INTRODUCTION

Power is the basic necessity for the economic development of a country. The
production of electrical energy and its per –capital consumption is deemed as an
index of the standard of living in a nation in the present day civilization.
Development of heavy or large scale industries, as well as medium scale industries,
agriculture, transportation, etc., totally depend on electric power resources of
engineers and scientists to find out ways and means to supply required power at
cheapest rate. The percaptia consumption on average in the world is around
1200KWH. The figure is very low for our country and we have to still go head in
power generation to provide a descent standard of living for people. The need for
immediate increase in the country’s power production in vital. So, we have to utilize
the available resources in better possible manner.

An AC generator is basically a device for converting mechanical energy

to electrical energy. The alternator makes use of the experiment fact that if a
conductor is moved through a magnetic field an e.m.f is induced in it. The
magnitude field of this induced e.m.f depends upon the length of conductor
actually in the field, the speed of the relative motion between the conductor and the
magnetic field, and the strength of the field. The direction of polarity of the induced
e.m.f is such that the resulting current flow and the magnetic field around the
conductor produced by it tend to oppose the motion which is producing the e.m.f.
In AC generator the stator holds the armature winding and rotor blocks up
the field winding . In generator, the armature is stationary , the field is rotating. For
the rotating magnetic field, the DC excitation is necessary. DC supply to the rotor
winding of a Turbo generator is required for voltage generation .This is know as
excitation. As the name suggests, when the generator gets excited , it produces the
voltage. The excitation is supplied using a DC machine called exciter. Exciter is
generally driven with the same shaft.
 ELECTRICAL MACHINES

Machine acts as a generator converts the mechanical energy into

electrical energy. The machine, which acts as a motor, converts electrical
energy into mechanical energy
The basic principle of rotating machine remains the same i.e.
“ FARADAY’S LAWS OF ELECTRO MAGNETIC

INDUCTION”.

Faraday’s first law states that whenever conductor cuts magnetic flux,
dynamically induced EMF is produced. This EMF causes a current flow if
the circuit is closed.
Faraday’s second law states that EMF induced in it, is proportional to
rate of change of flux.
e = -N dφ /dt
EMF induced will oppose both the flux and the rate of change of flux.
In the case of AC generators the armature winding is acts as stator and the
field winding acts as rotor.
Efficiency of a machine is equal to the ratio of output to input
η = Output / input = Output / output + losses
To increase the efficiency of any machine we must decrease the losses,
but losses are inevitable. There are different types of losses that occur in a
generator.
They are broadly divided into 2 types
(1) Constant losses
(a) Iron losses
(b) Friction and windage losses (air friction losses).
(2) Variable losses
(a) Copper losses
Electrical machines are of two types AC machines & DC machines.
AC machines are divided into single-phase AC machines and polyphase AC
machines
3 Phase AC machines are divided into
SYNCHRONOUS MACHINES:
Synchronous Generators (or) Alternators are those in which
the speed of the rotor and flux are in synchronism
2 ASYNCHRONOUS MACHINES:
These are the machines in which the flux speed and rotor
speed will not be the same.

Ex: Induction motors.

Inherently all the machines are AC machines. AC or DC depends
upon the flow of current in the external circuit.
Synchronous generators can be classified into various types based on
the medium used for generation.
1. Turbo-Alternators Steam (or) Gas
2. Hydro generators
3. Engine driven generators
In every machine they are two parts
(1) Flux carrying parts
(2) Load carrying parts
In large synchronous machines the stator have the load carrying parts,
i.e. armature and the rotor has the flux carrying parts i.e.; field winding.
Iron losses are also called as magnetic losses and core losses. They are
broadly divided into
(1) Hystersis losses
(2) Eddy current losses
These losses occur in the stator core.
Copper losses occur in both stator and rotor winding.
The general efficiency of a synchronous generator is 95-98%
The main parts in a synchronous-generator are
STATOR, ROTOR, EXCITATION SYSTEM, COOLING SYSTEM,
INSULATION SYSTEM, BEARINGS.
STATOR: -
1. Stator frame
2. Stator core
3. Stator windings
4. Stator end covers
5. Output leads / bushings

ROTOR: -
1. Rotor body
2. Rotor winding
3. Rotor shaft
4. Rotor retaining rings
5. Fans
6. Field connection

I. STATOR:
1. STATOR FRAME:
The stator frame is horizontally split type and welded
construction and supports the lamination core and the winding. Both the air
duct pieces and welded radial ribs provide for rigidly to the stator frame.
Two things are provided to the stator frame to support the stator
on the foundation. The stator firmly fixed to the foundation plates with bolt
through the feet.
2. STATOR CORE:
The stator core is made up of stacked insulation electrical sheet
steel lamination with a low loss index and suspended in the stator frame
from insulated rectangular guide bars. Axial compression of the stator core
is obtained by clamping fingers, pressure plates and non magnetic clamping
bolts, which are regulated from the core. The clamping finger ensures a
uniform clamping pressure, especially within the range of the teeth and
provided for uniform intensive cooling of stator core ends.
3. STATOR WINDING:
The stator winding is a fractional pitch two layer type, it
consisting of individual bars. The bars are located in slots of rectangular
cross section which are uniformly distributed on the circumference of the
stator core.
In order to minimize losses, the bars are compared of separately
insulated strands which are exposed to 360.degrees transposing
To minimize the stator losses in the winding, the strands of the
top and bottom bars are separately brazed and insulated from each other.

II. ROTOR:

1. ROTOR SHAFT:
Rotor shaft is a single piece solid forging manufactured from a
vacuum casting. Slots for insertion of field winding are milled into the rotor
body. The longitudinal slots are distributed over the circumference. So that
solids poles are obtained. To ensure that only high quality forgings are
used, strengthen test, material analysis and ultrasonic tests are performed
during manufacture of the rotor. After completion, the rotor is based in
various planes at different speeds and then subjected to an over speed test at
120% of rated speed for two minutes.
2. ROTOR WINDING AND RETAINING RINGS:
The rotor winding consisting of several coils, which are
inserted into the slots and series connected such that two coils groups from
one pole. Each coil consists of several connected turns, each of which
consists of two half turns which are connected by brazing in the end
section. The individual turns of the coils are insulated against each other,
the layer insulation L-shaped strips of lamination epoxy glass fiber with
nomex filler are used for slot insulation. The slot wedges are made of high
electrical conductivity material and thus act as damper winding. At their
ends the slots wedges are short circuited through the rotor body.
The centrifugal forces of the rotor end winding are contained by
single piece of non magnetic high strengthen steel in order to reduce stray
losses, each retaining rings with its shrinks fitted insert ring is shrunk into
the rotor body in an overhang position. The retaining rings is secured in the
axial position by a snap ring.

3. FIELD CONNECTION AND MULTICONTACTS:

The field current is supplied to the rotor through multi contact system
arranged at the exciter side shaft end.
III BEARINGS:
 The generator rotor is supported in two sleeve bearings. To
eliminate shaft current the exciter and bearing is insulated from foundation
plate and oil piping.

The temperature of each bearing is maintained with two RTD’s

(Resistance Temperature Detector) embedded in the lower bearing sleeve so
that the ensuring point is located directly below the Babbitt. All bearings
have provisions for fitting vibration pick up to monitor shaft vibrations.
The oil supply of bearings is obtained from the turbine oil system.

