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 TRAINING REPORT
ON
INSULATION AND MANUFACTURING PROCESS OF
500MW TURBO GENERATOR BARS

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Submitted By:
.
a
__________________
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Electrical Engineering (3rd Year)
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1
ACKNOWLEDGEMENT

―An engineer with only theoretical knowledge is not a complete engineer. Practical
knowledge is very important to develop and apply engineering skills‖. It gives me a
great pleasure to have an opportunity to acknowledge and to express gratitude to those
who were associated with me during my training at BHEL, Haridwar.

Special thanks to Mr. A.K Dhiman for providing me with an opportunity to undergo
training under his able guidance and offering me a very deep knowledge of practical
aspects of industrial work culture...

I express my sincere thanks and gratitude to BHEL authorities for allowing me to

undergo the training in this prestigious organization. I will always remain indebted to
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them for their constant interest and excellent guidance in my training work, moreover

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for providing me with an opportunity to work and gain experience.
.
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m
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_________________________
Electrical Engineering
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 Table of Contents
BHEL: AN OVERVIEW ............................................................................................. 4
Power Generation................................................................................................................... 4
Heavy Electrical Equipment Plant ......................................................................................... 5
COIL & INSULATION MANUFACTURING SHOP (BLOCK-IV)...................... 7
Introduction ............................................................................................................................ 7
Sections in Block IV .............................................................................................................. 8
MFG. Process flow chart of 500MW TG stator bar .............................................................. 9
MANUFACTURING PROCESS OF BARS ............................................................ 11
BAY-1 .................................................................................................................................. 11
Resin System ........................................................................................................................ 22
Testing.................................................................................................................................. 22
Tan∆ Test ......................................................................................................................... 22
H.V. (High Voltage) Testing ........................................................................................... 23

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BAY-2 .................................................................................................................................. 24

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Introduction: ..................................................................................................................... 24
.
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Insulation Check .............................................................................................................. 24
Conductor Tapping .......................................................................................................... 24
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Winding Boat Coil ........................................................................................................... 24

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Boat Insulation .................................................................................................................
Stack Pressing ..................................................................................................................
25
25
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Forming ............................................................................................................................ 25
Insulation.......................................................................................................................... 25
S.................................................................................................................... 25
Impregnation
Curing .............................................................................................................................. 26
Finishing .......................................................................................................................... 26
BAY -3 ................................................................................................................................. 27
Introduction: ..................................................................................................................... 27
ELECTRICAL MACHINES BLOCK (BLOCK — I) ........................................... 28
Introduction .......................................................................................................................... 28
Manufacturing Process......................................................................................................... 28
Turbo Generator ................................................................................................................... 29
CONSTRUCTIONAL FEATURES OF STATOR WINDING .......................................... 31
CONSTRUCTIONAL FEATURES OF ROTOR ............................................................... 32
CONCLUSION ........................................................................................................... 36
Bibliography .................................................................... Error! Bookmark not defined.
3
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Chapter 1
BHEL: AN OVERVIEW
BHEL is the largest engineering and manufacturing enterprise on India in the energy
related/infrastructure sector. BHEL was established more than 40 years ago, ushering in the
indigenous Heavy Electrical Equipment industry in India, a dream which has been more than
released with a well-recognized track record of performance. It has been earning profits
continuously since 1971-72.
BHEL caters to core sectors of India economy viz. Power Generation and
Transmission, Renewable Energy, Defense etc. The wide network of BHEL’s 14
manufacturing divisions, 4 power sector regional centers, 8 service centers, 15 regional
offices and a large number of projects sites spread all over India and abroad enables the
company to promptly serve as customer and provide them with suitable products, systems
and services- efficiently and at competitive prices. m
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BHEL has attained ISO 9001:2000 certifications for quality management and all the
.
manufacturing units divisions of BHEL have been upgraded to the latest ISO 9001:2000
a
version. All the major units divisions of BHEL have been awarded ISO 14001 certification

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for Environmental Management System and OHSAS-18001 certification for Occupational
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Health and Safety management System. BHEL become the first public sector Company in the

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country to win the coveted prize for in Haridwar unit under the CII Exim Award for the

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business excellence as per the globally recognized model of European Foundation for quality

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management. BHEL is the only PSU among the 12 Indian Companies to figure in ―Forbes
Asia Fabulous 50‖ list. It has also won the ―Business standard star Public Sector Company
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Award 2006‖. The company received MoU Excellence award for 2004-2005 and Merit
Certificate for MoU Excellence for 2005-2006.

Power Generation
Power generation Sector comprises Thermal Gas, Hydrogen, Nuclear power plant business.
As of 31.3.2007. BHEL supplied sets accounts for 80,781 MW or nearly 65% of the total
install capacity of 1, 25,414 MW in the country. Significantly these sets contribute 73% of
the total power generated in the country.
BHEL has proven turnkey capabilities for executing power projects from concepts to
commissioning. It possesses the technology and capability to produce Thermal sets with
super critical parameters up to 1000 MW unit rating and gas turbine generator sets of up to
300 MW units rating. Co-generating 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 also supplies circulating Fluidized Bed Combustion (CFBC) boilers for
thermal plants.
4
 The company has proven expertise in Plant Performance Improvement through
renovation, modernization and upgrading of a variety of Power plant equipment, besides
specialized know-how of residual life assessment health diagnostics and life extension of
plants. Overall, BHEL built Thermal sets achieved the highest ever PLH of 78.3% in 2006-
2007 which is 2.5% higher than the National average. The combined operating availability of
these sets was 84.7%.

Heavy Electrical Equipment Plant

BHEL's Heavy Electrical Equipment Plant (HEEP) was set up in technical collaboration with
USSR, for the manufacturing of power plant equipment, AC/DC motors of various rating
with associated control equipment and started production in January 1967. In 1976, BHEL
entered into a collaboration agreement with M/s Kraftwerk Union, AG of Germany for
design, manufacturing, erection and commissioning of large size steam turbines. More than
40 percent of the country's electrical energy is generated from the power equipment supplied
by BHEL, Haridwar.
BHEL offer wide ranging products and systems for T & D applications. Products

m
manufactured include power transformers, instrument transformers, dry type transformers,

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series – and stunt reactor, capacitor tanks, vacuum – and SF circuit breakers gas insulated

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.
switch gears and insulators.

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The products, which are manufactured in HEEP, are: - Steam Turbines, Turbo
Generators, hydro turbines, Gas turbines, etc
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 m
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COIL & INSULATION MANUFACTURING SHOP
(BLOCK-IV)
Introduction

As the complete one peace coil is not practicable so the coils are manufactured in two parts,
upper and lower bars. Out of the various BLOCKS as mentioned before the coil and
insulation manufacturing block is BLOCK-4. This block is known as the COIL AND
INSULATION MANUFACTURING block. Block-4 is a feeder block for insulating items,
winding with class-B Bituminous insulation and sheet metal components for all the products
of Block-1 i.e. Turbo-generators, Hydro-generators, A.C. and D.C. machines. There are three
BAYS in this block each bay manufactures stator bars and coils for different machines as
mentioned below:

BAY-I: Bar winding shop: manufacturing of stator winding bars of generator.

m
BAY-II: Manufacturing of heavy duty generator stator bars with New CNC M/c No. 3-

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464 i.e. Roebel bar centre.
BAY-III:
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Insulation detail shop: Manufacturing of hard insulation & machining of
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hares insulation part (Glass Textolite) such as packing, washer, insulation box,
wedges etc. & CNC taping machine.
Bar Shop: m
This shop is meant for manufacturing of stator winding coils of turbo-
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generator and hydro generator.

