BRIGHTENING LIVES

POWERING PROGRESS
TRAINING REPORT
SIX MONTHS INDUSTRIAL TRAINING
AT
 BHARAT HEAVY ELECTRICALS LIMITED
RANIPUR , HARIDWAR (UTTARAKHAND)

Submitted To: Submitted By:

DGM-A.K Dhiman Varun Singh
6280509210

RAYAT INSTITUTE OF ENGG. & INFO. TECH. , RAILMAJRA

DISTT.- S.B.S. NAGAR (PUNJAB)
CONTENTS:

INTRODUCTION.

BHEL – A Brief Profile.

BHEL – An Overview.

HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP).

TURBO-GENERATOR

COIL AND INSULATION(BLOCK-4)

 PROJECT UNDERTAKEN (DETAILS)

-MANUFACTURING PROCESS OF 500MW STATOR
BARS OF TURBO-GENERATOR.

REFERENCES
INTRODUCTION

BHEL was established more than 50 years ago when its first plant was setup in
Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India.
A dream which has been more than realized with a well recognized track record of
performance it has been earning profits continuously since 1971-72 and will
achieve a turnover of Rs 134,000 crore for the plan year 2012, showing a growth
of 50% in the plan. Bharat Heavy Electricals Limited is country’s ‘Navratna’
company and has earned its place among very prestigious national and
international companies. It finds place among the top class companies of the world
for manufacture of electrical equipments.

BHEL caters to core sectors of the Indian Economy viz., Power Generation's &
Transmission, Industry, Transportation, Telecommunication, Renewable Energy,
Defense, etc. BHEL has already attained ISO 9000 certification for quality
management, and ISO 14001 certification for environment management and
OHSAS – 18001 certification for Occupational Health and Safety Management
Systems. The Company today enjoys national and international presence featuring
in the “Fortune International -500” and is ranked among the top 10 companies in
the world, manufacturing power generation equipment. BHEL is the only PSU
among the 12 Indian companies to figure in “Forbes Asia Fabulous 50” list.

Probably the most significant aspect of BHEL’s growth has been its
diversification .The constant reorientation of the organization to meet the varied
needs in time with a philosophy that has led to total 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 manufacturers of power
plant equipments not only in 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 world over have placed orders with
BHEL covering individual equipment to complete power stations on turnkey basis.
BHEL – A BRIEF PROFILE

BHEL is the largest engineering and manufacturing enterprise in India in

the energy related infrastructure sector today. The wide network of BHEL's
14 manufacturing division, four power Sector regional centers, over 150
project sites, eight service centers and 18 regional offices, enables the
Company to promptly serve its customers and provide them with suitable
products, systems and services – efficiently and at competitive prices. While
the company contributes more than 75% of the national grid, interestingly a
share of 45% comes from its single unit. And this is none other than BHEL-
HARIDWAR

BHEL has:-

➢ Installed equipment for over 90,000MW of power

generation--- for utilities captive and industrial users.

➢ Supplied over 2, 25,000 MVA transformer capacity and

other equipment operating in transmission and
distribution network up to 400 kV (AC & DC).

➢ Supplied over 25,000 motors with drive control systems

to power projects, petrochemicals, refineries, steel,
aluminum, fertilizers, cement plants etc.

➢ Supplied Traction electrics and AC/DC locos to power

over 12,000 kms railway network.

➢ Supplied over one million valves to power plants and

other industries.
BHEL – An Overview

BHEL today is the largest Engineering Enterprise of its kind in India with
excellent track record of performance, making profits continuously since
1971-72.

BHEL's vision is to become a world-class engineering enterprise, committed

to enhancing stakeholder value. The company is striving to give shape to its
aspirations and fulfill the expectations of the country to become a global
player.
BHEL business operations cater to core sectors of Indian Economy.
➢ Power

➢ Industry

➢ Transportation

➢ Transmission

➢ Defenses etc.

The greatest strength of BHEL is its highly skilled and committed 60,000
employees. Every employee is given an equal opportunity to develop
himself and grow in his career. Continuous training and retraining, career
planning, a positive work culture and participative style of management all
these have engendered development of a committed and motivated
workforce setting new benchmarks in terms of productivity, quality and
responsiveness.
POWER SECTOR –
Power generation sector comprises thermal, gas, hydro and nuclear power plant
business .BHEL supplied utility sets accounts to 87,646 MW 65% of the total
installed capacity of 1,38,175 MW in the country , as against nil in 1969 -70.
As part of India’s largest Solar Power-based Island Electrification Project in India,
Bharat Heavy Electricals Limited (BHEL) has successfully commissioned two
Grid-Interactive Solar Power Plants of 100 KW each in Lakshadweep.
With this, the company has commissioned a total of eleven Solar Power Plants in
the Lakshadweep islands, adding over 1 MW of Solar Power to the power
generating capacity of the coral islands in the Arabian Sea.
➢ BHEL has proven turnkey capabilities for executing power projects
from concept to commissioning and manufactures boilers, thermal
turbine generator sets and auxiliaries up to 500MW.
➢ It possesses the technology and capability to procure thermal power
generation up to 1000MW.
➢ Co- generation and combined cycle plants have also been
introduced.
➢ For the efficient use of high ash content coal BHEL supplies
circulating fluidized boiler.
➢ BHEL manufacturers 235MW nuclear sets and has also commenced
production of 500MW nuclear turbine generator sets.

Custom made hydro sets of Francis, pelton and kaplan types for different head
discharge combination are also engineering and manufactured by BHEL.
In, all 700 utility sets of thermal, hydro, gas and nuclear have been placed on the
company as on date. The power plant equipment manufactured by BHEL is based
on contemporary technology comparable to the best in the world and is also
internationally competitive.
The Company has proven expertise in Plant Performance Improvement through
renovation modernization and up rating of variety of power plant equipment
besides specialized know how of residual life assessment, health diagnostics and
life extension of plants.
POWER TRANSMISSION AND DISTRIBUTION (T&D) ---
BHEL offer wide-ranging products and systems for T & D applications Products.
They manufactured include power transformers, instrument
transformers, dry type transformers, series – and shunt reactor,
capacitor tanks, vacuum – and SF6 circuit breakers gas insulated
switch gears and insulators.

A strong engineering base enables the Company to undertake turnkey delivery of

electric substances up to 400 kV level series compensation systems (for increasing
power transfer capacity of transmission lines and improving system stability and
voltage regulation , shunt compensation systems (for power factor and voltage
improvement) and HVDC systems (for economic transfer of bulk power). BHEL
has indigenously developed the state-of-the-art controlled shunt reactor (for
reactive power management on long transmission lines). Presently a 400 kV Facts
(Flexible AC Transmission System) project under execution.

INDUSTRY SECTOR –
BHEL is a major contributor of equipment and system to important industries like
–

➢ Cement
➢ Petrochemicals
➢ Fertilizers
➢ Steel papers
➢ Refineries
➢ Mining and telecommunication
BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for
reactive power management on long transmission lines). Presently a 400 kV
FACTS (Flexible AC Transmission System) projects is under execution.