EXCITATION SYSTEM:

In all industrial applications, the electrical power demand is ever

increasing. This automatically demands for the design, development and
construction of increasingly large capacity Synchronous generators. These
generators should be highly reliable in operation to meet the demand. This
calls for a reliable and sophisticated mode of excitation system.
 When the first a.c generators were introducing a natural choice for the
supply of field systems was the DC exciter. DC exciter has the capability for
equal voltage output of either polarity, which helps in improving the
generator transient performance. DC exciters, how ever, could not be
adopted for large rateings because of the problems in the design commutator
and brush gear, which is economically unattractive. Of –course, the
problems are not uncommon in power stations but Of the environment with
sulphur vapours, acidic fumes as in the cases of petrochemical and fertilizer
industries, exposure of DC exciter. This adds to the problem of design.
Types of a.c exciters are:
(1) High frequency excitation
(2) Brush less excitation
(3) Static excitation
The high frequency D.C exciter is a specially designed “inductor type
alternator” with no winding on its rotor. It is designed to operate at high
frequency to reduce the size of the rotor; the a.c exciter was very reliable in
operation. Though this system eliminates all problems associated with
commutator, it is not free from problems attributable to sliprings and its
brush gear. Thus brushless excitation system was introduced.
The BL exciter consists of field winding on the stator. This system
proved to be highly reliable and required less maintenance. Absence of
power cables and external ac power supplies males the system extremely
reliable. The problem associated with brushes like fast wear out of brush,
sparkling etc, are eliminated.
This suffers from the disadvantage of lack of facility for field
suppression in the case of an internal fault in generator.
The system comprises shaft driven AC exciter with rotating diodes.
PERMANENT MAGNET GENERATOR AND AVR:

This system is highly reliable with least maintenance and is ideally

suitable for gas driven generators.
The static excitation system was developed contemporarily as an
alternative to brush less excitation system. This system was successfully
adapted to medium and large capacity Turbo generators. Though the system
offers very good transient performance, the problems associated with slip
rings and brush gear system are still present.
This system consists of rectifier transformer, thyristor converts, field
breaker and AVR. This system is ideally suitable where fast response is
called for. The system is flexible in operation and needs very little
maintenance.
Thus, each excitation system has its own advantages and
disadvantages. The selection of system is influenced by the transient
response required, nature of pollution and pollution level in the power plant
and cost of equipment.

Exciters are those components, which are used for giving high voltage
to the generator during the start up conditions. The main parts that are
included in the exciter assembly are:
(1) Rectifier wheels
(2) Three phase main exciter
(3) Three phase pilot exciter
(4) Metering and supervisory equipment

RECTIFIER WHEELS:
The main components of the rectifier wheels are Silicon Diodes,
which are arranged in the rectifier wheels in a three-phase bridge circuit. The
internal arrangement of diode is such that the contact pressure is increased
by centrifugal force during rotation.
There are some additional components contained in the rectified
wheels. One diode each is mounted in each light metal heat sink and then
connected in parallel. For the suppression of momentary voltage peaks
arising from commutation, RC blocks are provided in each bridge in parallel
with one set of diodes. The rings from the positive shrunk on to the shaft.
This makes the circuit connections minimum and ensures accessibility of all
the elements.

THREE PHASE PILOT EXCITER:

The three phase pilot exciter is a six-pole revolving field unit; the
frame accommodates the laminated core with the three-phase winding. The
rotor consists of a hub with poles mounted on it. Each pole consists of
separate permanent magnets, which are housed, in non-metallic enclosures.
The magnets are placed between the hub and the external pole shoe with
bolts. The rotor hub is shrunk on to the free shaft end.
THREE PHASE MAIN EXCITER:
Three phases main exciter is a six-pole armature unit, the poles are
arranged in the frame with the field and damper winding. The field winding
is arranged on laminated magnetic poles. At the pole shoe, bars are provided
which are connected to form a damper winding.
The rotor consists of stacked lamination. Which are compressed
through bolts over compression rings. The three- phase winding is inserted
in the slots of the laminated rotor. The winding conductors are transposed
with in the core length and end turns of the rotor windings are secure with
the steel bands. The connections are made on the side facing of the rectifier
wheels. After full impregnation with the synthetic resin and curing, the
complete rotor is shrunk on to the shaft.
AUTOMATIC VOLTAGE REGULATOR:
The general automatic voltage regulator is fast working solid thyristor
controlled equipment. It has two channels, one is auto channel and the other
is manual. The auto channel is used for the voltage regulation and manual
channel.
Is used for the current regulation. Each channel will have it’s own
firing for reliable operation.
The main features of AVR are:
(1) It has an automatic circuit to control outputs of auto channel
and manual channel and reduces disturbances at the generator terminals
during transfer from auto regulation to manual regulation.
(2) It is also having limiters for the stator current for the optimum
utilization of lagging and leading reactive capabilities of turbo generator.
(3) There will be automatic transfer from auto regulation to manual
regulation in case do measuring PT fuse failure or some internal faults in
the auto channel.
(4) The generator voltage in both channels that is in the auto
channel and the manual channel can be controlled automatically.

COOLING SYSTEM:
Cooling is one of the basic requirements of any generator. The
effective working of generator considerably depends on the cooling system.
The insulation used and cooling employed is inter-related.
The losses in the generator dissipates as the heat, it raises the
temperature of the generator. Due to high temperature, the insulation will be
affected greatly. So the heat developed should be cooled to avoid excessive
temperature raise. So the class of insulation used depends mainly on cooling
system installed.
There are various methods of cooling, they are:
a. Air cooling- 60MW
b. Hydrogen cooling-100MW
c. Water cooling –500MW
d. H 2 & Water cooling – 1000MW
Hydrogen cooling has the following advantages over Air-cooling:
1. Hydrogen has 7 times more heat dissipating capacity.
2. Higher specific heat
3. Since Hydrogen is 1/14th of air weight. It has higher
compressibility
4. It does not support combustion.
DISADVANTAGES:
1. It is an explosive when mixes with oxygen.
2. Cost of running is higher.
Higher capacity generators need better cooling system.
The two-pole generator uses direct cooling for the rotor winding and
indirect air-cooling for the stator winding. The losses in the remaining
generator components, such as iron losses, windage losses, and stray losses
are also dissipated through air.
The heat losses arising in the generator interior are dissipated through
air. Direct cooling of the rotor essential eliminate hot spots and differential
temperatures between adjacent components, which could result in
mechanical stresses, particularly to the copper conductors, insulation and
rotor body. Indirect air-cooling is used for stator winding.
Axial-flow fans arranged on the rotor via draw the cooling air for
axial-flow ventilated generator via. Lateral openings in the stator housing.
Hot air is discharged via. Three flow paths after each fan.
FLOW PATH 1: it is directed into the rotor end windings space and cools
the rotor windings, part of the cooling air flows past the individual coils for
cooling the rotor end windings space via bores in the rotor teeth at the end of
the rotor body. The other portion of the cooling airflow is directed from the
rotor end winding space into the slot-bottom ducts from where it is
discharged into the air gap via. A large number of radial ventilating slots in
the coils and bores in the rotor wedges along these paths the heat of rotor
winding is directly transferred to the cooling air.
FLOW PATH 2: it is directed over the stator end windings to the cold air
ducts and into the cold air compartments in the stator frame between the
generator housing and rotor core. The air then flows into the air gap through
slot in the stator core where it absorbs the heat from the stator core and stator
winding.
FLOW PATH 3: It is directed into the air gap via. The rotor retaining-ring.
The air then flows past the clamping fingers via. Ventilating slot in the stator
core into the hot air compartments in the stator frame being discharged to the
air cooler. The flow path mainly cools the rotor retaining rings, the ends of
the rotor body and the ends of the stator core.
Flow 2&3 mix in the air gap with 1 leaving the rotor. The
cooling air then flows radially outward through ventilating slots in the core
within the range of the hot air compartments for cooling of the core and
winding. The hot air is discharged to air cooler.

OIL SYSTEM:
Lubrication oil is to be supplied in order that the rotor can be
easily ruined. Jacking oil is first given in order to shift the shaft near the
journal and so that it can be ruined easily. Jacking oil is given only at the
starting and it is stopped and further lube oil is given continuously. This oil
is to be continuously in order to reducing wear and tear on the bearing.
STATOR

The various losses in the generator are broadly classified as

below:

1. Iron losses/Core losses/Magnetic losses/Constant losses

i) Hysterisis losses
ii) Eddy Current losses.

