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STUDY OF TURBO GENERATOR

Summer internship report submitted

By

KASANI TIRUMALA TEJA

B181258

DEPARTMENT OF ELECTRICAL ENGINEERING RGUKT-BASAR

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ACKNOWLEDGEMENT

This project report is the outcome of 30 days (18 May-16 June) practical training
undergone at BHEL,Hyd. I am thankful to all the employees of BHEL who have
imparted the knowledge which enabled me to understand things practically. I am
extremely thankful to Mr. Mahesh Tammishetty. without whose sincere guidance
this project would not have been possible.

Finally I am thankful to group mates for their sincere cooperation

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 CERTIFICATE OF TRAINING
This certificate is awarded to

Mr. Kasani Tirumala Teja

(A student of B.Tech- EE , Rajiv Gandhi University Of knowledge Technologies, Basar
)

For
Completion of summer Industrial Training
In
A study on Manufacturing process of Turbo Generator

Bharat Heavy Electrical Limited Hyd

From 18 May 2023 to June 2023.

T.Mahesh (project guide)

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 TABLE OF CONTENTS

Title Page No.

01: INTRODUCTION 1

02: BHEL-a brief profile 2

03. BHEL - an overview 3-5

04. Press shop 6-7

05. Stator core Assembly 8

06. Stator coil shop 9-11

07. Stator winding shop 12-13

08. Heavy machine shop ` 14-15

09. Rotor coil/ copper shop 16-17

10. Rotor winding shop 18-20

11. VPI plant 21-23

12. Insulation shop 24-25

13. Balancing Tunnel 26

Bibliography 27
Conclusion 26

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 1. INTRODUCTION

In 1953, India took a major step towards the establishment of its heavy
engineering industry when Bharat Heavy Electrical Ltd., the first heavy
electrical manufacturing unit of the country was setup at Bhopal. It
progressed rapidly and three more factories went into production in 1965.
The main aim of establishing BHEL was to meet the growing power
requirement of the country. BHEL appeared on the power map of India in
1969 when the first unit supplied by it was commissioned at the Basin
Bridge Thermal Power Station in Tamil Nadu. Within a decade, BHEL had
commissioned the 100 unit at Santali. West Bengal ,BHEL had taken India
from a near total dependence on imports to complete self-reliance in this
vital area of power plant equipment BHEL has supplied 97% of the power
generating equipment. BHEL has already supplied generating equipment to
various utilities capable of generating over 18000 MW power. Today BHEL
can produce annually; equipment capable of generating 6000MW. This will
grow further to enable BHEL to meet all of India’s projected power
equipment requirement. As well as sizeable portion of export targets

Probably the most significant aspect of BHEL’s growth has been its
diversification. The constant reorientation of the organization to meet the
varied needs in time with time a philosophy that has led to the development
of a total capability from concepts to commissioning not only in the field of
energy but also in industry and transportation. In the world power scene,
BHEL ranks among the top ten manufactures of power plant equipment and
in terms of the spectrum of products and services offered, it is right on top.
BHEL’s technological excellence and turnkey capabilities have won it
worldwide recognition. Over 40 countries in the world over have placed
orders with BHEL covering individual equipment to complete power stations
on a turnkey basis. In 1978-79 export earnings reached Rs.122 crores, the
highest for any one-year. BHEL has its headquarters at New Delhi. Its
operations are spread over 11 manufacturing plants and number of
engineering and service divisions located across the country the service
divisions includes a network of regional branch offices throughout India.

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 02.BHEL- A Brief Profile

BHEL is the largest engineering and manufacturing enterprise in India in the

energy-related / infrastructure sector, today. BHEL is ushering in the
indigenous Heavy Electrical Equipment industry in India-a dream that has
been more than realized with a well-recognized track record of Performance
widespread value network comprising of 14 manufacturing companies,
which have international recognition for its commitment towards quality.
With an export presence in more than 60 countries, BHEL is truly India’s
ambassador to the world. BHEL’s vision is to become world-class
engineering enterprise, committed to enhancing stakeholder.

