell and tube type heat exchanger which cools
the hydrogen gas in the generator. The heat removed from the hydrogen
is dissipated through the cooling water. The cooling water flows through
the tubes, while the hydrogen is passed around the finned tubes.
The hydrogen cooler is subdivided in to identical sections which are
vertically mounted in the turbine end stator end shield. The cooler
sections are solidly bolted to the upper half stator end shield, while the
attachment at the lower water channel permits them to move freely to
allow for expansion.
The cooler sections are parallel connected on their water
sides. Shut off valves are installed in the lines before and after the cooler
sections. The required cooling water flow depends on the generator
output and is adjusted by control valves on the hot water side.

STATOR COOLING SYSTEM

Cooling of Stator Core: For cooling of stator core, cold gas is admitted
to the individual frame compartments via separate gas ducts.
From these compartments the gas flows in to the air gap through slots
in the core where it absorbs the heat from the core. To dissipate the
higher losses in the core ends, the cooling gas slots are closely spaced in
the core end sections to ensure effective cooling. These ventilating ducts
are supplied with cooling gas directly from the end winding space past
the clamping fingers between the pressure plate and core end section in to

58
air gap. A further flow path passes in to air gap along either side of the
flux shield
All the flows mix in the air gap and cool the stator bore surfaces.
The gas is then returned to the coolers via the axial-flow fan. To ensure
that the cold gas directed to the exciter end cannot be directly discharged
in to the air gap, an air gap choke is arranged with in the range of the
stator end winding cover and the rotor retaining ring at the exciter end.

Cooling of Stator winding, Phase connectors and Bushings: The

treated water used for the cooling of the stator winding, phase connectors
and bushings is designated as primary water in order to distinguish it
from the secondary coolant (raw water, condensate, etc.) the primary
water is circulated in the closed circuit and dissipates the absorbed heat to
the secondary cooling water in the primary water cooler. The pump is
supplied with hot primary water from the primary water tank and delivers
the water to the generator via the coolers. The cooled water flow is
divided in to two flow paths as follows:
1. Path 1 cools the stator windings. This flow path first
passes to a water manifold on the exciter end to the generator and from
there to the stator bars via insulated hoses. Each individual bar is
connected to the manifold by a separate hose. Inside the bars the cooling
water flows through hollow strands. At the turbine end, the water is
passed through similar hoses to another water manifold and then returned
to the primary water tank. Since a single pass water flow through the

59
stator is used, only a minimum temperature rise is obtained for both the
coolant and bars. Relative movements due to the thermal expansions
between the top and bottom bars are minimized.
2. Path 2 cools the phase connectors and bushings. The
bushings and phase connectors consists of thick walled copper tubes
through which the cooling water circulated. The six bushings and the
phase connectors arranged in a circle around the stator end winding are
hydraulically interconnected so that three parallel paths are obtained. The
primary water enters three bushings and exists from the three remaining
bushings.
The secondary water flow through the primary water cooler should be
controlled automatically to maintain a uniform generator temperature
level for various loads and cold water temperatures.

END WINDING VIBRATIONS

In case of power generating equipments, especially with the large
generators high reliability is one of the single most important factor.
Higher and higher outputs are achieved by introducing more effective
cooling methods and winding insulation materials. Since electromagnetic
forces are the function of the square of current. Stator windings have to
withstand higher vibratory forces continuously during its operation as
well as extremely large transient short circuit forces. These vibratory
forces not only generate dynamically mechanical stress in the winding
and support system, also causes friction in the adjacent bodies especially

60
in the overhang portion which vibrate with a differential phase
relationship. The excessive vibrations may lead to abrasion of the
insulation. In case of water cooled generators, these vibrations causes
cracks in winding, water conducting components like copper tubes,
Teflon hose joints, lugs etc. resulting in the hydrogen leakage, which is at
pressure higher than that of cooling water.
Stator winding overhang is very important for the consideration of
vibrations, because of its long unsupported portion. It consists of a
number of high current carrying conductors. This overhang is in the form
of conical basket fixed at the core end where as other end remains
unsupported. The whole structure is clamped together with the help of
support brackets and the coil overhang is fixed with the help of bracing,
clamping bolts etc.
Under normal conditions this overhang vibrates at 50 Hz due to the forces
between the current carrying conductors as well as the vibrations
transmitted to the core. If these vibrations are heavy, the insulation of the
winding in the overhang portion may fall due to the rubbing of
conductors and may break due to fatigue. But the design takes care of
these forces and resulting vibrations. The claming item is designed to
withstand these stresses. However over a along period of the time the
bracing may become loose resulting in increased vibration level. Heavy
vibration especially under the short circuit condition, are experienced and
whole the conical basket as a tendency to open out.
Stator end windings are subjected to three different vibratory forces:

61
1. Pulsating forces during start-up , shut down and normal operation.
2. Forces resulting from the restrained thermal expansion, which
depends upon generator load and coolant temperature.
3. Electromagnetic forces arising from abnormal operating
conditions especially during short-circuit conditions during
synchronization

SUPERVISION OF GENERATOR
Temperature Monitoring
1. Stator slot temperature: The slot temperatures are
measured with resistance temperature detectors (RTD'S). The platinum
measuring wire is embedded in a molded plastic body which provides for
insulation and pressure relief.
The RTD's are embedded directly in the stator slots between the bottom
and top bars at points where the highest temperatures are expected.
The RTD's are characterized by constant temperature vs. Resistance
characteristic, high mechanical strength and insensitivity to electrical and
magnetic fields.