2. Copper losses/ IVR losses/ winding losses.

3. Mechanical losses/ Friction & windage losses.

STATOR CORE:
The purpose of the stator core is two ways:
1. Support the winding
2. Carries the flux
So, the selection of material for building up of core plays a vital role.
The losses i.e.; magnetic losses are mainly two types.
1. Hysterisis Losses: Due to the residual magnetism in the material
2. Eddy Current Losses: Due to the EMF produced in the core of the
stator. In order to minimize the Hysterisis losses silicon alloyed steel
sheets are used for building up of core.
The sheets has the following composition,
Steel - 95.5%
Silicon -4%
Impurities -0.2%
 The sheets are 4% Silicon Alloyed COLD ROLLED NON-GRAIN
ORIENTED SHEETS (CRNGO). To reduce the Eddy Current Losses,
the core is build up of 0.5mm thickness laminations, which are insulated
from each other. The sheets are insulated by CLASS-B type of varnish.
LAMINATION PREPARATION:
The core is built up of 6 sectors, each of 60ºC cut accordingly to the
specifications. The cut steel is punched for slots and deburred up to 5
micron.
Depending on the temperature withstand ability of the machine the
laminations are insulated by varnish.

The insulation used is ALKYD PHENOLIC VARNISH dried at

suitable temperature. The lamination sheets are passed through a conveyor,
which has an arrangement to sprinkle the varnish, and a coat of varnish is
obtained. The sheets are dried by a series of heaters at a temperature of
around 300º-400ºC. Two coatings of varnish are provided in the above
manner. The thickness of varnish should be 8-10 microns when measured by
a mini tester. Each lamination should be dried for around 90sec at constant
speed. The prepared laminations are passed for various tests.
i) Xylol test- for proper coat of varnish this test is made. When Xylem is
applied for 1 min, varnish should not dissolve.

ii) Mandrel test- when wound around mandrel there should be no cracks.
iii) Viscosity test- it should be 40-45 cp.
iv) IR value test- for 20 layers the insulation resistance should have a
minimum value of 1 Mega Ohm at 23kg/cm2 pressure.
v) Hardness test – minimum 7H pencil hardness, the coating should not be
removed when scratched with a 7H pencil.

vi) Uniform test – coating should be done uniformly.

CORE ASSEMBLY:
1. Trial core assembly:
Three packets are assembled on the clamping plate and all relevant
checks are carried out. Critical checks are inside diameter of the core, final
inspection drift passage through the slot. After fulfilling the entire above
requirement the packets are disassembled.
2. Regular core assembly:
The packets assembly is carried out as per drawing requirement
the segments are staggered from layer to layer so that a core of high
mechanical strength and uniform permeability to magnetic flux is
obtained. Stacking mandrels and bolts are inserted into the winding slots
bores during stacking provide smooth slot walls. The length of each
packet of laminations should be as per the design. Between each packet
ventilation lamination sheets is assembled whose thickness is 0.65 mm
and on which “ I” beams is spot-welded. This provides the ventilation in
radial directions

.
3. Normal packets assembly:
The above process is repeated up to 800mm after attaining 800mm
first pressing is carried out as per drawing requirement. After completion of
the core assembly core lengths are checked in 8 to 12 locations either in
 clockwise or anti-clockwise direction if any variation in the core lengths is
being noticed replenish the core height in subsequent final core assembly.
After completion of core assembly clamping plate is assembled. All the
core lengths are checked around the outer& inner diameter clockwise as per
the drawing requirements. So under final pressure tension bolts are
assembled and the core bolts are tightened with the specified torque.
The clamping bolts running through the core are made of non-
magnetic steel and are insulated from the core and the pressure plates. The
pressure is transmitted from the pressure plates to the core by clamping
fingers. The clamping fingers extended up to the ends of teeth, thus
ensuring a firm compression in the area of the teeth.
Now first ring is welded on the both side under pressure similarly the
subsequent ring are also welded. The total vertical core is shifted
horizontally on exciter side and again winding brackets are assembled and
checked for 90°c as per the drawing requirements. After completion of
cleaning the total stator in all respects like filling lamination projections
sharp corners and interuption of foreign matter. Then the the stator is
subjected for core flux test to detect hot spots.

CONDUCTOR CONSTRUCTION:
Copper coils are received and examined for physical and electrical
properties in accordance to the specification. The conductors are cut in to
require size as per drawing requirement; this operation is called
CONDUCTOR CUTTING.

ROEBEL TRANSPORTATION:
 The strips are staggered and are bend for Roebel transposition. The
individual bars are transposed to 360°c, equalize the induced EMF in all
strands, to minimize the circulating currents and to reduce the skin effect and
it gives a good rigidity to the bars.
After alining both bottom dye and top dye conductors are pressed and
checked as per the drawing requirement and center to center length is been
checked, first and second bundle are assembled together to form a single
bundle and then an insulation sheet is kept in between two bars and they are
joined together to form a single bar.
PUTTY WORK:
Each individual bar consisting of uneven surface and width space are
filled with nomax and trivaltherom Mica fleece is placed on both the
surfaces and further taping is done by PTFE tape (Poly tetra Fluro Ethylene)
and are subjected for further processing.
STACK CONSOLIDATION:
The bars are subjected to a horizontal and vertical pressure
of150kgs/cmsquare at a temperature of 150deg.c for the duration of 2 to 3
hours. Passing gauges like no go gauges and go gauges and lamp test is
conducted for inter strip and inter half shorts.
FIRST & SECOND BEND OPERATION:
Bending operation is done on bending table. First and second bend is
carried out and to achieve the over hang , third bend formation the coil is
laid on universal former. Roto pax and harder is applied along with nomax
in between two halves of the overhang portion and hence consolidation is
carried out by keeping heating clamps.
CLEANING AND PREPARATION OF BARS:
Bars are cleaned and tested for inter strip and inter half shorts and subjected
for final tapping.

FINAL TAPPING:
Tapping is carried out on the bars by two ways, they are:-

1. Manual tapping
2. Machine tapping
Resin rich and Resin poor insulating materials are characterized by the
contact of the Epoxy Resin. In Resin rich system the content of Epoxy Resin
is 40% in tape so it is named as RESIN RICH SYSTEM, and in Resin poor
system the content of Resin is 8% in tape so named as RESIN POOR
SYSTEM.

RESIN POOR TAPPING:

Resin poor mica tape is used for resin poor bars; the first layer is carried out
by spreading the copper foils. Then 6x1/2 overlapping layers of resin poor
tape is wrapped.Throughout the length of the bar including 3rd bend i.e. and
2x1/2 over lapping layers of resin poor tape is carried out only in straight
portion one layer of split mica is warrped by spreading ocp at bottom such
that their must not be any overlapp between split mica tape ultimately OCP
is wrapped in the straight portion ECP is wrapped from the end of the
straight part up to overhang second bend. Starting from straight portion upto
3rd bend portion hyper seal tape is wrapped on both sides and sent for stator
winding.

Transition insulation – nomex glass fleece.

 Halves insulation ect. top bar- fine mica poly glass cloth.
Overhang separator coating- thoroughly mixes rotopox 164 &
hardener H 90 in 5:1ratio
Transposition filler- micanite.
Inner conductive tape – fleece tape with graphite
Outer carona tape- poly fleece tape
End carona protection tape-fleece tape with silicon carbide
Protective tape for overhang- glass tape
ICP - (Inner carona protection)
- Also Called Inner potential grading on the stack of the bars to
avoid inner corona discharges.
- To optimize insulation they’re by voltage stress grading.
- Provided with conductive fleece tape with a copper strip.
OCP - (outer carona protection)
- On the outer surface of the insulated startor bars.
- Conductive fleece tape.
- To provide effective path for outer corona discharges.
ECP- (end carona protection)
- Semiconductive tapes on both ends of the straight part of the
bars.
- To dampen the voltage surges through additional surface
capacitance

RESIN RICH TAPPING:

All the operations relevant to Resin Poor Tapeing are common up to
overhang consolidation only final tapping is differed. In resin rich system
i.e. 12x1/2 overlapping of resin rich tape is wrapped over the resin rich bar
and subjected for final baking operation. The bar is heated up to 90°c for the
duration of 60 minutes. This stage is known as GEL FORMATION and
again the bar is heated to 110°c with in the span of 30 minutes. During this
time the bar is tightened from the center towards the bend portion on both
sides. This stage is known as liquid formation from 90°c to 110°c, 15% of
resin is oozed out and remaining resin is consolidated for duration of 3 hours
at a temperature of 160°c and allowed for natural cooling. In straight
portion k8880 conductive coating is carried out and in bend portion semi
conductive coating is carried out. Red gel paint is carried out in both the
overhang portions. This process is repeated for each individual bar for the
total number of bars required. And HV and tan delta test is carried out for
each bar.

