The document details a training experience at Bharat Heavy Electricals Limited (BHEL) conducted in Haridwar, Uttarakhand, providing an overview of the company's history, structure, and operations. BHEL is recognized as India's largest engineering and manufacturing enterprise in the energy sector, contributing significantly to the power generation capabilities of the country and holding a strong international presence. The document outlines BHEL's diverse manufacturing capabilities, including thermal, nuclear, and hydro power plant equipment, along with its commitment to quality and innovative engineering solutions.

1. ( 2ND
JUNE-1ST
JULY-2016)
“BHARAT HEAVY ELECTRICAL S LIMITED”
RANIPUR ,HARIDWAR
(UTTARAKHAND)
V.TRAINING UNDER THE GUIDENCEOF :
MR. SATISH KUMAR SINGH
(SR.ENGR-ELECTRICAL MACHINEPLANNING )
SUBMITTED BY :
AVINASH KUMAR

2. B.TECH:-EE-1314105001

3. ACKNOWLEDGEMENT
“An engineer with only theoretical knowledgeis not a complete and well skilled
engineer. Practical knowledgeis very important to develop and to apply engineering skills”. It
gives me a great pleasureto havean opportunity to acknowledgeand to express gratitude to
those who were associated with me during my training at BHEL.
Special thanks to Mr. Satish kumar singh for providing me with an opportunity to undergo
training under his able guidance
I express my sincerethanks and gratitude to BHEL authorities for allowing me to undergo the
training in this prestigious organization. I will always remain indebted to them for their
constantinterest and excellent guidance in my training work, moreover for providing mewith
an opportunity to work and gain experience.

4. INDEX
 INTRODUCTION
 BHEL COMPANYPROFILEAND IT’S CONTRIBUTION
 BHEL HARIDWAR –AN OVERVIEW
 HEEP
 ELECTRICAL MACHINE BLOCK -1
 BLOCK-1:
1. TURBO GENERATOR:
i.STATOR(500Mw ,600mW)
 STATORFRAME
 STATORCORE
 STATORWINDING(THRI-500Mw,600mW)
 END COVERS
ii.ROTOR:
 ROTORSHAFT
 ROTORWINDING
 ROTORRETAINING RINGS
 ROTORFANS
iii. BEARINGS
iv. VENTILATIONAND COOLING
v. EXCITATIONSYSTEM AND ASSEMBLY
vi. TG ASSEMBLY(500mW,600mW)
vii.LSTG TEST BED
 BLOCK-4:
 CIMAND ACM
a.STATORBAR MANUFACTURING
b.INSULATION WITH QUALITY TEST

5. INTRODUCTION :
* BHEL is the largest engineering and manufacturing enterprise in India in the energy-related /
infrastructure sector, today. BHEL was established more than 40 years ago, 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 performance. The company has been
earning profits continuously since 1971-72.and paying dividends since 1976-77. In 1956 India took a major
step towards the establishment of its heavy engineering industry when Bharat Heavy Electricals Limited, the
first heavy electrical manufacturing unit of the country was set up at Bhopal. .The aim of establishment BHEL
was to meet the growing power requirement of the country.
BHEL has supplied 97% of the power generating equipment that was commissioned in India during 1979-80.
BHEL has supplied generating equipment to various utilities capable of generating over 18000MW power.
BHEL is one of the largest power plant equipment manufacturing firms in India and it ranks among the top ten
manufacturers globally. BHEL has covered up many power stations over 40 countries worldwide.
BHEL has its head quarters at New Delhi. Its operations are spread over 11 manufacturing plants and number
of engineering and service divisions located across th country. The service division includes a network of
regional offices throughout India.
BHEL’S 13 UNIT IN INDIA :
s.no Place units plants
1 HARIDWAR 2
2 BHOPAL 1
3 JHANSI 1
4 JAGDISHPUR 1
5 HYDERABAD 1
6 BANGALORE 3
7 RANIPET 1
8 RUDRAPUR 1

6. 9
10
GOINDWAL
TIRUCHIRAPPALI
1
1
A BRIEF HISTORY
The firstplantof whatis todayknownas BHEL wasestablishednearly40yearsago atBHOPAL andwas genesisof Heavy
Electrical EquipmentindustryinIndia.BHEListodaythe largestengineeringenterpriseof itskindinIndia,withawell
recognizedtrackrecordof performance makingprofitscontinuouslysince 1971-72. It achievedasalesturnoverof
Rs.1022 core in 1997-98. BHEL caters to core sectorsof the IndianEconomyvia,Power,Industry,Transportation,
Defense,etc. The wide networkof BHEL’s17 manufacturingdivisions, 2repairsunits,8 service centers ,8overseas
offices &4 power SectorRegional centers&about150 projectsitesenablesthe service atcompetitivepricesHaving
attainedISO9000 certification,BHELisnowembarkinguponthe Total QualityManagement.The company’sinherent
potential coupledwithitsstrongperformance overthe years,hasresultedinitbeingchosenasone of the ― Maharatna
PSUs(on1 February2013 )
whichare to be supportedbythe Governmentintheirendeavortobecome future global players.It isthe 7th largest
powerequipmentmanufacturer inthe world.Inthe year2011, it wasranked ninthmostinnovative companyinthe
worldbyUS businessmagazineForbes.BHEListhe only IndianEngineeringcompanyonthe list,whichcontainsonline
retail firmAmazonatthe second positionwithApple and Google atfifthandseventhpositions,respectively.Itisalso
placedat 4th
place inForbesAsia'sFabulous50 Listof 2010