2. Cold and Hot Gas Temperatures: The temp of the hot

and cold gasses is measured by RTD's upstream and downstream of the
hydrogen coolers, and the limit values are sensed with rod-type
thermostats. Separate RTD's are provided downstream of the coolers for
use with the hydrogen temp. Control system.

62
Temperature detectors located in the generator interior are mounted in gas
tight protective tubes welded to the stator frame
Thorough investigation and researches. As the end is subjected to
maximum vibrations as well as heating the end packets are made in form
Of monolithic pen cake using grade epoxy varnish. This type of design
allows the uniform transfer of pressure from press ring to complete core
And resists vibration at the same time approving heat transfer at the end
zone of the core. Natural frequency and stator body is kept away from
100 c/s per sec. The complete core is compounded with the help of a
bitumen compound in three stages. The main insulation is applied by
means of mica taping machine. After the final compounding the stator
winding bar is coated with anti corona coating paint which provides a
gradual potential gradient across the thickness of the insulation. The semi
conducting paint at the outlet of the slot is of different type so as to have
the smooth gradient of the Electro static field at the outlet from the slot.
B.H.E.L. has planned change over to epoxy mica thermosetting insulation
for stator bars. In the case of manufacture of the stator winding bar
special attention is paid to the quality of materials and for carrying out the
control, various inter stage manufacturing tests are introduced, some of
them are enumerated as follows :

63
64
 ROTOR SHAFT
The cylindrical rotor with non-salient pole forms one of the most
important parts of the turbo generator, which is loaded to the maximum
limit of mechanical strength of the material as well as heat transfer
capability. Due to the high speed of rotation high mechanical centrifugal
stresses are encountered in the rotor teeth as well as in the rotor retaining
ring. The rotor shaft is forged from a vacuum cast steel ingot.
The rotor shaft consists of an electrically active portion, the so
called rotor body, and the two shaft journals. Integrally forged flange
couplings to connect the rotor to the turbine and exciter are located
outboard of the bearings. Approximately two-thirds of the rotor body
circumference is provided with the longitudinal slots which hold the field
winding. Slot pitch is selected so that the two solid poles are displaced by
1800.
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 al twice the system
frequency. To reduce these vibrations, the deflections in the direction of
pole axis and the neutral axis are compensated by transverse slotting of
the pole.
The solid poles are also provided with the longitudinal slots to
hold the copper bars of the damper winding. The rotor wedges act as a
damper winding in the area of winding slots.

65
 After completion, the rotor is balanced in various planes at
different speeds and then subjected to an over speed test at 120% of rated
for two minutes
High mechanical properties. The composition of alloy steel used for
forging gives the following properties:
1. Tensile strength (UTS): 75 to 83 Kg. /mm2
2. Yield point: 55 to 68 Kg. /mm2
3. Relative elongation: 16% min.
The rotor forging is heat-treated and stress relieved at the forging plants
and is tested for the absence of various defects by conducting the
following test:
1. Ultra-sonic test
2. Sulpher prints
3. Check for residual stress
4. Test for mechanical strength

The rotor forging, before is dispatched to the manufacturing plant is heat

stabilized at 400 to 500 degree Centigrade on a special furnace where the
rotor rotates at a slow speed of 2 to 4 rpm. This heat stabilization avoids
permanent deformation of the shaft, which may be caused after the rotor
completely ready. The rotor is machined on the lathes followed by the
machining of the rotor slots on the special milling machine. The depth of
the rotor slot is governed by the thickness of the teeth at the root, which

66
depends upon the allowable mechanical stresses at this point. The rotor
winding in turbo generator is manufactured from
Silver bearing copper. It consists of 9 coils, each having seven turns.
The silver in small percentage of 0.6 to 1% added to increase softening
temperature encountered in operating life of the machine. The winding is
formed in the form of half coils, which are insulated by means of glass
textolite formed along with each turn of coils. Each coil is laid in the
rotor slot and is insulated from the steel of the rotor body by means of 'U'
shape slot trough.