BHEL has:-
 Installed equipment for over 90,000MW of power generation for
Utilities, captive and Industrial users.
 Supplied over 25000 Motors with Drive Control System to power
projects, Petrochemicals Refineries, Steel, Aluminium, Fertilizer,
Cement plant, etc.
 Supplied Traction electrics and AC/DC locos over 12000 km Railway
network.
 Supplied over one million values to Power Plants and other Industries.

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 03BHEL - An Overview

The first plant of what is today known as BHEL was established nearly 40
years ago at Bhopal & was the genesis of the Heavy Electrical Equipment
industry in India. BHEL is today the largest Engineering Enterprise of its
kind in India with excellent track record of performance, making profits
continuously since 1971-72.
BHEL business operations cater to core sectors of the Indian Economy like.
 Power
 Industry
 Transportation
 Transmission
 Defences etc.

Today BHEL has

14 Manufacturing Divisions
9 Service Centres
4 Power Sector Regional Centers
Over the years, Bharat Heavy Electrical Limited has emerged as world class
engineering and Industrial giant, the best of its kind in entire South East
Asia. Its business profile cuts across various sectors of engineering/power
utilities and industry. The company today enjoys national and international
presence featuring in the " fortune international-500” and is ranked among
the top 12 companies of the world, manufacturing power generation
equipment. BHEL has now 14 manufacturing division, 8 service centres and
4power power sectors regional enters besides a large number of project sites
spread over India and abroad. The company is embarking upon an ambitious
growth path through clear vision, mission and committed values to sustain
and augment its image as a world-class enterprise.

VISION
A world-class innovating, competitive and profitable engineering enterprise
providing total business solution.

MISSION
To be the leading Indian engineering enterprise providing quality products
system and services in the field of energy, transportation, infrastructure and
other potential areas.

VALUES
 Meeting commitments made to external & internal customers
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  Foster learning creative and speed of response
 Respect for dignity and potential of individual
 Loyalty and pride in the company
 Team playing

BHEL’s vision is to become world class engineering enterprise, committed

to enhancing stakeholder value. The greatest strength of BHEL is its highly
skilled and committed 44,000 employees. Spread all over India & abroad to
provide prompt and effective service to customers.

BUSINESS SECTOR

BHEL operations are organized around business sectors to provide a strong

market orientation. These business sectors are Power Indus and International
operations.

POWER SECTOR

 Power sector comprises of thermal, nuclear, gas and hydro business.

Today BHEL supplied sets account for nearly 65% of the total installed
capacity in the country as against nil till 1969-70.
 BHEL has proven turnkey capabilities for executing power projects from
concept to commissioning and manufactures boilers, thermal turbine
generator set and auxiliaries up to 500MW.
 It possesses the technology and capability to procure thermal power
generation equipment upto 1000MW.
 Co-generation and combined cycle plants have also been introduced.
 For efficient use of the high ash content coal-BHEL supplies circulating
fluidized boiler.
 BHEL manufactures 235MW nuclear sets and has also commenced
production of 500MW nuclear set. Custom-made huge hydro sets of
Francis, Elton and Kaplan types for differenthead- discharge combinations
are also engineered and manufactured by BHEL.

INDUSTRY SECTOR

BHEL is a major contributor of equipment and system to important

industries like
 Cement
 Petrochemicals
 Fertilizers
 Steel paper
 Refineries
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  Mining and Telecommunication

TRANSPORATION

BHEL supplies a wide equipment and system to Indian Railways.

## Electric locomotive
## Traction electric and traction control equipment

TELECOMMUNICATION

BHEL also caters to Telecommunication sector by way of small, medium

and large switching system.

MANUFACTURING DIVISIONS
 Heavy Electrical Plant, Piplani, Bhopal
 Electrical Machines Repair Plant (EMRP), Mumbai
 Transformer Plant P.O. BHEL, Jhansi.
 Bharat Heavy Electrical Limited Ranipur, Hardwar
 Heavy Equipment Repair Plant, Varanasi.
 Insulator Plant, Jagdishpur, Distt. Sultanpur.
 Heavy Power Equipment Plant, Ramachandra Puram,Hyderabad
 High Pressure Boiler Plant & Seamless Steel
Tube Plant,Tiruchirappalli.
 Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex, Ranipet.
 Industrial Valves Plant, Goindwal.
 Electronics Division, Bangalore
 Component Fabrication Plant, Rudrapur.
 Piping Centre, Chennai.
 Heavy Electrical Equipment Plant,Hardiwar
 Regional Operations Division, New Delhi

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 04.PRESS SHOP

1) 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 arrangement,
location and shape of inner walls is determined by the cooling circuit for the
flow of the gas and required mechanical strength and stiffness. The natural
frequency of the stator body is well away from any of exciting frequencies.
Inner and sidewalls are suitably blanked to house for longitudinal hydrogen
gas coolers inside the stator body.