7. :
BHEL COMPANYPROFILEAND IT’S CONTRIBUTION:
 POWER SECTOR
Power sector comprises thermal, nuclear, gas & hydro power plant business. Today, BHEL supplied sets
account for nearly 56,318 MW or 65% of the total installed capacity of 86,636 MW in as against nit till
1969-1970. BHEL has proven turnkey capabilities for executing power projects from concept to
commissioning. It posses the technology and capability to produce thermal power plant equipments up
to 1000MW rating and gas turbine generator sets up to a unit rating of 240 MW. Cogeneration and
combined cycle plants have been introduced to achieve higher plant efficiencies. To make efficient use
of the high ash content coal available in India, BHEL supplies circulating fluidized bed boilers to thermal
and combined cycle power plants. BHEL manufacturers 235 MW nuclear turbine generator sets and
has commenced production of 500 MW nuclear turbine generator sets. Custom-made hydro sets of
Francis, Pelt on and Kaplan types for different head-discharge combinations are also engineered and
manufactured by BHEL is based upon contemporary technology comparable to the best in the world &
is also internationally competitive.
 TRANSMISSION
BHEL also supplies a wide range of transmission products and systems up to 400 KV Class. These
include high voltage power and distribution transformers, instrument transformers, dry type
transformers, SF6 switchgear, capacitors, and insulators etc. For economic transmission bulk power
over long distances, High Voltage Direct Current (HVDC) systems are supplied. Series and Shunt
Compensation Systems have also been developed and introduced to minimize transmission losses. 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.

8.  TRANSPORTATION
A highpercentage of trainsoperatedbyIndianRailwaysare equippedwithBHEL’stractionand tractioncontrol
equipmentincludingthe metroatCalcutta.The company suppliesbroadgauge electrical locomotivestoIndianRailways
and diesel shuntinglocomotivestovariousindustries.5000/6000 hp AC/DClocomotivesdevelopedandmanufacturedby
BHEL have beenleasedtoIndianRailways.Batterypoweredroadvehiclesare alsomanufacturedbythe company.
 INTERNATIONALOPERATION
BHEL’s products,servicesandprojectshave beenexportedtoover50 countriesrangingfromUnitedStatesinthe west
to NewZealandinfarEast. The cumulative capacityof powergeneratingequipmentsuppliedbyBHELoutside Indiais
over3000MW. The company’soverseaspresence includesprojectsinvariouscountries.A few notableonesare 150 MW
(ISOI) gasturbine toGermany,utilityboilersandopencycle gasturbine plantstoMalaysia,Tripoli-west,powerstationin
Libyaexecutedonturnkeybasis,thermal powerplantequipmenttoMaltaand Cyprus,HydrogeneratorstonewZealand
and hydropowerplantequipmenttoThailand.BHELhas recentlyexecutedmajorgas-basedpowerprojectsinSaudi
Arabiaand Oman,a Boilercontract inEgypt andseveral TransformercontractsinMalaysiaand Greece
 RENEWABLE ENERGY
TechnologiesofferedbyBHELfor non-conventionalandrenewable sourcesof energyinclude:windelectricgenerators,
solarphotovoltaicsystem, standalone andgrid-interactivesolarpowerplants,solarheatingsystems,solarlanternsand
battery-poweredroadvehicles.The companyhastakenupR&D effortsfordevelopmentof multi-junctionamorphous
solarcellsandfuel cellsbasedsystems.
 INDUSTRIES
BHEL isa majorcontributorof equipmentandsystemstoindustries:cement,sugar,fertilizer,refineries,petrochemicals,
paper,oil andgas, metallurgical andprocessindustries.The companyisamajor producerof large-size thyristor devices.
It alsosuppliesdigital distributedcontrol systemforprocessindustriesandcontrol &instrumentationsystemsforpower
plant and industrial application. The range of system & equipment supplied includes: captive power plants, co -