ROTOR SHAFTS

ROTOR WINDING

Construction of Rotor bar

In the 500MW turbo generator, there are two poles in the rotor
and there are seven coils in each pole. The seven coils named as A, B, C,
D, E, and F & G. A coil has six conductor and remaining six coils have
nine conductors. The conductors are made of copper with a silver content
of approximately 0.12%. as compare to electrolyte copper, silver alloyed
copper features high strength properties at high temperatures so that coil

67
deformations due to thermal stresses are eliminated. For manufacturing
the rotor bars, the number of operations are as follows:
1. Number punching: Pole number, coil number and conductor
number are punched on the coil.
2. Marking: Center line of coil and centers of gas inlets are marked.
3. Drilling of gas inlets & outlets: For the passage of gas ducts are
formed having diameter of 21mm &25mm.
4. Chamfering on gas outlets and inlets: Cooling ducts edges are
chamfered.
5. Deburring: After drilling and chamfering, extra chips on the bar are
removed by using rubbing paper.
6. Cleaning of canal by brush passing: A brush is passed through the
canal to remove the chips.
7. Rinsing in trichloroethylene: to remove oil, grease bars are rinsed
in trichloroethylene.
8. Filling and caucking of fillers: Fillers are filled in the ducts for
providing appropriate path to the gas.
9. Annealing of ends: ends are heated up to 500-5400C and then
quenched in water.
10. Edge wise bending: Bars are bended at the end portion according to
the proper marking.
11. Pressing of bends: bends are presses to adjust the increased
thickness at the bend portion up to normal thickness.
12. Annealing of overhang portion:

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13. Radius bending: Cylindrical forming is done and length of bar is
maintained.
14. End cutting milling of overhang portion:
15. Filler brazing: To cover the empty space an extra conductor
16. Deburring:
17. Cleaning of canal by brush &compressed air:

WINDING
Construction: The field winding consists of several coils inserted in to
the longitudinal slots of the rotor body. The coils are wound around the
poles so that one north and one south magnetic pole is obtained.
The hollow conductors have a trapezoidal cross-section and are provided
with two cooling ducts of approximately semi-circular cross-section. All
conductors have identical copper and cooling duct cross-sections.
The individual conductors are bent to obtain half turns, after insertion in
to the rotor slots, these turns are combined to form full turns, and the
series connected turns of one slot constituting one coil. The individual
coils of the rotor winding are electrically series connected.

Insulation: The insulation between the individual turns is made of

layers of glass fiber laminate. The coils are insulated from the rotor body
with L-shaped strips of glass fiber laminate with nomex filler. To obtain

69
the required creep age paths between the coil and the frame, thick top
strips of glass fiber laminate are inserted below the slot wedges. The
spaces between the individual coils in the end winding are filled with
insulating members which prevent coil movement.

Rotor slot wedges: To protect the winding against the effects of the
centrifugal force, the winding is secured in the slots with wedges. The
slot wedges are made from a copper-nickel-silicon alloy featuring high
strength and good electrically conductivity, and are used as damper
winding bar. The slot wedges extend below the shrink seats of the
retaining rings. The rings act as short-circuit rings to induced currents in
the damper windings.

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 unobstructed shaft deflection al the end windings.

70
 The shrunk on the end ring at the free 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 for additional
protection against axial displacement of the retaining ring.
To reduce the stray losses and retain strength, the rings are made
of non-magnetic cold-worked material. The retaining ring shrink-fit areas
act as short-circuit rings to induced currents in the damper system. The
shrink seats if the retaining ring are coated with nickel, aluminum and
silver by a three-step flame spraying process.

FIELD CONNECTIONS
The field current is supplied to rotor winding through radial terminal
bolts and two semicircular conductors located in the hollow bores of the
exciter and rotor shafts. The field current leads are connected to the
exciter leads at the exciter coupling with Multikontakt plug in contact
which allows for unobstructed thermal expansion of the field current
leads.
FANS
The generator cooling gas is circulated by an axial-flow fan located on
the turbine end shaft journal. To augment the cooling of the rotor

71
Winding, the pressure established by the fan works in conjunction with
the gas expelled from the discharge ports along the rotor.
The moving blades of the fan are inserted into T-shape grooves
in the fan hubs. The fan hubs are shrink-fitted to the shaft journal spider.
The generator cooling gas is circulated by two single stage axial flow
propeller type fans. The fans are shrinking fitted on either side of rotor
body.

Fan hubs are made of alloy steel. Fan blades which are precision
Castings with special alloy are machined in the tall portion. To check the
fan blades from coming out of the hub, ground tapered pins are used by
reaming the two components together.

ROTOR COOLING SYSTEM

For direct cooling of the rotor winding, cold gas is directed to the rotor
end windings at the turbine and exciter ends. The rotor is symmetrical
relative to the generator centre line and pole axis. Each coil quarter is
divided in to two cooling zones. The first cooling zone consists of the
rotor end winding and the second one of the winding portion between the
rotor body end and the mid point of the rotor. Cold gas is directed to each
cooling zone through separate openings directly before the rotor body
end. The hydrogen flows through each individual conductor in closed
cooling ducts. The heat removal capacity is selected such that

72
approximately identical temperatures are obtained for all conductors. The
gas of the first cooling zone is discharged from the coils at the pole centre
in to a collecting compartment with in the pole area below the end
winding. From there the hot gases pass in to the air gap through pole face
slots at the end of rotor body. The hot gas of the second cooling zone is
discharged in to the air gap at mid-length of the rotor body through radial
openings in the hollow conductors and wedges.

73
 ACTIVITIES ON THE ROTOR SHAFT

• Deburring and cleaning of rotor shaft.

• Painting of rotor shaft.

• Assembly of field lead bar.

• Lying of coil.