The main features of core are –

1. To provide mechanical support.

2. To carry efficiently electric, magnetic flux.
3. To ensure the perfect link between the core and rotor.
Preparation of Lamination

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05. STATOR CORE ASSEMBLY

CONSTRUCTIONAL FEATURES STATOR CORE

It consists of thin laminations. Each lamination made of number of individual

segments. Segments are stamped out with accurately finished die from the sheets
of cold rolled high quality silicon steel.

Before insulation on with varnish each segment is carefully debarred. Core is

stacked with lamination segments. Segments are assembled in an interleaved
manner from layer to layer for uniform permeability. Stampings are held in a
position by 20 core bars having dovetail section. Insulating paper pressboards are
also put between the layer of stamping to provide additional insulation and to
localize short circuit. Stampings are hydraulically compressed during the
stacking procedure at different stages. Between two packets one layer of
ventilating segments is provided. Steel spacers are spot welded on stamping.
These spacers from ventilating ducts where the cold hydrogen from gas coolers
enter the core radialy inwards there by taking away the
heat generated due to eddy current losses. The pressed core is held in pressed
condition by means of two massive non-magnetic steel castings of press ring. The
press ring is bolted to the ends of core bars. The pressure of the pressure ring is
transmitted to stator core stamping through press fringes of non-magnetic steel and
duralumin placed adjacent to press ring. To avoid-heating of press ring due to end
leakage flow two rings made of copper sheet are used on flux shield. The ring
screens the flux by short-circuiting.

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06.STATOR COIL SHOP

This Block manufactures stator bars for all types of TGs

The steps involving in the process of stator bar manufacturing are as follows:

- Conductor Draw from Store.

- Conductor cutting and end cleaning.

- Transposition of conductor.

- Assembly of all conductors to be used in stator Bars.

- Putty work

- Straight part consolation

- Blending & Glung

- Preparation for taping .

- Surface finishing of stator bar

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 1. Conductor cutting :
In this process the pre-insulated copper conductor is cut into number of pieces of
required length (length given in drawing as per design) insulation is removed from
both ends of the copper
conductor out.

2. 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 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.

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3.Crossover insulation :
The pre insulation of the copper conductor may get damaged due to
mechanical bending in die during transposition, hence the insulating spacers are
provided at the crossover portion of the conductors. A filler material
(insulating putty of moulding micanite) is provided along the height of the bar to
maintain the rectangular shape and to cover the difference of level of conductors.

3. Stack Consolidation :

The core part of the bar stack is pressed in press (closed box) under pressure
(varies from product to product) and temperature of 1600 C for a given period. The
consolidated stack is withdrawn from the press and the dimensions are checked.

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 07. STATOR WINDING SHOP

➢ 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 semiconducting 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 etiolate spacers are put
to have proper tightness. In between top and bottom bars, spacers are also put.

➢Ending Winding –
In the end winding, the bars are arranged close to each other. Any gaps due to design or
manufacturing considerations are fitted with curable prepay with spacer in between. The
prepay 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 two layers. Bus bars are connected to bring out the three phases and six
neutrals. Bus bars are also hollow from inside. These bus bars are connected with
terminal bushing. Both are water cooled. Brazing the two lugs properly makes
connection.

Each conductor must be capable of carrying rated current without overheating.The stator
winding consists of two layers made up of individual bars. Windings for the stators are made
of copper strips wound with insulated tape which is impregnated with varnish, dried under
vacuum and hot pressed to form a solid insulation bar. These bars are then placed in the
stator slots and held in with wedges to form the end turns.
These end turns are rigidly placed and packed with blocks of insulation material to withstand
heavy pressure.