9. generation plants DG power plants, industrial steam turbines, industrial boilers and auxiliaries. Water heat recovery
boilers, gas turbines, heat exchangers and pressure vessels,centrifugal compressors, electrical machines, pumps,
valves, seamless steel tubes, electrostatic precipitators, fabric filters, reactors, fluidized bed combustion boilers,
chemical recoveryboilers andprocesscontrols.The Companyisa majorproducer of large-size thruster devices. It also
supplies digital distributed control systems for process industries, and control & instrumentation systems for power
plant and industrial applications. BHEL is the only company in India with the capability to make simulators for power
plants, defense and other applications.
An Overview :-BHEL HARIDWAR
 VISION:
A worldclassEngineeringEnterprise committedtoEnhancingstakeholder value.
 MISSION:
To be an IndianMultinationalEngineeringEnterprise providingtotal Businesssolutionsthroughquality
products,systemsandservicesinthe fieldsof Energy,Industry,TransportationInfrastructureandother
potential areas.
 VALUES:-
 . Meeting commitments made to external & internal customers.
 . Foster learing,creativity and speed of response.
 . Respect for dignity and potential of individuals.
 . Loyality and pride in the company.
 . Team playing.
 . Zeal to excel.
 . Integrity and fairness in all matters.
BHEL, Haridwar Complex:
 AREA:-At the foothillsof the majesticHimalayas&onthe banksof a holyGangesin Ranipurnear
HARIDWARis locatedHeavyElectricalsEquipmentPlantof BharatHeavyelectrical Ltd. The main Administrative
Buildingisadistance of about6 km fromHaridwar Railwaystation. BHEL,whollyownedbythe governmentof
Indiaisan integratedengineeringcomplex consistingof several plantsinIndia,where about70,000 workersare
busyin design&manufacturingof a wide range of heavyelectrical equipment.Atpresent70% of the Country’s
electrical energyisgeneratedbythe setsmanufacturingbyBHEL, Haridwar
. BHEL HARDWARisbroadlydividedintotwo parts:

10. A) - CFFP: – Central FoundryForge Plant B) - HEEP: – HeavyElectrical EquipmentPlant
1. CFFP AREA-0.845sqkmapprox
2.HEEP AREA-1.0sqkm
A) CFFPis dividedintofollowingshops:
 Forge Shop
 Machine Shop
 Steel MeltingShop(SMS)
 Steel Foundry
 PatternShop
 Cast Iron(CI) Foundry
B) - HEEP isdividedintofollowingblocks:
 BLOCK-1 TurboGenerators,ACMachines
 BLOCK-2 Fabrication(Steam,Hydro&gas Turbine)
 BLOCK-3 Gas & SteamTurbine
 BLOCK-4 CIM (Coil & Insulation Manufacturing) &ACG(Apparatuscontrol Gear)
 BLOCK-5 Heatexchangers,ForgingandFabrication
 BLOCK-6 Stamping
 BLOCK-7 WoodenPackingworks
 BLOCK-8 Fabrication,seamlesstubesandheatexchanger
HEEP PRODUCT PROFILE:-
S.NO Products Installed capacity
(Licensed)
1. Thermal Sets 3000mW
2. Hydro Sets 625mW
3. Electric Machines 450mW
4. Gas Turbines @60MW to 600
MW
6. Super Rapid gun 3 nos

11. FACILITIES IN HEEP
S.no Area/block Major facilities product
1 Block-I
(Electrical
Machines (Electrical
Machines
Machine shop,windingbar
preparation,assembling,
painting
section,packingand
preservation ovenspeed
balancing,testbed,test
stand,micalastic
impregnation,
babbittingetc.
T G,exciters,Motors(AC&
DC
2 Block-II
(Fabrication
Block) Marking,cutting,
straightening,gas
cutting,press,welding
grinding,
assembly,heattreatment,
cleaningand
shotblasting,machining,
fabrication
of pipe coolers,painting.
Steamturbines,hydro
turbines,gasturbines,
turbine blades,special
tooling
3 Block-III
(Turbine and
Auxiliaryblock) (Turbine and
Steamturbines,hydro
turbines,gasturbines,
turbine blades,special

12. Auxiliaryblock)
Machining,assembly,
preservation
and packing,teststands/
station,
painting,grinding,
broaching,facing,
wax metting,milling,
polishingetc
tooling.
4 Block-IV (Feeder
block)
Bar winding,mechanical
assembly,
armature windings,sheet
metal
working,machining,copper
profile
drawing,electroplating,
impregnation,
machiningandpreparation
of
insulatingcomponents
plastic
moulding,pressmoulding
Windingsforturbo
generators,hydro
generators,insulation
for ACand DC motors,
insulatingcomponents
for TG, HG and
Motors, control panels,
contact relays, master
control etc.
5 Block-V Fabrication,pneumatic
hammerfor
forging,gasfiredfurnaces,
hydraulic
manipulators.
Fabricatedpartsof
steamturbine water
box,storage tank,
hydroturbines
assembliesand
components.
6 Block-VI
(fabrication)
Welding,drillingshot
blasting,CNC
flame cutting,CNCdeep
drilling,shot
blasting,sheetmetal work,
assembly.
Fabricatedoil tanks,
hollow guide blades,
rings,stator frames,
7 Block-VI
(Stampingand
Dia
manufacturing)
Machining,turning,
grinding,jig
boring,stampingpress,de-
varnishing,
de-greasing,de-rusting,
varnishing,
spotwelding,painting.
All typesof dies,
includingstampingdies
and pressforms
stampingforgenerators
& motors.