The range of system and equipment supplied includes:-

➢ Captive power plants

➢ High speed industrial drive turbines
➢ Industrial boilers and auxiliaries
➢ Waste heat recovery boilers
➢ Gas turbine pump, valves, seamless steel tubes
➢ Heat exchangers
➢ Process control etc.

TRANSPORTATION—
BHEL is involved in the development design, engineering, marketing, production,
installation, and maintenance and after-sales service of Rolling Stock and traction
propulsion systems. In the area of rolling stock, BHEL manufactures electric
locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP,
both for mainline and shunting duly applications. BHEL is also producing rolling
stock for special applications viz., overhead equipment cars, Special well wagons,
Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use,
BHEL manufactures traction propulsion systems for other rolling stock producers
of electric locomotives, diesel-electric locomotives, electrical multiple units and
metro cars. The electric and diesel traction equipment on India Railways are
largely powered by electrical propulsion systems produced by BHEL. The
company also undertakes retooling and overhauling of rolling stock in the area of
urban transportation systems. BHEL is geared up to turnkey execution of electric
trolley bus systems, light rail systems etc. BHEL is also diversifying in the area of
port handing equipment and pipelines transportation systems.

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

HEAVY ELECTRICAL EQUIPMENT PLANT

(HARIDWAR)

At Haridwar, against the picturesque background of Shivalik Hills, 2 important

manufacturing units of BHEL are located viz. Heavy Electrical Equipment Plant
(HEEP) & Central Foundry Forge Plant (CFFP). The hum of the construction
machinery working started under Shivalik Hills during early 60s and sowed the
seeds of one of the greatest symbol of Indo Soviet Collaboration – Heavy
Electrical Equipment Plant.
Consequent upon the technical collaboration between India and USSR in 1959,
BHEL’s prestigious unit, Heavy Electrical Equipment plant (HEEP), was
established in October, 1963, at Hardwar. It started manufacturing thermal sets in
1967 and now thermal sets of 210, 250 and 500 MW, including steam turbines,
turbo-generators, condensers and all associated equipments, are being
manufactured. This unit is capable of manufacturing thermal sets up to 1000 MW.
HEEP-manufactured gas turbines, hydro turbines and generators, etc., are not only
successfully generating electrical energy within and outside the country, but have
also achieved a historic record of the best operational availability.

VISION
World-class , innovative, competitive and profitable engineering enterprise
providing total global business solutions.

MISSION
The leading Indian engineering enterprise providing quality products systems and
services in the fields of energy, transportation, infrastructure and other potential
areas.

VALUES
➢ Meeting commitments made to external and internal customers.
➢ Foster learning creativity and speed of response.
➢ Respect for dignity and potential of individuals.
➢ Loyalty and pride in the company.
➢ Team playing
➢ Zeal to excel.
➢ Integrity and fairness in all matters.
 ESTABLISHMENT AND DEVELOPMENT STAGES:

➢ Established in 1960s under the Indo-Soviet Agreements of 1959 and

1960 in the area of Scientific, Technical and Industrial Cooperation.
➢ DRR – prepared in 1963-64, construction started from October '63
➢ Initial production of Electric started from January, 1967.
➢ Major construction / erection / commissioning completed by 1971-72
as per original DPR scope.
➢ Stamping Unit added later during 1968 to 1972.
➢ Annual Manufacturing capacity for Thermal sets was expanded from
1500 MW to 3500 MW under LSTG. Project during 1979-85 (Sets up
to 500 MW, extensible to 1000/1300 MW unit sizes with marginal
addition in facilities with the collaboration of M/s KWU-Siemens,
Germany.
➢ Motor manufacturing technology updated with Siemens collaboration
during 1984-87.
➢ Facilities being modernized continually through Replacements /
Reconditioning-Retrofitting, Technological / operational balancing.

CLIMATIC AND GEOGRAPHICAL CONDITIONS:

➢ Haridwar is in extreme weather zone of the UTTARAKHAND and
temperature varies from 2oC in Winter (December to January) to 45oC
in Summer (April-June); Relative humidity 20% during dry season to
95-96% during rainy season.
➢ Longitude 78o3' East, Latitude 29 o55'5" North.
 ➢ Height above Mean Sea Level = 275 meters.

➢ Situated within 60 to 100 KMs of Foot-hills of the Central Himalayan

Ranges; Ganges flows down within 7 KMs from the Factory area.
➢ HEEP is located around 7 KMs on the Western side of Hardwar city.

POWER & WATER SUPPLY SYSTEM:

➢ 40 MVA sanctioned Electric Power connection from UPC Grid (132

KV / 11KV / 6.6 KV) (Connected load – around 185 MVA)
➢ 26 deep submersible Tube Wells with O.H. Tanks for water supply.
➢ A 12 MW captive thermal power station is located in the factory
premises.

MAIN PRODUCTS:

➢ Steam Turbines
➢ Hydro Turbines
➢ Gas Turbines
➢ Turbo Generators
➢ Medium Size Motors.
DIFFERENT BLOCKS AT HEEP-
PLANT FACILITES:
S.No. Area/ Block Major Facilities Products
1. Block –I Machine Shop., Turbo

Windings bar Generator,

(Electrical
preparation assembling, Generator
Machines)
painting section, exciters, motors

packing& preservation, (AC& DC)

over speed balancing,

test bed test stand,

babbiting, micalastic

impregnation etc.

2. Block – II Markings, welding Large size

,Cutting, straightening, fabricated

(Fabrication
gas cutting press, , assemblies/
Block)
grinding, assembly, heat components for

treatment, cleaning & power

Shot blasting, equipments

machining, fabrication

of pipe coolers, painting

3. Block –III Machining, facing wax Stem turbines,

melting, broaching, hydro turbines,

(Turbines &
assembly preservation & gas turbines,
Auxiliary Block)
packing, test stands/ turbine bladders,

station, painting special tooling.

ELECTRICAL MACHINES BLOCK (BLOCK-I)

INTRODUCTION---

➢ Block-I is designed to manufacturing Turbo Generators, Hydro

generators and large and medium size AC and DC Electrical
machines.
➢ The Block consist of 4 bays: Bay-1 (36*482 meters), Bay-2
(36*360 meters) and Bay-3 and Bay-4 of size 24 *360 meters
each. For handling and transporting the various components
over-head Crane facilities are available, depending upon the
products manufactured in each Bay. There are also a number of
self-propelled electrically-driven transfer trolleys for the inter-
bay movement of components /assemblies.
➢ Conventional bay -wise broad distribution of products is as
follows :
BAY– ROTOR ROTOR ROTOR OVER SPEED LARGE SIZE
SHAFT SHAFT WINDIN AND TURBO
1
MACHININ SLOTTING G BALANCING GENERATOR
G TUNNEL S