• Inter coil connection.

74
• First pressing (heating & curing).

• Dismantling the fixture, liner measurement.

• Slot liner preparation & fitting of overhang portion.

• Drilling of centre wedges.

• Slot wedging, preparation of FLCB.

• FLCB & CC bolt assembly, He leakage test.

• Brazing connection piece & second pressing.

• Preparation for retaining ring mounting.

• Dry out & H.V. test.

• Intermediate ring & compressor hub mounting.

• Drilling and locking of compressor hub.

• Silver plating of axial hole.

• Balancing

75
• Polishing & Run out check.

• Final H.V. test & He test.

• IR test & Impedance test

BEARINGS
The generator rotor is supported on the end-shield mounted on the journal
bearings on both ends. A third bearing is located between the exciters. To
eliminate the shaft currents all the bearings are insulated from the stator
frame and foundation plates resides inside to eliminate shaft currents. A
temperature sensing thermocouple is embedded in the lower bearing
sleeve so that the measuring points are located directly below the Babbitt.
Vibrations of the bearings are measured by vibration pick-ups. The two
generator bearings and exciter bearings are connected to turbine oil
assembly.

SHAFT SEALS
Shaft seals are provided at the points where the rotor shaft passes through
the stator casing. These radial seal rings are guided in the seal carrier
rings which in turn are bolted to the end shields. These are insulated to

76
prevent the flow of shaft current. The seal rings are lined with Babbitt in
the shaft journal side and the gap between the seal ring and the shaft is
kept optimum to provide effective sealing by forming a continuous stable
oil-film.

77
 AUXILLARY SYSTEMS
GAS SYSTEM
The gas system consists of following components:

78
• CO2 system
• H2 system
• N2 system
• Compressed air supply
• Gas dryer

CO2 system: Carbon dioxide shall be made available with a purity ≥

99.9% v/v. the remaining 0.1% v/v shall be free of ammonia, sulphur
dioxide. Gauge pressure should be in between 1 to 2.5 bar.
As a precaution against explosive mixtures, air must never be
directly placed hydrogen during generator filling. The generator must be
scavenged or purged with an inert gas, carbon dioxide being used for this
purpose. The carbon dioxide is supplied in steel bottles in the liquid state.
The bottles should be provided with the riser to ensure complete
emptying. The liquid gas is stored under pressure is fed to the gas valve
rack via a shutoff valve.

H2 system: The hydrogen gas shall be made available with a purity ≥

99.9% v/v. the remaining 0.1% v/v shall be free of ammonia, sulphur
dioxide. Gauge pressure should be in between 8 to 9 bar.
The hydrogen bottles are connected to the manifold on the bottle
rack. Valves on the bottle and valves on the manifold allow replacement

79
of individual bottles during operation. The hydrogen is stored in the steel
bottles at a very high pressure.
N2 system: The nitrogen gas shall be made available with a purity ≥
99.9% v/v. the remaining 0.1% v/v shall be free of ammonia. Oxygen
and water must not applicable.
The nitrogen purge during initial operation ensures a complete
removal of oxygen from the primary water circuit, thus eliminating the
risk of corrosion attack.
The nitrogen purge during the shutdown prevents the formation of an
explosive hydrogen-air mixture, during operation hydrogen may enter in
to the primary water tank by diffusion at the insulating hoses.
The nitrogen available from a bottle is passed to a pressure reducer for
expansion and admitted in to the primary water tank via nitrogen supply
line.
Compressed air supply: To remove the carbon dioxide from the
generator, a compressed air supply with compressed air filter is connected
to the general air system. Under all operating condition, except for carbon
dioxide purging, the compressed air hose between the filter and the
generator pipe system should be disconnected.

Gas dryer: A small amount of the hydrogen circulating in the generator

for cooling is passed through a gas dryer. The gas inlets and gas outlets
pipes of the gas dryer are connected at points of the generator with

80
different static heads, so tat the gas is forced through the dryer by the
differential pressure only.
The gas dryer is a pressure-resistant chamber filled with
moisture adsorbent material. The absorbent material can be reactive at
any time when the generator is running by means of a heater, a fan and a
changeover valves.

81
82
 BRUSHLESS 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:
The merits of brush-less excitation system are:-
(a) Completely eliminates brush gear, slip rings, field breaker and
excited bus or cable.
(b) Eliminates the hazard of changing brushes and leads.
(c) Carbon dust is no longer produced and hence the operation is
fully dust free.
(d) Brush losses are eliminated.
(e) Operating costs are reduced.
(f) The system is best suited for atmospheres contaminated with oil,
salt, chemical etc.and where sparking may be a fire hazard

83
(g) The system is simple and requires practically no maintenance
except for an occasional inspection. Maintenance costs are thus reduced.
(h) Ideally suited for locations where maintenance is likely to be rare
due to continuous demand on the m/c.
(i) Brush-less system with shaft mounted pilot exciter is of self
generating type and the excitation is unaffected by system faults and
disturbances.
(j) Reliability is better.
(k) Ideally suited for large sets.
(l) 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 by the permanent magnet
pilot exciter is rectified and controlled by AVR to provide a variable dc
current for exciting the main exciter. The three phase ac induced in the
rotor of the main exciter. The three phase ac induced in the main exciter
is rectified by the rotating rectifier bridge and fed to the field winding of
the generator rotor through the dc leads in the rotor shaft.
A common shaft carries the rectifier wheels, the rotor of the main
exciter and the permanent rotor of the pilot exciter. The shaft is rigidly
coupled to the generator rotor. The exciter shaft is supported on a bearing

