JSS ACADEMY OF TECHNICAL

EDUCATION

TRAINING AT :
BHARAT HEAVY ELECTRICALS LIMITED
RANIPUR, HARIDWAR (U.P.)

Name :RAHUL KUMAR GUPTA

Class: IV YEAR
Branch : ELECTRICAL ENGG.
Roll No. : 0709120071

JSS MAHAVIDYAPEETHA
JSS ACADEMY OF TECHNICAL EDUCATION, NOIDA
C-20/1, SECTOR – 62, NOIDA- 201 301
 PREFACE

Practical knowledge means the visualization of the

knowledge, which we read in our books. For this, we perform
experiments and get observations. Practical knowledge is very
important in every field. One must be familiar with the problems
related to that field so that he may solve them and become a
successful person.

After achieving the proper goal in life, an engineer has to

enter in professional life. According to this life, he has to serve an
industry, may be public or private sector or self-own. For the
efficient work in the field, he must be well aware of the
practical knowledge as well as theoretical knowledge.

To be a good engineer, one must be aware of the industrial

environment and must know about management, working in such a
industry, labor problems etc., so that he can tackle them
successfully.
 Due to all the above reasons and to bridge the gap between
theory and practical, our engineering curriculum provides a practical
training of 30 days. During this period, a student works in the
industry and gets all type of experience and knowledge about
the working and maintenance of various types of machinery.
I have undergone my 30 days training (after VI Semester) at
BHARAT HEAVY ELECTRICALS LIMITED. This report is
based on the knowledge, which I acquired during my 30 days
training period at the plant.
 INTRODUCTION

In 1956, India took a major step towards the

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

B.H.E.L appeared on the power map of India in 1969 when the

first unit supplied by it was commissioned at the Basin Bridge
Thermal Power Station in Tamil Nadu. Within a decade, BHEL
had commissioned the 100 unit at Santaldih. West Bengal.
BHEL had taken India from a near total dependence on imports to
complete self-reliance in this vital area of power plant equipment
BHEL has supplied 97% of the power generating equipment.
BHEL has already supplied generating equipment to various
utilities capable of generating over 18000 MW power. Today
BHEL can produce annually; equipment capable of generating
6000MW. This will grow further to enable BHEL to meet all of
India’s projected power equipment requirement. As well as sizeable
portion of export targets.
 Probably the most significant aspect of BHEL’s
growth has been it’s diversification. The constant reorientation of the
organization to meet the varied needs in time with time a
philosophy that has led to the development of a total capability
from concepts to commissioning not only in the field of energy
but also in industry and transportation.

In the world power scene, BHEL ranks among the top ten
manufactures of power plant equipment and in terms of the spectrum
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 one-year. BHEL has its headquarters at New Delhi.
Its operations are spread over 11 manufacturing plants and
number of engineering and service divisions located across the
country/ the service divisions includes a network of regional
branch offices throughout India.
 BHEL-A Brief Profile

BHEL is the largest engineering and manufacturing enterprise

in India in the energy-related / infrastructure sector, today. BHEL is
ushering in the indigenous Heavy Electrical Equipment industry in
India-a dream that has been more than realized with a well-
recognized track record of Performa
A widespread network comprising of 14 manufacturing
companies, which have international recognition for its commitment
towards quality. With an export presence in more than 60 countries,
BHEL is truly India’s ambassador to the world. BHEL’s vision is
to become world class engineering enterprise, committed to
enhancing stakeholder value.
BHEL has:-

 Installed equipment for over 90,000MW of power

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

The first plant of what is today known as BHEL was established

nearly 40 years ago at Bhopal & was the genesis of the Heavy
Electrical Equipment industry in India.

BHEL is today the largest Engineering Enterprise of its

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

BHEL business operations cater to core sectors of the Indian

Economy like.

 Power

 Industry

 Transportation

 Transmission

 Defenses etc.
Today BHEL has

 14 Manufacturing Divisions

 9 Service Centers

 4 Power Sector Regional Centers

 150 Project sites

BHEL’s vision is to become world -class engineering

enterprise, committed to enhancing stakeholder value. The
greatest strength of BHEL is its highly skilled and committed
44,000 employees.