Why do we call it bar?

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It is quite difficult (rather impossible) to manufacture, handle and wind in the stator slot of

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generator of higher generation capacity because of its bigger size and heavy weight. That is
why we make coil in two parts. One part its bottom part of coil called bottom or lower bar
and other part of coil is called top bar or upper bar.

.Turbo-Generators: The manufacturing of bars of standard capacity such as 100MW,

130MW, 150MW, 210/235MW, 210/250MW, 500MW. The plant has capacity and
technology to manufacture 800MW and 1000MW generators.

Types of generators: The generator may be classified based upon the cooling system used in
the generators such as: THRI, TARI, THDI, THDD, THDF, THFF, and THW.
 T => First alphabet signifies the type of generator i.e. turbo- generator or Hydro-
generator.
 H/A => Second alphabet stands for the cooling media used for the cooling of rotor i.e.
hydrogen gas or air.
 R/D/F/I => Third alphabet signifies the type of cooling of rotor e.g. radial, indirect,
forced, direct etc.
7
 I/D/F => Last alphabet stands for the type of cooling of stator e.g. indirect cooling, direct
cooling, and forced cooling.
 W => Cooling media used for cooling of stator coil e.g. water.

Sections in Block IV

(a) Assembly Section

 Mechanical Assembly Section: - It is equipped with small size drilling machines,
welding sets and hydraulic testing equipment for manufacturing turbo-generator
mechanical assemblies.
 Close Cubical Assembly Section

(b) Stator Bar Winding Section

 Conductor cutting, insulation and transposition section having facilities for
transposing the bars.
 Stack consolidation section, forming and lug brazing sections have block type
m
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hydraulic press, steel former and induction brazing installations respectively.

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 Insulation taping sections with automatic taping facilities in air-conditioned
.
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temperature covering maximum slot portion each overhung ay both ends.
 Baking and pressing section having baking moulds for simultaneous curving of
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straight and overhead portion with electrical heating.

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(c) Armature Winding, Rotor coil and Stator bar Section :-

rich discontinuousu
Coils are diamond pulledd type with Class-B (bitumen) and Class-F (conventional or resin

t epoxy insulation) and Class-H Silicon insulation for machines ranging

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from 5 to 460 KW capacity.
This section has the following work centers:-
 Conductors cutting, U- bending and terminal conductor cutting machines, U- bending
machines and terminal baths.
 Forming and Insulation of DC coils.
 Main and Interpole Winding: - It is having semi-automatic winding machine.
 Planking, boat pulling and diamond pulling machine.
 Insulation and pressing of AC coils: - it is equipped with hydraulic presses of 608 T
capacities.

(d) Impregnation Section :-

It is equipped with impregnation tank, ovens for impregnation of DC pole coils.

8
(e) Insulation Section :-
 Insulating details, machining is equipped with small size lathes, milling and radial
drilling machines and jet cutting saw.
 Press Molding Section: - It has electrical ovens, hydraulic presses, shearing and
circular saw cutting machines for manufacturing press molded components of all the
electrical machines.
 Plastic Molding Section: - Is equipped with various presses for plastic molded parts.
 Bitumen Mica Tape Manufacture: - Is equipped with mica tape manufacturing
machine and lathe for slitting mica tape to the required size.

MFG. Process flow chart of 500MW TG stator bar

1. Conductor draws from store.

2. Conductor cutting and end cleaning.
3. Transposition of conductor.
4. Assembly of all conductors to be used in stator bars.
5. Cross over insulation. m
6. Consolidation if slot portion of bar.
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7. I.S Test (i.e. inter strand test).
.
8. Forming of bar (to shape overhang portion). a
9. Pickling of bar ends (1).
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10. Mounting of contact sleeve & bottom part of water box.

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11. Brazing of contact sleeve & bottom part of water box.

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12. Pickling of bar ends (2).

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13. Mounting of water box leak test.
14. Re-Pickling.
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15. Water flow and Nitrogen test.
16. Thermal Shock Application.
17. Helium leak test.
18. Reforming of bar (i.e. overhang portion).
19. Insulation of bar on CNC machine.
20. Impregnation & curing of bar insulation.
21. Surface finishing of stator bar.
22. OCP on stator bar.
23. Preparation of bar for HV and Tan δ test.
24. If O.K. Dispatch to Block-1 for lying in the generator.

9
 m
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.
Figure 1 Main Products of CIM, Block-IV
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Figure 2. Layout of CIM, Block-IV

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Chapter 2
MANUFACTURING PROCESS OF BARS

BAY-1

Some points of manufacturing process is in brief as below –

1. Insulation Check

For the manufacturing of stator bars insulated copper conductors are brought from
Bangalore, it’s of two type’s i.e. solid copper conductor & hollow copper conductors
which are used in water cooled stator layer glass insulation.
 Insulating materials and the conductors are ensured to be certified.
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 If required the insulation is checked by the respective agencies.

2. Conductor cutting . c
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This process is done by automatic CNC machine. In this process the pre-insulated copper
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conductor is cut into number of pieces of required length (length given in drawing as per

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design) insulation is removed from both ends of the copper conductor out.
Lower Bar:
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Conductor Sizet
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Length Number of conductors
8*4.6*1.5mm(Hollow) 10200mm Hollow - 20
8*2.8mm(Solid) 10200mm Solid - 20

Upper Bar:

Conductor Size Length Number of conductors

8*4.6*1.5mm(Hollow) 10500mm Hollow - 20
8*1.3mm(Solid) 10500mm Solid - 40

3. 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

11
 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.

Transposition is done in two ways:

 Half Pitch Transposition: - In this transposition, the first conductor at one end of the bar
becomes the last conductor at the other end of the bar.
 Full Pitch Transposition: - In this method of transposition, the first conductor at one end
of the bar becomes the last conductor in the mid of the bar and then again becomes the
first conductor at the other end of the bar.

1. To reduce eddy current losses.

2. Equalize the voltage generator.
3. To minimize skin effect of ac current, small cross section of conductor is used and
also hollow conductors are used to effect cooling by D.M water.
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.
4. Crossover insulation:

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The pre insulation of the copper conductor may get damaged due to mechanical bending

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in die during transposition, hence the insulating spacers are provided at the crossover

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portion of the conductors. A filler material (insulating putty of molding micanite) is
provided along the height of the bar to maintain the rectangular shape and to cover the
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difference of level of conductors. To eliminate inter turn short at bends during edge wise

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bending and leveling of bars in slots portion for proper stacking.