STATOR WINDING:
The three-phase stator winding is a fractional pitch two-layer type
consisting of individual bars; each stator slot accommodates two bars.
It is a double layer lap winding with 60o phase spread fractional
Windings are used to reduce higher order harmonics and pitch of the
winding is so Selected that 5th and 7th harmonics are greater reduced.
The slot bottom bars and top bars are displaced form each other by one
winding pitch and connected at their ends to form coil groups. The coil
groups are connected together with phase connectors inside the stator frame.
This arrangement and shape of the bars at the results in a cone shaped
winding having particularly favorable characteristics both in respect of its
electrical properties and resistance of only one turn insulation and main
insulation identical.
Stator core received after the core assembly is checked for the
availability of foreign matter, so coil projections are checked in each slot.
HGL drift is passed in each and every slot to detect bottom core projections.
Winding holders are adopted and binding rings are assembled on both sides.
The HGL binding rings are centered to the core and then bottom bars are
laid. Each bar is pressed with a pressing fixture to obtain specified
dimensions. By adopting this above procedure the entire bottom bars are laid
in respective slots. After completing of bottom bar layer reinforcing the
overhang portion by tying with nipping glass sleeve.
Temporary wedging is carried out, HV testing is done and then
stiffeners are assembled. Top bars are laid by pressing each bar with a
pressing fixture and all the bars are laid in respective slots. In between top
and bottom bars HGL spacers are kept. And then top bars are tested.
Individual eye jointing and bracing is carried out. Then after eyes
jointing individual eyes are insulated with fine mica tape. After completion
of eyes jointing connector rings are assembled & connected as per drawing
and three neutral and three phases terminal are terminated out. Once again
HV test is carried out before sending the stator to impregnation.

CONNECTION OF BARS:
 Brazing makes the electrical connection between the top and
bottom bars. One top bars strand each is brazed to one strand of the
associated bottom bar so that beginning of each strands is connected without
having any electrical contact with the
Remaining strands. This connection offers the advantage that circulating
current losses
In the stator bars are kept small. The strands are insulated from each other at
the brazed joints. The coils connected are wrapped with dry mica/glass
fabric tapes half overlapped. The thickness of the wrapper depends on the
machine voltage. The gaps between the individual coil commendations
being sufficiently large, no additional insulation is required.

PHASE CONNECTORS:
The phase connectors consist of flat copper sections, the cross
section of which results in a low specific current loading. The connections
to the stator winding are of riveted and soldered tape and are like-wise
wrapped with dry mica/glass fabric tapes.
The phase connectors are firmly mounted on the winding support using
clamping pieces and glass fabric tapes.

TERMINAL BUSHINGS:
1. ARRANGEMENT OF TERMINAL BUSHINGS
The beginning and ends of the three phase windings are brought out from the
stator frame through bushings, which provides for high voltage insulation.
The bushings are bolted to the stator frame at the exciter end by their
mounting flanges. Bushing type current transformers for metering and
relating may be counted on the Bushings courtside the stator frame. The
generator main leads are connected to the terminal connectors outside the
stator frame.

2. CONSTRUCTION OF TERMINAL BUSHINGS:

The bushing conductor consists of high conductivity copper buses. All
connection flanges are silver-plated to minimize the contact resistances of
the bolted connections. The supporting insulator of glass silk cloth is
impregnated with epoxy resin. The copper buses are attached to the insulator
only at one end and are thus free to expand. Flexible connectors allow for
thermal expansion between the terminal bushing and the phase connectors.
To prevent eddy current losses and inadmissible overheating, the mounting
flange is made of glass silk cloth as well.

3. COOLING OF TERMINAL BUSHINGS:

To dissipate the heat the terminal bushings are directly cooled with cold
air. Cold air form the discharge end of the fan is pressed in to the insulator.
The hot air is returned to the suction in take of the fan via the passage
between the two copper buses.
ROTOR
The rotor shaft is forged from a vacuum degassed steel ingot.
Comprehensive test ensures adherence to the specified mechanical and
magnetic properties as well as a homogeneous forging.
The rotor consists of electrically active portion and two shafts ends.
An integrally forged flange coupling to connect the rotor to the turbine is
located out board of the bearing.
Approximately 60% of the rotor circumference is provided with
longitudinally slots, which hold the field windings slot pitch is selected so
that the two solid poles are displayed by 180 degrees.
Due to the non-uniform slot distribution is on the circumference,
different moments of inertia are obtained in the main axis of the rotor. This
in turn causes varying shaft deflections at twice the system frequency. To
reduce these vibrations the deflections in the direction of the poles axis and
neutral axes are equalized by the transverse slotting of the poles.
The rotor teeth at the ends of the rotor body are provided with axial
and radial holes enabling the cooling air to be discharged into the air gap
after intensive cooling of the end windings.
Rotor windings Construction:
The field winding consists of several series connected coils inserted
into the longitudinal slots of the rotor body the coils are wound so that, two
poles are obtained.
The solid conductors have a rectangular cross-section and are
provided with axial slots for radial discharge of the cooling gas. All
conductors have identical copper and cooling duct cross-section.
The individual conductors are bent to obtain half after insertion into
rotor slots. These turns are combined of from full turns the series connected
turns of one slot constitute one coil the individual coils of the rotor winding
are electrically series connected so that one north and one south magnetic
pole are obtained.
VENTILATION CONSUME & 90° BENDING:
First the conductors are checked for their quality and ventilation holes
are punched and they are checked for burr. Then edge wise bending is made.
The conductors are bent more than 90o so that it will sustain spring back
effect. Debugging ventilation slots by relevant tools.
ANNEALING:
Then the conductors are heated and pressed at the bending so that the cross
section of the conductors will be maintained equal through out. This process
is called annealing.

DOVETAIL PUNCHING&WINDOW DIMENSION:

A small portion near the bend is removed so that it does not cause any
damage to the insulation trough while lying in the slots. This process is
called relief filing. Then dovetail punching is made which provides good
brazing process when two conductors are joined. Window dimensions for
the conductors are checked. The dimension of the window decreases from
top to bottom conductors.
CLEANING:
Then the conductors are cleaned with thinner (acetone) and then air-dry
varnish is applied. Then keeping the conductors on a dummy rotor makes
radial bending. For the conductors away from the poles prebrazing is done.

Conductor material: The conductors are made with silver content of

approximately 0.1% as compared to the electrolytic copper; silver alloyed
 copper features high strength properties at high temperatures so that coil
deformations due to thermal stresses are eliminated.
Insulation: The insulation between the individual terms is made of layer of
glass fiber laminate with numex filler.