Spread all over India & abroad to provide prompt and effective
service to customers.
BUSINESS SECTOR

BHEL operations are organized around business sectors to

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

POWER SECTOR

Power sector comprises of thermal, nuclear, gas and hydro

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

 BHEL has proven turnkey capabilities for executing power

projects from concept to commissioning and manufactures
boilers, thermal turbine generator set and auxiliaries up to
500MW.

 It possesses the technology and capability to procure

thermal power generation equipment up to 1000MW.
  Co-generation and combined cycle plants have also been
introduced.

 For efficient use of the high ash content coal-BHEL supplies

circulating fluidized boiler.

 BHEL manufactures 235MW nuclear sets and has also

commenced production of 500MW nuclear set.

Custom-made huge hydro sets of Francis, Elton and Kaplan types

for different head- discharge combinations are also engineered and
manufactured by BHEL.
INDUSTRY SECTOR

BHEL is a major contributor of equipment and system to

important industries like

 Cement

 Petrochemicals

 Fertilizers

 Steel paper

 Refineries

 Mining and Telecommunication

 The range of system and equipment supplied including captive power
stations

 High speed industrial drive turbines

 Industrial boilers and auxiliaries

 Waste heat recovery boilers
 Gas turbines pump, valves, seamless steel tubes
 Heat exchangers
 Process control etc.

TRANSPORATION :-

BHEL supplies a wide equipment and system to Indian

Railways.

 Electric locomotive

 Traction electric and traction control equipment

TELECOMMUNICATION:-
 BHEL also caters to Telecommunication sector by way of
small, medium and large switching system.

BHEL has divided into many blocks:-

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

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

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

4) Block-4:-
In block -4winding for turbo generator, hydro generator,
insulation of A.C&D.C motors insulating component for turbo
generator, hydro generator motors are manufactured &
assembled

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

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

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

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

 Heavy Electrical Plant, Piplani, Bhopal

 Electrical Machines Repair Plant (EMRP), Mumbai
 Transformer Plant P.O. BHEL, Jhansi.
 Bharat Heavy Electrical Limited :
o Central Foundry Forge Plant., Ranipur, Hardwar
 Heavy Equipment Repair Plant, Varanasi.
 Insulator Plant, Jagdishpur, Distt. Sultanpur.
 Heavy Power Equipment Plant, Ramachandra Puram,
Hyderabad
 High Pressure Boiler Plant & Seamless Steel Tube Plant,
Tiruchirappalli.
 Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex,
Ranipet.
 Industrial Valves Plant, Goindwal.
  Electronics Division :
o Electronics Systems Division.
o Amorphous Silicon Solar Cell Plant (ASSCP).
o Electro porcelains Division.

BANGALORE

 Component Fabrication Plant, Rudrapur.

 Piping Centre, Chennai.
 Heavy Electrical Equipment Plant,
 Regional Operations Division, New Delhi
 HEEP: AN OVERVIEW
Over the years, Bharat Heavy Electrical Limited has
emerged as world class engineering and Industrial giant, the best of
its kind in entire South East Asia. Its business profile cuts across
various sectors of engineering/power utilities and industry. The
company today enjoys national and international presence
featuring in the " fortune international-500” and is ranked among
the top 12 companies of the world, manufacturing power generation
equipment. BHEL has now 14 manufacturing division, 8 service
centers and 4power power sectors regional centers besides a
large number of project sites spread over India and abroad.

The company is embarking upon an ambitious growth path

through clear vision, mission and committed values to sustain and
augment its image as a world-class enterprise.

VISION

A world-class innovating, competitive and profitable

engineering enterprise providing total business solution.

MISSION

To be the leading Indian engineering enterprise providing

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

 Meeting commitments made to external & internal customers

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

MANUFACTURING PROCESS OF
TURBO GENERATOR & STATOR BAR

BRIEF SUMMARY: ABOUT THE BAR SHOP

  This shop is meant for manufacturing of stator winding coils of
generator that may be turbo generator or hydro generator.