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5. Stack Pressing:-

This process is basically done to consolidate the solid as well as the hollow conductors
into a single bar, the insulating material provide at crossover positions which has gluing
properties melts and helps in the proper consolidation of the bar. In this process the bar is
pressed both vertically and horizontally in the Pressing Machine. The pressing machines
are also provided with the heaters
Each bar is loaded on each tier of heating plate and it is then provided with an initial
pressure of 35±5 kg per cm2 and an initial temperature of 100-110° C. then the
temperature is allowed to raise to the maximum of 160°C, this temperature is kept for at
least one hour with a final pressure of 80±10 kg per cm2 vertically and 70±10 kg per cm2
horizontally.
After pressing the bar at specified pressure and maximum temperature for one hour,
the bars are then cooled placing them on cooling plates through which water is allowed to

12
 follow below 50°C. The cooled bars are checked for their heights and widths at pressed
portion of the bar.
This complete process performed above is for one half of the bar. The same process is
then repeated for the other half of the bar similarly and then checked for bar’s height and
width at pressed portions as done before. Then the ends of both the bars are cleaned with
rectified spirit and sand paper for the inter strand test

6. Inter Strand Short test: -

The consolidation bar 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. (300V A/C supply).
For this test all the bare conductors at both the ends are separated from each other so
that they do not short circuit. Then a live wire is connected to a conductor and received
from it consecutive conductor to light a lamp. Hence if the lamp lights up it shows short
circuit between the two conductors due to improper insulation between them. It shows
insulation failure between the conductors, these conductors are then replaced and bar is
followed through all the previous processes. Similarly all the conductors are checked for
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any short circuit. After passing both the half bars from I.S.T. the bars are combined

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together and pressed into a single bar. A sheet of mica glass insulation is provided
.
between the two halves as the insulation also has some gluing property to consolidate the
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two halves into a single bar. All the steps of pressing are again followed for the complete
bar and then it is allowed to cool.
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7. Forming: -
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In heavy generators each stator coil is very large in size and hence its manufacturing is

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difficult as it will be very difficult to handle and process the complete coil. So each coil is
manufactured in two halves i.e. Upper half and Lower half. The bars which are processed
till this process are straight and hence they are required to be formed into the upper half
or the lower half. Hence this process of forming is very important as in this process the
bars are bending from both the ends of the bar i.e. at exciter side and turbine side at
specific angles and shape as per design.
This process is done manually. First the former is set according to the design making
different angles at different positions. Each bar of a variant is bent or formed at same
angle. Once the former is set, the bar is mounted on it and formed manually by melleting
it from both the ends.
After forming the formed portion of the bars are assumed to get loose creating air
gaps between the conductors due to such a heavy melleting. Thus the formed portion of
the bar are clamped at different places and provided with heaters to reconsolidate the
formed portion. After few hours the bar is then allowed to cool at room temperature.

13
8. End Conductor Cutting:

Due to heavy malting of the bar for forming it from both the side i.e. exciter side and
turbine side, the conductors of the bar are produced at the ends of the bar. Therefore to
bring all the conductors of the bar in a plane End Conductor Cutting is required to be
done. Both the solid and hollow conductors are cut and from both the sides of the bar.
Also this process of cutting of the hollow conductors helps in opening of vents of hollow
conductors from both the ends of the bar.

9. Pickling Process:

After the forming and cutting process of the bar and due to the transportation of the bar,
there accumulate very minute particles of dust on the ends of the bar. These particles may
cause hindrances at the time of brazing and may create some air gaps.
So, in order to remove these unwanted particles, basically the oil particles pickling
process is performed. The basic solution used for this process is called pickling solution.
The constituents of the pickling solution are:
 Sulphuric acid (H2SO4)-10%
m
 Phosphoric acid (H3PO4)-5%
c o
 Hydrogen peroxide (H2O2)-5%
.
 Water (H2O) a
m
There are many other solutions used in this process, these are:
 Ammonia
a
yn
 Thinner
 Water
d
tu
 Rectified spirit
 Nitrogen
S
In this process the following steps are involved:
 The end of the bar is dipped in thinner to remove the dust or oil particles.
 The end is then dried with the help of N2 gas.
 Then the bar end is dipped in pickling solution for 5 to 10 minutes.
 This is then followed with dipping in water.
 As there is acid in the pickling solution, so accordingly to neutralize the acidic effect
of the acid it has to be treated with some base, so the bar is then dipped in Ammonia
(10%).
 It is then followed with dipping in water.
 As water takes a lot of time to evaporate, it may let the tiny chemical particles on the
bar to react with it and leave spots on the bar, this may weaken the insulation at those
particular points and thus damage it, further it may lead to poor brazing. So in order to
avoid such a damage the bar is dipped in rectified spirit to make the water contents
evaporate as soon as possible.
 The bar is then dried with N2 gas.
14
  Finally it is wrapped with cotton cloth to avoid any manual touch which may deposit
any dust particle on it until it is ready for brazing. The same process of pickling is
then preformed on the other end of the bar.

10. Contact Sleeve Mounting:

After the pickling process is complete, contact sleeve and water box bottom parts are
mounted on both the ends of the bar. Contact sleeve, as clear from the name itself, it is a
rectangular sleeve which is used to make contact between upper and lower bars when laid
out in the generator to form a complete coil. All the solid conductors are cut from the
ends of the bar after the contact sleeve except the outer solid conductors. None of the
conductor is cut before the contact sleeve so that to make proper contact between the
upper and the lower bars.
The water box is mounted in two halves; first the water box bottom part is mounted
after the contact sleeve keeping some distance between them.
Both the ends of the bar are then again pickled along with contact sleeve and water
box bottom part following the same procedure of pickling.
m
11. Brazing of coil lugs: -
c o
.
a
For water cooled generator bars, the electrical connection contact and water box for inlet
m
and outlet of water are brazed. The contact sleeves, which are used to make contact
a
yn
between the upper bar and the lower bar to form a complete coil and the water box
bottom part, both together are called Coil Lug, so the brazing of these two parts at the end

d
of a bar is called Coil Lug Brazing. Brazing is basically the process of fixation of both the

tu
contact sleeve and water box bottom part or we can say both are properly consolidated

S
using brazing material at high temperatures.
Consolidation is properly done so that no air gap is left which would adversely affect
the conducting properties of the contact sleeve and the bar.

The two types of brazing processes are:

 Thermal brazing (using LPG)
 Induction brazing

As induction brazing is more beneficial than thermal brazing as it does not requires any
inflammable gas for heating. So now a day’s Induction brazing process is used. For brazing
as we use very high temperature so that is possible due to carbon strips fixed on the brazer.
Carbon has very high resistance and when the current is allowed to pass through it due to
induction the material to be brazed i.e. Contact Sleeve gets super heated. Induction heating is
hence faster and even more efficient than thermal heating.

15
 When the contact sleeve becomes red hot at 750ºC, the brazing material is then
pushed to fill the air gaps and to consolidate the contact sleeve on the bar. It is then allowed
to cool.

The types of brazing materials used are:

 LAG 15P ( Alloy Silver 15 Phosphorous)
 LAG 40Cd ( Alloy Silver 40 Cadmium)

Same process of brazing is then repeated for the water box bottom part. After the brazing of
water box bottom part the bar is then allowed to cool at room temperature.