BAY– EXCITER STATOR STATOR TOTAL TEST BED

SHAFT BODY WINDIN IMPREGNATI
2
MACHININ MACHINING G ON
G

BAY ROTOR SHAFT SEAL DC

SUPPORT BODY MOTOR
—3
BEARING WINDIN
G
(EARLIE
R)
BAY COOLING ARRANGEME
FANS NT AND
—4
MACHININ OTHER
G PARTS

BASIC TURBO GENERATOR DEPARTMENTS: -

➢ MACHINE SHOP.
➢ T/G ROTOR WINDING.
➢ H/G IRON ASSEMBLY.
➢ EXCITER.
➢ T/G STATOR WINDING.
➢ TOTAL IMPREGNATION TECHNIQUE.
➢ T/G IRON ASSEMBLY.
➢ T/G MAIN ASSEMBLY.
➢ L.S.T.G ROTOR WINDING.
➢ L.S.T.G STATOR WINDING.
➢ L.S.T.G MAIN ASSEMBLY.
➢ TEST BED.
 TURBO GENERATOR

Turbo generator or A.C. generators or alternators operates on

the fundamental principles of ELECTROMAGNETIC INDUCTION. In
them the standard construction consists of armature winding mounted
on stationary element called stator and field windings on rotating
element called rotor. The stator consists of a cast-iron frame , which
supports the armature core , having slots on its inner periphery for
housing the armature conductors. The rotor is like a flywheel having
alternating north and south poles fixed to its outer rim. The magnetic
poles are excited with the help of an exciter mounted on the shaft of
alternator itself. Because the field magnets are rotating the current is
supplied through two slip rings. As magnetic poles are alternately N
and S, they induce an e.m.f and hence current in armature
conductors. The frequency of e.m.f depends upon the no. of N and S
poles moving past a conductor in 1 second and whose direction is
given by Fleming ’s right hand rule.

SYNOPSIS OF THE FUNCTION OF T.G.:

1. The generator is driven by a prime mover which is steam turbine

in this case.
2. The other side of generator is provided by a rotating armature of
an exciter which produces A.C. voltage. This is rectified to D.C.
by using a rotating diode wheel.
3. The rear end of above exciter armature is mounted by a
permanent magnet generator rotor.
4. As the above system is put into operation, the PMG produces
A.C. voltage.
5. The voltage is rectified by thyristor circuit to D.C.
6. This supply is given to exciter field. This field is also controlled
by taking feedback from main generator terminal voltage, to
 control exciter field variation by automatic voltage regulator.
The rectified DC supply out of exciter is supplied to turbo
generator rotor winding either through brushes or central which
will be directly connected to turbo generator. This depends on
the type of exciter viz. DC commutator machines or brushes
exciter.
7. The main A.C. voltage is finally available at the stator of Turbo
Generator.

LSTG AREA

LARGE SIZE TURBO GENERATOR (LSTG)

 In these types of generators steam turbine does the
function of prime mover which rotates the rotor of LSTG and the field
winding is supplied D.C. by an exciter.

Main types of T.G. are:-

1. THRI
2. TARI
3. THDI
4. THDD
5. THDF
6. THFF

1st LETTER = (here-T)

= 3-phase turbo generator

2nd LETTER = (here H or A)

=Medium present for generator cooling
(H= hydrogen, A or L=air)

3rd LETTER=type of rotor cooling employed

R= radial,
F= direct water cooling
 D= direct axial gas cooling)

4th LETTER= type of as used for stator winding cooling

I= indirect gas cooling
D= direct gas cooling
F= direct water cooling

COMPONENTS OF T.G. :-

➢ STATOR –
1. Stator frame
2.Stator core
3.Stator winding
4.End covers.

➢ ROTOR –

1. Rotor shaft
2. Rotor windings
3. Rotor retaining rings

➢ BEARINGS

➢ COOLING SYSTEM

➢ EXCITATION SYSTEM

STATOR
 The generator stator is a tight construction supporting and
enclosing stator winding, core and hydrogen cooling medium.
Hydrogen is contained within the frame and circulated by fans
mounted at either end of rotor. The generator is driven by a direct
coupled steam turbine at the speed of 3000 rpm.

The generator is designed for continuous rated output.

Temperature detector or other devices installed or connected within
the machine, permits the winding core and hydrogen temperature,
pressure and purity in machine.

STATOR FRAME

The stator frame is used for housing armature conductors. It is

made of cylindrical section with two end shields which are gas tight
and pressure resistant. The stator frame accommodates the
electrically active parts of stator i.e. the stator core and the stator
winding.
 The fabricated inner cage is inserted in the outer frame after the
stator has been constructed and the winding completed.

STATOR CORE:-

The stator core is stacked from the insulated electrical sheet

steel lamination and mounted in supporting rings over the insulated
dovetail guide bars. In order to minimize eddy current losses core is
made of thin laminations. Each lamination layer is made of individual
sections. The ventilation ducts are imposed so as to distribute the gas
accurately over the core and in particularly to give adequate support
to the teeth.

The main features of core are –

1. To provide mechanical support.

2. To carry efficiently electric, magnetic flux.
 3. To ensure the perfect link between the core and rotor.

STATOR WINDING:-

Each conductor must be capable of carrying rated current

without over heating.
The stator winding consists of two layers made up of individual bars.
Windings for the stators are made of copper strips wound with
insulated tape which is impregnated with varnish, dried under vacuum
and hot pressed to form a solid insulation bar. These bars are then
placed in the stator slots and held in with wedges to form the end
turns.
These end turns are rigidly placed and packed with blocks of insulation
material to withstand heavy pressure.

The stator bar consists of hollow (in case of 500 MW generators)

solid strands distributed over the entire bar cross-section, so that
good heat dissipation is ensured. In the straight slot portion the
strands are transposed by 540 degrees. The transposition provides for
mutual neutralization of the voltage induced in the individual strands
due to slot cross field and end winding flux leakage and ensure that
minimum circulating current exists. The current flowing through the
conductors is thus uniformly distributed over the entire cross section
so that the current dependent losses will be reduced.
The alternate arrangement of one hollow strand and two solid
strands ensures optimum heat removal capacity and minimum losses.
The electrical connection between top and bottom bars is made by
connecting sleeve.

Class “F” insulation is used.

The no. of layer of insulation depends on machine voltage. The bars
are brought under vacuum and impregnated with epoxy resin, which
has very good penetration property due to low viscosity. After
impregnation bars are subjected to pressure with nitrogen being used
as pressurizing medium (VPI process). The impregnated bars are
formed to the required shape on moulds and cured in an oven at high
temperature to minimize the corona discharge between the insulation
and slot wall a final coat of semiconducting varnish is applied to the
surface of all bars within the slot range. In addition all bars are
provided with an end corona protection to control the electric field at
the transition from the slot to end winding. The bars consist of a large
no. of separately insulated strands which are transposed to reduce the
skin effect.
INSULATION OF BARS:-

A. Vacuum pressed impregnated micaclastic high voltage

insulation:-

The voltage insulation is provided according to the proven resin

poor mice base of thermo setting epoxy system. Several half
overlapped continuous layer of resin poor mica tape are applied
over the bars. The number of layers or thickness of insulation
depends on the machine voltage. To minimize the effect of radial
forces windings hold and insulated rings are used to support the
overhang.

