Here I am disclosing my I internship presentation.

1. MANUFACTURING
PROCESS OF
TURBO GENERATORS
BHARATH HEAVY ELECTRICALS LIMITED, HYDERABAD
GUIDED BY:- PRESENTED BY:-
DR. MOHAN KRISHNA .S VINIT M.P.
ASST. PROFESSOR 15030141-EEE-36
EEE DEPARTMENT
EEE DEPARTMENT

2. CONTENTS
1.STATOR
2.ROTOR
3.BEARING
4.COOLING SYSTEM
5.EXCITATION SYSTEM
• INTRODUCTION ABOUT BHEL
• ABOUT BHEL HYDERABAD
• TURBO GENERATORS
• IMPORTANT SHOPS IN BHEL HYDERABAD

3. MAJOR EQUIPMENTS MANUFACTURED
Industry
equipment
Power
equipment
Transmission
equipment
Transportation
Non
Conventional
Energy Source
equipment
R&D
Products
Compressors, Diesel Generating Set,
Industrial Motors & Alternators, Gas
Turbines, Power Semiconductor Devices,
Steam Generators and Steam Turbine,
Turbo-Generators, Seamless Steel Tubes
and Soot blowers
Air preheaters, Boilers,
Pulverizers, Generators,
Motors and Turbo-
Generators and valves.
Power Transformers/Reactors,
Instrument Transformers.
Switchgears, Control & Protection
Equipment's, Thyristor
equipment's, Insulators Bushing
and Capacitors.
Electric Rolling
Stock, Electrics for
Rolling Stock and
Urban
Transportation
Mini/Micro Hydro Set,
Solar Photovoltaics and
Wind Electric
Generators.
Fuel Cells, Surface
Coatings,
Automated
storage &
Retrievals, Load
Sensors.

4. ABOUT BHEL HYDERABAD
4
The Hyderabad unit was set up in 1963.
Started its operations with manufacture of Turbo-generator sets and auxiliaries for 50 and
270 MW thermal utility sets.
BHEL-Hyderabad unit has collaborations with world renowned MNCs like M/S General
Electric, USA, M/S Siemens, Germany, and M/S Nuovo Pignone, etc.
BHEL HYDERABAD
NUOVO
PIGNONE
GENERAL
ELECTRIC
SIEMENS

5. 3.Steam Turbines
2. Gas turbines
4. Compressors7. Pulverizes
8. Oil Field Equipments
9. Switch gear/circuit
breakers
5. Heat exchangers6. Pumps
IMPORTANT PRODUCTS MANUFACTURED AT BHEL,
HYDERABAD
1. Generators and Exciters

6. TURBO-GENERATORS
6
• A turbo generator converts the mechanical energy into electrical
energy.
• The mechanical emotion is generated
in turbo-generator by using the heat
in the form of saturated steam.
• It works on the principle of FARADAYS LAWS OF
ELECTRO MAGNETIC INDUCTION and represented by
THE FLEMINGS LEFT HAND RULE.

7. COMPONENTS OFTUBRO GENERATOR
7
• STATOR
1. Stator Frame
2. Stator Core
3. Stator Windings
4. End Covers
• BEARING
• ROTOR
1. Rotor Shaft
2. Rotor Windings
3. Rotor Retaining Rings
and fans Bearings
• COOLING SYSTEM
• EXCITATION SYSTEM

8. MANUFACTURING PROCESS OF
TURBO-GENERATOR
8
There are 11 steps in the manufacturing process of turbo-generators
They are:-
1. Press shop
2. Light machine shop
3. Heavy machine shop
4. Copper shop
5. Coil shop
6. Insulation shop
7. Rotor winding shop
8. Stator winding shop
9. Vapour impregnation shop(VPI)
10. Assembly shop
11. Testing shop.