12. End Conductor Cutting

As is clear from the name itself this is the process of cutting of extra conductors i.e. the
hollow conductors left after the water box bottom part are cut from both the ends of the

m
bar. These conductors are required to be cut so that water box top part with a nozzle is to

o
be mounted on the water box bottom part. The vents of the hollow conductors are visible
c
.
from the ends of the water box bottom part. The openings of the vents of the hollow
conductors are then checked to be uniform.
a
m
After cutting of extra conductors from both the ends of the bar, pickling process is

a
done. Same pickling process as mentioned before is then done at both the ends of the bar

yn
for removing the dust particles, oil particles and other unwanted impurities which we
assume to be there after the brazing process of the contact sleeve and water box bottom
d
part. After pickling the bar ends are then wrapped in cotton cloth until the water test is
performed.
tu
S
13. Water Test:

Water test is performed so that there not any blockage in the vents and also to check the
flow of water. Flow should be uniform i.e. all the vents should have same water flow.
In this test water is supplied from one side of the bar and is collected from the other
side of the bar in a tank and is supplied back to the first end. Flow of the water is
checked by measuring the distance of the flow of water.
If there is any kind of blockage inside the hollow conductors of the bar then it is
indicated by flow of water i.e. flow of water will be not uniform and the bar is assumed
to be chocked. Then cocked conductors are changed or repaired and the bar is reformed
and water test is again performed to check the flow of water.

16
14. Brazing Of Water Box Top Part:

Brazing of water box top part is done with water box bottom part in brazing section of
Block-4.For this it should be kept in mind that water box bottom part should have same
material as that of water box top part.
The difference in previous brazing and this brazing is that, now flux is also introduced
with brazing material and also flux is mixed with copper chips. Copper chips are added
to make the electrical contact between the top and bottom part without the copper chips
this will be not possible.
In this brazing material is formed in the shape as that of water box side where it has to
be brazed. Brazing material is formed in square shape for top and bottom part and in ring
shape for the brazing of nozzle for water flow. Then both the parts are heated with
induction brazer as done earlier. It is heated until they become red hot then the brazing
material melts due to its low melting temperature then the melting temperature of the
water box top and bottom part. Brazing material is also introduced at the boundaries until
it is completely consolidated that is the entire air gap is completely filled.
After the brazing of water box top part the bar is then allowed to cool at room

m
temperature.

c o
15. Checking Of Threads and Pickling Process:
.
a
As mentioned earlier that water box top part has got nozzle for flow of water, it also has
m
a
got threads which is provided for the proper fixation of water supply through water pipe

yn
to the bar. These threads are checked for its uniformity by fixing water pipe to the
nozzle. If threads are not found satisfactory than the nozzle is replaced with new one

d
and again its threads are checked.

tu
Also the pickling process is again done for the removal of any dust particles and

S
lubricants etc. the detail of this process is same as mentioned earlier in pickling process.

16. Nitrogen leak test: -

As the name suggests Nitrogen gas is the main constituent of the test. This test is similar
to puncture test that is inflated tube is dipped in water for any leakage, the air bubbles
gives us the exact position of the puncture.
Similarly on the same steps this test is performed. Basically this test is performed to
check any leakage in bar i.e. to check the brazing. In this test nitrogen at a pressure of
10Kg/Cm2 is forced from one end of the bar and other end of the bar is blocked then the
pressure of 10Kg/Cm2 is maintained and both the ends of the bar are dipped in water.
The bubbles if there any tells us that brazing is weak or not done properly. So if bubbles
appear then brazing is done again and same test is performed for the proper brazing of
water box top and bottom part.
Then both the ends of the bar wrapped in cotton cloth so that it is not disturbed i.e. to
17
 avoid any manual touch which may deposit any dust particle on it until it is ready for
brazing.

17. Internal Pickling

After various test performed on the bar the pickling process i.e. removal of any dust
particles lubricants etc is done only on outer surface of the bar (ends). But from inside it
is assumed that there must be some impurities, foreign material must be present. For this
purpose inside pickling is done.
As mentioned earlier same process is repeated but from inside of the hollow
conductors this time.
In this process the following steps are involved:
 The thinner is passed through the bar to remove the dust or oil particles.
 The dried with the help of N2 gas.
 Then the pickling solution is passed for 5 to 10 minutes.
 Then water is flowed in the bar.

m
 As there is acid in the pickling solution, so accordingly to neutralize the acidic effect

o
of the acid it has to be treated with some base, so the bar is filled with Ammonia

c
.
(10%).
 It is then followed flowing of water again.
a
 As water takes a lot of time to evaporate, it may let the tiny chemical particles in the
m
a
bar to react with it and leave spots in the bar, this may weaken the insulation at those

yn
particular points and thus damage it, further it may lead to poor brazing. So in order to
avoid such a damage the rectified spirit is flowed in the bar to make the water

d
contents evaporate as soon as possible.

tu
 The bar is then dried with N2 gas.

S
 Finally it is wrapped with cotton cloth to avoid any manual touch which may deposit
any dust particle on it until it is ready for brazing.

18. Baroscopic Testing

This test is performed to check the impurities or foreign material inside the bar. To look
inside with naked eye is not possible so we use baroscopic for this purpose.
So after internal pickling we use a baroscopic to look inside the bar. Baroscopic is
having a probe having a LED (light emitting diode). LED is used to provide light inside
the bar. The probe of the baroscopic is inserted from one end of the bar and seen from a
magnifying lens. The probe gives a light which is reflected by the sides of the bar
(inside) and with the help of magnifying lens we get a clear image that what is there in
the bar.
If impurities are present then these are removed then only after the bar is send to next
operation.

18
19. Water Test:

Here again water test is performed. In earlier water test water flow was checked without
the water box top part. But now the top part is brazed to the bottom part and to check its
flow this test is performed.
Also to check the proper flow from the nozzle this test is performed. In this test water
is forced or pushed from one end of the bar and flow of water is checked from other end
of the bar. This test tells us the presence of any choke vents of water box top part. If any
choke vent is present then it is repaired or whole of the water box top part is changed
with new one.

20. Thermal Shock Test:

Thermal shock test is performed to check whether the bar can withstand extreme
conditions i.e. when the generator is working or running at about 3000 Rpm. This is
achieved by thermal shock test.
Thermal shock test consist of series of hot water & cold water cycles alternatively. So
firstly hot water at temperature of about 90ºC is passed through the bar and then cold

m
water at about room temperature 27ºC approx. is flowed inside the bar alternatively. This
process is repeated again and again.
c o
.
This process is repeated for about 26 times i.e. it has 26 cycles of hot and cold water.
a
So this test tells us the strength of the bar so that it can withstand the working conditions

m
of the generator. Temperature of the bar is taken in account according to the working

a
temperature of the generator. The cycles of hot (800C) and cold (300C) water are flown

yn
through the bar to ensure the thermal expansion and contraction of the joints.

d
tu
21. Helium Leakage Test:

S
Helium test is the most important test of all, because helium test is performed to check
any minute leakage within the bar and at the brazed portion. Any minute leakage which
couldn’t be checked by water test can easily be observed by helium test because helium
is one of the lightest gases. So this is also the customers check point, before performing
this test customer is by called and they see themselves the test being performed and if
They find the test all right then only the bar is send to next process.
In helium test, whole of the bar is wrapped in the polythene excluding the end points.
The helium gas at pressure of 11Kg/Cm2 is passed through the bar and a probe connected
to the gauge is inserted inside the polythene at different places. The gauge will show
deflection if there is any helium atom present. Gauge will show reading even if 1 helium
atom in 100000 atoms is present. This test checks the strength of brazing and insulation.