The transposition provides for mutual neutralization of the voltage induced in the individual
strands due to slot cross field and end winding flux leakage and ensure that minimum
circulating current exists. The current flowing through the conductors is thus uniformly
distributed over the entire cross section so that the current dependent losses will be reduced.
The alternate arrangement of one hollow strand and two solid strands ensures optimum heat
removal capacity and minimum losses. The electrical connection between top and bottom
bars is made by connecting sleeve.

Class “F” insulation is used.

The no. of layer of insulation depends on machine voltage. The bars are brought under
vacuum and impregnated with epoxy resin, which has very good penetration property due to
low viscosity. After impregnation bars are subjected to pressure with nitrogen being used as
pressurizing medium (VPI process). The impregnated bars are formed to the required shape

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on moulds and cured in an oven at high temperature to minimize the corona discharge
between the insulation and slot wall a final coat of semiconducting varnish is applied to the
surface of all bars within the slot range. In addition all bars are provided with an end corona
protection to control the electric field at the transition from the slot to end winding. The bars
consist of a large no. of separately insulated strands which are transposed to reduce the skin
effect.

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08. HEAVY MACHINE SHOP

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

ROTOR

The moving or rotating part of generator is known as rotor. The axial length of
shaft of the rotor is very large as compared to its diameter in case of turbo generators.
It is coiled heavily (field coils) as it has to support large amount of current and
voltage. Rotor revolves in most generators at a speed of 3000rpm. Field coils are
wound over it to make the magnetic poles and to maintain magnetic strength the
winding must carry a very high current. As current flows heat is generated, but the
temperature has to be maintained because as temperature raises problems with
insulation becomes more pronounced. With good design and great care this problem
can be solved.

ROTOR SHAFT:-

Rotor shaft is a single piece. The longitudinal slots are distributed over its circumference.
After completion, the rotor is balanced in the various planes and different speed and then
subjected to an over speed test at 120% of rotor speed. The rotor consists of electrically
active portion and two shaft ends approximately 60 % of rotor body circumference have
longitudinal slots which hold the field winding. Slots pitch is selected so that the two solid
poles are displaced by 180 degree the rotor wedges act as damper winding within the range
of winding slots. The rotor teeth at the rotor body are provided in radial and axial poles
enabling cooling air to be discharged.

The rotor shaft is a single piece solid forging manufactured from a vacuum casting.

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 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.
-
On 2/3 of its circumference approximately the rotor body is provided with longitudinal
slot to accommodate field winding. The slot pitch is selected in such a way that two
solid poles displaced by180 C are obtained. For high accuracy the rotor is subjected to
20% over speeding for two minutes. The solid poles are provided with additional slots
in short lengths of two different configurations. One type of slots served as an outlet
for hydrogen which has cooled the overhang winding and other type used to
accommodate finger of damper segments acting as damper winding.

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 09.Rotor coil / copper shop

After preliminary turning, longitudinal slots are milled unsophisticated horizontal slot
milling machine. The slot house the field winding consists of several coils inserted into
the longitudinal slots of rotor body-
1.1. Copper Conductor –
The conductors are made of hard drawn silver bearing copper. The rectangular cross
section copper conductors have ventilating duct son 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 colon the
rotor model.

Following Steps are involved in manufacturing of Rotor Bars depending upon the
capacity of the generator.

- Slot Punching
- Scraping
- 1st Annealing
- Edge Bending
- Pressing
- 2nd Annealing
- Radius Bending
- Moulding
- Finishing
-
Significance of Important Processes :
1. Slot Punching: In THRI, the cooling of Rotor is Radial type where the blades on the
rotor force H2 to pass through the slots and cool the rotor. For this reason, slots are
inevitable as they increase the surface area of cooling of rotor bars.
2. Annealing: Every metal responds to thermal shocks in different way. Copper when
moulded by hammering, develops cracks due to brittleness. So, annealing cures this.
3. Radius Bending: This is the most important part of the process. The arc required to
make a full concentric coil is done through this process on a mould by

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hammering manually There are 7 types of Rotor bars depending upon the
arc. They are numbered here from A through G. A has the least arc while
G has the largest arc. They are arranged in concentric manner to generate
a concentrated field through rotor’s physical poles

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10.ROTOR WINDING

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–
.
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 coilon the rotor model.
Insulation –
The individual turns are insulated from each other by layer of glass 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.