B. Corona Protection:-

To prevent the potential difference and possible corona discharge

between the slot wall and the insulation, the section of bars are
provided with outer corona protection. The protection consists of
polyester fluce tape impregnated in epoxy resin with carbon and
graphite as fillers. At the transition from the slot to the end winding
portion of the stator bars a semiconductor tape is impregnated.

C. Resistance Temperature Detector:-

The stator slots are provided with platinum resistant thermometer

to record and watch the temperature of stator core and tooth
region and between the coil sides of machine in operation. All AC
machines rated for more than 5 MVA or with armature core longer,
the machine is to be provided with at least 6 resistance
thermometers. The thermometer should be fixed in the slot but
outside the coil insulation. When the winding has more than one
coil side per slot, the thermometer is to be placed between the
insulated coil sides. The length of resistance thermometer depends
upon the length of armature. The leads from the detector are
brought out and connected to the terminal board for connection
onto temperature meter or relays. Operation of RTD is based on
the prime factor that the “electric resistance of metallic conductor
varies linearly with temperature”

END COVERS:-

The end covers are made up of fabricated steel or aluminum

castings. They are employed with guide vans on inner side for
ensuring uniform distribution of air or gas.
MANUFACTURING OF VARIOUS PARTS OF STATOR:-

Stator Core Assembly Section:-

This section is present in BAY-1. Two no. core pits with core
building and pressing facilities are available in this section. The section
is also equipped with optical centering device, core heating installation
and core loss testing facilities.

Iron Assembly Section:-

In BAY-2 this section has facilities for stator core assembly of

Turbo-generators and Heavy Electric Motors.

Stator Winding Section:-

This section is present in BAY-1. The section is located in a dust-

proof enclosure with one no. winding. Platform with two no. rotating
installation for assembly of winding. Resistance brazing machines and
high voltage transformers are also available in this section.
 Bar Preparation Section:-

This section is present in BAY-1. This section consists of milling

machine for long preparation, installation for insulation of tension
bolts for stator and preparation of stator winding before assembly.
The three phase winding is afractional pitch two layer type consisting
of individual bars.

Armature Section:-

This section is equipped with installations like bandaging machines,

tensioning devices, Magnetic putty application machine and 45 KW MF
brazing machines for laying windings in large size DC armatures.

Cooling:-

Heat losses arising in the generator are dissipated through hydrogen. The
heat dissipating capacity of hydrogen is eight times to that of air.

ROTOR

The moving or rotating part of generator is known as rotor. The axial length
of shaft of the rotor is very large as compared to its diameter in case of
turbo generators. It is coiled heavily (field coils) as it has to support large
amount of current and voltage. Rotor revolves in most generators at a
speed of 3000rpm. Field coils are wound over it to make the magnetic poles
and to maintain magnetic strength the winding must carry a very high
current. As current flows heat is generated, but the temperature has to be
maintained because as temperature raises problems with insulation
becomes more pronounced. With good design and great care this problem
can be solved.

ROTOR SHAFT:-

The rotor shaft is cold rolled forging 26N1 or MOV116 grade and it is
imported from Japan and Italy.

Rotor shaft is a single piece. The longitudinal slots are distributed over
its circumference. After completion, the rotor is balanced in the
various planes and different speed and then subjected to an over
speed test at 120% of rotor speed. The rotor consists of electrically
active portion and two shaft ends approximately 60 % of rotor body
circumference have longitudinal slots which hold the field winding.
Slots pitch is selected so that the two solid poles are displaced by 180
degree the rotor wedges act as damper winding within the range of
 winding slots. The rotor teeth at the rotor body are provided in radial
and axial poles enabling cooling air to be discharged.

Various Steps Involved In Rotor Machining:-

➢ SHAFT MACHINING:-

It involves finishing of shaft by machining it with a central lathe

machine. It is done in accordance to the engineering drawing design.
Special care is taken to maintain the tolerance level.

➢ SLOTTING:-

Two types of machines do slotting, air cooled and liquid cooled.

Slotting is done diametrically. First the shaft is made to rest on two
horizontal plates and is firmly attached to them with the help of chains
which exerts load and with the help of jack so that it handles the
vibrations produced during the slotting process.
Now the centre is marked and slotting is done. After slotting is
done through one side the shaft is rotated to the diametrically opposite
end of the slotted portion and then again slotting of that portion is
done. It is done in diametrically opposite ends so as to prevent
bristling of slot due to mechanical vibrations.

➢ ROTOR WINDING :-
Rotor winding involves coiling of rotor. It is a two pole rotor.
Rotor coils are made of pure copper + 0.2% silver, which has high
tensile as well as temperature bearing properties. The coil doesn’t
deform even at high temperatures as on adding silver the thermal stresses
are eliminated. Rotor winding is also known as field winding which is
wound in longitudinal slots in rotor.

➢ ROTOR SLOT WEDGES :-

To protect the rotor windings against the effects of centrifugal force and the
secured in slots with wedges.
Slot wedges are made of copper-nickel-silicon alloy featuring high
temperature resistance and high strength.

There is retaining ring, which protects the rotor from the impact of
centrifugal force on end windings.
Comprehensive tests such as ultrasonic examination and liquid penetration
examination are carried out in the coils.
To ensure low contact resistance, retaining rings are coated with nickel,
aluminum and silver by three step flame-spraying process.

ROTOR WINDING:-

The winding consist of several coils inserted into the slots and
the series connected such that two coils group to form one pole. Each
 coil consist of several series connected turns each of which consist of
two half turns connected by brazing in end section. The individual turn
of coil are insulated against each other by interlayer insulation. L-
shaped strip of laminated epoxy glass fiber with nomex filter are used
for slot insulation.

The slot wedges are made up of high electrical conductivity

material and thus act as damper winding. At their ends, the slots
wedges are short circuited through the rotor body. When rotor is
rotating at high speed, the centrifugal forces tries to lift the winding
out of slots, they are contained by wedges.

Construction of field windings:-

The field winding consists of several series connected coils into the
longitudinal slots of body. The coils are wound so that two poles are
obtained. The solid conductors have a rectangular cross-section.
These coils are formed arranging together the 14 no. of strips which makes
a half of the coil which means that total 28 strips are used to make single
coil of the field winding.
Depending upon the type of cooling there are 8 solid and 6 hollow strips in
each half of the coil.

Let us understand it with help of the flow chart:

➢ Coils placed together.

➢ Then Teflon insulation is done on them.
➢ A total of 13 layers are wrapped.
➢ Then epoxy glass tape is wrapped around.
➢ A card board of paper thickness is placed to keep the
Coils separated.
➢ Then a varnish of 7556 is wrapped on it.
➢ Then kept free heating of about 6 hrs is done.
 ➢ Then a free heating of about 1.5 hr is done at low pressure of
about 30 kg and 115*c temperature.
➢ Then for 45 minutes it is heated at temperature of about 130*c
and pressure is increased to 200 kg.
➢ Then keeping the pressure constant the temperature is raised to
around 160*c and coils are heated for around 3 hrs.
➢ Then the coils are removed off the pressure gradually and
cooled by spraying water so now the temperature reaches 60*c
then left to cool slowly and the coils are ready to be wedged in
the slots.

