BHEL was established in the year 1964 and from the year 1974 it started earning profits.

It has 15 manufacturing divisions.8 service Centres across India.BHEL has its market all over the world covering 75 countries producing about 9000 MW of generators to countries such as Malaysia,Iran,UAE,Bhutan.Egypt,New Zealand,Japan,Bangladesh,Kuwait Etc.

BHEL has more than 50,000 employees working in it till December,2011 the total turn-over of the BHEL was estimated to 49,301 crores with the profit of about 6,489.5 crores.
The Domestic customers of the BHEL in the market are NTPC,ONGC,BPCL,NFC,Nuclear power corporation,Reliance,hindustan Oils,oil india,state electric boards,refineries and cement plants.

TURBO GENERATORS-DEFINITION.

PRINCIPLE OF OPERATION.
STATOR. ROTOR. COOLING SYSTEM. EXCITATION SYSTEM. TESTING SYSTEM. INSULATION SYSTEM.

Whenever there is a Relative motion between a conductor and magnet,then an EMF is induced in the conductor.the induced EMF is directly proportionally to the rate of change of flux and the no. of turns.

Turbo-generator is a turbine directly connected to an Electric generator for generation of electric power .large steam powered turboGenerators provide majority of worlds electricity.

Major components of turbo-generators are the Active Parts and the support parts.Stator winding,Rotor winding,Stator core comes under the active parts and stator frame,rotor shaft,rotor retaining rings, Cooling and excitation systems come under the support parts.

Active parts:

Support parts:

Stator core. Stator winding. Stator end cover. RTDS. Rotor winding.

Stator frame. Rotor shaft. Rotor retaining rings. Bearings. Cooling system. Excitation system.

stator frame. Stator core. Stator coils. Stator windings. Stator end covers. Terminal bushings.

Stator frame is the heaviest component of the generator. Consists of two partsbottom part and the top part. Each part consists of end plates,axial ribs and radial ribs. Core is mounted on stator frame.

Manufacturing of the stator core.

Lamination preparation
Assembly of laminations in stator core.

Stator core is the component which supports the stator-coils mechanically and effectively. Stator core is built up of six sectors,each at 60 degres cut.The cut steel is punched for the slots And de-burred upto 5 microns.Depending upon the temperature,laminations are insulated by varnish. In order to minimize hystersis and Eddy current losses of rotating magnetic field;core is built of thin laminations.

Laminations are made up of special silicon steel called cold roll non-grain oriented steel is a special steel consists of 4% silicon. Laminations are then treated with the arrangement of sprinkle the varnish and varnish coat is obtained.At around 300-400 degrees these are dried and finally two coating of varnish is obatained till 12-18 micro meter thickness.here the varnish we use is Alkyd phenolic varnish. Smoothness of surface called BURR can be eliminated by the De-burring machines and eddy current losses by varrnishing the laminations. Slots are puched on every laminations for the guiding purpose when stator is assembled.

Assembling of the stator core is done by assembling the stator laminations on one onother in a cage without stator frame.To obtain optimum compression and eliminate looseness,laminations are hydraulically compressed and heated. When stacks reach at certain height ;it is kept under pressure and fixed with clamping bolts and pressure plates. Clamping bolts are made up of nonmagnetic steel to prevent allow the flow of eddy currents.In core end portion,the cooling ducts are spaced to ensure more intensive cooling.

Two bars top and bottom bar constitute an Entity called as a coil.High purity(99%) copper conductor strips are used to make the coils,this results in high strength properties at high temperature and also reduces hydrogen and oxygen embattlement in bar. High voltage insulation is provided by mica base of themrmosetting epoxy system tape are applied over bars. To minimize corona dischages between insulation and slot wall;bars are finally wrapped with the semi-conductor tapes.

 Induced copper bars are tranposed 360 degrees to equalize the induced EMF in all strands,to minimize circulating currents,skin effect also minimized and gases good rigidity to bar. Bar winding is called roebel winding.Roebel transposed greatly reduces eddy current losses in conductors.

After insulated bars are placed in slots of stator Core,all gaps and spaces due to design and manufacuring are filled with pads Glass fabric material capable of being impregnated. The bars are shaped so that winding placed in slots,comes in shape and properly shaped windings are obtained.

Stator terminals

Connecting rings

Clamping plates & rings

HGL end windin support

Insulated copper bars Placed in slots to Form 3-phase winding

To fairly manufacture, transport the main sections like stator frame and stator end covers.the stator end covers are attached to end flanges of stator frame and also rest on foundation plate.
End covers are made up of aluminium castings.

Beginning and end of 3-phase windings are brought out of stator frame through bushings,which produces high voltage insulation to stator frame at exciter end.Generator main leads are connected to terminal connectors outside of stator frame.

Rotor function is that it acts like An electromagnet by taking currents from excitation system.it is coupled to turbine to take the driving torque and thus produce a flux,which leads to generation of a current. Rotor is made from vaccum cast steel.About 60% of rotor body circumference have longitudinal slots which holds the winding. Basically there are two types of rotors,They are: salient-pole type rotor. cylindrical pole type rotor

ROTOR SHAFT. ROTOR SLOTS. ROTOR WINDING. ROTOR WEDGES. ROTOR FANS. BEARINGS.

Rotor shaft is made up of degassed alloy steel to impart required mechanical and magnetic properties.

Rotating fans are attached to shaft by means of keys.The shaft is dimensioned as required for torque to be transmitted.