84
between the main and pilot exciters. The generator and exciter rotors are
supported on three bearings.
Mechanical coupling of the two shaft assemblies results in simultaneous
coupling of dc leads in the central shaft bore through the Multicontact
electrical contact system consisting of plug-in bolts and sockets. This
contact system is also designed to compensate for length variations of the
leads due to thermal expansion.
The various components of the brushless exciter are

• Permanent magnet pilot exciter

• Automatic voltage regulator
• Slip rings for field ground fault detection
• Three phase main exciter
• Rectifier wheels
• Cooling system

PERMANENT MAGNETIC PILOT EXCITER

The three phase pilot exciter is a 16 poles revolving-field unit. The frame
accommodates the laminated core with the three phase winding. The rotor
consists of hub with mounted
Poles. Each pole consists of 12 separate permanent magnets which are
housed in a non-magnetic metallic enclosure. The magnets are braced
between the hub and the external pole shoe with bolts. The rotor hub is
shrunk on to the free shaft end.

85
 PMG

AUTOMATIC VOLTAGE REGULATOR

Also known as thyristor voltage regulator. It converts the three phase ac
generated by the permanent magnet exciter in to the variable dc to excite
the stator of the main exciter.

SLIP RINGS FOR FIELD GROUND FAULT

DETECTION
The field ground fault detection system detects the high-resistance and
low -resistance ground fault in the exciter field circuit. It is very
important for safe operation of a generator, because a double fault causes
magnetic unbalances with very high currents flowing through the faulted
part, resulting in its destruction with in a very short time. The field
ground fault detection system consists of two stages.
If the field ground fault detection system detect a ground fault, an alarm
is activated at R< 80 kΏ. If the insulation resistance between the exciter
field circuit and ground either drops to R< 5 kΏ the generator electrical
protection is tripped. The generator is automatically disconnected from
the system and de-excited.

THREE PHASE MAIN EXCITER

86
The three phase main exciter is a six-pole revolving armature unit.
Arranged in the stator frame, the poles with field and damper winding.
The field winding is arranged on the laminated magnetic poles. At the
pole shoe, bars are provided. Their ends being connected so as to form a
damper winding between two poles. A quadrature-axis coil is fitted for
inductive measurement of the exciter current.
The rotor consists of stacked laminations, which are compressed
through bolts over compression rings. The three-phase winding is inserted
in the slots of the laminated rotor. The winding conductors are transposed
with in the core length, and the end turns of the rotor winding are secured
with steal bands. The connections are made on the side facing the rectifier
wheels. The winding ends are run to a bus ring system to which the three
phase leads to the rectifier wheels are connected. After full impregnation
with synthetic resin and curing, the complete rotor is shrunk onto the
shaft. A journal bearing is arranged between main exciter and pilot
exciter and has forced oil lubrication from the turbine oil supply.

RECTIFIER WHEELS
The main component of the rectifier wheels are the silicon diodes which
are arranged in the rectifier wheels in a three-phase bridge circuit. The
contact pressure for the silicon wafer is produced by a plate spring
assembly. The arrangement of the diodes is such that this contact pressure
is increased by centrifugal force during rotation. Two diodes are mounted
in each aluminum alloy heat sink and connected in parallel. Associated

87
with each heat sink is a fuse which serves to switch off the two diodes if
one diode fails.
For suppression of the momentary voltage peaks arising from
commutation, each wheel is provided six RC networks consisting of one
capacitor and one damping resistor each, which are combined in a single
resin encapsulated unit.
The insulated and shrunken rectifier wheels serves as dc buses for the
negative and positive side of the rectifier bridge. This arrangement
ensures good accessibility to all components and a minimum of circuit
connection. The two wheels are identical in their mechanical design and
differ only in the forward directions of the diodes.
The direct current from the rectifier wheels is fed to the leads arranged
in the center bore f the shaft via radial bolts. The three phase alternating
currents is obtained via copper conductors arranged on the shaft
circumference between the rectifier wheels and the three-phase main
exciter. The conductors are attached by means of banding clips and
equipped with screw on lugs for the internal diode connections. One
three-phase conductor, each is provided for the four diodes of a heat sink
set.

RECTIFIER WHEELS

COOLING SYSTEM

88
The exciter is air cooled. The cooling air is circulated in a closed circuit
and recooled in two cooling sections arranged along side the exciter. The
complete exciter is housed in an enclosure draw the cool air in at both
ends and expels the warmed air to the compartment beneath the base
plate.
The main exciter enclosure receives the cool air from the fan after it
passes over the pilot exciter. The air enters the main exciter from both
ends and is passes in to the ducts below the rotor body and discharged
through radial slots in the radial core to the lower compartment. The
warm air is then returned to the main enclosure via the cooler section.