Then the coils placed in the slots and tighten up to prevent the loosening by
tightening rings.
There are 7 turns per pole per pitch and rotor of 210 MW is ready to
test.There is a slight difference in formation of coils 500 MW turbo-
generators.

In those generators the coils are arranged in the following manner.

➢ Firstly they alternate hollow and solid conductors.
➢ There are two solid conductors for every hollow strip and they
are marked as

 A---- Which has 7 conductors.

 B---G where they have 9 conductors each coil.
 They are transposed by 540* as it removes air gap and
improves cross over insulation.
 It increases mechanical strength and help in producing
equal E.M.F across all the conductors.
 The insulation is molding mica mite.
  Testing involving the coils are thermal shock testing hot
and cold.
 This testing is done to check the strength of brazing so
that there is no water leakage and as a result it can bear
thermal stresses easily.

Nitrogen test is also performed for cleaning and leakage purposes and
finally impregnating it through vacuum impregnation technique.
The vacuum impregnation technique is the latest technique to
insulate the windings of stator and not used in rotors of any of the
generators being used in the power plants nowadays.
The process above is discussed is also known as transposition, which
involves the bending of the strips used in forming the coil of either
rotor or stator.

Conductor material:-

The conductors are made up of copper with silver content of approx.

0.1%. As compared to electrolytic copper silver alloyed copper
features high strength properties at high temperature so that coil
deformations due to thermal stresses are eliminated.

Insulation:-
The insulation between the individual turns is made up of layer of glass
fiber laminate the coils are insulated from the rotor body with L-shaped strip
of glass fiber laminate with nomex interlines to obtain the required leakage
path between the coil and rotor body, thick top strips of glass fiber laminate
are inserted below wedge. The top strip are provided with axial slots of
same cross-section and spacing and used on the rotor winding.
ROTOR RETAINING RINGS –

The centrifugal forces of the end windings are contained by

piece rotor retaining rings. Retaining rings are made up of non-
magnetic high strength steel in order to reduce the stray losses. Ring
so inserted is shrunk on the rotor is an over hang position. The
retaining ring is secured in the axial position by snap rings. The rotor
retaining rings withstand the centrifugal forces due to end winding.
One end of each ring is shrunk fitted on the rotor body while the other
hand overhangs the end winding without contact on the rotor shaft.
This ensures unobstructed shaft deflection at end windings. The
shrunk on hub on the end of the retaining ring serves to reinforce the
retaining ring and serves the end winding in the axial direction. At the
same time, a snap ring is provided against axial displacement of
retaining ring. To reduce the stray losses and have high strength, the
rings are made up of non-magnetic cold worked material.

ROTOR FANS –

The cooling air in generator is cold by two axial flow fans located
at the rotor shaft one at each end augment the cooling of the winding.
The blades of fan have threaded roots for screwed into the rotor shaft.
Blades are drop forged from aluminum alloy. Threaded root fastenings
permit angle to be changed. Each blade is screwed at its root with a
threaded pin.

BEARINGS –

The turbo generators are provided with pressure lubricated self

aligning type bearing to ensure higher mechanical stability and
reduced vibration in operation. The bearings are provided with
suitable temperature element to monitor bearing metal temperature in
operation.

The temperature of each bearing monitored with two RTD’s

(resistance thermo detector) embedded in the bearing sleeve such
that the measuring point is located directly below Babbitt. Bearing
have provision for vibration pickup to monitor shaft vibration.

To prevent damage to the journal due to shaft current, bearings

and coil piping on either side of the non-drive and bearings are
insulated from the foundation frame.

➢ FIELD CURRENT LEAD IN SHAFT BASE

Leads are run in axial direction from the radial bolt of the exciter
coupling. They consist of low semi-circular conductors insulated from
each other and from the shaft by a tube.
The field current leads are coupled with exciter leads through a
multi contact plug in which allows unobstructed thermal expansion of
field current.

ROTOR ASSEMBLY:-
 Rotor winding assembly and rotor assembly and rotor assembly
like rotor retaining ring fitting. All these four assemblies are carried
out in a ROTOR ASSEMBLY SECTION present in BAY-1. This section
is also in a dust-proof enclosure with no. of rotators, rotor bars laying
facilities and MI heating and mounting of retaining rings.

MACHINE SECTION:-

This section is present in BAY-2 (Turbo- Generators and Heavy

Motors). This section is equipped with large size CNC and conventional
machine tools such as Lathes and Vertical Boring, Horizontal Boring
machine, Rotor slot milling and Radial drilling machines for machining
stator body, rotor shaft End shields, Bearing etc for Turbo-
generators. Same section is present in Bay-3 (Medium size motors)
equipped with Medium size machine tools for machining components
for medium size AC and DC machines and smaller components of
Turbo-generators and Hydro generators .

VENTILLATION AND COOLING SYSTEM:-

VENTILATION SYSTEM-

The machine is designed with ventilation system having rated

pressure. The axial fans mounted on either side of rotor ensure
circulation of hydrogen gas. The rotor is designed for radial ventilation
by stem. The end stator is packets and core clamping and is
intensively cooled through special ventilation system. Design of special
ventilation is to ensure almost uniform temperature of rotor windings
and stator core.

COOLING SYSTEM –

STATOR COOLING SYSTEM –

The stator winding is cooled by distillate water which is fed from

one end of the machine by Teflon tube and flows through the upper
bar and returns back through the lower bar of a slot. Turbo generator
requires water cooling arrangement over and above the usual
hydrogen cooling arrangement. The stator is cooled in this system by
circulating demineralized water trough hollow conductors. The cooling
was used for cooling of stator winding and for the use of very high
quality of cooling water. For this purpose DM water of proper
specifying resistance is selected. Generator is to be loaded within a
very short period. If the specific resistance of cooling DM water goes
beyond preset value. The system is designed to maintain a constant
rate of cooling water flow through the stator winding at a nominal inlet
with temperature of 40 degree centigrade, the cooling water is again
cooled by water which is also demineralized to avoid contamination
with any impure water in case of cooler tube leakage, the secondary
DM cooling water is in turn cooled by Clarified water taken from
clarified water header.

ROTOR COOLING SYSTEM –

The rotor is cooled by means of gap pickup cooling, where the

hydrogen gas in the air gap is sucked through the scoops on the rotor
and is directed to flow along the ventilating canals milled on the sides
of the rotor coil, to the bottom of slot where it takes a turn and comes
out on the similar canal milled on the other side of the rotor coil to the
hot zone of the rotor, Due to the rotation of the rotor, a positive
section as well as discharge is created due to which a certain quantity
of a gas flows and cools the rotor. The method of cooling gives
uniform distribution of temperature. Also this method has an inherent
of eliminating the deformation of copper due to varying temperature.