HR BARS
 Manufacturing of bars of different capacity depends upon the
water head available at site. The hydro generator is air called
generator of lesser length.

TURBO GENERATOR BAR

 For the turbo generator the manufacturing of bars of standard
capacity such as 100 MW, 130MW, 150MW, 210/235MW,
210/250MW. This plant has capacity and technology to
manufacturing 800 MW generators.

TYPE OF GENERATORS

 The generator may be classified based upon the cooling

system used in the generators such as;
THRI, TARI, THDI, THDD, THDF, THFF, THW
T =i.e. Turbo Generator or Hydro Generator.
 H/A =i.e. Hydrogen Gas or Air.
R/D/F/I =i.e. Radial, indirect, forced, direct etc.
I/D/F =i.e. Indirect cooling, direct cooling, forced cooling.
W =i.e. cooling media used for cooling of stator coil
e.g. water.

MATERIAL CHECKING

 First we check the material of the conductor. And the total

insulation upon the conductor. The width of the copper
conductor should be:
a. For Lower bar = 8 x 2.8mm (Solid)
b. For Upper bar = 8 x 1.3mm (Solid)
c. For Hollow conductor = 8 x 4.6 x 1.5mm (Solid)

CONDUCTOR CUTTING AND END CLEANING

 This process is done by the automatic CNC machine, in this
process the length of lower bar & upper bar is decided as
following as per drawing-

 Lower Bar
 a. Solid conductor length = 10,200mm (10
Plates)
b. Hollow conductor length = 10,200mm (10 Plates)
 Upper Bar
a. Solid conductor length = 10,050mm (10
Plates)
b. Hollow conductor length = 10,050mm (10 Plates)
This insulation is removed from both ends after the cutting of
conductor i.e. 500mm for both lower & upper bar.

TRANSPOSITION OF CONDUCTOR
 Transposition means changing or shifting of position of each
conductor in active care (slot) part. After cutting the required
number of conductors are arranged on the comb in staggered
manner and than bands are given to the conductor with the
help of bending die at required distance.

 Setting of die
a. Comb of setting for lower bar’s
Die 1st Die 2nd Die 3rd
2200.2mm 3735.3mm 6586.2mm
b. Comb of setting for Upper bar’s
Die 1st Die 2nd Die 3rd
2109mm 3620.2mm 6496.2mm
This process is repeated to making another half of the bar.

CROSS OVER INSULATION

 Cross over insulation is give to the conductor for the protection

in which the insulating spacer are provided at the cross over
portion. In this insulation the No-max paper is used.
Here the filter material (insulating putty of moulding micanite)
spacer is provided along the high of bar to maintain the rectangular
shape. The size of spacer should be –
1st Band = 146mm
2nd Band = 219mm
3rd Band = 292mm

STACK CONSOLIDATION OR PRESSING

 The core part of the bar stack is pressed in press under the
pressure between 70kg to 80kg (various from product to
product) and the temperature between 90 Deg.C to 160 Deg.C
for a given period. Here four bars is pressed in one time and six
 to eight plates are used for pressing. After that the consolidated
stack is withdrawn from the press.

INTER STAND SHORT TEST (I.S.S.Test)

 In this test first we make the distance to the non insulating

portion of the bar. Here we check the short between any two
conductor. After this test the bars are again go for the second
pressing. In which attached full slot separator between two half
bar no-max paper and tapped with transparent film. In this test if
any error is found then it has to be rectified.

FORMING OF BAR

 In this operation the straight bar stack is formed as per overhang

profile. In this process bars should be formed on universal
former and marked for the thermal space. After it they are
moved for cutting of extra conductor.

ZERO PICKLING OF BAR END

 Pickling is the process of the cleaning of components by the

chemicals. The pickling solutions are:
a. Water = 100 parts by weight
 b. Sulphuric Acid = 10 parts by weight
c. Phosphoric Acid = 5 parts by weight
d. Hydrogen per Oxide = 5 parts by weight

The temperature should be maintain 50 Deg.C to 60 Deg.C. The

end portion of bar is dipping in this solution upto 10 to 15 min.