13. BLOCK :-1
A.TURBO GENERATOR :
A turbogeneratoristhe combinationof a turbine directlyconnectedtoan electricgeneratorforthe generation
of electricpower.Largesteam-poweredturbogeneratorsprovide the majorityof the world'selectricityandare alsoused
by steam-powered turbo-electricships .Smaller turbo-generators with gas turbines are often used as auxiliary power units.
For base loads diesel generators are usually preferred, since they offer better fuel efficiency, but, on the other hand, diesel
generators have a lower power density and hence, require more space.it consist generally of a stationery part called Stator and
a rotating part called Rotor. Stator houses the armature winding. The rotor houses the field winding. DC voltage is applied to
field winding through the slip rings. When the rotor rotates, the lines of magnetic flux cut through the winding. This induces an
electromagnetic EMF in the stator winding. The magnitude of emf is given by following formula:
E = 4.44* ø *ƒ*N volt
Where
ø = strength of magnetic field

14. ƒ = frequency in hertz
N = number of turn in stator winding
ƒ = frequency = P*n / 120
where,
P = number of poles
n = number of revolution per second of rotor.
Working principle of TG
 The generator rotor is driven by prime mover and on driver side gas/ diesel/ steam hydro depending on the
equipment to which it is meant for.
 The non-drive side of rotorisequippedwitharotatingside of armature whichproduces AC voltage. This is rectified
to DC by using a DC. commutator / rotating diode wheel depending upon the type of exciter.
 The rear end of above exciter armature is mounted with a permanent magnet generator rotor.
 As the above rotating system put into operation, the PMC produces AC voltage.
 The voltage is rectified by thyristor circuit to DC.
 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.
 The main AC voltage of generator is finally available to turbo generator stator.
LARGE SIZE TURBO GENERATOR (LSTG)
These types of generators are those which has taken steam turbine. Their prime mover and current is supplied by
exciter system.
Main types are:-
 THRI
 TARI-
 THDI

15.  THDD
 THDF
 THFF
Basic terms are:-
T = turbo generator
A = air cooled
H = hydrogen cooled
R = radial cooling with gas
D = direct axial cooling with gas
F = direct axial cooling with water
I = indirect cooling
COMPONENTS OF T.G. :
A.STATOR –
 Stator frame
 STATOR CORE
 Stator winding
 End covers

16. B.ROTOR –
 Rotor shaft
 Rotor winding
 Rotor retaining rings.
C. BEARINGS
D. COOLING SYSTEM
E. Rotor retaining rings.
STATOR :- The generatorstatoris a tightconstructionsupportingandenclosingstatorwinding,core
and hydrogen cooling medium. Hydrogen is contained within frame and circulated by fans mounted at either
endof rotor.The generatorisdrivenbydirect coupledsteamturbine atthe speed of 3000 rpm.The generator is
designed for continuous rated output. Temperature detector and other device installed or connected within
machine, permit the windings core and hydrogen temperature, pressure, and purity in machine.

17. STATOR FRAME:
Stator bodyisa totallyenclosedgastightfabricatedstructure made upof highqualitymildsteel andausteniticsteel.It is
suitablyribbedwithannularringsininnerwallstoensure highrigidityandstrengthanditalsohelp toreduce vibration
and to withstandthe gasthermal pressure .The arrangement,locationandshape of innerwallsisdeterminedbythe
coolingcircuitforthe flowof the gas andrequiredmechanical strengthandstiffness.The natural frequencyof the stator
bodyis well awayfromanyof exitingfrequencies.Innerandsidewallsare suitablyblankedtohouse forlongitudinal
hydrogengascoolersinside the statorbody.Itsupportsthe laminatedcore andwindingthe statorcomprisesaninner
frame and outerframe.The innercage is usuallyfixedinthe yoke byanarrangementof springto damperthe double
frequencyvibrationsinherentintwopole generator
The fabricatedinnercage isinsertedinthe outerframe afterthe stator core has beenconstructedandthe winding
completed.Footingsare providedthe statorfoundationshieldsenclose the endsof heavyendframe andformmounting
of generatorbearandradial shaft.R is subdividingthe frame andaxial memberstoformductsfrom whichthe cooling
giventoendfrom radial ductin the core andis recirculated.The horizontallymountedwatercooledgascoolensbeing
so arrangedthe it may be cleanedonthe waterside withoutopeningthe machine toatmosphere.All weldedjoints
exposedtohydrogenare speciallymade topreventleakage.The complete frame issubjectedtohydraulictestata
pressure of 7 atm.
STATOR CORE –
It consistsof thinlaminations.Eachlaminationmade of numberof individualsegments.
Segmentsare stampedoutwithaccuratelyfinisheddie fromthe sheetsof coldrolledhigh
qualitysiliconsteel.Beforeinsulationonwithvarnisheachsegmentiscarefullydebarred.
Core is stackedwithlaminationsegments.Segmentsare assembledinaninterleaved
mannerfromlayerto layerforuniformpermeability.Stampingsare heldinapositionby
20 core bars havingdovetail section.Insulatingpaperpressboardsare alsoputbetweenthe

