Manufacture & Assembly of

Turbo Generator
BHEL Haridwar
Submitted by: Manish Snehi
11115051
BTech EE 4
th
year.
BHEL An Overview
BHELs first plant was set up in BHOPAL in 1960s under
Indo-Soviet agreement.
BHEL is the largest engineering and manufacturing
enterprise in India.
It has been earning profits continuously since 1971-72.
The wide network of BHEL has 14 manufacturing division,
150 project sites, eight service centers and 18 regional
offices.

About BHEL Haridwar unit
Two manufacturing units in BHEL.

HEEP (Heavy Electrical Equipment Plant)
There are eight blocks in the HEEP namely 1-8.
CFFP (Central Foundry And Forge Plant)
Steel Melting Shop
Steel Foundry Shop
Light Foundry Shop
Forge shop



HEEP
Block-1:- (Electrical Machine Final Assembly)
Block-2:- (Gas & Steam Turbine Fabrication Block)
Block-3:- (Gas & Steam Turbine Manufacturing Block)
Block-4:- [CIM (Coil & Insulation Manufacturing)Block]
Block-5:- (Heat Exchangers Fabrication Block)
Block-6:- (Stampings Block)
Block-7:- (Wooden Packing works Block)
Block-8:- (Heat Exchanger Tubes Block)

Turbo-generator
A turbo generator is a turbine directly connected to electric
generator for the generation of electricity. They are mostly
used as large capacity generator driven by steam/gas turbine.
Turbo generator operates on the fundamental principles of
ELECTROMAGNETIC INDUCTION.
E.M.F. (Voltage) is induced in a closed path due to change of
flux linkages and is proportional to rate of change of flux
linkages.
It converts mechanical energy into electrical energy.
It is a turbine directly connected to electric generator for the
generation of electricity.



Basic equation for sizing of electrical machines
P=K.As.B.D^2 L .ns
Here
P = MW output
As = Electric Loading (Amp.)
B = Magnetic Loading (gauss)
D = Stator bore diameter (cm)
L = Stator core length (cm)
ns = Rated speed
D^2 L = Volume of Rotor or Size of the Machine
Features of TG & HG

Turbo generators in Thermal, nuclear, Gas station
High speed 3000 rpm
No. of poles 2 poles
Horizontal construction
Cylindrical rotor

Hydro generators in hydel plants
Low speed 500 to 1000 rpm
No. of poles 6 or more
Vertical construction
Salient type of rotor

Types of Generator

The generator classified,as based upon the used cooling system in it
such as: TARI, THRI, THDD, THDF, THDI, THFF.
T= First word denotes type of generator i.e. turbo generator or hydro
generator.
A/H= Second word stands for medium used for the cooling of rotor as air
or hydrogen gas.
R/D/I/F= Third word signifies cooling of rotor as radial, forced,indirect,
direct.
D/I/F= Last word signifies type of cooling if stator as indirect cooling,
forced cooling, direct cooling.
W= Medium being used for cooling of stator coil as water
Nomenclature of Turbo-generator

TARI 108/46
THRI 108/44
THDF 115/59
MAIN PARTS OF TURBO GENERATOR

Stator - Stator Frame (Fabrication & Machining)
Core Assembly - Stator Core, Core Suspension Arrangement
End Shields
Stator Winding Assembly - Stator Winding, Winding Assembly,
Connecting Bus bar
Rotor - Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor,
Rotor Assembly
Completing Assembly - Bearing Assembly, Shaft Seal Assembly,
Oil Catchers, Insert Cover etc
Exciter
Auxiliary System

Stator Frame
Rigid fabricated cylindrical frame and is
the heaviest section in the generator
Withstands weight of core & winding,
forces & torques during operation
Provisions for filling hydrogen gas.
Provision for temperature measurements
Foot plates for supporting on foundation
Provision for H2 coolers

Stator Core

The stator core is made from the insulated electrical sheet lamination to minimize
eddy current losses. Each lamination layer is made of individual sections.
The main features of core are:
1. To carry electric & magnetic flux efficiently.
2. To provide mechanical support.
3. To ensure perfect link between the core and rotor.

The composition of silicon steel(used as material of core),for reduction of hysteresis loss
is:
Steel-95.8%
Silicon-4.0%
Impurities-0.2%

Stator winding
Stator insulation
Stator end cover
Rotor
Rotating part of turbo generator
A high strength alloy steel single forging prepared by vacuum cast steel.
Longitudinal slots for housing field winding
Damper winding is provided which safeguards the asymmetrical and
asynchronous operative conditions.
Rotor of cylindrical type used in turbo generator.
Supported on two journal bearings.
Provision of axial fan for forced ventilation.

Rotor Winding
The field winding consists of
several series connected coils
inserted into the longitudinal slots
of rotor body. The coils are wound
so that two poles are obtained.
The conductors are made up of
copper with a silver content of
approximately of 0.1%.
Rotor Insulation (HGL)
Field connection (rotor field &
exciter)
Rotor Fan
Excitation System

The process of generating a magnetic field by
means of an electric current is called excitation.
It provides power to the field windings thus produce
field for rotor.

Types of exciter:
Brush type exciter / Static excitation
Brush less exciter

Brush Type/Static Excitation
Rotor Field Winding is connected to Slip ring
mounted on Rotor.
Excitation is provided by current transfer by
contact through Carbon Brushes, Slip ring and
field lead.

BRUSH LESS EXCITATION SYSTEM
Main parts are:
Pilot exciter
Main exciter
Rectifier wheel
Automatic voltage regulator
Rectifier wheel
Components in the rectifier wheel are as follows:
1. Silicon diodes
2. Aluminium heat sink
3. Fuses
4. RC circuit
The main component in the rectifier wheel
is silicon diodes which are arranged in
rectifier wheel in three phase bridge
circuit. The direct current from rectifier
wheel is fed to DC leads and then to the
field winding of the rotor.




Advantage Of Brush Less Exciter Over Brush Type
Exciter




Eliminates Slip Rings, Brush gear and Field Breaker
Eliminates all problems associated with transfer of
current via sliding contacts
Minimum operating and maintenance cost
High response excitation with fast acting AVR
Brush Losses are eliminated

Cooling System
AIR COOLED TURBO GENERATOR:
In Air Cooled Turbo generator stator winding is indirectly air cooled whereas the rotor
winding and stator core is directly air cooled. This type of cooling is applicable for
rating of 30 MW- 60 MW generators. In this type of turbo generator there are vertically
side mounted cooler in a separate housing
HYDROGEN COOLED T.G.
HYDROGEN/WATER COOLED T.G.
Advantages of Hydrogen as Cooling Medium:

a) Increased efficiency: The density of H2 is only 0.07 times the density of
air and therefore the power required to circulate H2 is less than that
required in air.
b) Increase in rating: H2 has a heat transfer coefficient 1.5 times and its
thermal conductivity is 7 times that of air. Consequently when H2 is used
as a coolant, the heat is more rapidly taken up from the machine parts
and dissipated.
c) Elimination of fire hazard: The outbreak of fire inside the machine is
impossible as H2 does not support combustion.
d) Smaller size of coolers: The size of cooler required is smaller in size.

Generator technical data
REFERENCES

http://www.bhel.com/about_publication.php
http://en.wikipedia.org/wiki/Turbo_generator
http://en.wikipedia.org/wiki/Hydrogen-
cooled_turbogenerator
A text book of electrical machines by P.S.BIMBRA
A text book of electrical technology by B.L.THERAJA
BHEL Internal material
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