During this pickling process some aciditic properties are

effected to the end portion of bar. So to neutralization of it dipped the
bars again in the ammonia solution. For the shining of end part the
bars are dipped in ethyal alcohol (C2H5OH) solution and dry with
nitrogen Pressure.

COIL LUG MOUNTING

 In this process contact sleeve and the bottom part of the water
box are adjust at the give dimensions. The operation of
 mounting of contact sleeve and bottom part of water box is
complete in following steps-
a. Check the dimension of contact sleeve and water box bottom
part.
b. Stand by bar for setting of lug.
c. Setup to the solid conductor in each row as per drawing.
d. Then insert the contact sleeve upon the solid and hollow
conductor and temporally installed to it. And also installed the
bottom part of water box.
e. Maintain the gap between contact sleeve and bottom part of
water box approx 20mm.
After the lug mounting cutting of extra solid conductor.

MAIN BRAZING

 There are the following steps to brazed the lug.

a. Stand by bar of setting for brazing.
 b. Then heated the lug point through the two indictor at the
temperature of 700 Deg.C .
c. For brazing use brazing alloy L-Ag-15P by four person. This is
the silver platinum alloy wire of melting point 700 Deg.C to 750
Deg.C.
d. This Temperature is give through the laser rays.

CONDUCTOR CUTTING, FACE MILLING AND DEBBERING

 After the main brazing bars is moved for cutting of extra part of
conductors as per drawing. Here cut the end part of the bottom
part of water box and taken for face milling.
 In this process the conductor is given the accurate shaped as per
the measurement and it is taken in account that any part of the
surface is not left uneven and dull.
 Then in Debbering, the bars edges are many a time left with
twigs and sharp needle type mettle cutting known as bar and this
process of removing is known as Debbering.

FIRST PICKLING
  This is the same process of pickling which is done before the lug
mounting or zero pickling. After this pickling process the bar is
moved the brazing of top part of water box in both side.

BRAZING OF TOP PART

 Thought the induction process the top part of water box is

brazed in both side.

As per the previous main brazing first we stand by bars of setting

for brazing then we attached the top part from the bottom part of
water box. Then healed the top part by top inductors at the
temperature of 400Deg.c.

For this type of brazing use L-Ag-40Cd. This is the alloy silver
academy which ,.h have 40% cadmium and the melting point is 400
Deg.C to 500 Deg.C. This brazing is done for both end.

After the brazing the bars is go for second pickling which is the same
process as previously explain.

WATER FLOW TEST

  Thought this test check the flow water equivalently in the
hollow conductor of the bar. There is the following steps of
checking-
a. Water should be exit all the total hollow conductor.
b. If some burrs are jammed it should be removed to give very
high pressure of water and clean with the help of solid wire.
c. The main point of testing is that the water flow into the bar and
exit from the water box fall down approximately to cover 1 Mtr.
From each conductor.

NITROGEN LEAK TEST

 In this test the bar is tested for leakage into the components of
bar. In this test flow of nitrogen gas with pressure of 10kg/Cm2
to check the leakage in to the hollow conductor. If leakage
found the bar is rejected.

THERMAL SHOCK TEST

  The cycles of hot (80 Deg.C) and cold (30 Deg.C) water are
flew thought the bar to ensure the thermal expansion and
contraction of the joints. The time of low of hot & cold water
should be approx 32 to 40min and give the time between to flow
of hot & cold water is 5 min. this process is applied atleast 8
hours.

HELIUM LEAKAGE TEST

 In this test the bar’s end is tested to flow of helium gas with the
given pressure if the end part of the bar is leakage then the
helium gas is covered the surface of water box and indicator
indicate the point of leakage.

INSULATION

 For the insulation sunmika therm tape or sunmika pleese tape is

used which is the combination of mica + glass + varnish. It is
used for corona protection. In this insulation to layer of pleese
tape + to layer of therm tape and after them again to mica pleese
tape is used.
  Process of Insulation
a. Clean the bar.
b. Clean with chemical or thinner.
c. Taping
d. Realizing film from the mica plastic section.
In insulation the wall thickness of insulation is subjected to the
generating voltage of the machine.