9. STATOR
THE STATOR CONSISTS OF 4 IMPORTANT PARTS
1. Stator Frame
2. Stator Core
3. Stator Windings
4. End Covers
WITH THEIR AUXILIARY COMPONENTS LIKE
RIBS, GUIDE BARS, COOLING SYSTEM.
9

10. 1. STATOR FRAME( LIGHT MACHINE SHOP):-
• The stator frame is of welded steel
single piece construction.
• It supports the laminated core and
winding.
• It consists of ribs and has efficient
cooling system.
• Guide bars are welded inside the
stator frame over which the core is
assembled.
10

11. 2. STATOR CORE (PRESS SHOP):-
• The stator core is made of silicon steel
with high permeability and low
hysteresis and eddy current Losses.
• The sheets are suspended in the stator
frame from insulated guide bars.
• Stator laminations are coated with
synthetic varnish.
• Stator laminations are stacked and
held between sturdy steel clamping
plates with non-magnetic pressing
fingers which welded to the stator
frame. 11

12. 3. STATOR WINDING (COPPER SHOP):-
• The stator windings consist of two
layers made of individual copper
bars.
• To minimize losses, bars are
separately insulated strands
(transposed by 360 degrees).
• Each bar consists of a large number
of separately insulated strands to
reduce the skin effect losses.
• To minimize stray losses in end
windings, strands of top and
bottom bars are separately brazed
and insulated from each other.
12

13. 4. END COVERS (HEAVY MACHINE SHOP):-
• The end covers are made of
fabricated steel or aluminum alloy
castings.
• They are employed with guide
vanes on inner side for ensuring
uniform distribution of cooling air
or gas.
13

14. ROTOR
• THE MAJOR PARTS OF ROTOR ARE
1. ROTOR SHAFT
2. ROTOR WINDINGS
3. ROTOR RETAINING RINGS
4. ROTOR FANS.
.
14

15. 1.ROTOR SHAFT (HEAVY MACHINE SHOP):-
• Rotor shaft is a single piece solid
forming manufactured form a
vaccum casting.
• It is forged from a vaccum cast steel
ingot.
• Slots for insertion or the field
winding are milled into rotor body.
• The longitudinal slots are disturbed
over the circumference such that
two solid poles are obtained.
• The range of rotor shaft is 12 to 15
meters
15

16. 2. ROTORWINDINGS (COIL SHOP, INSULATION SHOP):-
• The windings consist of several coils
inserted into the slots and series
connected such that two coil groups
form one pole.
• Each coil consists of several series
connected turns, each of which
consists of two half turns connected
by brazing in the end section.
• The rotor bearing is made of silver
bearing copper ensuring an
increased thermal stability.
• The individual turns of coils are
insulated against each other by
interlayer insulation.
• L-shaped strips of laminated epoxy
glass fiber fabric with Nomex filter
are used for slot insulation
16

17. CONTINUED……….
• The field winding consists of several series
connected coils inserted into the longitudinal slots
of rotor body.
• The coils are wound so that two poles or four poles
are obtained.
• The solid conductors have a rectangular cross
section and are provided with axial slots for radial
discharge or cooling air.
• All conductors have identical copper and cooling
duct cross section.
• The conductors are made of copper with a silver
content (0.1%).
• The insulation between the individual turns is made
of layer of glass fiber laminate.
• The coils are insulated from the rotor body with L-
shaped strips of glass fiber laminate with nomex
interlines.
• To protect the winding against the effects of
centrifugal forces, the winding is secured in the slots
with wedges. 17

18. CONTINUED……….
• The slot wedges are made of copper
alloy featuring high strength and good
electrical conductivity.
• They are also used as damper winding
bars.
• The slot wedges extend beyond the
shrink seats of retaining rings.
• The wedge and retaining rings act on
the damper winding in the event of
abnormal operations.
• The rings act as a short circuit rings in
the damper windings.
• The spaces between the individual
coils in the end winding are filled with
insulated members that prevent coil
movement. 18