SUPERVISION OF EXCITER
The most essential measuring and supervisory devices at the exciter are:
Temperature monitoring system
Fuse monitoring system
Ground fault detection system
Excitation current measuring device
1. Temperature monitoring system: The exciter is provided with
devices for monitoring the temperatures of the cold air after the exciter
cooler and the hot air leaving the rectifier wheels and main exciter.

89
2. Fuse monitoring system: The indicator flags of the fuse on the
rectifier wheels may be checked during operation
3. Ground fault detection system: Two slip-rings are installed on the
shaft between the main exciter and the bearing. One is connected to star
point of the three-phase winding of the main exciter and the other to the
frame. These slip-rings permit ground fault detection.
4. Excitation current measuring device: the excitation current is
measured indirectly through a coil arranged between two poles of the
main exciter. The voltage induced in this coil is proportional to the
excitation current thus enabling a determination of the excitation current.

BRUSHLESS EXCITER

QUALITY
QUALITY ASSURANCE: BHEL’s quality objective is to achieve and
sustain a reputation for quality at competitive prices in the national and

90
international markets for its entire product range. From concept to
commissioning of its products BHEL is totally committed to quality.
BHEL's carefully monitored quality program begins with the receipt of
materials. A full-fledged Goods Inspection Cell of quality
Control working in liaison with the laboratories carries out stringent
acceptance tests to ensure that only the best quality material is available
for processing. Manufacturing processes are closely monitored to see
That there is strict adherence to the specifications and test requirements
including the surveillance of storage and preservation of finished goods.

VACUUM PRESSURE IMPREGNATION SYSTEM:

Such systems generally utilize optimum quantity of resin adduct along
with accelerator/ catalyst as a binder for the tapes for ease of handling
and taping. For injection of bonding resin into the porous insulation,
normally epoxy resins with anhydride curing agents or polyester resins
with corresponding curing agents have been used. These impregnating
compounds and curing enable to obtain thermosetting insulation systems
meeting the desired thermal class.
For class F insulation, normally solvent less epoxy resin with anhydride
hardeners is used. The lowest vapor pressure of accelerator/ hardener
present in the impregnate determines the level of vacuum for volatile
removal..

91
INSULATION SYSTEM WITH VPI TOTAL
IMPREGNATION
In this system the bare copper conductor is insulated with glass/ polyester
backed mica paper tape containing suitable accelerator to provide
sufficient turn insulation.
Stack of the slot portion is consolidated in the boat shape by using hot
curing epoxy polyester fleece prepare with hot pressing on the heated
hydraulic press. Further the coil boats are pulled to the required shape on
coil pulling m/c. Overhang and slot portions are then insulated with
accelerator containing resin poor mica tape. Slot corona protection and
end corona protections are applied with a suitable overlap. Overhang of
the coils is finally provided with a diffusion barrier tape to prevent the out
flow of epoxy impregnate from the insulation. The coils are tested for
inter-turn with impulse voltage and for main insulation with DC high
voltage.
These insulated coils are then laid in the stator with suitable packing. The
top of the slot is filled by hot curing magnetic putty for reducing noise
and improving efficiency. This is cured before impregnation of the
wound stator.
Overhang bracing is provided by porous and compressible glass hard mat
spacers containing accelerator. These spacers provide very Good bonding
b/w the coil sides as these are having tendency to swell on impregnation.
Finally, the wound stator is impregnated under vacuum and pressure in

92
epoxy impregnating resin. After completion of impregnation process the
wound core is cured.

STUDY OF A.C. MOTORS

A.C. MOTORS:
BHEL Haridwar stands out as an outstanding example in develop- ment
of AC Machines. First AC machine to role out of the plant was; a 66 kW,
low voltage, flame proof AC motor for MAMC, Durgapur during 1967.
Since then there is no looking back. Rapid strides have been made, both
in design as well as manufacture. Nearly 200 designs have been
developed and more than 2800 A.C. motors; with different mountings,
enclosures and cooling arrangements, manufactured and supplied so far;
for driving fans, pumps, mills, compressors, M-G sets etc. in Thermal and
Atomic Power plants; core industries like Steel, Cement, Coal / Mining,
Fertilizers and Refineries; Metallurgical plants; Paper and Rubber
industries; Irrigation scheme and so on.
BHEL Haridwar is fully equipped with all the facilities to
manufacture AC motors of ratings 150 to 20000 kW. For over past two
decades, the plant has been making efforts to develop medium and large
capacity AC motors.

The present manufacturing range is given below:

Squirrel cage Induction Motors - 150 to 20,000 kW
Slip ring Induction Motors - 200 to 10,000 kW

93
Synchronous Motors - 500 to 20,000 kW

DEVELOPMENT OF A.C. MOTORS

Manufacture of AC motors commenced in BHEL at Bhopal plant in 1965
& at Haridwar plant in 1967 with USSR collaboration. These
technologies were fully absorbed and extensive work in the field of
indigenization carried out. Besides this, in-house developments to meet
specific requirements of the customers also continued

MEDIUM CAPACITY CLASS ‘B’ SERIES

During early 70’s nearly 200 design variants in capacity range of 355 to
1400 kW, were worked out on series basis to bridge the gap in the
database provided by the collaborators. All the designs of this series
Were developed using conventional motors, from this class ‘B’ series,
have been supplied to various Cement and Rubber plants all over the
country.