18. layerof stampingto provide additional insulationandtolocalize shortcircuit.Stampings
are hydraulicallycompressedduringthe stackingprocedure atdifferentstages.Between
twopacketsone layerof ventilatingsegmentsisprovided.Steel spacersarespotweldedon
stamping.These spacersfromventilatingductswhere the coldhydrogenfromgascoolers
enterthe core radialyinwardsthere bytakingawaythe heatgenerateddue toeddycurrent
losses.The pressedcore isheldinpressedconditionbymeansof twomassive non-
magneticsteel castingsof pressring.The pressringisboltedtothe endsof core bars. The
pressure of the pressure ringistransmittedtostatorcore stampingthroughpressfringesof
non-magneticsteel andduraluminplacedadjacenttopressring.Toavoid-heatingof press
ringdue to endleakage flowtworingsmade of coppersheetare usedon flux shield.The
ringscreensthe flux byshort-circuiting.Tomonitorthe formationof hotspotsresistance
transducerare placedalongthe bottomof slots.To ensure thatcore lossesare withinlimits
and there are no hot spotspresentinthe core.The core losstestisdone after C ompletionof core assembly.
The main features of core are –
 To provide mechanical support
 To carry efficientlyelectric,magneticflux
 To ensure the perfectlinkbetweencore androtor.
STATOR WINDING –
The stator has a three phase,double layer,shortpitchedandbartype of windingshavingtwoparallel paths.Eachslots
accommodatedtwobars.The slotlowerbarsand slotupperare displacedfromeachotherbyone windingpitchand

19. connectedtogetherbybusbarsinside the statorframe inconformitywiththe connectiondiagram.Eachbar consistsof
solidaswell ashollowconductorwithcoolingwaterpassingthroughthe latter.Alternate arrangementhollow andsolid
conductorsensure anoptimumsolutionfor increasingcurrentandtoreduce losses.The conductorsof small
rectangularcross sectionare providedwithglasslappedstrandinsulation.A separatorinsulatesthe individual layers
fromeach other.The transpositionprovidesformutual neutralizationof voltageinducedinthe individualstrandsdue to
the slotscross fieldandendwindingfield.The currentflowingthroughthe conductorisuniformlydistributedoverthe
entire barcross sectionreduced.Toensure thatstrandsare firmlybondedtogetherandgive dimensionallystabilityin
slotportion,a layerof glasstape is wrappedoverthe complete stack.Barinsulationisdone withepoxymica
thermosettinginsulation.Thisinsulationisvoidfreeandpossesbettermechanical properties.Thistype of insulationis
more reliable forhighvoltage.Thisinsulationshowsonlyasmall increase indielectricdissipationfactorwithincreasing
testvoltage.The bar insulationiscuredinanelectricallyheatedprocessandthusepoxyresinfillall voidsandeliminate
air inclusions.
END COVERS –
The endcoversare made up of fabricatedsteel oraluminumcastings.Theyare employedwithguide vans
on innerside forensuringuniformdistributionof airor gas.
ROTOR:-
Rotor revolvesinmostmoderngeneratoratspeedof 3000 revolutionsperminute.Itisalsoaselectromagnetandto
give itnecessarymagneticstrength,the windingmustcarrya veryhighcurrent.The passage of currentthrough
windingsgeneratesheat.Butthe temperature mustnotbe allowedtobecome toohigh,otherwise difficultieswill be
experiencedwithinsulation.Tokeepthe temperaturecrosssectionof the conductorscouldnotbe increasedbutthis
wouldintroduce anotherproblems.Inordertomake roomfor large conductor,bodyand thiswouldcause mechanical
weakness.Withgooddesignandgreatcare thisproblemcanbe solved.

20. ROTOR SHAFT –
Detailsof shaftare givenhere –
Length= 9 meter(approx.)
Diameter= 1 meter(approx.)
Material – alloysteel
Numberof poles= 2
The rotor shaft iscoldrolledforging26N1 or MOV116 grade andit isimportedfromJapanand Italy.
Rotor shaftisa single piece formingmanufacturedcastings.Itisforgedfromavacuum cast steel slotsforinsulationof
the fieldwindingare made intothe rotorbody.The longitudinal slotsare distributedoverthe circumference.Toensure
that a highqualityproductisobtained,strengthof material analysisandultrasonicare performedduringthe
manufacturingrotor.The highmechanical stressresultingfromthe centrifugalforce andshortcircuit,torque calledfora
highspecifiedmechanicalandmagneticpropertiesaswell ashomogenousforging.Aftercompletion,the rotoris
balancedinthe variousplanesanddifferentspeedandthensubjectedtoan overspeedtestat120% of rotor speed.The
rotor consistof electricallyactiveportionandtwoshaftendapproximately60b% of rotor bodycircumference have
longitudinalslotswhichholdsthe fieldwinding.Slotspitchisselectedsothatthe twosolidpolesare displacedby180
degree the rotorwedgesactas damperwindingwithinthe range of windingslots.The rotorteethatthe rotor bodyare
providedinradial andaxial polesenablingcoolingairtobe discharged.
ROTOR WINDING–