19. 3. ROTOR RETAINING RINGS (HEAVY MACHINE SHOP):-
• The centrifugal forces of the rotor end
winding are contained by single piece
rotor retaining rings.
• Retaining rings are made of non-
magnetic high strength steel in order to
reduce stray losses.
• Each retaining ring with its shrink fitted.
Insert ring is shrunk on the rotor in an
overhang position.
• The retaining ring is secured in the axial
position by snap rings.
19

20. 4. ROTOR FANS (LIGHT MACHINE SHOP) :-
• The cooling air in generator is circulated
by two axial flow fans located on the
rotor shaft one at each end.
• The blades of the fan have threaded
roots for being screwed into the rotor
shaft.
• The blades are drop forged from
aluminum alloy.
• Each blade is secured at its root with a
threaded pin.
20

21. BEARINGS
BEARINGS ENSURE HIGHER MECHANICAL
STABILITY AND REDUCED VIBRATION IN
OPERATION
21

22. 1.BEARINGS (LIGHT MACHINE SHOP)
• The turbo generators are provided with
pressure lubricated self - aligning
elliptical type bearings to ensure higher
mechanical stability and reduced
vibration in operation.
• The temperature of each bearing is
monitored with two RTDs (Resistance
Thermo Detector).
• To prevent damage to the journals (due
to shaft currents, bearings and oil piping
on either side of the non-drive),End
bearings are insulated from the
foundation frame(split insulation).
• Bearings are manufacturing in light
machine shop with cast steel metal.
22

23. VENTILATION AND
COOLING

24. 1.VENTILATION AND COOLING
• Turbo generators are designed with the
following ventilation systems:
• Closed circuit air cooling with water or
air coolers mounted in the pit.
• Closed circuit hydrogen cooling with
water or hydrogen coolers mounted
axially on the stator frame
24

25. EXCITER
THE EXCITER IS BRUSHLESS MAINLY CONSISTING OF:
• RECTIFIER WHEELS
• THREE PHASE MAIN EXCITER
• THREE PHASE PILOT EXCITER
• METERING AND SUPERVISORY EQUIPMENT

26. 1.EXCITER
• The brushless exciter is an AC exciter
with rotating armature and stationary
field.
• The armature is connected to rotating
rectifier bridges for rectifying AC
voltage induced in the armature to DC
voltage.
• The pilot exciter is a PMG(Permanent
Magnet Generator). The PMG is also an
AC machine with stationary armature
and rotating field ( the permanent
magnets).When the generator rotates
at the rated speed, the PMG generates
220v at 150 Hz to provides power
supply to automatic voltage regulator.
26

27. VARIOUS SHOPS
IN BHEL
HYDRABAD
MAJOR SHOPS IN BHEL HYDARABAD INCLUDE
• VPI( VAPOUR PRESSURE IMPREGNATION)
• TESTING SHOP

28. TESTING (TESTING SHOP)
• Over speed test of rotor before assembly at 120%
rated speed for 2 minutes
• Mechanical run and measurement of mechanical
losses & vibrations at rated speed
• Measurement of mech. Losses (OC and SC
characteristic)
• Evaluation of Efficiency by separation of losses
method
• High Voltage test of stator and rotor windings
• Measurement of rotor impedance (rotor inside
stator) , DC resistances and insulation resistance of
RTDs , Insulation resistance of stator and rotor
windings before and after High Voltage test

29. VACUUM PRESSURE
IMPREGNATION (VPI SHOP)
• Vacuum Pressure Impregnation (VPI) is a process
that uses vacuum and pressure to seal porous
materials with varnish or resin.
• The process is used primarily for high-voltage
motors and generators to fill gaps in materials to
create a void free insulation in various devices

30. TEAM
30
VINIT M.P.
15030141-EEE-036
(PRESENTER)
B.HARIPRASAD
D. PRADEEP KUMAR
SRIDHAR K.

31. MVINITBTECH15@CED.ALLIANCE.EDU.IN
KSRIDHARBTECH15@CED.ALLIANCE.EDU.IN
THANKYOU
VINIT M.P.
150303141-EEE-036
SRIDHAR K
150303141-EEE-029