19
22. Reforming:
After all the previous processes which had undergone on the bar it is assumed that the
shape of the bar is deformed from its original shape due to handling of the bar from one
place to another for different processes. So to keep the shape of the bar as per design, the
bar is checked if it is found distorted then it is reformed in the previous former machine
by placing the bar on the former and malleting.

23. 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. Insulation is
basically done to prevent any kind of short circuit between the bar and the stator core
when the bar is assembled in the stator of the machine. The stator bars are insulated with
Micalastic (trade name) insulation. High quality mica, selected epoxy resins and a
matching vacuum impregnation process are the characteristic features of the micalastic
insulation for large turbo generators.
The bar is provided with 14 layers of insulation. Out of these fourteen layers, 12
layers are provided by using a machine called CNC TAPPING MACHINE manufactured
by a company named MICAMATION. The rest of the two layers are provided manually.
m
The insulating material varies as according to the rating of the machines as follows:
 For 500 MW : Mica Splitting Tape
c o
 For THRI : Mica Glass .
a
During machine taping in the slot portion the transition from machine to hand taping is

m
adjusted at the start of the bend for a tape width for every layer from bar center. After
a
about half the number of layers, the taping is to be started further at the bend.

yn
The mica tape consists of a thin high strength baking material to which the mica is

d
bounded by synthetic resin. The number of layers i.e. the thickness of insulation is

tu
determined by the voltage of the machine.

S
24. Impregnation and baking :

a) Thermo reactive 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
vacuum 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.

c) VPI Micalastic System: - The bars already lay in closed fixture and full fixture is
impregnated (dipped) in resin and then fixture with box is baked under given
temperature for given duration.

20
 d) VIP Micalastic System: - The individual (Separate) bar is heated in vacuum and
impregnated in resin. Then bar is taken out and pressed in closed box fixture and then
baked at given temperature for given duration.

25. Micalastic Insulation and Impregnation

For insulation with micalastic, the conductor strands are arranged together to form a
compact assembly and set to the required shape. This assembly is then baked with epoxy
resin to give it mechanical strength required for further processing. The bars are then
dried under vacuum and impregnated with synthetic resin, which by reason of its low
viscosity penetrates the insulation thoroughly and eliminates all voids. After impregnation
under vacuum, the bars are subjected to pressure, with nitrogen being used as pressurizing
medium. The impregnated bars with direct conductor cooling are then brought to the
required dimensions in moulds and cured in an oven at a high temperature.
This complete process involves pressing of the bars, drying by heating, impregnation
in resin and finally curing. These processes are discussed briefly below:

m
o
 Pressing: The bars are pressed to bring them back to the original dimensions.
c
.
 Drying: The stator windings are to be dried under vacuum 0.1 m bar at (60±5) °C for

a
15 hours, minimum. The drying temperature is to be increased to (65±2) °C if the

m
initial viscosity of the impregnating resin mixture is high.

a
The temperature distribution should be as uniform as possible. The drying under

yn
vacuum can be stopped if the pressure rises, 10 minutes after closing of vacuum valve
is less than 0.06 m bar.
d
 Impregnation: The impregnation resin mixture is to be heated in the working tank, to

tu
(60±3) °C or in case of higher initial viscosity. At a temperature of 50ºC, the

S
impregnating resin mixture is to be degassed with 1-5 m bar vacuum. Subsequently
the stator windings are to be dipped continuously in resin hardener mix such that the
highest locations of the windings are at least 100 mm below the resin level. After 10
minutes of resin stabilization, pressure is increased by application of nitrogen.
Pressure is to be gradually increased in uniform stages within 80 minutes to 4 bars
and to be maintained for 120 minutes in the impregnation tank.
The impregnation of the stator winding is to be monitored continuously.
Further it is to be decided whether to increase the pressure or to stop the impregnation
process, however the total period of nitrogen pressure cycle shall in any case not
exceed 4 hours. The impregnation tank during shut down is to be closed and kept
either filled with nitrogen (1.1bar) or low vacuum.
 Curing: To prevent heating in the overhang portion, the curing of the impregnated
stator winding is to be done with a maximum 160°C hot air. The curing period is
extended for such a long time till the measurement positions in the core indicate
(140±5) ºC for minimum 8 hours.

21
26. Finishing: - The baked and dimensionally correct bars are sanded - off to smoothen the
edges and the surface is calibrated, if required, for the dimension.

27. 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.

Resin System
a) Rich resin or Thermo reactive 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 20-250C. Its shelf life is one year when kept at
temperature 200C which could be increased when kept at temperature of 50C.
b) Poor resin or Micalastic insulation system: In this type of insulation the bond content in

m
the resin is 5-7% and insulating material is prepared with accelerator treatment. The

o
temperature control need not required. The insulating material is applied on job and then

c
.
the same is impregnated (fully dipped) in the resin.

Testing a
m
a
yn
When the bar is dried it is wrapped with aluminum sheet to make outer surface of the bar
conducting so that tan δ and H.V. (High voltage test) can be performed. After these tests the

d
coating of red gel is applied at both the ends of the bar.

Tan∆ Test tu
S
Test is performed to find the capacitance of the bar because bar will act as capacitor when it
is laid in the stator of the generator. In this test Schearing Bridge which works on the
principle of wheat-stone bridge is used to find the unknown capacitance of the bar. For good
efficiency, capacitance of the bar should be high but we never approach pure capacitance.
In this test also same bar which is wrapped with aluminum is used to make the bar
conductive throughout the outer surface of the bar. The two conducting material i.e. the
aluminum sheet and the conductors of the bar act as two plates of the capacitor and the
insulation on the bar act as dielectric medium for the capacitor. The capacitance of the bar is
found and of angle of deviation due to impurity in the insulation is obtained from the
formula:
C4 * R4 * 10-4 = tan δ
For different ratings of the bar the acceptable value of tan δ is fixed according to their
insulation requirement as per design considerations.

22
H.V. (High Voltage) Testing

This test is also known as insulation test because this test is performed to check the insulation
of the bar. In this test the bar which is already wrapped with aluminum is used. High voltage
is applied to the bar using auto-transformer and it is increased in steps according to the
working voltage of the generator. If the insulation is weak the bar will puncture at the place
of weaker insulation. For 500 MW the working voltage of the bar is 64.5 KV & for 210 MW
the working voltage of the bar is 63 KV. If any of the bar fails this test i.e. bar is punctured at
any point then the bar is sent back for re-insulation and all the processes are repeated again.

m
c o
.
a
m
a
yn
d
tu
S

23
Chapter 3
BAY-2
Introduction:
Bay 2 is the manufacturer of stator bars of hydro generators, stator coils of AC motors and
stator coils of DC Exciter. The stator coils of AC motors of up to 11 KV, stator bars of Hydro
generators of 200 MW and DC Exciters of all the 500 MW THRI generators are
manufactured in this bay.

