Manufacturing of Turbo Generators

BHEL-AN OVERVIEW
BHEL is one of the largest power plant equipment manufacturing firms in India and it ranks among the top ten manufacturers globally. BHEL has covered up many power stations over 40 countries worldwide . It progressed rapidly and three more factories went into production in 1965. The aim of establishment BHEL was to meet the growing power requirement of the country.

BHEL manufactured 97% of the power generating equipment that was commissioned in India during 1979-80.

 TURBO GENERATOR
TURBO GENERATOR A turbo generator is a mechanical device that issued to produce electrical power. It does so by turning a large turbine that is connected to a generator, which converts mechanical energy to electrical energy. In a turbo generator turbine is directly connected to an electric generator for the generation of electric power. In Turbo generators a furnace is used and it heats water under high pressure so that it turns into steam

Fig:-Hydrogen Cooled Turbo Generator

 STATOR FRAME
ABOUT
The outer casing is of gastight and pressure resistant welded construction.

The frame is made up of a non magnetic material to prevent the eddy current losses.

 Stator core

The stator core is made of insulated steel laminations. The thickness of the laminations and the type of steel are chosen to minimize eddy current and hysteresis losses To remove the heat, a large number of space segments, are made along whole length of the core to pass the cooling agent through it and keep the stator core cool. The stator core is then

Fig:Rotor.

Horizontal and vertical finishing machine for

 Finished rotor The rotor has 2 large spaced

sides, it creates two poles on the rotor which works as north and south poles when rotor rotates. These special shapes helps the rotor to keep on rotating after initial starting. Windings are placed in these spaces.

 ROTOR AFTER FINAL ASSEMBLY

Coils are placed in the gaps which allows the flow of current when the rotor rotates The hydrogen gas is circulated within the rotor enclosure, and cooled by a

Fig:-

Final assembly of Turbo Generator

Here you can see the turbo generator under its final assembly. The testing of this turbo generator is done at the same place. The central part consists of the cooling system which keeps the rotor cool and for the cooling of the stator part tubes are mounted on the stator bars, cooling agents are flown through these tubes which protects the generator from overheating. Its rotor is connected to the motor to check the Turbo generator working properly.

Fig:-

View from the Exciter end.

At this end of the Turbo Generator exciter is connected, the exciter is connected directly to it. As coolant mostly Hydrogen is used. But Air, water, nitrogen etc. can also be used. The tube on the upper part is for the flow of coolant to absorbs heat ,to keep the temperature of the generator below its limits.

can see the internal view of exciter There are the fuses and the capacitors mounted on the exciter part to generate starting toque and fuse to prevent from the over current.

Fig:-

Exciter .
Exciter enables the synchronous generator to generate its own reactive energy. The exciter also regulates its own power.

The following are routine tests on GENERATOR.

1) Mechanical run test and vibration measurement. 2) Short circuit characteristic and losses measurement. 3) Open circuit characteristic and loses measurement 4) Phase sequence check. 5) Shaft voltage measurement 6) Impedance measurement at standstill, at 1/3,2/3 and 3/3 of rated speeds. 7) Insulation Resistance measurement on stator and Rotor winding. 8) PI value measurement. 9) High Voltage Test on stator and rotor winding. 10) RTDs Checks. 11) DC Resistance measurement on stator and rotor winding.

QUERI ES