Characteristics of copper to be used are:

Density 8900kg/m3
Melting point 1083
Thermal conductivity w/m-oc 350
Coefficient of thermal expansion at 20 oc/oc 16.7x10-6
Resistively ohm -m 0.01724x10-5
Resistance temperature coefficient at 20oc, -1oc 0.00393
Specific heat J/kgoc 390

Arrangements of insulation in laying of copper in the slots:

♦ Turn insulation of glassoflex in straight part.
♦ Turn insulation of glassoflex in overhang before bend.
♦ Turn insulation of glassoflex at bends
♦ Turn insulation of glassoflex in overhang after bend.
♦ Shellac varnish P-80
♦ Insulating troughs.
The connections for the coils on both the poles will be as follows:

Pole 1 TS pole 2
 ES
(+) (-)
Location of parts in rotor winding:
Rotor slot wedges:
To protect the winding against the effects of the centrifugal force the
winding is firmly secured in the slots with wedges. They are made from an
alloy featuring high strength and good electrical conductivity and are also as
damper winding bars the slot wedges extend below the shrink seats of the
retaining rings the ring acts as short circuit in the damper windings.
End winging spacing:
The spaces between the individual coils in end windings are filled
with insulating members the insulating members prevent coil movements
and are used for intensive cooling of the rotor end windings.
Rotor retaining rings:
The rotor retaining rings balance the centrifugal force due to the end
windings. One `end of each rings is shrunk on the rotor body while the other
end of the ring overhangs the end winding without contacting on the shaft
this ensures an unobstructed shaft direction of the end winding.
The shrunk on the hub at the free end of the retaining ring serves to
reinforce the retaining ring and secures the end winding in the axial direction
at the same time. A snap ring is provided for additional against axial
displacement of the retaining ring. To reduce the stray losses and have high
strength the rings are made up of non-magnetic cold worked materials.
Comprehensive test such as ultrasonic examinations and liquid penetrate
examination ensures adherence to the specified mechanical properties the
retaining ring shrink-fit areas. These act as short circuit rings to the induced
currents in the damper system to ensure low contact resistance the shrink
seats of the retaining rings are coated with nickel aluminum and silver by a
three step spraying process.
Field connections:
The field connections provide electrical connections between the rotor
winding brush less exciters.
Terminal lug:
The terminal lug of a copper conductor of rectangular cross-section one end
of the terminal lug is braced to the rotor winding while the other end is
screwed to the radial bolt.
Radial bolt:
The field current lead located in the shaft bore is connected to the terminal
lug at the end winding through a radial bolt. The radial bolt is made from
steel and screwed into the field current lead in the shaft before.
Field current lead in shaft bore:
The leads are run in the axial directions from the radial bolt to the end of the
rotor. They consist of two semicircular conductors insulated from each other
by an intermediate plate and from the shaft by a tube.
Rotor fan:
The generator cooling air is circulated by two axial fans located on the shaft
at both end two augment the cooling or the rotor winding the pressure
established by the fan works in conjunction with the air expelled from the
discharged along the rotor. The moving blades of the fan have threaded roots
for being screwed into the rotor shaft the blades are dropped forged from an
aluminum alloy the threaded root fastening permits the blade angle to be
adjusted each blade is secured at its root with a threaded pin.
BALANCING:
After rotor is manufactured rotor is balanced .It is desired that every
rotor should run smoothly in its bearings. In order to achieve it the rotor
should be balanced before assembling. The larger the rotor the more the
balancing is required. Balancing of rotor is carried out in two steps
1. Static balancing 2. Dynamic balancing
Static balancing:
In static balancing, the rotor is put on two plain rails. Rails replace
the shaft at the bearing ends. The rails should be perfectly horizontal as
possible. The rotor should be in position to swing on these rails without
friction. Then the eccentric force is balanced. This static balancing is only
useful to bring the center of gravity very near to the axis of the shaft but for
exact balancing dynamic balancing is needed.
Dynamic balancing:
It helps to find not only forced but also torques on the shaft when
the machine runs. This method of balancing helps to balance the deviation of
the axis of center of gravity from axis of rotation. Rotation is essential for
dynamic balancing. Turbo generators are generally dynamically balanced
under rotor hot conditions. The weights on either side of the axis of the rotor
are determined. The centrifugal force on the bearings is measured and
weights on either side of the axis of the rotor are not the same then the
difference of weights are added to the required side of the axis. In this way,
the rotor is balanced.
 For obtaining the most accurate balancing, it is to be carried out in the
presence of vacuum.

INSULATION SYSTEM
In Electrical Machines insulation is most important requirement to
sustain high voltages and basically insulation is the heart for electrical
machines. Insulation is the property which has enormous resistance to the
conductivity that is basically the forbidden gap between valance and
conduction bands are very large I.e. formic level very high in insulating
materials .The property of good insulating material is non-conductive to
electricity and conductor for heat. A good insulating material needs the
following properties.
1. The basic function of insulation is to provide insulation to live wire or live
wire to earth.
2. It should be good conductor to heat and bad conductor to electricity.
3. It should withstand the designed mechanical stress.
4. It should have good chemical and thermal resistively and environmental
resistively.
An insulator should satisfy the following properties for an electrical system
are 1. ELECTRICAL PROPERTIES
2. MECHANICAL PROPERTIES
3. THERMAL PROPERTIES
4. CHEMICAL PROPERTIES
INSULATING MATERIALS:
Insulating materials or insulates are extremely diverse in origin and
properties. They are essentially non-metallic, are organic or inorganic,
uniform or heterogeneous in composition, natural or synthetic. Many of
them are of natural origin as, for example, paper, cloth, paraffin wax and
natural resins. Wide use is made of many inorganic insulating materials such
as glass, ceramics and mica. Many of the insulating materials are man-made
products and manufactured in the form of resins, insulating films etc., in
recent years wide use is made of new materials whose composition and
organic substances. These are the synthetic Organo-silicon compounds,
generally termed as silicones.
An ideal insulating material should have:
 (1) High dielectric strength sustained at elevated temperatures.
(2) High receptivity or specific resistance
(3) Low dielectric hysterics
(4) Good thermal conductivity
(5) High degree of thermal stability i.e. it should not determine at high
temperatures.
(6) Low dissipation factor
(7) Should be resistant to oils and liquid, gas flames, acids and alkalis.
(8) Should be resistant to thermal and chemical deterioration.

CLASSIFICATION OF INSULATING MATERIAL:

The insulating material can be classified in the following two ways.
I. Classification according to substance and materials.
II. Classification according to temperature.
Classification according to substance and materials:
a) Solids (Inorganic and organic)
EX: Mica, wood slate, glass, porcelain, rubber, cotton, silks, rayon,
ethylene, paper and cellulose materials etc.
b) Liquids (oils and varnishes)
EX: linseed oil, refined hydrocarbon minerals oils sprits and synthetic
varnishes etc.
c) Gases
EX: Dry air, carbon dioxide, nitrogen etc.

CLASSIFICATION ACCORDING TO TEMPERATURE:

Class Permissible Materials
temperature
Y 90° Cotton, silk, paper, cellulose, wood etc neither impregnated nor
immersed in oil. These are unsuitable for electrical machine and
apparatus as they deteriorate rapidly and are extremely hygroscopic.
A 105° Cotton, silk & paper, natural resins, cellulose esters, laminated wool,
varnished paper.
E 120° Synthetic material of cellulose base
B 130° Mica, asbestos, glass fiber with suitable bonding substance
F 155° Material of class B with binding material of higher thermal stability.
H 180° Glass fiber and asbestos material and built up mica with silicon resins.
C Above Mica, porcelain, quartz, glass (without any bonding agent) with silicon
180° resins of higher thermal stability.