The processes involved in the manufacturing of AC motors are as follows:

Insulation Check
For the manufacturing of stator coils of AC motors, insulated copper conductors of specific
dimensions rolled on the drums are brought from Bangalore. Before performing any process
on that conductor, the insulation of the conductor is checked.
m
o
 Insulating materials and the conductors are ensured to be certified.
c
.
 If required the insulation is checked by the respective agencies.
a
m
a
yn
Conductor Tapping
The copper conductor is first provided with two layers of insulation, this is also known as
d
double layer tapping. The insulation tape used in this is Micafabriglass Tape. In this process

tu
the copper drums are loaded on the stand and tapping rolls on taping heads of the Tapping

S
machine. The copper conductor is insulated with two layer of tape in butt as per design and
hence the insulated copper conductor is again rolled on the drum from other side of the
machine. The insulation on the copper is checked, which is provided by the automatically
moving tapping rolls with some tension.

Winding Boat Coil

The next process is forming a boat shape coil with the insulated copper conductor. In this
process the former of the boat shape coil, which is adjustable in length, is first set as per
length of the coil required according to the design. The number of conductors per turn and the
total number of turns in a coil are all set according to the design. The insulated copper
conductor drums are loaded on stand on one side of the former, the former is then rotated and
hence a boat shaped coil of specified length and specific number of turns is formed.
The boat coil is then checked for its length and number of turns.

24
Boat Insulation
The boat coil is then sending to the insulation block for its insulation. Here the complete boat
coil is insulated with single layer of polythene and then the stack consolidation length of the
coil is marked and the coil is send for the next process.

Stack Pressing
In this process the press plank is first cleaned then the boat coil is loaded in the press. The
boat coil is cured for 35 minutes at 155 ± 5 °C under high pressure (to ensure closing of box)
after attaining the temperature. 0.1 mm filler gauge should not go inside the box. The stack
length and width of the boat coil is checked at slot portions. The pressing of the boat coil is
done for the consolidation of the coil. The length of heating plates should be approximately
equal to the stack consolidation length of coil.

Forming
The forming of the boat coil is done in an automatic machine i.e. Schumann Pulling Machine.

m
The machine is first set, and then the forming plates are mounted for overhang on the
o
machine. The forming plates mounted are according to the overhang design of the coil. The
c
.
required variant of boat coil is pulled into the diamond shape. The loading of boat coil should
a
be as per the variant of boat coil given in the design. The coil dimensions and geometry of the

m
coil is then checked on the Universal Model. The terminals of the coil are set according to the

a
design and also the first bends and the overhang portions are marked.

yn
Insulation d
tu
In this process the slot portion and the first bends of the coil are insulated with accelerator

S
treated Mica Tape as per design. For the stator coil of 11 KV AC motor, total 8 layers of
insulation tapping are provided i.e. three layers at the slot portion and the rest five layers all
over the coil. Generally for the stator coils of low rating motors total five layers of insulation
tapping is provided. The insulation tape used is Epoxy Mica Paper tape. Red tape is the
finishing tape provided at the overhang portions of the coil. The black colored insulation tape
in conducting in nature and it is provided at the slot portion of the coil. The insulation tape at
the bend portions of the coil is grey in color and is semi conducting in nature.
Then the perimeters and width of the insulated coil is checked at the slot portion of the coil.
A release film is to be provided on the entire coil including coil terminals. On slot portion
two layers of release film is provided. The coil is now sending for the next process.

Impregnation
For impregnation pressing strips are mounted on the coil. The pressing strips are checked to
be closed properly. The coils are then impregnated in micalastic resin as per design.

25
 The impregnation resin mixture is to be heated in the working tank, to (60±3) °C or in case
of higher initial viscosity. At a temperature of 50ºC, the impregnating resin mixture is to be
degassed with 1-5 m bar vacuum. Subsequently the stator windings are to be dipped
continuously in resin hardener mix such that the highest locations of the windings are at least
100 mm below the resin level. After 10 minutes of resin stabilization, pressure is increased by
application of nitrogen. Pressure is to be gradually increased in uniform stages within 80
minutes to 4 bars and to be maintained for 120 minutes in the impregnation tank.
The impregnation of the stator winding is to be monitored continuously. Further it is to be
decided whether to increase the pressure or to stop the impregnation process, however the
total period of nitrogen pressure cycle shall in any case not exceed 4 hours. The impregnation
tank during shut down is to be closed and kept either filled with nitrogen (1.1bar) or low
vacuum.

Curing
After the impregnation of the coil, it is then cured at 140 ± 10 ºC for 18 hours after attaining
the required temperature. Curing of the coil is done for the proper consolidation of the coil.

m
The regime is then required to be checked. The pressing strips are disassembled after the

o
curing of the coil. The dimensions of the coil are then checked.
c
.
Finishing a
m
a
In this process the release film is removed and the coil is finished with sand paper. The

yn
straight length of the coil is marked. The coil is then coated with corona protection varnish as
per design and then the coil is allowed to dry properly for 6 hours. The slot portion
d
dimensions and the quality coating varnish are then checked.

tu
The coil is checked for its insulation using tan δ and H.V. (High Voltage) Test.

26
 BAY -3
Introduction:

Bay 3 is the manufacturer of insulating material of different shapes and sizes as required
according to the design. This bay is also called as I.D. Section (Insulation Design Section).
For the manufacturing of insulations, different raw materials having insulating properties are
brought by this section. The raw materials having different insulating properties are then
processed in this section and molded to different shapes as per design.
The raw materials used in this bay are:
 Glass based Textolite Sheet
 Cotton based Textolite Sheet
 Paper based Textolite Sheet
 Mica Glass sheet
 Teflon Sheet
 Mica Sheet
 Nylon Sheet
 Ebonite
m
 Perpex Glass Sheet
c o
 Nomex Paper
.
 Asbestos Sheet
a
 Asbestos Paper
m
a
n
All the insulating raw materials mentioned above are in the decreasing order of their
y
are categorized accordingd
insulating property. The insulating materials used in the manufacturing of insulation moulds

u
to their laying requirement in the machine i.e. if an insulation
mould is to be fixedtin the place where the risk of fire is more then at those places moulds of
S
Glass based Textolite sheet are preferred because cotton based or paper based textolite sheet
could catch fire at those places.
Teflon Sheet has an important property and i.e. Teflon is non heat transferring material. So
an insulating mould of Teflon is placed above the bearings of the rotor so that is any fault in
the bearings of the rotor produces any heat then it is prevented by this material to get
transferred to the rotor, and hence prevents the rotor of the machine.
For the manufacturing of insulation moulds, the glass insulation raw material in fibers is
first pressed into blocks in a pressing machine with the help of heaters and hydraulic
pressure. Fibers are made into blocks because if fiber is used as it is then volume of the
material will be very large. So blocks are placed on weighing machine and then weighed
equal to the product required according to design. So then these blocks are placed in the
mould and heated and molded in the shape as that of the mould by applying sufficient
pressure and temperature.

27
Chapter 4
ELECTRICAL MACHINES BLOCK (BLOCK — I)
Introduction
1. Block-I is designed to manufacture Turbo Generators.

2. The block consists of 4 bays- Bay-I (36*482 meters), Bay-II (36*360 meters) and Bay-III
and Bay-IV (Of size 24*360 meters each).

3. 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.

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4. Testing facilities for Turbo generator are available in Bay-II.