IMPREGNATION AND BAKING

1. Thermoreactive system: In case of rich resin insulation the bar

is pressed in closed box in heated condition and baked under
pressure and temperature as per requirement for a given period.
2. Micalastic system: In case of poor resin system the insulated
bars are heated under vaccum and impregnated (dipped) in
heated resin so that all the air gaps are filled, layer by layer with
resin then extra resin is drained out and bars are heated and
baked under pressed condition in closed box fixture.

VPI Micalastic System

 The bars already laid in closed fixture and full fixture is

impregnated in resin and then fixture with box is baked under
given temperature for the given duration.
VIP Micalastic System

 The individual bar is heated in vaccum and impregnated in

resin. Then bar is taken out and pressed in closed box fixture
and then baked at given temperature for given duration.

FINISHING

 The baked and dimensionally correct bars are sanded-off to

smoothen the edges and surface calibrated if required for the
dimension.

CONDUCTING VARNISH COATING

 OCP (Outer Corona Protection) Coating: The black semi-

conducting varnish coating is applied on the bar surface on the
core length.
 ECP (End Corona Protection) Coating: The grey semi-
conducting varnish is applied at the bend outside core end of
bars in gradient to prevent from discharge and minimize the end
corona.
TESTING

1. Tan Test: This test is carried out to ensure the healthiness of

dielectric (insulation) i.e. dense or rare and measured the
capacitance loss.
2. H.V. Test: The each bar is tested momentarily at high voltage
increased gradually to three times higher than rated voltage.

DISPATCHED FOR WINDING

 If the bar is passed in all the operation and testing after

completing then the bar is send for stator winding.
 TURBO GENERATORS

(a) Air Cooled Generators Upto 200 Mw Range (Type:

TARI ) Salient Design Features

 Stator core and rotor winding direct

air-cooled
 Indirect cooling of stator winding
 Horizontally split casing design of
stator
 Vertically side mounted coolers in a
separate housing
 Micalastic bar type insulation system
 Separately assembled stator core and
winding for reducing the manufacturing cycle
 Brushless/static excitation system
(b) Hydrogen Cooled Turbogenerators Of 140-260 Mw Range
(Type: THRI ) Salient Design Features

 Stator core and rotor winding directly

 hydrogen cooled
 Indirect cooling of stator winding
 Rigid core bar mounting
 Micalastic insulation system
 End shield mounted bearings
 Top ripple springs in stator slots
 Ring type shaft seals
 Symmetrical ventilation.
 ROTOR
 Acts as an Electromagnet.
 Coupled to Turbine rotor to take the driving torque and thus
produces a flux.
 Two Types of Rotor :
o Forged Steel Rotor
o Laminated Rotor
Constructional Feature Of Rotor
 Rotor Shaft :
 Details of shaft are given here
 Length : 9 m (app)
 Dia : 1 m (app)
 Material : Alloy steel
 No. of poles : 2
 Rotor Windings : Multi-turn, manufactured from Semi hard, Ag
alloyed coil with ventilation holes punched in it.
 Insulation : Overall winding insulation is provided by epoxy
glass laminated troughs located in the slots.

 Rotor Wedge : To protect the winding against centrifugal force.

 Retaining Ring : Made up of non-magnetic alloy of Steel fitted
to end of the rotor
 Fans : Blades made up of Aluminium alloy die forgings.
 Excitation Lead : The excitation lead provides electrical
connections between rotor windings and output from brushless
exciter.
 Bearings : Plain bearings with rings are used for circulation of
oil.
 Slip rings : Made up of Steel, insulated by mica strips to supply
excitation current to the rotor winding.
 Brush Gear : Brush of natural graphite composition with low
coeff. of friction are used.
EXCITER

1. The Exciter consist of:

 Rectifier wheels
 Three phase main Exciter
 Three phase pilot Exciter
 Cooler
 Metering and supervisory equipment.