INSULATING MATERIAL FOR MACHINES:

Shelf life
Name of Insulation (In months) Application
Material Class At At
20 oC 5oc
1. Samicatherm calmica glass-n, F 6 12 Main insulation of stator
mimica, domica, folium, bars
filamic novobond-s, epoxy
therm laxman isola
calmicaflex
2. Samica flex H 4 8 Overhang insulation of
motor coils, at 3rd bends of
multi turn coil
3. Vectro asbestos B/F 2 8 Main pole coils of
(365.02/365.32) synchronous machines
4. (used in resin rich)
5. Epoxide pepreg glasscloth F 6 12 Winding holders and
interhalf insulation
6. Polyester resin mat&rope 6 Bar to winding
holder&stiffner groove of
support segment of
clamping plate
7. Glassoflex F 6 12 Interturn insulation of rotor
Turbo laminate winding
8. Hyper seal tape F 6 12 As finishing layer in
overhangs of motor coils
9. SIB775 or 4302 varnish F 6 12 Stack Consolidation of
stator bars
10. SIB475 or 4301 varnish F 6 12 Base coat varnish before
taping of stator bars
11. SIB 643 or8003 Varnish or 4 8 Conductive coat in straight
K8886 varnish portion of stator bars
12. SIB 642 or 8001 varnish 4 8 At slot emerge portion on
stator bars

I. ELECTRIAL PROPERTIES:
1. INSULATON RESISTANCE:
It may be defined as the resistance between two conductors usually
separated by insulating materials. It is the total resistance in respect of
two parallel paths, one through the body and other over the surface of
the body.
2. DIELECTRIC STRENGTH:
The voltage across the insulating material is increased slowly the
way in which the leakage current increases depend upon the nature
and condition material.
3. POWER FACTOR:
Power factor is a measure of the power losses in the insulation and
should be low. It varies with the temperature of the insulation. A rapid
increase indicates danger.
4. DIELECTRIC CONSTANT:
This property is defined as the ratio of the electric flux density in the
material .To that produced in free space by the same electric force.
5. DIELECTRIC LOSS:
The dielectric losses occur in all solid and liquid dielectric due to
(a) Conduction current
(b) Hysterisis.
II. THERMAL PROPERTIES:
Specific heat thermal conductivity.
1. Thermal plasticity
2. Ignitability
3. Softening point
4. Heat Aging
5. Thermal expansion.

III. CHEMICAL PROPERTIES:

1. Resistance to external chemical effects

2. Resistance to chemical in soils
3. Effect of water.

IV. MECHANICAL PROPERTIES:

1. Density
2. Viscosity
3. Moisture absorption
4. Hardness of surface
5. Surface tension
6. Uniformity.
EFFECT OF MOISTURE ON INSULATION:

Thermal property
Chemical property
Electrical property
Physical and mechanical property.

INSULATION RESISTANCE IS EFFECTED BY

THE FOLLOWING FACTIOR (Resistance between two conductor):

1) It falls with every increase in temperature.

2) The sensitivity of the insulation is considerable in the

presence of moisture.

3) Insulation resistance decrease with increase in applied

voltage.

EPOXY RESINS:

These resins are product of alkaline condensed of epichlorohydrin and

product of alkaline condensed of epichlorohydrin and polyhydric
compounds.

PROPERTIES:

1) Epoxy resins have good mechanical strength less shrinkage and

excellent dimensional stable after casting.

2) Chemical resistance is high.

3) Good adhesion to metals.

4) To impact hardness certain organic acid anhydrides and alphabetic

amines are mixed.
APPLICATION:

1) They are used in the manufacture of laminated insulating boards.

2) Dimensional stability prevents crack formation in castings.
3) They are also used as insulating varnishes.

EPOXY RESINS:

Epoxy resins are poly ethers derived from epi-chlorohydrin and

Bis-phenol monomers through condensation polymerization process.

In epoxy resins cross-linking is produced by cure reactions. The liquid

polymer having reactive functional group like oil etc, otherwise vacuum as
pre polymer. The pre polymer of epoxy resins allowed to react curing agents
of low inductor weights such as polyamines, polyamides, polysulphides,
phenol, urea formaldehyde, acids anhydrides etc, to produce the three
dimensional cross linked structures.
Hence epoxy resins exhibit outstanding toughness, chemical inertness
and excellent mechanical and thermal shock resistance. They also posses
good adhesion property. Epoxy resins can be used continuously up to 300°F,
but withy special addition can withstand a temperature of up to 500°F.

Epoxy resins are made use as an efficient coating material. This

includes coating of tanks containing chemicals, coating for corrosion and
abrasion resistant containers. Epoxy resins are made up of as attractive
corrosion and wear resistant floor ware finishes.

These are also used as industrial flooring material. They are also used as
highways Surfacing and patching material. Molding compounds of epoxy
resins such as pipe fitting electrical components bobbins for coil winding
and components of tooling industrial finds greater application in industries.

The epoxy resins similar to polyester resins can be laminated and fiber
reinforced (FPR) and used in glass fiber boats, lightweight helicopters and
aeroplanes parts.
In the modern electronic industry, the application of epoxy resins is
great. Potting and encapsulation (coating with plastic resin) is used for
electronic parts. Most of the printed circuits bodies are made of lamination
epoxy resin which light but strong and tough.
INSULATING MATERIAL FOR LAMINATIONS: -
The core stacks in modem machines are subjected to high pressers
during assembly and subjected to high pressures during assembly and there
fore to avoid metal-to-metal contact, laminations must be well insulated. The
main requirements of good lamination insulation are homogeneously in thin
layers toughness and high receptivity.
We use varnish as insulating material for laminations.
VARNISH

This is most effective type of insulation now available. It makes the

laminations nest proofs and is not effected by the temperature produced in
electrical machines varnish is usually applied to both sides of lamination to a
thickness of about 0.006mm. On plates of 0.35mm thickness varnish gives a
stacking factor about 0.95.In order to achieve good insulation properties the
following processes are in BHEL.
• THERMOPLASTIC PROCESS OF INSULATION
• THERMOSETTING PROCESS OF INSULATION

BHEL is practicing only thermosetting process of insulation so

Thermosetting types of insulation are of two types:
• RESIN RICH SYSTEM OF INSULATION
• RESIN POOR SYSTEM OF INSULATION

MATERIAL FOR RESIN RICH BARS:

• Preprag
• Nomex
• Epoxy resin rich mica tape
• Glass tape
• PTFE tape
 VARNISH
• Mica powder
• Graphite powder
• Conductive varnish
• Semiconductor varnish
MATERIAL FOR RESIN POOR HALF BARS
• EPOXY glass cloth
• Nomex glass fleece
• Fine mica polyester glass cloth
• Nomex
• Form micanite
• Form mica tape
• Copper foil
• Polyester fleece tape with graphite for ICP
• Polyester fleece for OCP
• Polyester fleece tape with silicon carbide
• Mica splitting tape
VARNISH
• Polyester glass tape
• Rutapox
• Hardener (H-90)
MATERIAL FOR RESIN POOR DIAMOND COILS
• Treated trivoltherm
• Impregnated polyester fleece
• Glass mat with accelerator
• Hostofon folium
• Synthetic fiber tape
• Resin poor mica tape
• Polyester fleece tape with graphite
• Semiconductor asbestos tape
• Polyester glass tape
• Polyester fleece tape
• Nomex polyamide adhesive tape
RESIN RICH SYSTEM:
In olden days, Resin Rich system of insulation is used for all Electrical
Machines. In insulator contains nearly 40% of EPOXY RESIN, so it gives
good thermal stability Resin Rich Insulation consists of the following
materials in percentage
1. MICA PAPER TAPE -40-50%
2. GLASS PAPER TAPE-20%
3. EPOXY RESIN-40%
The bars are insulated (or) taped with RESIN RICH TAPE and place
in the Pre-assembled stator core including stator frame.
In resin rich system of insulation Mica paper will give a good dielectric
strength and Glass fiber tape will give a good mechanical strength and
Epoxy resin can withstand up to 155 degree Centigrade so it gives a good
thermal properties. Resin rich and Resin poor insulating materials are
characterized by the contact of the Epoxy Resin. In Resin rich system the
content of Epoxy Resin tape is 40% so it is named as RESIN RICH
SYSTEM, and in Resin poor system the content of Resin tape is 8%. By VIP
impregnation process, the required amount is added to then conductor bars
after assembling the core and placing the winding in the core. In resin rich
system before placing of coils in the stator slots the rich tape will be
wrapped over the bars. Nevertheless, this system has the following
disadvantages:
1. This system is very time consuming and very long procedure.
2. Total cost of the system is more.