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1) Rotor Wedges –

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.

2) 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.

The centering rings are shrink 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.

3) Fans –

Two single stage axial flow propeller type fans circulate the generator cooling gas.
The fans are shrink fitted on either sides of rotor body. Fans hubs are made of alloy

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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 thegroove of the fan hub.

Field Lead Connections –

A field lead bar, which has similar construction as, does the connection
between current carrying bolt and field winding that of semi flexible
copper leads (they are insulated by glass cloth impregnated with epoxy
resin for low resistance and ease of assembly).

Cooling Of Rotors :
For direct cooling of rotor winding cold gas is directed to the rotor end
wedges at the turbine and exciter ends. The rotor winding is symmetrical
relative to generator centerline and pole axis
cooling zone is discharged into the air gap at the mid length of the rotor
body through radial openings in the hollow conductors and wedges.

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11.VPI PLANT

DESCRIPTION OF WORK:

1 VACCUM SYSTEM
a. Cleaning of vacuum pumps. Draining water contacted in the pumps. Top up/
replace as per the
condition of the oil.
b. Cleaning of moisture separators and condenser’s after every impregnation.
c. Check for proper functioning of vacuum valve of PEIFFER UNO 250A Vacuum
pumps and Roots
pump WKP 2000.
d. Check for proper functioning of pneumatically operated valve in the vacuum
Circuit.
2 RESIN SYSTEM
a. Check for proper functioning of pneumatically operated valves in the resin
circuit.
b. Check the insulation of resin piping and replace if necessary.
c. Dismantling and cleaning of resin pipelines of any deposits of resin wherever
necessary.
d. Cleaning resin outlets at storage tanks. Collect resin samples as and when
required for testing.
3 TROLLEYS
a. Clean and ensure free movement of wheels of job transport trolley, preheating
furnace trolley
and post heating furnace trolley.
b. Check the drives for the trolley for proper functioning. Top up oil levels in the
gear boxes.
c. Clean the trolleys after every impregnation.
4 CHILLING PLANT
a. Check the brine pumps for any leakages and arrest.
b. Ensure free movement of manually operated gate valves in the water and glycol
lines.
c. Clean brine tanks and cooling towers once in a quarter.
d. Maintaining brine water mix (glycol and water) in required proportion.
5 JOB ROTATOR
a. Check the free movement of rollers.
b. Check and top up oil levels in all gear boxes of the drive.
c. Clean the covers and the rotator of any deposits of resin after every
impregnation.
6 NITROGEN STORAGE TANK
a. Drain out the water collected every quarter.
b. Nitrogen leakages in pneumatic panel after every impregnation.
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c. Maintenance of nitrogen dryer.
Page 2 of 5 SIGNATURE AND SEAL OF CONTRACTOR
7 INSTRUMENTATION.
a. Coordinate repair and calibration of all the instruments of impregnation plant,
preheating oven
and post –curing Ovens. Instruments include vacuum meters, pressure gauges and
temperature
gauges etc.
8 PRE HEATING FURNACE
a. Check and arrest the steam leakages.
b. Check the electrical heating system.
c. Check the circulation blowers, door operation for proper functioning.
9 POST HEATING FURNACE
a. Check the brick lining of combustion chambers.
b. Check for proper functioning of circulating blowers, exhaust blowers, pilot
ignition system.
c. Check the hand and pneumatic operated valves.
d. Check the insulation of ducting and repair where necessary.
e. Check for leakage in heat exchangers.
f. Vacuum leak rate test of vacuum system and resin tanks once in a quarter.
g. Check the hydraulic systems for door opening for vertical and horizontal
impregnation for
impregnation tanks.
10 MISCELLANEOUS
a. Check the platform lifting mechanism.
b. Clean all sight glasses in resin storage tanks once in quarter and once after every
impregnation
for impregnation tanks.
c. Maintaining the leak rate by plugging the leakages in the vacuum system and
resin tanks.
d. Cleaning the pits of water and other wastes once in a month.
e. Maintaining the proper lighting in control room, pits and other plant lighting
other than roof
lighting.
f. Resin leakages from pipelines to be arrested.
g. Scrap and clean Impregnation tanks of resin material once in a quarter.
h. After every impregnation, door gaskets should be cleaned.
i. Cleaning the tubs after every impregnation. Cleaning the job handling nylon belt
slings after
every impregnation.
11 WORK INVOLVED
Breakdown and Preventive maintenance of V.P.I. Plant item no 02-1676, steam
furnace for preheating,