. c
5. There is a special test bed area for testing of T.G. of capacity of 500 MW Unit sizes.
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Manufacturing Process
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(Block — II, V, VI, VIII), d
Fabricated components are received in respective machine sections from Fabrication blocks

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t foreign sources for Turbo Generators. Stampings are received from
while castings and forgings are received from sister unit CFFP and

S block, block—VI and coils, bars, insulating details and sheet metal
other indigenous and
stampings manufacture
components are received from coils and insulation manufacture and apparatus and control
gear box (block — IV).

1. Turbo Generators –

a) Making of blanks is done for checking the availability of machining allowances.

b) Machining of the major components is carried out in Bay - I & Bay - II and other
small components in Bay - III and Bay - IV. The boring and facing of stators are done
on CNC horizontal boring machine using a rotary table. The shaft is turned on lathe
having swift 2500 mm and the rotor slots are milled on a special rotor slot milling
machines.

c) In case of large size Turbo Generators core bars are welded to stator frame with the

28
 help of telescopic centering device. The centering of core bar is done very precisely.
Punching is assembled manually and cores are heated and pressed in number of stages
depending on the core length.

d) Stator winding is done by placing stator on rotating installation. After lying of lower
and upper bars, these are connected at the ends, with the help of ferrule and then
soldered by resistance soldering.

e) Rotor winding assembly is carried out on special installation where coils are
assembled in rotor slots. The pressing of overhang portion is carried out on special
ring type hydraulic press, whereas slot portion is pressed manually with the help of
rotor wedges. Coils are wedged with special press after laying and curing. The
dynamic balancing of rotors is carried out on the over speed balancing installation.
500 MW Turbo Generators are balanced in vacuum balancing tunnel.

f) General assembly of Turbo Generators is done in the test bed. Rotor is inserted in the
stator and assembly of end shields; bearings etc. are carried out to make generators
ready for testing. Prior to test run the complete generator is hydraulically tested for
leakages.
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.
g) Turbo Generators are tested as per standard practices and customer requirements.
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Turbo Generator
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500 MW Turbo generators at a glance -
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2-Pole machine with the following features:-
 Direct cooling of stator winding with water.
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 Direct hydrogen cooling for rotor.
 Micalastic insulation system
 Spring mounted core housing for effective transmission of vibrations.
 Brushless Excitation system.
 Vertical hydrogen coolers

Salient technical data-

 Rated output : 588 MVA , 500 MW

 Terminal voltage : 21 KV
 Rated stator current : 16 KA
 Rated frequency : 50 Hz
 Rated power factor : 0.85 Lag
 Efficiency : 98.55%

29
Important dimensions & weights -

 Heaviest lift of generator stator : 255 Tons

 Rotor weight : 68 Tons
 Overall stator dimensions [L*B*H] : 8.83m*4.lm*4.02m
 Rotor dimensions(Dia. and length) : 1.15m and 12.11m
 Total weight of turbo generator : 428 Tons

Unique installations-

Heavy Electrical Equipment Plant, Haridwar is one of the best equipped and most modern
plants of its kind in the world today. Some of the unique manufacturing and testing facilities
in the plant are:

TG Test Bed-

New LSTG [Large Scale Turbo Generator] Test Bed has been put up with indigenous know-
how in record time for testing Turbo generators of ratings 500 MW and above up to 1000

m
MW. It caters to the most advanced requirement of testing by employing on-line computer
for data-analysis.
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.
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Other major facilities are as follows –


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Major facilities like stator core pit equipped with telescopic hydraulic lift, micalastic plant
a
for the manufacture of stator bars, thermal shocks test equipment, rotor slot milling

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machine etc. have been specially developed by BHEL.

 12 MW/10.8 MW, 6.6d

u the 500 MW Turbo-generator at the TEST Bed. The motor has
KV, 3000 RPM AC non salient pole, synchronous motor have
t
been used for driving
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special features to suit the requirement of TG testing (500 MW and above). This is the
largest 2-pole (3000 rpm).

Over speed balancing vacuum tunnel -

For balancing and over speeding large flexible Turbo generators rotors in vacuum for ratings
up to 1,000 MW, an over speed and balancing tunnel has been constructed indigenously. This
facility is suitable for all types of rigid and flexible rotors and also high speed rotors for low
and high speed balancing, testing at operational speed and for over speeding.

Generator transportation -

 Transport through300 Tons 24-Axle carrier beam railway wagon specially designed
indigenously and manufactured at Haridwar.
 The wagon has been used successfully for transporting one generator -from Calcutta Port
to Singrauli STPP.
30
CONSTRUCTIONAL FEATURES OF STATOR WINDING
1) General –

The stator has a three phase, double layer, short pitched and bar type of windings
having two parallel paths. Each slots accommodated two bars. The slot lower bars and slot
upper are displaced from each other by one winding pitch and connected together by bus bars
inside the stator frame in conformity with the connection diagram.

2) Conductor Construction –

Each bar consists of solid as well as hollow conductor with cooling water passing
through the latter. Alternate arrangement hollow and solid conductors ensure an optimum
solution for increasing current and to reduce losses. The conductors of small rectangular cross
section are provided with glass lapped strand insulation.

A separator insulates the individual layers from each other. The transposition provides
for mutual neutralization of voltage induced in the individual strands due to the slots cross

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field and end winding field. The current flowing through the conductor is uniformly
distributed over the entire bar cross section reduced.
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To ensure that strands are firmly bonded together .
a
and give dimensionally stability in
slot portion, a layer of glass tape is wrapped over the complete stack. Bar insulation is done
minsulation is void free and posses better
a is more reliable for high voltage. This
with epoxy mica thermosetting insulation. This

nin dielectric dissipation factor with increasing test

mechanical properties. This type of insulation

y
insulation shows only small increases

d
voltage. The bar insulation is cured in an electrically heated process and thus epoxy resin fill

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all voids and eliminate air inclusions.

3) Method Of S Insulation –

Bar is tapped with several layers of thermosetting epoxy tape. This is applied
continuously and half overlapped to the slot portion. The voltage of machine determines the
thickness of insulation. The tapped bar is then pressed and cured in electrical heated press
mould for certain fixed temperature and time.

4) Corona Prevention –

To prevent corona discharges between insulation and wall of slots, the insulation in
slot portion is coated with semiconductor varnish. The various test for manufacturing the bar
are performed which are as follows-

(a) Inter turn insulation test on stuck after consolidation to ensure absence of inter short.
(b) Each bar is subjected to hydraulic test to ensure the strength of all joints.

31
(c) Flow test is performed on each bar to ensure that there is no reduction in cross section
area of the ducts of the hollow conductor.
(d) Leakage test by means of air pressure is performed to ensure gas tightness of all joints.
(e) High voltage to prove soundness of insulation.
(f) Dielectric loss factor measurement to establish void free insulation.

5) Laying Of Stator Winding –

The stator winding is placed in open rectangular slots of the stator core, which are
uniformly distributed on the circumference. A semi conducting spacer is placed in bottom of
slots to avoid any damage to bar due to any projection. Driving in semi conducting filler
strips compensates any manufacturing tolerances.

After laying top bar, slot wedges are inserted. Below slots wedges, high strength glass
texolite spacers are put to have proper tightness. In between top and bottom bars, spacers are
also put.

