INDEX

1. INTRODUCTION
2. BHEL ’S CONTRIBUTION IN DIFFERENT SECTORS
3. BHEL HARIDWAR – AN OVERVIEW
4. TURBO GENERATORS
5. VENTILATION AND COOLING
6. EXCITATION SYSTEM
7. TESTING
8. MOTOR WINDING
INTRODUCTION
In 1956 India took a major step towards the establishment of its
heavy engineering industry when Bharat Heavy Electricals Limited.
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 the country.
BHEL’s Units in India
LOCATION 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
BHEL’S CONTRIBUTION IN
DIFFERENT SECTOR
• POWER SECTOR
• TRANSMISSION
• TRANSPORTATION
• INTERNATIONAL OPERATIONS
• RENEWABLE ENERGY
• INDUSTRIES
An Overview
At the foothills of the majestic Himalayas & on the banks of a holy
Ganges in Ranipur near HARIDWAR is located a Heavy Electricals
Equipment Plant of Bharat Heavy Electrical Ltd.
BHEL, wholly owned by the government of India is an integrated
engineering complex consisting of several plants in India, where
about 5000 workers are busy in design and manufacturing of a wide
range of Heavy Electrical Equipment.
At present 70% of the Country’s electrical energy is generated by the
sets manufactured by BHEL, Haridwar.
 BHEL HARDWAR is broadly divided into two parts:
A) - CFFP: – Central Foundry Forge Plant
B) - HEEP : – Heavy Electrical Equipment Plant
CFFP is divided in to following shops:
 Forge Shop
 Machine Shop
 Steel Melting Shop (SMS)
 Steel Foundry
 Pattern Shop
 Cast Iron (CI) Foundry
B) - HEEP is divided into following blocks:
 BLOCK -1 Electrical Machine shop (Turbo Generators)
 BLOCK -2 Heavy Fabrication Shop (Steam, Hydro & gas Turbine)
 BLOCK -3 Gas & Steam Turbine Manufacturing Shop
 BLOCK -4 CIM (Coil & Insulation Manufacturing)
 BLOCK -5 Forging and Fabrication Plant
 BLOCK -6 Stamping & Die Shop
 BLOCK -7 Carpentry Shop
 BLOCK -8 Heat exchange Shop
TURBOGENERATORS
• A turbogenerator is a turbine directly connected to an electric generator for the
generation of electric power.
• Operating principle: “FARADAY’S LAW OF ELECTROMAGNETIC INDUCTION”.
• Whenever conductor cuts magnetic flux, dynamically induced emf is produced.
This emf causes a current flow if the circuit is closed.
SPECIFICATIONS
• Rated KVA rating- 210MW
• Rated Current- 9050A
• Power Factor- 0.85
• Rated Frequency- 50Hz
• Rated Speed- 3000rpm (anticlockwise)
• Terminal Output Voltage- 15.75kV
• Type of insulation- Class B
• Length of stator- 4580mm
• Diameter of stator- 3960mm
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:-
1. THRI
2. TARI
3. THDI
4. THDD
5. THDF
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. :-
 STATOR
Stator frame
Stator core
Stator winding
End covers
 ROTOR
Rotor shaft
Rotor winding
Rotor retaining rings
 BEARINGS
 COOLING SYSTEM
 EXCITATION SYSTEM.
STATOR
The generator stator is a tight construction supporting and enclosing
stator winding, core and hydrogen cooling medium. Hydrogen is
contained within frame and circulated by fans mounted at either end
of rotor. The generator is driven by direct coupled steam turbine at
the 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.
STATOR FRAME
 Stator body is a totally enclosed gas tight fabricated
structure made up of high quality mild steel and
austenitic steel. It is suitably ribbed with annular rings in
inner walls to ensure high rigidity and strength.
 The stator frame is of welded steel single piece
construction.
 It support the laminated core and winding.
 It consist of ribs and has efficient cooling system.
 Guide bars are welded inside the stator frame over
which the core is assembled .
STATOR CORE
 The stator core is made up of silicon steel with high
permeability and low hysteresis and eddy current losses.
 The sheets are suspended in the stator frame from
insulated guide bars.
 Stator laminations are coated with the synthetic vanish.
 Stator laminations are stacked and held between sturdy
steel clamping plates with non-magnetic pressing fingers
which welded to the stator frame.
Stator Winding
 It consists of two layer made of individual copper bars.
 To minimise losses , bars are separately insulated
strands(transposed by 360 degree ).
 Each bar consist of large number of separately
insulated strands to reduce the skin effect losses.
 To minimise stray losses in end windings , strands of
top and bottom bars are separately brazed and insulated
from each other.
It is done by placing stator on rotating installation. The
stator has a three phase, double layer lap winding.
END COVERS
 The end covers are made of fabricated steel or aluminium alloy castings.
 They are employed with guide vains on inner side for ensuring uniform
distribution of cooling air or gas.
ROTOR
 Solid rotors are manufactured from forged alloy steel with suitable
alloying elements to achieve very high mechanical and superior
magnetic properties.
 Rotor consists of electrically active portion and two shaft ends.
 60% of rotor body circumference has longitudinal slots which hole
the field winding.
 Rotor winding: the field winding consists of several series
connected coils inserted into the longitudinal slots of rotor body. The
coils are wound so those two poles (one north pole and south pole)
are obtained.
ROTOR WINDING
 The winding consists of several coils inserted into the slots
and series connected such that two coil groups from one
pole.
 Each coil consist of several series connected turns, each of
which consist of two half turns connected by brazing in the
end section.
 The rotor bearing is made of silver bearing copper ensuring
an increased thermal stability.
 The individual turns of coils are insulated against each
other by inter layer insulation.
 L shaped strips of laminated epoxy glass fibre fabric with
nomex filter are used for slot insulation.
ROTOR SHAFT
 It is a single piece solid forming manufactured
from a vaccum casting.
 It is forged from a vaccum cast steel ingot.
 Slots for insertion or the field winding are milled
into rotor body.
 The longitudinal slots are disturbed over the
circumference such that two solid poles are
obtained.
 The range of rotor shaft is 12-15 metres.
ROTOR RETAINING RINGS
 The centrifugal forces of the rotor end windings are contained by single piece
rotor retaining rings.
 They are made of non magnetic high strength steel in order to reduce stray
losses.
 Each retaining rings with its shrink fitted insert ring is shrunk on the rotor in an
overhang position.
 The retaining ring is secured in the axial position by snap rings.
BEARINGS
 The turbo generators are provided with pressure lubricated self
aligning elliptical type bearings to ensure higher mechanical stability
and reduced vibration in operation.
 The temperature of each bearing is monitored with two RTDs, to
prevent damage to the journals (due to shaft current, bearings and
oil piping on the either side of the non drive), end bearings are
insulated from the foundation frame (split insulation).
 Bearings are manufacturing in light machine shop with cast steel
metal.
COOLING SYSTEM
 Turbogenerators are designed with following ventilation systems:
 Closed circuit air cooling with water or air coolers mounted in the
pit.
 Closed circuit hydrogen cooling with water or hydrogen coolers
mounted axially on the stator frame.
EXCITER
 The brushless excitor is an AC excitor with rotating armature and
stationary field.
 The armature is connected to rotating rectifier bridges for rectifying
AC voltage induced in the armature to DC voltage.
 The pilot excitor is a PMG (permanent magnet generator). The PMG
is also an AC machine with stationary armature and rotating field.
 When the generator rotates at the rated speed, the PMG generates
220 Volt at 150 Hz to provide power supply to automatic voltage
regulator.
THANKYOU