This document summarizes a training that was done at Bharat Heavy Electricals Limited (BHEL) in Haridwar, India. BHEL is one of India's largest public sector undertakings that manufactures electrical equipment like generators, motors, and power plant accessories. The training was conducted at BHEL's Heavy Electrical Equipment Plant in Haridwar, which is divided into 8 blocks that each manufacture different components of large turbo generators up to 800MW in size. The document describes the various components of a turbo generator set including the stator, rotor, turbine, and exciter. It provides details on the manufacturing process and equipment used to produce generators.

1. A PPT ON TRAINING DONE AT BHEL
HARIDWAR
SUBMITTED TO :
PROF. NARAYAN RAM PATEL
SUBMITTED BY:
DEEPAK SINGH
11EJIEE015
7th SEM

2. WHAT IS BHEL ?
• BHEL stands for Bharat Heavy Electricals
Limited.
• It is one of the most important PSUs of our
country.
• It manufactures a wide range of electrical
equipment like generators, motors, exciters
and other power plant accessories.

3. • BHEL business operations cater to core sectors
of the Indian Economy like:
Power
Industry
Transportation
Transmission
Defence

4. MANUFACTURING DIVISIONS OF BHEL
 Heavy Electrical Plant, Piplani, Bhopal
 Electrical Machines Repair Plant (EMRP),
Mumbai
 Transformer Plant P.O. BHEL, Jhansi
 Heavy Electrical Equipment Plant Ranipur,
Haridwar
 Central Foundry Forge Plant Ranipur, Haridwar
 Heavy Equipment Repair Plant, Varanasi
 Insulator Plant, Jagdishpur, Distt. Sultanpur

5.  Heavy Power Equipment Plant, Ramachandra
Puram,Hyderabad
 High Pressure Boiler Plant & Seamless Steel
Tube Plant,Tiruchirappalli
 Boiler Auxiliaries Plant, Indira Gandhi
Industrial Complex, Ranipet
 Industrial Valves Plant, Goindwal
 Electronics Division, Bangalore
 Component Fabrication Plant, Rudrapur
 Piping Centre, Chennai
 Regional Operations Division, New Delhi

6. BHEL HARIDWAR
• It is divided in 2 units i.e. Heavy Electrical
Equipment Plant (HEEP) and Central Foundry
Forge Plant (CFFP).
• We did our training at HEEP plant.
• HEEP plant is divided into 8 blocks.
• Turbo generators are manufactured at HEEP
plant.
• Each block manufactures different
components of a turbo generator.

7. BHEL HEEP PLANT, HARIDWAR

8. VARIOUS BLOCKS AT HEEP
1) Block 1
In block 1 mainly stator, rotor shaft and exciter
are manufactured and assembled for LSTG
(Large Size Turbo Generators).
2) Block 2
In block two large size fabricated
assemblies/components for power equipment
are manufactured & assembled.

9. 3) Block 3
In block -3 steam turbines, gas turbines and turbines
blade are manufactured and assembled.
4) Block 4
In block -4 winding for turbo generator, insulating
components for turbo generator are manufactured &
assembled.
5) Block 5
In block -5 fabricated parts of steam turbine are
manufactured & assembled.

10. 6) Block 6
In block -6 fabricated oil tanks, hollow guide blades,
rings, stator frames, rotor spiders are manufactured
& assembled.
7) Block 7
In block -7 all types of dies including stamping dies,
stamping for generators & motors are
manufactured & assembled.
8) Block 8
In block -8 LP heaters, ejectors, steam coolers, oil
coolers, ACG coolers, oil tanks are manufactured &
assembled.

11. TYPES OF TURBO GENERATORS
The generator may be classified based upon the
cooling system used in the generators such as:
THRI, TARI, THDI, THDD, THDF, THFF, THW
 T = Turbo Generator
 H/A/W = Hydrogen, Air, Water
 D/F/I = Radial, Indirect, Forced
 W = (Water) cooling media used for cooling of
stator coil

12. COMPLETE TURBO GENERATOR SET
• Stator
• Rotor
• Turbine
• Exciter

13. STATOR OF TURBO GENERATOR
• The stator of a turbo generator consists mainly
of stator core and stator winding.
• The stator winding is the armature winding.
• When rotor rotates a 3 phase emf is induced
in the armature winding.
• Basically hydrogen gas may be filled inside
stator for cooling purpose.

14. STATOR CORE
• A stator core looks like:-

15. • The stator core has slots in it so that the stator
winding can be housed in the stator.
• The stator core is made up of ferromagnetic
material so as to allow maximum amount of
flux through it.
• Since the flux passing through the stator is
varying, the stator core is made up of thin
laminations to avoid eddy current losses in the
core.

16. STATOR WINDING
• The stator has 3 phase, double layer, short
pitched and bar type of windings having two
parallel paths.
• Each slot accommodates 2 bars.
• Each bar consists of hollow as well as solid
conductors.
• Hollow conductors are used to make water
flow through them for cooling purpose.

17. • The hollow and solid conductors are arranged
in alternate arrangements.
• A picture showing stator winding bars :-

18. TURBO GENERATOR ROTOR
The rotor comprises of following components:-
• Rotor shaft
• Rotor winding
• Rotor wedges
• Fans
• Field lead connections

19. ROTOR SHAFT
• Turbo generators are high speed generators
since they are used in steam and gas power
plants.
• Because of high speed the diameter of turbo
generator rotor has to be less.
• Therefore, the turbo generator rotor is of
cylindrical type.
• The rotor shaft is made of high quality steel so
as to permit flow of magnetic flux through it.

20. • The rotor shaft is machined and slots are cut
into the cylindrical structure for rotor winding.
• For better accuracy and flawless machining,
Computerised Numeric Control (CNC) lathe
machines were being used for cutting, boring,
etc.

21. A ROTOR SHAFT

22. A CNC LATHE MACHINE

23. ROTOR WINDING
• Slots are cut into the cylindrical rotor along
the axis for placing rotor winding.
• The rotor winding is excited by dc supply from
an exciter.
• The rotor is cooled by the hydrogen gas filled
in the stator.
• Field connections are taken out from the rotor
to supply dc.

24. TURBINES
The various types of turbines are :-
• High speed turbines
• Low speed turbines
• Intermediate speed turbines
A turbine is connected to the rotor shaft of the
generator. When highly pressurized steam/gas
falls on the turbine, it rotates. This makes the
rotor to rotate and emf is induced in stator
windings.

25. A LOW SPEED TURBINE

26. A HIGH SPEED TURBINE

27. EXCITER
• An exciter is a dc generator which is used to
provide dc supply to the field winding of the
rotor.
• The exciter is connected to the rotor shaft and
rotates with the rotor.
• An ac generator may also be used as an exciter
and in that case the output of the exciter is
first rectified and then given to the field
winding of the rotor.

28. AN EXCITER

29. CONCLUSION
• BHEL has now started manufacturing Large
Size Turbo Generators (LSTG) of capacity as
large as 800MW and this company has been
earning profits since its inception. It has been
a fruitful experience to undergo training
program at BHEL Haridwar and it has truly
made me aware to the work environment of
the industry.