The three phase pilot exciter has a revolving field with

permanent-magnet poles. The three-phase ac generated by the
permanent-magnet pilot exciter is rectified and controlled by the TVR
to provide a variable dc current for exciting the main exciter. The
three phase ac induced in the rotor of 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 carrier the rectifier wheels, the rotor of the
main exciter and the permanent-magnet rotor of the pilot exciter. The
shaft is rigidly coupled to the generator rotor. The exciter shaft is
supported on a bearing between the main and pilot exciters. The
generator and exciter rotors are thus supported on total of three
bearings.

Mechanical coupling of the two shaft assemblies results in

simultaneous coupling of the dc leads in the central shaft bore through
the multikntakt 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.

Rectifier Wheels:-

The main components 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 diode is such that
this contact pressure is increased by the centrifugal force during
rotation.
Additional components are contained in the rectifier wheels.
Two diodes each are mounted in each aluminum alloy heat sink and
thus connected in parallel. Associated with each heat sink is a fuse
which serves to switch off the two diodes if one diode falls (Loss of
reverse blocking capacity).
For suppression of the momentary voltage peaks arising from
commutation, each wheel is provided with 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 connections. The two wheels are identical in their
mechanical design and differ only in the forward direction of the
diodes.
The direct current from the rectifier wheels is fed to the dc leads
arranged in the center bore of the shaft via radial bolt.
The three-phase alternating current 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 connection. One three phase conductor each is provided
for the four diodes of a heat sink set.
Three-phase Main Exciter:-

The three-phase main exciter is a six-pole revolving-armature

unit. Arranged in the stator frame are the poles with the 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 consist of stacked laminations, which are compressed
by through bolts over compression rings. The three phase winding is
inserted in the slots of the laminated rotor. The winding conductors
are transposed within the core length and the end turns of the rotor
winding are secured with steel bonds. 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
also connected. After full impregnation with synthetic resin and
curing, the complete rotor is shrunk on to the shaft.
A general bearing is arranged between main exciter and pilot exciter
and has forced-oil lubrication from the turbine oil supply.

Three-Phase Pilot Exciter:-

The three-phase pilot exciter is a 16 pole revolving-field unit.

The frame accommodates the laminated core with the three-phase
winding. The rotor consist of a hub with mounted poles. Each pole
consist of 10 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 onto the
free shaft end.

Cooling of Exciter:-
 The exciter is air cooled. The cooling air is circulated in a closed
circuit and recooled in two cooler sections arranged alongside the
exciter.
The complete exciter is housed in an enclosure through which
the cooling air circulates.

The rectifier wheels, housed in their own enclosure, draw the

cool air in at both ends and expel the warmed air to the compartment
beneath the base plate.
The main exciter enclosure receives cool air from the fan after it
passes over the pilot exciter. The air enters the main exciter from both
ends and is passed into ducts below the rotor body and discharged
through radial slots in the rotor core to the lower compartment. The
warm air is then returned to the main enclosure via the cooler
sections.
Replacement of air inside Exciter
Enclosure:-

When the generator is filled with hydrogen an adequate

replacement of the air inside the exciter enclosure must be ensured.
The air volume inside the exciter enclosure requires on air change rate
of 125 m3/h.
While the generator is running the air leaving the exciter
enclosure via the bearing vapour exhaust system and the leakage air
outlet in the foundation provides for a pull-through system. The
volume of air extracted from the cooling air circuit is replaced via the
filters located at the top of the enclosure.
 When the generator is at rest, the air dryer of the exciter unit
discharges dry air inside the exciter enclosure via the leakage air filter
and leakage air outlet at the shaft as well as through the bearing
vapour exhaust system of this system is in service.

CONCLUSION

The second phase of training has proved to be quite

faithful. It proved an opportunity for encounter with such huge
machines like turbo-generator hydro generator etc.

The architecture of B.H.E.L., the way various units are

linked and the way working of whole plant is controlled make the
students realize that Engineering is not just structural description but
greater part is planning and management. It provides an
opportunity to learn tech. Used at proper place and time can save a lot
of labour.
 But there are few factors that require special mention.
Training is not carried in true spirit. It is recommended that there
should be projectors especially for trainees where presence of
authorities is ensured.

However, training has proved to be satisfactory. It has allowed

us an opportunity to get an exposure of the practical implementation
of theoretical fundamentals.