HYDROGEN COOLING SYSTEM –

Hydrogen is used as a cooling medium in large capacity

generators in views of highest carrying capacity and low density. Also
in order to prevent used hydrogen from generators, casing and sealing
system is used to provide oil sealing. The system is capable of
performing following system –

➢ Filing in and purging of hydrogen safely without bringing in

contact with air.
➢ Maintaining the gas pressure inside the machine at desired value
at all the times.
➢ Providing indication to the operator about the condition of the
gas inside the machine I e the pressure, temperature and purity.
➢ Continuous circulation of gas inside the machine through a drier
in order to remove any water vapors that may be present in it
➢ Indication of liquid level in the generator and alarm in case of
high level.

GENERATOR SEALING SYSTEM –

Seals are employed to prevent the leakage of hydrogen from the

stator at the point of rotor exit. A continuous film between a rotor
collar and the seal liner is maintained by measurement of the oil at
pressure above the casing hydrogen gas pressure.
 BLK-I

EXCITATION SYSTEM:-

EXCITER:-
 EXCITER ROTOR

The basic use of given exciter system is to produce necessary

DC for turbo generator system. Principal behind this is that PMG is
mounted on the common shaft which generates electricity and that is
fed to yoke of main exciter. This exciter generates electricity and this
is of AC in nature. This AC is that converted into DC and is that fed to
turbo generator via C/C bolt. For rectifying purpose we have RC block
and diode circuit. The most beautiful feature is of this type of exciter
is that is automatically divides the magnitude of current to be
circulated in rotor circuit. This happens with the help of AVR regulator
which means automatic voltage regulator. A feedback path is given to
this system which compares theoretical value to predetermine and
than it sends the current to rotor as per requirement.
 The brushless exciter mainly consists of:-

1. rectifier wheels
2. three phase main exciter
3. three phase pilot exciter
4. Metering and supervisory equipment.

The brushes exciter is an AC exciter with rotating armature and

stationery field. The armature is connected to rotating rectifier bridges
for rectifying AC voltage induced to armature to DC voltage. The pilot
exciter is a PMG (permanent magnet generator). The PMG is also an
AC machine with stationery armature and rotating field. When the
generator rotates at the rated speed, the PMG generates 220 V at 50
hertz to provide power supply to automatic voltage regulator.

A common shaft carries the rectifier wheels the rotor of main

exciter and the permanent magnet rotor of pilot exciter. The shaft is
rigidly coupled to generator rotor and exciter rotors are than
supported on these bearings.
BAY IV (SMALL AND MISCELLANEOUS COMPONENTS)

Facilities available in the various sections are as follows:-

MACHINE SECTION:-

The machine section of Bay-4 is equipped with small and

medium size CNC & conventional machine tools like centre lathes,
milling, radial drilling, cylindrical grinding, slotting, copy turning lathe,
internal grinding and surface grinding machines. Small-size and
miscellaneous components for Turbo-generators, Hydro generators
and Motors are machined in this section.

POLE COIL SECTION

COILING SECTION

This section is equipped with baking oven , pneumatic shearing machines ,

semi-automatic winding machines , pole straightening installations , electric
furnace for bright annealing of copper , tinning installation and hydraulic
press (800 Ton capacity ) for manufacturing Pole Coils of DC motors , AC
synchronous motors and hydro generators . Pole assembly is also carried
out in this section.

Manufacturing of coils (hydro generators) taken in this section. German

copper coils are initially in the form of rolls. These rolls are then undergoes
following processes to change into copper coils which are then mounted with
poles.

1. ANNEALING PROCESS:-

➢ This is the process of hardening or softening any metal.

➢ Initially copper rolls are hard & if it undergoes annealing then it
may breaks so firstly to make it soft so that it can easily change
to winding.
➢ This process is carried out in the annealing furnace.

2.WINDING PROCESS:-

This process undergo following steps:

➢ Take out the softened copper rolls for pole coil winding.
➢ Winding is done with the help of change plate & winding
template so ensure major working dimensions of change plate &
winding template with respect to tool drawing.
➢ Adjust & set the winding machine as per the product standards
using gear rack, change plate & winding template. Ensure
parallelity of winding template with respect to machine platform.
Maintain height of winding template with platform. Wind the coil
in anticlockwise direction.

NOTE:-

✔ The joint in the copper coil shall be located in the straight

part of longer side.
✔ If required heating by gas torch of copper profile at corner
zone at temperature between 100-150 degree centigrade is
allowed. This is to make easier bending.

3.BRAZING:-

➢ Braze the joint with brazing alloy Ag40Cd.

➢ Remove the coil with machine with 2 to 3 turns extra than the
actual number of turns for preparation of end-half turns.
➢ Carry out bright annealing of the coil. Take out the coil from the
oven after annealing.

4. PRESSING:-

➢ Pressing of coil is done by hydraulic pressure of 800 tons.

➢ This process is carried out in order to remove wrinkles from the
coil.
 ➢ This process is carried out after every process. In this process,
set the coil on the mandrel for pressing then slide the coil under
press and press the coil.
➢ Take out the coil from press.

4. FIXING:-

➢ Fix the accessory on the stretching machine.

➢ Put the coil on the stretching machine& pull the coil to the
drawing dimensions.
➢ Dress the conductors along periphery & take out the coil.
➢ Check window dimensions as per drawing.

4. SEPARATION:-

➢ Remove the buckling of each coil manually.

➢ Grind the bulging of the copper at place of binding (inner side)
with pneumatic grinder.
➢ Check the thickness of the profiled copper with the gauge.
Grinding shall be uniform & of smooth finish.
➢ Round of sharp edges.

** Again press the coil as in pt.5 & take out the coil from the press.

4. PICKLING:-
➢ Send the coil for pickling to block 4 & check the quality of
pickling.
➢ Press the coil again after pickling then remove pressure and
take out.
➢ Prepare end half turn as per drawing with template.
➢ Braze item 2 & 3 corresponding to the variant with end half turn
with brazing alloy

Ag 40 Cd.

➢ Remove extra material, clean and check with gauge.

➢ Adjust the end half turn with top & bottom turn of coil braze the
joint.
➢ Remove extra material and check thickness of the gauge.
➢ Check the distance from center axis of pole coil as per drawing.

4. FINISHING:-

➢ Hang the coil on stand and separate out turns

➢ Remove black spots, burrs the sharp edges and clean the coil
turns with cotton dipped in thinner.
➢ Press the coil again and check the height of the coil under press
to check dimensions as per drawing.
Take out the coil from the press and send for insulation.

4. INSULATION:-

➢ Hang the coil on stand and separate out the turn.

➢ Clean each turn with cotton dipped in thinner.
➢ Apply Epoxy varnish on both sides of each turn with brush
uniformly all over the leaving top & bottom turn.
➢ Cut strips of Nomax paper as per contour of coil with
technological allowance 3 to 5 mm on either side.
➢ Stick two layers of Nomax strips between each turn.
➢ Coat varnish layer between two layers of Nomax also.
➢ Let the excess varnish to flow out some time

4. BAKING AND PRESSING OF COIL:-

➢ Place the coil on mandrel putting technological washer at top &

bottom of the coil.
➢ Heat the coil by DC up to 100 +/-5o C , and maintain for 30 to
40 minutes.
➢ Switch off the supply and elongate the coil and tight the
pressing blocks from sides.
➢ Start heating coil again and raise temperature gradually in steps
up to 130 +/- 5o C , with in 10 +/- 10 minutes.
➢ Apply 110 tones pressure and maintain for 20 to 30 minutes.
Then after every half an hour, increases the pressure and
temperature according to product requirement.
➢ Stop heating and then allow cooling the coil under pressure
below 50o C, and taking out the coil from the press.