21. The windingconsistof several coilsinsertedintothe slotsandthe seriesconnectedsuchthattwocoilsgroup to form
one pole.Each coil consistof several seriesconnectedturnseachof whichconsistof twohalf turnsconnectedbybrazing
inendsection.The individual turnof coil are insulatedagainsteachotherbyinterlayerinsulation.L-shapedstripof
laminatedepoxyglassfiberwithnomex filterare usedforslotinsulation. The slotwedgesare made upof highelectrical
conductivitymaterial andthusactas damperwinding.Attheirends,the slotswedgesare shortcircuitedthroughthe
rotor body. Whenrotor isrotatingat high speed,the centrifugal forcestriestoliftthe windingoutof slots,theyare
containedbywedges
CONSTRUCTION –
The fieldwindingconsistseveral seriesconnectedcoilsintothe longitudinalslotsof body.The coil are woundthattwo
polesare obtained.The solidconductorshave arectangularcross-sectionandare providedaxialslotsforradial or
coolingair.All conductorshave identical copperandcoolingsection
. CONDUCTOR MATERIAL–
The conductors are made up of copperwithsilvercontentof approx.0.1% . As comparedto electrolyticcoppersilver
alloyedcopperfeatureshighstrengthpropertiesathightemperature sothatcoil deformationsdue tothermal stresses
are eliminated.The conductorsare made of harddrawn silverbearingcopper.The rectangularcrosssectioncopper
conductorshave ventilatingductsonthe two sidesthusprovidingachannel forhydrogenflow.Twoindividual
conductorsplaced-one overthe otherare benttoobtainhalf turns.Furtherthese half turnsare brazedin seriestoform
coil on the rotor model.
INSULATION:-

22. The insulationbetweenthe individual turnsismade upof layerof glassfiberlaminate the coils are insulatedfromthe
rotor bodywithL-shapedstripof glassfiberlaminate withnomex interlinestoobtainthe requiredleakage pathbetween
the coil and rotor bodythicktop stripsof glassfiberlaminate are insertedbelow wedge.The topstripare providedwith
axial slotsof same cross-sectionandspacingandusedonthe rotorwinding.
END WINDING BRACING:-
The spaces betweenthe individual’scoilsinthe endworkingare withinsulatedmembersthatpreventcoil movement
the insulationbyHor L highglasslamination
ROTOR RETAINING RINGS :–
The centrifugal forcesof the endwindingsare containedbypiece rotorretainingrings.Retainingringsare made u of
non-magnetichighstrengthsteelingordertoreduce the stray losses.Eachretainingringswithitsshrinkfitted.Insert
ringis shrunkon the rotor isan overhangpositionThe retainingringissecuredinthe axial positionbysnaprings.The
rotor retainingringswithstandthe centrifugalforcesdue toendwinding.One endof eachringisshrunkfittedonthe
rotor bodywhile the otherhandoverhangsthe endwinding.withoutcontactonthe rotor shaft Thisensures
unobstructedshaftdeflectionatendwindings.The shrunkonhubonthe endof the retainingringservestoreinforce
the retainingringandservesthe endwindinginthe axial direction.Atthe same time,asnapringis providedagainst
axial displacementof retainingringThe shrunkslotof currentTo reduce the stray lossesandhave highstrength,the
ringsare made up of non-magneticcoldworkedmaterial.
ROTOR FANS –
The coolingair ingeneratoriscoldby twoaxial flow fanslocatedatthe rotor shaftone at each endaugmentthe cooling
of the winding.The pressure establishedbythe worksinconjunctionwiththe expelledfromthe discharge pathalong
the rotor The bladesof fanhave threadedrootsforscrewedintothe rotor shaft.Bladesare dropforgedfromaluminum
alloy.Threadedrootfasteningspermitangle tobe changedEachblade isscrewedat itsroot witha threadedpin.
BEARINGS
The turbo generatorsare providedwithpressurelubricatedself-aligningtype bearingtoensure highermechanical
stabilityandreducedvibrationinoperation.The bearingsare providedwithsuitabletemperature elementdue to
monitorbearingmetal temperature inoperationThe temperatureof eachbearingmonitoredwithtwoRTD’s(resistance
thermodetectorembeddedinthe bearingsleevesuchthatthe measuringpointislocateddirectlybelow Babbitt.These
RTDs are monitoredtemperature scannerinthe control panel andif the temperature exceedsthe prescribelimit.
Bearinghave provisionforvibrationpickuptomonitorshaftvibration..
To preventdamage tothe journal due to shaftcurrent,bearingsandcoil pipingoneitherside of the non-driveand
bearingsare insulatedfromthe foundationframe.Forfascinatingandmonitoringthe healthinessof bearinginsulation,
shaftinsulationisprovided
VENTILATION AND COOLING SYSTEM