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producer gas fired furnace for post curing and job rotator. During the impregnation
cycle plant should be
manned by one fitter and one electrician round the clock to attend to any
breakdown on the plant. When
the plant is idle sufficient manpower to be employed to carry out preventive
maintenance as per the
checklist. In addition one supervisor to guide during breakdowns and during
preventive maintenance.

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12.Insulation Shop

The individual turns are insulated from each other by layer of glass prepay
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 moulding
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.

➢ Method Of 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.
➢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 manufacture the bar are performed which areas 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.
(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.

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 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.

Conducting varnish coating :

(i) OCP (Outer Corona Protection) Coating :-The black semiconducting varnish
coating is applied on the bar surface on the core length.

(ii) ECP (End Corona Protection) Coating:The grey semiconducting varnish is

applied at the bend outside core end of bars in gradient to prevent from discharge and
minimize the end corona

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13.BALANCING TUNNEL
Rotors are a critical component used to convert electric or electromagnetic energy
into rotational motion. For rotors to operate reliably, they must maintain even
weight distribution across the rotational axis. Too much weight on one side creates
uneven mass distribution known as “unbalance”.
Rotating parts in any mechanical assembly can become unbalanced. Uneven
weight distribution of a rotating component causes the part’s rotational center to be
out of alignment with the geometric axis. When unbalance occurs, the operational
efficiency and safety of the system in which the rotor operates are
compromised. Rotor balancing can help to prevent issues caused by unbalance,
reducing noise and vibration and extending the life of your system.
BALANCING METHODS

A. Principles of Factory Balancing

Vibration causes undesirable alternating stresses in bearings and supporting
structures which may lead to equipment failure. The basic requirement for rotor
balancing is that the residual unbalance of the rotor is less than therequired balance
tolerance. Below are the general highlights
for a two plane balance:
• The rotor is rotated at a continuous speed between 500 to 800 RPM (dependent
on rotor diameter).
• The transmitted unbalance force and phase angle are measured at both balance
planes.
• The correction weight and angular position are calculated and added to both
planes or at one plane at a time (after the rotor as come to a stop).
• The new transmitted unbalance force and phase angle are measured and
compared with the balance tolerance.
• The process is repeated as needed until the balance
tolerance is achieved.
B. Adding Weight to Rotors
The correction weights are added differently depending on the type of rotor and
motor manufacturer. Electric motors with cast aluminum bar construction are cast
with sprues on the end ring. During balancing, washers are added and the sprues
are permanently deformed (flattened) to retain the washers. The sprues can also be
removed during the process.
Copper bar rotors are balanced by welding or bolting the correction weights
directly on the end plates.

C. Principle of Trim Balancing

The vector method will be discussed in this paper for single plane balancing, but
can be used for two-plane balancing. This method can be used in field balancing or
if a rotor is required to be balanced at design speed.
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BIBLIOGRAPHY

1. Scribd.com
2. Electrical Machine Design(AK Sawhney)
3. www.bhelhyd.co.in

CONCLUSIONS

The industrial training at BHEL Hyd, provided important knowledge in the

field of construction of turbo alternators and their components.. Besides the
production of new alternators the plant also repairs damage done’s. With the
ever increasing pressure of industry BHEL is striving hard to continue
leading in this era of fierce competition.
A separate training in charge should be made in each department which can
help us getting through that department very well. Though technicians are
helpful but sometimes due to work load we have to be satisfied just by
viewing the scenario. However the training has cleared our perception about
practical implementation of theoretical concepts and make us realize the
working culture of BHEL where sun never dawns.

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