4. CLEANING AND DRYING:-

 ➢ Clean outer and inner surface of projected insulation by means
of shop made scrubber.
➢ Flow dry compressed air after cleaning.
➢ Check height and window dimensions as per drawing.
➢ Check no gap between the turns.
➢ Test the coil from inter turn test at 116 volts AC at a pressure of
480 tons in 5 minutes.
➢ Coat the coil with two layers of epoxy red gel.

TURBO ROTOR COIL SECTION:-

This section is equipped with copper straightening and cutting machines,

edge bending machines, installation for forming and brazing, 10-block
hydraulic press and installation for insulation filling. Rotor coils for water
cooled generators (210 /235 MW) are manufactured in this section.

IMPREGNATION SECTION:-

This section is equipped with electric drying ovens, Air drying booths, Bath
for armature / rotor impregnation. Rotors / armatures of AC and DC motors
are impregnated in this section.

BABBITING SECTION:-
This section is equipped with alkaline degreasing baths, hot and cold rinsing
baths, pickling baths, tinning bath, and electric furnaces and centrifugal
 Shot Blasting
babbitting machines, Babbitting of bearing liners for Turbo generators,
Turbines, Hydro generators, AC motors and DC motors is carried out in this
section.
TEST STAND:

Turbo-generators Test Bed -The Test Bed for Turbo-generators and Heavy
motors is equipped with one no. 6 MW drive motor and a tests pit for
carrying out testing of Turbo-generators and Heavy motors. Open circuit,
short circuit, temperature rise, hydraulic and hydrogen leakage test etc., are
carried out here for Turbo-generators. AC motors up to 11 MVA capacity and
DC machines up to 5000 amps and 850 volt can also be tested. Two DC
drive motors of 2200 KW and one of 1500 KW are available for type testing
of motors. Data logging equipment is also available.

LARGE SIZE TURBO GENERATOR TEST STAND (LSTG):-

It is equipped with a 12 MW drive motor and two number test pits. Open
circuit ,short circuit , sudden short circuit , temperature rise , hydraulic &
hydrogen leakage tests are carried out here Large size Turbo-generators.
This test bed can presently test Tgs of unit capacity up to 500 MW. With
certain addition in facilities (Higher capacity Drive motor and EOT cranes
and modification in controls and auxiliary systems), Turbo-generators of unit
size up to1000 MW can be tested.

HELIUM LEAK TEST –

PURPOSE –

To check any leakage of gas from stator and rotor as if there is any
leakage of gas used for cooling such as hydrogen then it may cause
an explosion.
Testing of stator frame involves two types of testing:

HYDRAULIC TESTING AND PNEUMATIC TESTING

Hydraulic testing involves in empty stator frame with attached end

shields and terminal box is subjected to a hydraulic test at 10 bar to
ensure that it will be capable of withstanding maximum explosion
pressure.
The pneumatic testing involves filling of hydrogen in the sealed stator
frame and then soap water is used to check the leakage of welding.
BREIF SUMMARY OF C.I.M- BLOCK -4

BAY-1: Bar winding shop: Manufacturing of stator bars of generator.

BAY-2: Manufacturing of motor stator coil, DC armature coil, main pole
Coil , inter-pole coil, equalizer coil etc.
BAY-3: Insulating detail shop: Manufacturing of hard insulation &
machining of hard insulation part such as packing, washer,
insulation box, wedges etc.
Bar Shop: This shop is meant for manufacturing of stator winding coils of
generator that may be turbo-generator or hydro-generator.

Why do we call it bar: It is quite difficult to manufacture, handle and wind the
coil in stator slot of generator of higher generation capacity because of its bigger
size and heavy weight. That is why we make coil in two parts. One part is bottom
part of coil called bottom or lower bar and other part of coil is called top bar or
upper bar.

HG bars: The manufacturing of bars of different capacity as required by the

consumer depends upon the water head available at site. The Hydro generator is
air
cooled generator of lesser length in comparison to its bigger diameter.

Turbo-Generator: The manufacturing of bars of standard capacity such as

100MW,130MW, 150MW, 210/235MW, 500MW. The plant has capacity and
technology to manufacture 800MW and 1000MW generators.

Insulation Classification:
Thermal classification of insulation depends upon the temperature withstand
capacity of the insulation.
Class- Y upto 90’c
Class- A upto 105’c
Class- E upto 120’c
Class- B upto 130’c
Class- F upto150’c
Class- H upto 180’c
Class- C > 180’c and upto 220’c
Type of generators:
The generator may be classified based upon the cooling system used in the
generator such as:

 THRI
 TARI
 THDI
 THDD
 THDF
 THFF

1st LETTER = (here-T)

= 3-phase turbo generator

2nd LETTER = (here H or A)

=Medium present for generator cooling
(H= hydrogen, A or L=air)

3rd LETTER=type of rotor cooling employed

R= radial,
F= direct water cooling
D= direct axial gas cooling)

4th LETTER= type of as used for stator winding cooling

 I= indirect gas cooling
D= direct gas cooling
F= direct water cooling

Resin system:
a) Rich resin or Thermoreactive insulation system: In this type of
insulation system the bond content in resin is 35-37%. The raw materials are
ready to use and require preservation and working on temperature 20-25’c.
its shelf life is one year when kept at temperature 20’c which could be
increased when kept at temperature of 5’c.

b) Poor resin or Micalastic insulation system: In this type of

insulation the bond content in the resin is 5-7% and insulation material is
prepared with accelerator treatment. The temperature control need not
required. The insulating material is applied on job and then the same is
 impregnated in the resin.

TURBO GENERATOR

Turbo generator or A.C. generators or alternators operates on the fundamental

principles of ELECTROMAGNETIC INDUCTION.
In them the standard construction consists of armature winding mounted on
stationary element called stator and field windings on rotating element called
rotor.
The stator consists of a cast-iron frame , which supports the armature core , having
slots on its inner periphery for housing the armature conductors. The rotor is like a
flywheel having alternating north and south poles fixed to its outer rim.
The magnetic poles are excited with the help of an exciter mounted on the shaft of
alternator itself. Because the field magnets are rotating the current is supplied
through two slip rings. As magnetic poles are alternately N and S, they induce an
e.m.f and hence current in armature conductors. The frequency of e.m.f depends
upon the no. of N and S poles moving past a conductor in 1 second and whose
direction is given by Fleming ’s right hand rule.