INTRODUCTION TO CLASS ‘F’ INSULATION

Simultaneously, Class’F’insulation materials and systems were
introduced in the existing Class‘B’designs pertaining to medium & large

94
size Horizontal & Vertical AC motors. Now, we are in position to convert
and supply all the AC motors with class ‘F’ insulation.

LARGE SLIP RING MOTORS :

Five designs of large size slip ring Induction motors have also been
developed using Class‘F’insulation and more than 20 motors have been
supplied to various plants.

LARGE SQUIRREL CAGE INDUCTION MOTORS:

Besides above, large AC motors with pedestal bearings using Class ‘F’
insulation have now been provided with rolling bearings housed in end-
shields. This has made the design more compact and eliminated provision
of forced oil lubrication etc.

SYNCHRONOUS MOTORS:
AC synchronous motors of few specific designs have also been
manufactured and supplied to various plants. The notable ones are; 10.8
MW, 2 pole, non-salient pole motor; 9 MW, 12 pole, salient pole motor
and 1600 kW, 8-pole sync. Induction motor.

FLAME PROOF MOTORS:

Low as well as high voltage flameproof motors in capacity range of 50 to
400 kW, have already been developed at BHEL, Haridwar. More than
150 motors have been supplied to various mines. The prototypes were

95
successfully tested at Central Mining Research Station, Dhanbad and
certified by Director General of Mines Safety These motors also bear ISI
mark / certification.

VERTICAL MOTORS :
Strides made in the design of medium and large size Vertical Squirrel
cage induction motors have been even more rapid.

LARGE
Based on Soviet designs of large vertical motors, nearly 30 designs; in
capacity range of 400 to 1560 kW with CACA, SPDP, CACW enclosures
have been developed and supplied to various projects. The designs
received from Soviet union employed guide bearings. These were
substituted by rolling bearings. This resulted in compact and simplified
construction with considerably less maintenance problems.

MEDIUM
These designs were developed entirely with indigenous efforts with
rolling bearing arrangements. More than 90 motors; comprising of 6
designs, supplied from the plant are satisfactorily driving condensate
extraction and circulating water pumps at various Thermal Stations.

96
 TOWARDS NEW TECHNOLOGY
In order to keep abrest with the new technology & rapid advance- ments
taking place in the field of insulation in different parts of the world,
BHEL entered into collaboration with Siemens, West Germany in the
area of AC & D.C. machines. New modern facilities have been added at
BHEL, Haridwar plant to augment the quality and reliability of AC
motors. More than 1000 motors have already been successfully designed
and manufactured based on new philosophy.

SPECIAL DESIGN MOTORS

The capacity range of special design motors extends up to 20,000 kW,
with SPDP and CACA enclosures. These are tailor made designs to suit
the specific requirements of the customers both in horizontal and vertical
motors.

NEW SERIES OF AC MOTORS

Based on types of construction and cooling arrangements, various types

of motors are broadly classified as under:-
• L-Series
• R-Series

97
Following are the general Features of above Series of motors:

• Compact Construction
• Torsion ally rigid, robust frame.
• Class-F, Micalastic insulation based on VPI technology.
• Magnetic slot sealing in stator for low stray losses & Noise and high
efficiency.
• Improved efficiency
• Low noise level with means for further reduction.
• Steel liners used around rotor bars to ensure bar tightness.
• Rotor bars - SC Ring joints inductively brazed and ultrasonically
tested
• Rotors dynamically balanced at rated speed
• Terminal boxes and standard monitoring devices as per customer
requirements.
• Shaft height and fixing dimensions as per IEC / IS Standards
• Motor shipped completely assembled for quick and easy
installation at site

Following are the special features of L & R series of motors:

L-Series:

98
These are medium size motors with horizontal (IMB3) and Vertical
(IMV10) mountings having IP-55 degree of protection and IC511 cooling
arrangement.
The stator frame is of welded construction. The axial cooling tubes are
expanded into the end walls of the stator frame which forms a concentric
tube nest cooler. These machines have closed circuit cooling with a
concentric tube nest cooler, which forms an integral part of the frame and
with shaft mounted external and internal fans.
The internal cooling air (double-ended, symmetrical cooling system)
flows thorough radial ducts in the rotor and stator cores and thus,
transfers the heat to the cooling tubes. A parallel stream of cooling air
flows over the stator winding overhang and transfers the heat generated at
these points to cooling tubes.
An external radial-flow fan, fitted beyond the non-drive end bearing,
blows fresh air thorough the cooling tubes and thus the heat is dissipated
to the outside atmosphere.