23. VENTILATION SYSTEM-
The machine isdesignedwithventilationsystemhavingratedpressure. The axial fansmountedoneitherside of rotor
ensure circulationof hydrogengas.The rotorisdesignedforradial ventilationbystem.The endstatoris packetsand
core clampingandisintensivelycooledbythroughspecial ventilationsystem.Designof special ventilationistoensure
almostuniformtemperatureof rotorwindingsstatorcore.Embeddedresistance temperature detectordocontinuous
monitoringof hydrogentemperature atpartof generator.
COOLING SYSTEM –
STATOR COOLING SYSTEM –
The stator windingiscooledbydistillate waterwhichisfedfromone endof the machine byTeflontube andflows
throughthe upperbar and returnsback throughthe lowerbar of a slot.Turbogeneratorrequireswatercooling
arrangementoverandabove the usual hydrogencoolingarrangement.The statoriscooledinthissystembycirculating
demineralizedwatertroughhollowconductors.The coolingwasusedforcoolingof stator windingandforthe use of
veryhighqualityof coolingwater.Forthispurpose DMwaterof properspecifyingresistance isselected.Generatoristo
be loadedwithinaveryshortperiod.If the specificresistance of coolingDMwatergoesbeyondpresetvalue.The
systemisdesignedtomaintainaconstantrate cooingwaterflow throughthe stator windingata nominal inletwith
temperature of 40 degree centigrade.Asitislookworking,the coolingwaterisagaincooledbywaterwhichisalso
demineralizedtoavoidcontaminationwithany impure waterincase of coolertube leakage the secondaryDMcooling
wateris inturn cooledbyClarifiedwatertakenfromclarifiedwaterheader.
ROTOR COOLING SYSTEM–
Each turn is subdividedintoeightparallel coolingzones.One coolingzone includesthe slotsfromthe centertothe end
of the rotor body,while anothercovershalf the endwinding.The coolinggasforthe slotportionisadmittedintothe
hollowconductorsthroughmilledopeningsdirectlybefore the endof the rotorbodyandflowsthroughthe hollow
conductorto the centerof the rotor body.The hot gas is thendischargedintothe airgap betweenthe rotorbodyand
stator core through radial openingsinthe conductorsandrotorslot wedges.The coolinggaspassagesare arrangedat
differentlevelsinthe conductorassemblysothateach hollow conductorhasitsowncoolinggasoutlet.

24. The coolinggas forend windingsisadmittedintothe hollow conductoratthe endof rotor bodythe endof rotor body.
It flowsthroughthe conductorsapproximate uptothe pole centerforbeingdirectedintoacollectingcompartmentand
isthendischargedintothe air gap viaslots.Due to the rotationof the rotor, a positive sectionaswell asdischarge is
createddue to whicha certainquantityof a gas flow andcoolsthe rotor.The methodof coolinggivesuniform
distributionof temperature.
HYDROGENCOOLING SYSTEM –
Hydrogenisusedas a coolingmediuminlarge capacitygenerallyinviewsof highheatcarryingcapacityandlowdensity.
But inviewssitsforminganexplosivemixturewithoxygen.Properarrangementforpuring,maintainingthe purityinthe
generatorhave tobe made Alsoinorderto preventusedhydrogenfromgenerators,casingsealingsystemisusedto
provide oil sealingThe systemiscapable of performingfollowingsystem –
 Filinginandpurgingof hydrogensafetywithoutbringingincontactwithair.
 Maintainingthe gaspressure inside the machineatthe desiredvalue atall the times.
 Provide indicationtothe operatoraboutthe conditionof the gas inside the machine i.e.the pressure,
temperature andpurity.
 Continuouscirculationof gasinside the machine throughadrierinorderto remove anywatervapor that may
be presentinit.
 Indicationof liquidlevel inthe generatorandalarmincase of highlevel.
GENERATOR SEALING SYSTEM–

25. Sealsare employedtopreventthe leakagepf hydrogenfromthe statorat the pointof rotor exit. A continuousfilm
betweenarotorcollarand the seal linerismaintainedbymeasurementof the oil atpressure above the casinghydrogen
gas pressure. .
EXCITATION SYSTEM:

26. The basic use of givenexcitersystemistoproduce necessaryDCforturbo generatorsystem.Principal behindthisthat
PMG ismountedon the commonshaft which systemthisexcitergenerateselectricityandthisisof AC innature.ThisAC
isthat convertedintoDCand is that fedtoturbo generatorviaC/Cvoltfor rectifyingpurpose.We have forRC bockand
diode circuit.The mostbeautiful feature isof thistype of exciteristhatisautomaticallydividesthe magnitudeof current
to feedbackpathisgiventothissystemwhichcomparestheoretical value topredetermine andbe circulatedinrotor
circuit.Thishappenswiththe helpof AVRregulatorwhichmeansautomaticvoltage regulator.A feedbackpathisgiven
to thissystemwhichcomparestheoretical value thenitsendsthe currenttorotoras per requirement.
The brushless exciter mainly consists of:-
 rectifierwheels
 three phase mainexciter
 three phase pilotexciter
 Meteringandsupervisoryequipment
The brushlessexciterisanAC exciterwithrotatingarmature andstationeryfield.The armature isconnectedto
rotatingrectifierbridesforrectifyingACvoltage inducedtoarmature toDC voltage.The pilotexciterisaPMG
(permanentmagnetgenerator).The PMGisalso an ACmachine withstationeryarmature androtatingfield.
Whenthe generatorrotatesat the rated speed,the PMGgenerates220 V at 50 hertzto provide powersupplyto
automaticvoltage regulator.
A commonshaftcarriesthe rectifierwheelsthe rotorof mainexciterandthe permanent magnetrotorof pilot
exciter.The shaftisrigidlycoupledtogeneratorrotorand exciterrotorsare than supportedonthese bearings.
TESTING(LSTG BED):
LSTG-LARGE SCALE TURBO GENERATOR TEST BED .
TESTINGS –
 Thisprocedure isfor highvoltage testonstator windingof turbogenerator
SCOPE–
Thisprocedure coversthe highvoltage testonstator winding.
PURPOSE–