The cuts at the outer periphery of the ring Stampings are uniformly spaced slots accomodating bars of damping winding. Number of slots depends on the number of poles,accommodate the field windings.

Windings of rotor are made of copper with silver contents of approximately 0.1%. When compared to electrolytic copper,silver alloyed and features high strength properties at higher temperature and also thermal stresses are eliminated.

Rotor wedges are made of alluminim bronze with trapezoidal shape.they are tight is slots and are in discrete length.They are mechanically strong,having good electric conductivity and nonmagnetic properties. Cooling gas discharges into air gap through the holes drilled in the wedges.

The concentric shaped overhang of the rotor winding is retained in place against centrifugal force by non-magnetic cold expanded steel rings called retaining rings. The high quality of rings are ensured by mechanical and non-destructive tests.The wedges and the retaining rings ensure the damper circuit of the rotor.

Two axial flow fans located on shaft at both end to circulate the generator cooling air. Fans consists of aluminum alloy die forged blades fixed to the hub through its bolts.

Cooling is the basic requirement of any generator, effective working of a generator depends on the cooling system only.

Iron losses.

a) Hystersis losses
b) Eddy current losses Copper losses. Mechanical loses. These losses in generator are dissipates as heat and it raises the temperature,due to this insulation will be greatly effected,so cooling comes into play effectively here.

Air cooling-60MW. Hydrogen Cooling-100MW.

Water Cooling-500MW.
Hydrogen and water cooling-1000MW.

Capacity of the machine. Losses in the machine.

Size of the machine.

Environment where the machine is used.

In the early 50s,conventional excitation system with D.C exciter enjoyed an unchallenged position and was adopted universally for all turbo-generaors.D.C Excitor were replaced by A.C and then A.C by brushless exciatation to overcome the prob;ems related to commutator and brushless gear.As the brusless excitor failed to suppress the field,so static exciatation system was developed for large and medium turbo-generators upto 1600 MVA.

D.C Excitation system. Brushless Excitation system. Static excitation system.

In the D.C Excitation system,DC exciter is connected to the field winding of turbo generator through a field breaker.Current is current by an automatic voltage regulator depending upon the generator voltage and load parameters.

There are different systems involved in D.C excitation;Some of them are: D.C exciter is separately excited by AVR.PMG provides AC power supply to tht AVR. Exciter has three field windings,Shunt magnetising and demagnetising winding.shunt is connected to armature terminals and other two are connected to AVR. In this system;exciter has two windings,one is connected to compound unit and the other to the AVR.Compound unit takes input from the power transformer.this winding provides about 70% of the excitation power.

Rectifier transformer. Thyristor converter. A field breaker.

An AVR.

Fast response. More efficient and low maintnance

To Ensure that all functional requirements are fulfilled,and to estimate the performance of generator,the turbo-generators are required to undergo some tests.All the components of the turbo-generators are individually tested on the certain conditions and operations. Testing is carried out in three stages;they are: 1.Tests conducted on STATOR. 2.Tests Conducted on ROTOR. 3.ROUTINE TESTS.

First the tests on the stator and the rotor are carried out,then finally routine tests are carried out.

 Testing of turbo-generators stator bars. Testing of turbo generators stator winding.

a) Inter-turn insulation tests. b) ring flux test on stator core.

Testing of Resistance Temperature Detector(RTD).

Testing of turbo-generators rotor winding. High-voltage test.

Mechanical run and measurements of vibrations at rated speed. Short-circuit test. Open-circuit test. High voltage test on stator and rotor windings(at rest).

Each and every component of the turbo-generator is being insulated with the insulating material for the better reliability and continous availability in the service of the stator and rotor.

Insulation system for Stator.

Insulation system for Rotor.

Strand insulation. Turn insulation. Ground wall insulation.

Rotor slot and turn insulation. End winding and blocking. Retaining ring insulation.

A Conductor formed from smaller strands is easier to bend into the required shape than one large conductor.

Stranding a conductor gives a large enough cross sectional area to the conductor and thereby reducing the skin effect and nullifying the losses.

The highest mechanical stresses tend to occur in the coil forming process,which requires the insulation so turn insulation is necessary for the stator. Purpose of the turn-insulation is to Prevent the shorts between the turns in a coil.

Ground wall insulation is the component that separates the copper conductors from the grounded stator core. Ground wall insulation is critical for the operation of a generator.

Corresponding to the voltage level of the machine,the stator coil is to be insulated with suitable layers of kapton mica wrapper. Separation of Nomex are also between top and bottom layer of winding.

Material selected for slot insulation will Vary depending on temperature,voltage and power rating of the machine. Slot insulation has evolved over time from mica splitting composite with craft papers,glass or asbestos cloth or slot armor pieces.

In End winding Insulation;each turn is Separated from adjoining turns by a strip of sheet insulation. The turn-tape is used on every turn outside the slot section which is made up of Bstate epoxy or resin impregnated mica paper.

The retaining rings insulation is inserted between the radial outer of the field coils and the retaining rings. Number of materials have been used for retaining ring insulation.sheet materials made with epoxy and fiber cloth is used.

 The working of the turbo-generator is studied i.e, the stator,

rotor and the excitation system,coling system of the turbo generators

The Testing is one of the important operations of a generator.Testing means examining the different characteristics of generator.

In earlier days mica tapes were used for the insulation But due to newer developments that have been replaced by thermoplastic process of insulation.thermoplastic is no longer used in larger machines and hence thermosetting resin system took place.

Study of turbo-generators gives the overall and operational precautions of large turbo-generators.