6) Ending Winding –

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In the end winding, the bars are arranged close to each other. Any gaps due to design

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or manufacturing considerations are fitted with curable prepag with spacer in between. The

a
prepag material is also placed between the brackets and binding rings. Lower and upper
layers are fixed with epoxy glass ring made in segment and flexible spacer put in between
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a
two layers.

also hollow from inside. These y

n
Bus bars are connected to bring out the three phases and six neutrals. Bus bars are

dproperly makes connection.

bus bars are connected with terminal bushing. Both are water-

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cooled. Brazing the two lugs
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CONSTRUCTIONAL FEATURES OF ROTOR
The rotor comprises of following component:
1) Rotor shaft
2) Rotor winding
3) Rotor wedges and other locating parts for winding
4) Retaining ring
5) Fans
6) Field lead connections

32
1) Rotor Shaft –

The rotor shaft is a single piece solid forging manufactured from a vacuum casting.
Approximately 60 % of the rotor body circumference is with longitudinal slots, which hold
the field winding. The rotor shaft is a long forging measuring more than 9m in length and
slightly more than one meter in diameter. The main constituents of the steel are chromium,
molybdenum, nickel and vanadium. The shaft and body are forged integral to each other by
drop forging process.

Following tests are done: -

(a) Mechanical test

(b) Chemical analysis
(c) Magnetic permeability test
(d) Micro structure analysis
(e) Ultrasonic examination
(f) Baroscopic examination

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On 2/3 of its circumference approximately the rotor body is provided with longitudinal slot to

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accommodate field winding. The slot pitch is selected in such a way that two solid poles

.
displaced by 180o C are obtained. For high accuracy the rotor is subjected to 20% over
a
speeding for two minutes. The solid poles are provided with additional slots in short lengths

m
of two different configurations. One type of slots served as an outlet for hydrogen which has

a
cooled the overhang winding and other type used to accommodate finger of damper segments

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acting as damper winding.

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2) Rotor Winding–t
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After preliminary turning, longitudinal slots are milled on sophisticated horizontal slot
milling machine. The slot house the field winding consists of several coils inserted into the
longitudinal slots of rotor body–

2.1. Copper Conductor –

The conductors are made of hard drawn silver bearing copper. The rectangular cross
section copper conductors have ventilating ducts on the two sides thus providing a
channel for hydrogen flow. Two individual conductors placed-one over the other are
bent to obtain half turns. Further these half turns are brazed in series to form coil on
the rotor model.

33
 m
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 2.2. Insulation –The individual turns are insulated from each other by layer of glass
prepag strips on turn of copper and baked under pressure and temperature to give a
monolithic inter turn insulation. The coils are insulated from rotor body by U-shaped
glass laminate module slot through made from glass cloth impregnated with epoxy
varnish.
At the bottom of slot D-shaped liners are put to provide a plane seating surfaces for
conductors and to facilitate easy flow of gas from one side to another. These liners
are made from molding material. The overhang winding is separated by glass
laminated blocks called liners. The overhang winding are insulated from retaining
rings segments having L-shape and made of glass cloth impregnated by epoxy resin.

2.3. Cooling Of Winding –

The rotor winding are cooled by means of direct cooling method of gap pick-up
method. In this type of cooling the hydrogen in the gap is sucked through the
elliptical holes serving as scoop on the rotor wedges and is directed to flow along
lateral vent ducts on rotor cooper coils to bottom of the coils. The gas then passes

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into the corresponding ducts on the other side and flows outwards and thrown into
the gap in outlet zones.
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.
In this cooling method the temperature rise becomes independent of length of

a
rotor. The overhang portion of the winding is cooled by axial two systems and

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sectionalized into small parallel paths to minimize temperature rise. Cold gas enters

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the overhang from under the retaining rings through special chamber in the end

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shields and ducts under the fan hub and gets released into the air gap at rotor barrel
ends.
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3) Rotor Wedges –t
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For protection against the effect of centrifugal force the winding is secured in the slots
by slot wedge. The wedges are made from duralumin, an alloy of copper, magnesium and
aluminum having high good electrical conductivity and high mechanical strength.

The wedges at the ends of slot are made from an alloy of chromium and copper.
These are connected with damper segments under the retaining ring for short circuit induced
shaft current. Ventilation slot wedges are used to cover the ventilation canals in the rotor so
that hydrogen for overhang portion flows in a closed channel.

4) Retaining Ring –

The overhang portion of field winding is held by non-magnetic steel forging of

retaining ring against centrifugal forces. They are shrink fitted to end of the rotor body barrel
at one end; while at the other side of the retaining ring does not make contact with the shaft.

35
 The centering rings are shrinking fitted at the free end of retaining ring that serves to
reinforce the retaining ring, securing, end winding in axial direction at the same time. To
reduce stray losses, the retaining rings are made of non-magnetic, austenitic steel and cold
worked, resulting in high mechanical strength.

5) Fans –

Two single stage axial flow propeller type fans circulate the generator cooling gas.
The fans are shrinking fitted on either sides of rotor body. Fans hubs are made of alloy steel
forging with three peripheral grooves milled on it. Fan blades, which are precision casting
with special alloy, are machined in the tail portion so that they fit into the groove of the fan
hub.

6) Field Lead Connections –

6.1 Slip Rings –The slip ring consists of helical grooved alloy steel rings shrunk on the
body shaft and insulated from it. The slip rings are provided with inclined holes for

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self-ventilation. The helical grooves cut on the outer surfaces of the slip rings improve

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brush performance by breaking the pressurized air pockets that would otherwise get
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formed between the brush and slip rings.
.
a
6.2 Field Lead –The slip rings are connected to the field winding through semi flexible
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a
copper leads and current-carrying bolts placed in the shaft. The radial holes with

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current carrying bolts in the rotor shafts are effectively sealed to prevent the escape of
hydrogen.

d
A field lead bar, which has similar construction as, does the connection between

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current carrying bolt and field winding that of semi flexible copper leads (they are

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insulated by glass cloth impregnated with epoxy resin for low resistance and ease of
assembly).

CONCLUSION
The second phase of training has proved to be quite faithful. It proved an opportunity for
encounter with such huge machines like turbo-generator hydro generator etc.
The architecture of B.H.E.L., the way various units are linked and the way working of
whole plant is controlled make the students realize that Engineering is not just structural
description but greater part is planning and management. It provides an opportunity to learn tech.
Used at proper place and time can save a lot of labor.
However, training has proved to be satisfactory. It has allowed us an opportunity to get an
exposure of the practical implementation of theoretical fundamentals.

36
 BIBLIOGRAPHY
 BHarat Heavy Electrical Ltd. BHEL Turbo Generators Manual. In BHEL, BHEL
product technical Manual.
 Bharat Heavy Electricals Limited. (2005). Bharat Heavy Electricals Ltd. Product
Information. Retrieved May 2010, from http://www.bhel.com
 Bharat Heavy Electricals Ltd. (1993). BHEL Pro/E Manuals. Haridwar: BHEL.
 meena, A. (n.d.). electrical report at BHEL haridwar. Retrieved May 2010, from
Scribd: http://www.scribd.com/doc/31295276/electrical-report-at-BHEL-haridwar
 Verma, A. (2010, May). Daily Diary. BHEL visiting notes . Haridwar, Uttrakhand,
India.

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