27. Thistestis conductedtocheck whetherthe insulationisproperlyplacedornot.The insulationplacedoverthe winding
shouldbe suchthat theymake half overlapwithnextwrappingof the tape.Thistestisexclusivelyconductedtotestthe
healthlinesof insulationof winding
 Testprocedure forhighvoltage onrotor windingof TG.
SCOPE–
Thisproducesthe highvoltage testonrotor winding
PURPOSE–
Thistestis conductedtocheck whetherthe insulationisproperlyplacedor not.
 Thisprocedure formeasurementof DCresistance of statorand rotorwindingof TG.
SCOPE–
Thisprocedure coversthe measurementof DCresistance of statorwinding.
PURPOSE–
Thistestis connectedtomeasure the resistance contentpresentinthe conductingmaterialof statorandrotor.
 Testprocedure formeasurementof impedance of rotorwindingwith50hertzsupply .
SCOPE–
Thisprocedure coversthe measurementof impedance of rotorwinding50 hertzsource.
TEST EQUIPMENTS –
 50 hertzpowerfrequencyACsource
 AC voltmeter(0-30,75, 150)
 AC ammeter(0-5ampere)
 Multimeter
 Currenttransformer(50/5 A)
 Connectingleads
BLOCK-4 IS ASO CALLED CISM BLOCK .IT HAS TWO PARTS
1.CIM
2. ACM

31. HIGH VOLTAGE TEST:
1.ROTOR WINDING
2.STATOR WINDING
Thistestis conductedtocheck whetherthe insulationisproperlyplacedornot.Thisprocedure coversthe measurement
of DC resistance of statorwinding
TEST EQUIPMENTS –
 50 hertzpowerfrequencyACsource
 AC voltmeter(0-30,75, 150)
 AC ammeter(0-5ampere)
 Multimeter
 Currenttransformer(50/5 A)
 Connectingleads
HELIUM LEAK TEST –
PURPOSE –

32. To check anyleakage of gas from stator and rotor as if there isany leakage of gasusedfor coolingsuchas hydrogenthen
it maycause an explosion.
Micalastic High – Voltage Insulation:
High-voltage insulationisprovidedaccordingtothe provenMicalasticsystem.Withthisinsulationsystem,several half –
overlappedcontinuouslayerof micatape are appliedtothe bars.The mica tape isbuiltupfrom large area mica splitting
whichare sandwichedbetweentwopolyesterbackedfabriclayerswithepoxyasanadhesive.The numberof layers,i.e.,
the thicknessof the insulationdependsonthe machine voltage.The barsare driedundervacuumandimpregnatedwith
epoxyresinwhichhasverygoodpenetrationpropertiesdue toitslow viscosity.Afterimpregnationundervacuum, the
bars are subjectedtopressure,withnitrogenbeingusedaspressurizingmedium(VPIprocess).The impregnationbars
are formedtothe requiredshape inmoldsandcuredinan overat hightemperature.The high- voltage insulation
obtainedisnearlyvoid-freeandischaracterizedbyitsexcellentelectrical,mechanical andthermal propertiesinaddition
to beingfullywaterproof andoil resistant.Tominimizecoronadischargesbetweenthe insulationandslotwall,afinal
coat of semi conductingvarnishisappliedtothe surfacesof all bars withinthe slotrange.Inaddition,all barsare
providedwithanendcoronaprotection,tocontrol the electricfieldatthe transitionfromthe slottothe endwinding
and to preventthe formationof creepage sparkconcentrations.

33. CONCLUSION
Training at B.H.E.L. has proved to be quite faithful. It proved an opportunity
for encounter with such huge machine liketurbo-generators. The architecture of B.H.E.L.,
the way various units are linked and the way working of wholeplant is controlled make
the studentsrealizethat 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 timecan save a lot of labour.
But thereare few factors that require special mention. Training is not
carried in n true spirit. It is recommended that thereshould be projectorsespecially for
traineeswhere presence of authoritiesisensured.
However, training hasproved to be satisfactory. It has allowed us an opportunity toget
an exposure of thepractical implementation of theoretical fundamentals.
THANKU YOU!!

34. .