In order to minimize the over all cost of the machine and to reduce the time
cycle of the system, the VACUUM PRESSURE IMPREGNATION
SYSTEM is being widely used. This process is very simple, less time
consuming and lower cost.
BHEL, HYDERABAD is equipped with the state of the art
technology of VACUUM PRESSURE IMPREGNATION.
TESTING OF TURBO GENERATOR

To ensure that all functional requirements are fulfilled,

and to estimate the performance of generator, the TURBO
GENERATORS are required to undergo some tests. For
testing, the TURBO GENERATOR was mechanically coupled to
a drive motor-motor generator set with gearbox. The rotor
was excited by thyristor converter system located in an
independent test room and the operation was controlled from
the test gallery.

The following first two tests will be conducted on the stator

and rotor before assembling and the third and final routine
tests will be conducted after assembling the turbo generator.

TESTS CONDUCTED ON ROTOR

TESTS CONDUCTED ON STATOR
ROUTINE TESTS ON TURBO GENERATORS
 TESTING OF TURBO GENERATOR ROTOR WINDING

Details of process tests to be performed at various stages:

HIGH VOLTAGE TEST:

1. After mounting the excitation lead and slip rings and before
actually commencing the winding, the slip rings are to be tested.

First, measure the insulation resistance with 1000v Megger,

if the insulation condition is found satisfactory, then perform High
Voltage test for one minute, the test of which is to be determined
according to the following equation.
U2=Ut+1 KV
Where U2 is test voltage
Ut is 10*rated rotor voltage
However the resulting test voltage U2 should be neither
lower than 2.5KV nor above 4.5KV.
After the high voltage test, measure the insulating condition
again with 1000V Megger.

2. The next test is to be carried out after placing all the coils in the
respective rotor slots and before clamping the pressing
equipment. Measure the insulating condition with a 1000V
Megger. It must not be lower than 1MΩ for each KV of the tested
voltage. Then measure the ohmic resistance of the winding.
3. After tightening the winding with the pressing and tightening
equipment and before actually baking the winding, measure the
ohmic resistance of the winding. Then check the polarity of the
winding.

While clamping care should be taken to see that the

pressing rings and other equipment are insulated from the
winding and rotor body, by inserting insulation in every slot under
the shims of the equipment.

4. After baking and forming of the winding and removing of the

clamping equipment and after the rotor cools down to ambient
temperature, measure the insulation resistance with 1000V
Megger.

If the insulation condition is satisfactory, perform High

Voltage test for one minute with a value of 1.15Ut
Where Ut is 10 times the rated rotor voltage.
After performing the High Voltage test, measure again the
insulation condition.

5. After driving the central wedges only in position, measure the

insulation resistance and if found satisfactory, perform High
Voltage test with a value of 1.10Ut for 10 sec, i.e., just reaching
the value and then bringing down to zero.
 After driving all the wedges in position, measure the
insulation resistance and if found satisfactory, perform High
Voltage test with a value of 1.10Ut for one minute.

6. After putting all the bracing’s, mounting of the end-retaining

ring and just before dispatch of the rotor for further machining.
Measure the insulation resistance.
Measure the ohmic resistance of the winding and perform
High Voltage test with a value of 1.05Ut for one minute.

7. After machining of the rotor, and before its dispatch to the

centrifugal tunnel, measure the insulation resistance.

8. After setting the rotor in the centrifugal tunnel, check the

insulation resistance and the ohmic resistance, while the rotor is
at rest. Check again the insulation condition at 3000 rpm.

Measure again the insulation resistance after the rotor is

balanced and just before its dispatch to the winding shop.

9. Finally, just before the dispatch of the finished rotor measure

the insulation resistance and perform High Voltage test with a
value of 1.0Ut for one minute.

MEASUREMENT OF D.C RESISTANCE:

 The D.C resistance value of rotor winding is measured by
using a Micro Ohmmeter. First connect the micro ohmmeter to
230V AC supply. And measure the resistance and the temperature
using RTD. This resistance at T temperature has to be converted
to resistance at 20º C by using the formula:
R20= Rt * (235+20)/(235+T) milli ohms.

Where R20= Resistance at 20º C in mΩ

T= temp in degree Celsius
Rt= measured resistance of winding in mΩ .
A deviation of ± 10 % from design values is acceptable.

MEASUREMENT OF IMPEDANCE:

By applying 50-200 V in steps of 50 V, Impedance value is

measured at standstill and at the rated speed.
Impedance is measured by using the formula:
Z=V/I
Where Z =impedance in ohms;
V =voltage in volts;
I =current in amps;

In the measurement of Impedance there will be a graph

plotted between voltage v/s current. In this, there is no perfect
value for the impedance but the only condition is that the
impedance should increase with the increase in voltage.
 TESTING OF TURBO GENERATOR STATOR BARS

FOR RESIN RICH SYSTEMS, STATOR BARS WILL BE TESTED

IN THE FOLLOWING ORDER:

1). After bars manufacturing bars are tested at four times

the rated voltage.
Ut=4*Urated

2). Individual bars will be tested for tanδ . δ Is the angle

between actual current and line current. When the insulation is
perfect and dielectric strength is optimal δ is zero. But due to the
presence of impurities in the insulation there will be a phase angle
difference between the two currents.
This tanδ measurement is known as loss angle
measurement or dielectric loss measurement. tanδ values should
be within 2%.
 3). Outer corona protection resistance is measured and this
value should be within the range of 75-300Ω /Sq.cm.

4). Interstrip and Interhalf shorts are checked. Interstrip

means between the conductor strips and interhalf means between
the halves. This shorts are checked by a series bulb test.

TESTING OF TURBO GENERATOR STATOR WINDING

HIGH VOLTAGE TEST:

FOR RESIN RICH SYSTEMS THE STATOR WINDING WILL BE

TESTED IN THE FOLLOWING ORDER:

1). After lying bottom bars, bars are subjected to (2Un+7)

KV
Where Un is the rated voltage

2). After lying top bars, bars are subjected to (2Un+5) KV

Where Un is the rated voltage

3). After lying bottom, top and eyes joining, High Voltage
test is conducted for (2Un+3) KV
Where Un is the rated voltage
 4). After final assembling and connections, customer witness
test is carried at (2Un+1) KV
Where Un is the rated voltage

5). Interhalf shorts are also checked

FOR RESIN POOR SYSTEMS THE FOLLOWING TEST IS

CARRIED OUT:

Bars are subjected for Inter strip and Inter half shorts tests.

INTER TURN INSULATION TEST:

The insulation between the windings of the rotor is tested by
applying a high frequency current of about 500HZ. The insulation
should be able to withstand this test.

RING FLUX TEST ON STATOR CORE:

Ring flux test is carried out on the stator core before winding
is put in the slots. The rated flux density is generated in the stator
core by passing current in it. This results in the temperature rise
and generation of heat. The stator core is observed for the
temperature rise through its surface by using RTD’s. If there is any
hot spot found in the core, it is detected. Then it is rectified by
carrying out electrolysis using phosphoric acid as electrolyte.

MEASUREMENT OF D.C RESISTANCE:

The D.C Resistance of stator winding is measured by using
Micro Ohmmeter. Connect the micro ohmmeter to 230V AC
supply. Connect the measuring leads of micro ohmmeter across R
phase of stator terminals. Measure the resistance and repeat the
step for Y and B phases. Record the stator RTDs value.
R20= (Rt * (235+20)/(235+T)) mΩ .
Where R20= Resistance at 20º C in mΩ
T= temp in degree Celsius
Rt= measured resistance of winding in mΩ .
The variation of maximum and minimum value of stator DC
resistance upto 5% is acceptable.