STATOR WINDING IN TURBO GENERATOR

Each conductor must be capable of carrying rated current without over heating.
The stator winding consists of two layers made up of individual bars. Windings for
the stators are made of copper strips wound with insulated tape which is
impregnated with varnish, dried under vacuum and hot pressed to form a solid
insulation bar. These bars are then placed in the stator slots and held in with
wedges to form the end turns.
These end turns are rigidly placed and packed with blocks of insulation material to
withstand heavy pressure.
The stator bar consists of hollow (in case of 500 MW generators) solid strands
distributed over the entire bar cross-section, so that good heat dissipation is
ensured. In the straight slot portion the strands are transposed by 540 degrees. The
transposition provides for mutual neutralization of the voltage induced in the
individual strands due to slot cross field and end winding flux leakage and ensure
that minimum circulating current exists. The current flowing through the
conductors is thus uniformly distributed over the entire cross section so that the
current dependent losses will be reduced.
The alternate arrangement of one hollow strand and two solid strands ensures
optimum heat removal capacity and minimum losses. The electrical connection
between top and bottom bars is made by connecting sleeve.
Class “F” insulation is used.
The no. of layer of insulation depends on machine voltage. The bars are brought
under vacuum and impregnated with epoxy resin, which has very good penetration
property due to low viscosity. After impregnation bars are subjected to pressure
with nitrogen being used as pressurizing medium (VPI process). The impregnated
bars are formed to the required shape on moulds and cured in an oven at high
temperature to minimize the corona discharge between the insulation and slot wall
a final coat of semiconducting varnish is applied to the surface of all bars within
the slot range. In addition all bars are provided with an end corona protection to
control the electric field at the transition from the slot to end winding. The bars
consist of a large no. of separately insulated strands which are transposed to
reduce the skin effect.

PROJECT:
MANUFACTURING PROCESS OF 500 MW
TURBO-GENERATOR STATOR WINDING BAR-:-

FLOW CHART OF THE PROCESS:

✔ Conductor Draw from Store.

✔ Conductor cutting and end cleaning.

✔ Transposition of conductor.

✔ Assembly of all conductors to be used in stator Bars.

✔ Cross over insulation.

✔ Consolidation if slot portion of Bar.

✔ I.S. Test (i.e. inter strand test).

✔ Forming or Bar (to shape overhang portion).

✔ Pickling of bar ends (1)

✔ Mounting of Contact sleeve & bottom part of water box.

✔ Brazing of Contact sleeve & bottom part of water box.
✔ Pickling of bar ends (2)
✔ Mounting of water box leak test.
✔ Repickling.
✔ Water flow and N2 test.
✔ Thermal Shock Application.
✔ Helium Leak Test.
✔ Reforming of Bar. (i.e. overhang portion).

✔ Insulation of bar on CNC machine.

✔ Impregnation an curing of bar insulation.
✔ Surface finishing of stator bar.
✔ OCP on stator Bar.
✔ Preparation of bar for HV and TanQ Test.
✔ If O.K. Dispatch to Bicck-1 for laying in the generator.
 CONDUCTOR BARS

MFG PROCESS:
CUTTING:
This process is done by automatic 3-444CNC machine. In this process the pre
insulated copper conductor is cut into number of required length. Insulation is
removed from both ends of the conductor cut.
Lower Bar :
Conductor size 8*4.6*1.5 mm (Hollow)
 8*2.8 mm (Solid)

L - 10200 mm c- 500 mm

Number of conductors in 1 Bar Hollow - 20

Solid - 20

Upper Bar :
U – 10050 mm c- 5 mm

Conductor size 8*4.6*1.5 mm (Hollow)

8*1.3 mm (Solid)

Number of conductors in 1 Bar Hollow - 20

Solid - 40
Transposition: Transposition means changing/shifting of position of each conductor in
active core (slot) part. After cutting the required number of conductors, the conductors are
arranged on the comb in staggered manner and then bends are given to the conductors with
the help of bending die at required distance. Then the conductors are taken out from the comb
and die and placed with their ends in a line and transposition is carried out. This process is
repeated for making another half of the bar which would be mirror image of the first half. The
two halves of the bar are overlapped over each other and a spacer is placed between the two
-halves.
1-Equalize the voltage generator.
2-To minimize skin effect of ac current so small cross section of conductor is used and also
hollow conductor are used to effect colling by D.M. water.
3-To reduce the eddy current loses.
-To reduce eddy current losse
3. Crossover Insulation :
The pre insulation of the copper conductor may get damaged due to mechanical
bending in die during transposition, hence the insulating spacers are provided at
the crossover portion of the conductors. A filler material (insulating putty or
moulding micanite) is provided along the height of the bar to maintain the
rectangular shape and to cover the difference of level of conductors.To eliminate
inter turn short at bends during edges wise bending and leveling of bars in slots
portion for proper stack pressing.

4. Stack Consolidation :
The core part of the bar stack is pressed in press (closed box) under pressure
(varies from product to product) and temperature of 160 C for a given period. The
consolidated stack is withdrawn from the press and the dimensions are checked.

5. Inter Strand Short Test:

The consolidated oar stack is tested for the short between any two conductors in
the bar, if found then it has to be rectified.This is done to ensure that no local
current is flowing due to short circuit between conductors.(300 A/C supply)

6. Forming :The straight bar stack is formed as per overhang profile (as per
design), The overhang portion is consolidated after forming.
7. Brazing of coil lugs :
For water cooled generator bars, the electrical connection contact and water box
for inlet and outlet of water are brazed.

8. Nitrogen Leak Test :

The bar is tested for water flow test, nitrogen leak test and pressure test for given
duration.

9. Thermal shock test:

The cycles of hot (80C) and cold (30°C) water are flew through the bar to ensure
the thermal expansion and contraction of the joints.

10. Helium leakage test:

After thermal shock test bar is tested for any leakage with the help of helium gas.

11. Insulation:
The bar is insulated with the given number of layers to build the wall thickness of
insulation subjected to the generating voltage of the machine.

12. Impregnation and baking:

a) 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.

b) Micalastic system: In case of poor resin system the insulated bars are heated
under vaccum and the 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 (dipped) in resin and then fixture with box is baked under given
temperature for given duration.

VIP Micalstic system: The individual (separate) 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.
13. Finishing:
The baked and dimensionally correct bars are sanded-off to smoothen the edges
and the surface is calibrated, if required, for the dimension.

14. Conducting varnish coating:

i) OCP (Outer Corona Protection) coating: The black semi-conducting varnish
coating is applied on the bar surface on the core length.

ii) 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.

15. Testing:
a) Tan@ test: This test is carried out to ensure the healthiness of dielectric
(Insulation) i.e. dense or rare and measured the capacitance loss.

b) H.V. Test: Each bar is tested momentary at high voltage increased gradually
to three times higher than rated voltage.
16. Dispatched for Winding :
The bars preserved with polythene sleeves to protect from dust, dirt, oil, rain etc
are send to Block-I (Electric Machines Production Block – I, Turbo Generators
and Hydro Generators) for winding.
REFERENCES

 Material provided by the training incharge .

 Internet.
 Electrical machines(J.B.GUPTA).