Technical Data:
Ratings: 150 to 5000 KW
Voltages : 3.3 to 11 KV, 50 HZ.
No. of poles : 2 to 18 poles.
Shaft Heights : 560, 630, 710, 800, 900 mm
Bearings : Rolling / Sleeve Bearings

99
R- Series:
These are medium and large size motors with horizontal (IMB3) and
Vertical (IMV10) mountings.
These motors are designed on modular concept to adapt to various
degrees of protection and cooling arrangements i.e. in SPDP, CACW &
CACA enclosures with top or side mounted coolers.

THE INSULATION SYSTEMS OF ELECTRIC

MOTORS
BHEL is engaged in the design and manufacturing of electric motors
since past more than 3 decades. Modern electric motors are subjected to
frequently variable high level stresses with large amount of power packed
in a small volume and improved insulation system.
In the insulation system of electric motors there have been major
developments through introduction of improved materials, technologies
and processes resulting in significant improvements in electrical,
mechanical and thermal characteristics as well as performance reliability
of insulation. The advancements have led to reduction in manufacturing
cycles, use of environmental friendly materials, more compact designs
etc.

INSULATION SYSTEMS FOR HIGH VOLTAGE

STATOR WINDINGS:

100
High voltage insulation basically comprises of three main components,
which are:
• Mica as main insulation.
• Carrier to support mica and hold the binder.
• A binder to bond the mica and carrier together.
Continuing demand for greater output from a given frame size has led to
the need for finding space for more active material in the slot and also
operation at higher temperature. With the advancement and developments
in material science and technology to overcome the limitations of
bituminous insulation system with respect to growing demand, epoxide
insulation system was established in mid seventies.

VACUUM PRESSURE IMPREGNATION SYSTEM

Such systems generally utilize optimum quantity of resin adduct along
with accelerator/ catalyst as a binder for the tapes for ease of handling
and taping. For injection of bonding resin into the porous insulation,
normally epoxy resins with anhydride curing agents or polyester resins
with corresponding curing agents have been used. These impregnating
compounds and curing enable to obtain thermosetting insulation systems
meeting the desired thermal class.

For class F insulation, normally solvent less epoxy resin with anhydride
hardeners is used. The lowest vapors pressure of accelerator/ hardener
present in the impregnate determines the level of vacuum for volatile

101
removal. The components of tapes namely mica paper, bond and backing
material have considerable influence on the short term characteristics and
long time endurance.

SALIENT FEATURES OF VPI PROCESS

• Coils are laid in the stator still in the flexible condition and can
easily be inserted into the core slot and further forming of insulated and
cured coil is no longer necessary.
• In this system the winding overhang bracing is also impregnating
resulting in very high mechanical strength and better resistance against
short circuit stresses.
• Slot portion and overhang portions of the coils are insulated with the
same tape applied continuously. The coil connections, group connections
and phase connections are also taped and impregnated along with the
main insulation resulting in high reliability.
• Due to total impregnation fine resin coating is provided even on the
entire surface of the core which is otherwise difficult to access to paint.

The insulation prepared with VPI process is having better compact- ness
and absence of voids due to complete removal of air and volatile matters
during vacuum phase and complete penetration of resin in complete
matrix of insulation. This insulation system adopted by BHEL is a highly
proven system and has been supported by excellent operational
experience of the machines.

102
The system has better short term as well as long term behavior and longer
operating life. Inter-turn behavior, tan delta values, dielectric loss energy
etc. is better as compared to resin rich insulation system. A typical tan
delta curve of a coil manufactured with VPI system is given:

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 CONCLUSION
As discussed earlier the scope and prospects of B.H.E.L. is very bright.
B.H.E.L. has emerged as the largest engineering and manufacturing
enterprise of its kind in INDIA with an excellent track record
performance. The company is engaged in engineering, manufacture and
development of a wide variety of electrical and mechanical equipment for
generation, transmission and utilization of electrical power and energy.
The company today enjoys the national and international presence
featuring in the 'FORTUNE INTERNATIONAL 500' and is ranked
among the top 12 companies in the world for manufacturing power
generation equipment.
As a part of its continuous journey in attaining excellence in quality
management, HEEP Haridwar has also received with the global
recognition with the award of ISO-9001 certification by Bureau Quality
International for its products.
Only recently in the 1996-97 financial budget, the finance minister Mr. P.
Chidambaram listed B.H.E.L. among the so-called Navratan's or the
leading P.S.Us. B.H.E.L. has the distinction of winning the Productivity
Awards at national level instituted by National Productivity Council in
the field of power generation, transmission and distribution equipment
manufacturing sectors many as 46 employees of B.H.E.L.,
Haridwar have been honored with different awards for there contribution
through innovative suggestions, development of new devices, fixtures,
modifications in designs leading to increased production, productivity

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and improvement in quality besides financial savings to the
organization.HEEP Haridwar has also won no. of national and
international awards, which include Best Material Handling Award
(1989), Best Organization Award (1989), and INSAAN Award for
excellence in Suggestion Schemes (1991).

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 BIBLIOGRAPHY

1) B.H.E.L SITES

2) B.H.E.L. MANUALS

3) P.S BHIMBRA

4) TURBO GENERATOR (500MW) MANUAL

5) DAILY DIARY

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