MEASUREMENT OF LEAKAGE REACTANCE:

This test is done without rotor inside the stator.
Base Impedance Xn= En/(√(3) * In) Ω
Where En= rated line to line voltage
In= rated line current

Total Armature leakage reactance (XL):

XL= √(Z²-R²)
Where Z=U/((√3) * I)
R= P/(3* I²)
U= voltage measured during the test
I= current measured during the test
P= power measured during the test
Resistance per phase is negligible compared to Z. Therefore
measurement of P is not required.
XL=Z=U/((√3)*I) Ω
 % XL= (XL/ Xn) *100

MEASUREMENT OF INSULATION RESISTANCE AND

CONTINUITY TEST OF RESISTANCE TEMPEREATURE
DETECTOR (RTD):
Short all the RTD leads together and connect one lead of
megger to it. Run the megger and note down the Insulation
resistance value after 60 seconds. This insulation resistance value
should not be less than 1MΩ .
Remove the RTD terminals i.e. open the RTD terminals and
connect to the multimeter. Note down the resistance value of RTD.
For three wire RTD check the continuity between shorted
terminals.

CAPACITANCE AND TAN δ MEASUREMENT OF STATOR

WINDING:
Stator winding has two values of capacitance’s.
1). Capacitance with respect to ground called ground
capacitance (Cg).
2). Capacitance with respect to other windings called mutual
capacitance.
Measurement of capacitance is done using Schering Bridge
and a standard capacitor.
1). High Voltage applied to one of the phases and remaining
phases are connected to body of stator Cg+2Cm.
2). High Voltage to all the phases. 3Cg.
Cx = capacitance to be measured
Cn = standard capacitor
 G = galvanometer
R3+S = variable resistance
C4= variable capacitance
N= parallel step fixed resis.
R4= standard resistor
Raise the transformer voltage to 0.2 Un
Where Un = rated voltage of machine.
Balance the Schering Bridge with proper selection (R3+s)
and C4. And note down the values of C4 and R3+S
Take reading at 0.4Un, 0.6Un, 0.8Un and Un.
Cx= (Cn*R4*(R3+100))/(N*(R3+s) µ f
% tan δ =(( Π *R4* C4)/10000)*100
C4 and Cn are in µ f
R3, R4 ,N and S are in Ω

ROUTINE TETSTS ON TURBO GENERATOR

MECHANICAL RUN AND MEASUREMENT OF VIBRATIONS AT

RATED SPEED:
The machine is rolled and run at rated speed after ensuring
the bearing oil and kept at rated speed for stabilization of bearing
temperatures.
The vibrations are measured at rated speed on both the
bearing housings in Horizontal, Vertical and Axial directions.
The temperature of stator is monitored by monitoring RTDs
embedded in core, tooth and winding.
 The vibrations should be less than 5 microns and noise level
should be in between 75-90 db.

SHORT CIRCUIT TEST:

The machine is prepared for short circuit characteristic using
current transformers and shorting the terminals as shown in fig.
The machine is run at rated speed and drive motor input
voltage and current are noted and machine is excited gradually in
steps, at 20%, 40%, 60%, 80%, 100% rated current of machine
(In).
The excitation is reduced and cut off. The speed is reduced
and the machine is cooled at lower speed. The temperature are
checked from machine RTDs. The machine is stopped when it is
sufficiently cooled down. The stator winding temperature should
be less than 60°C)
From the Short Circuit test, we will get copper losses.
The short circuit characteristics is plotted from SCC results
by selecting X-axis as field current and Y-axis as % rated current.

OPEN CIRCUIT TEST:

The machine is prepared for Open Circuit Characteristic as

shown in the fig.
The machine is run at rated speed and the motor input
voltage and current are noted and machine is excited gradually in
steps, cat 20%, 40%, 60%, 80%, 90%, 95%, 100%, 105%, 110%
and 120% of rated voltage of machine (En).
At 100% rated voltage the following parameters are noted:
 Shaft voltage
Checking of phase sequence
Bearing vibration
RTDs readings
The excitation is reduced, cut off, the speed is reduced, and
the machine is cooled at lower speed. The temperatures are
checked from machine RTDs. The machine is stopped when it is
sufficiently cooled down. The stator core temperatures to be less
than 60°C.
From the Open Circuit test, we will get Iron losses.
The Open Circuit Characteristics is plotted on a graph paper
from OCC results by selecting X-axis as field current and Y-axis as
% rated voltage.

MEASUREMENT OF SHAFT VOLTAGE:

When the rotor shaft rotates inside the stator there will be
some induced EMF will be developed inside the rotor. In addition,
this voltage will go to the bearings and pedestal and to the earth
as it is grounded and it will again come back to the pedestal, to
the bearings through the earth. It will become a cyclic process.
This voltage has to be reduced otherwise, the rotor will get
heated. For this bearing pedestal is placed on, insulation called
HGL.

When the machine is under Open Circuit Characteristic

testing shaft voltage is measured with multimeter and high input
impedance AC voltmeter across the two ends of the rotor at 100%
rated voltage. The shaft voltage should be as minimum as
possible.

CHECKING OF PHASE SEQUENCE:

When the machine is under OCC condition at 100% rated

voltage, phase sequence of generator is checked using a phase
sequence indicator across PT.

MEASUREMENT OF ROTOR IMPEDANCE (rotor inside stator):

A variable 50 Hz A.C voltage of single phase is applied

across the input leads and readings of voltage and current are
noted down from 50v-200v in steps of 50V.
Impedance is measured by using the formula:
Z=V/I
Where Z =impedance in ohms;
V =voltage in volts;
I =current in amps;
Rotor Impedance is measured at standstill and at rated
speed of the machine.
The impedance of rotor at standstill and at rated speed is
plotted as applied voltage v/s Impedance.
MEASUREMENT OF INSULATION RESISTANCE OS STATOR
AND ROTOR WINDNGS BEFORE AND AFTER HIGH VOLTAGE
TEST (machine at rest):
Insulation Resistance of the stator and rotor windings is
measured separately before and after high voltage test using
Megger of 2500 V for stator & 1000 V for rotor windings.
The Insulation Resistance values are taken at 15 sec and at
60 sec
The ratio of insulation resistance at 15 sec and 60 sec is
known as Absorption Coefficient.
Absorption Coefficient = IR at 60″ / IR at 15″
This Absorption Coefficient for High Voltage test should be
>= 1.3

HIGH VOLTAGE TEST ON STATOR AND ROTOR

WINDINGS(MACHINE AT REST):
The High Voltage is applied to winding by increasing
gradually to required value and maintained for one minute and
reduced gradually to minimum. The transformer is switched off
and winding is discharged to earth by shorting the terminal to
earth using earthing rod connected to earthed wire. The test is
conducted on all the phases and rotor winding seperately.
When High Voltage test is done on one phase winding, all
other phase windings, rotor winding, instrumentation cables and
stator body is earthed.
High Voltage test levels:
Stator winding = (2 Ut + 1) kV
Rotor winding = (10* Up) V
Where Ut = Rated voltage of the machine under test
Up = Excitation voltage
MEASUREMENT OF POLARISATION INDEX OF STATOR
WINDING:

In the measurement of the polarization index of stator

winding, stator output terminals are subjected to 2.5 kV Megger
for a duration of 1 minute and 10 minutes. And the respective
insulation values are noted down.
Polarization Index is the ratio of Insulation Resistance value
at 10 min and Insulation Resistance value at 1 min.

Polarization Index = Insulation resistance at 10′ / Insulation

resistance at 1′
The polarization index value should be greater than 2

MEASUREMENT OF D.C RESISTANCE OF STATOR AND

ROTOR WINDINGS IN COLD CONDITION:

In cold condition means that measuring the D.C resistance

of the stator and rotor windings before testing.
D.C Resistance’s of stator and rotor windings are measured
seperately using micro ohmmeter. The instrument terminals are
connected to the machine terminals and proper range in the
meter is selected.
Variation in the values of D.C Resistance of 3 phases of
stator windings up to 5% is acceptable.
MEASUREMENT OF D.C RESISTANCES AND INSULATION
RESISTANCE OF RTDs:
The D.C Resistance’s and insulation resistance’s of RTDs are
measured using multimeter and Megger respectively.

EVALUATION OF SHORT CIRCUIT RATIO:

From the test data Short Circuit Ratio is calculated using the
formula

S.C.R= Field current at 100% Rated voltage from OCC/ Field

current at 100% rated current from SCC