EEN – 499

Training Seminar
By:
Yashveer Singh Yadav

B-Tech 4th Year,

Department of Electrical Engineering,
Indian Institute of Technology Roorkee.
Enrollment No. - 16115120
Internship Details:
• BHEL Haridwar
• Period – 1st June to 30th June,2019
Contents:
• Brief history
• BHEL Haridwar : An Overview
• Turbo Generator
• Stator
• Rotor
• Ventilation and Cooling System
• Conclusion
 Brief History:
• It was established in 1964 Bhopal.
• HEIL‐Heavy electrical (India) limited was merged with BHEL in 1974.
• As of Dec 2015, 63.06% of shares are hold by Indian govt.
• Got its Maharatna status in 2013.
• Total installed capacity (Domestic and Overseas) of BHEL made
equipment's is 135GW.
• BHEL holds 57% share of installed capacity, and 65% in power generated
with thermal sets.
• BHEL has supplied its products to 76 countries.
 BHEL Haridwar: An Overview
 BHEL Haridwar is broadly divided in to two parts:
A) CFFP: – Central Foundry Forge Plant
• Forge Shop
• Machine Shop
• Steel Melting Shop (SMS)
• Steel Foundry
• Pattern Shop
• Cast Iron (CI) Foundry
B) HEEP is divided into following blocks:
• BLOCK‐1: manufacturing of turbo generators of all rating, assembly and testing of TG up to
1000MW.
• BLOCK‐2: Provides fabricated jobs used for manufacturing Turbo generators and turbines.
• BLOCK‐3: Manufactures turbine of all ratings up to 1000MW.
• BLOCK‐4 (CIM): manufacture insulation items used in TG and TG stator winding bars.
• BLOCK‐4(ACM): Manufactures rotor coils and control gear for all ratings.
• BLOCK‐5: Manufactures fabrication items for EM and turbine block.
• BLOCK‐6: Manufactures stampings for turbo generators.
• BLOCK‐7: Supplies wooden boxes for material dispatch.
• BLOCK‐8(HXE): Manufactures heat exchangers and coolers.

 After initial setting up of the plant during the year 1964-72, in collaboration with the Soviet
Union, the plant facilities and infrastructures have since been continuously upgraded under
various investment projects Stamping Unit Project, LSTG Project, Motor Project, Governing
Components Project, TG Facilities Modernization, TG Facilities Augmentation, Quality
Facilities Augmentation, EDP projects, Gas Turbine Project, Facilities have also been added
and establishments have been created for new projects in Defense and Aviation Project.

 The Over Speed Vacuum Balancing Tunnel created for rotors up to 1300 MW (32T, 6.9 M — dia
bladed rotor, 6 rpm up to 4500 rpm) is one of the 8 of its kind in the entire world. The total
spectrum of sophisticated, unique and other facilities at HEEP, Haridwar are the state-of-the-
art in manufacturing processes and can be utilized for a variety of products' manufacture.
 Turbo Generator:
• The AC generator or alternator is based on the principle of electromagnetic induction and
consist generally of a stationery part called Stator and a rotating part called Rotor. Stator houses
the armature winding. The rotor houses the field winding. DC voltage is applied to field winding
through the slip rings. When the rotor rotates, the lines of magnetic flux cut through the
winding. This induces an electromagnetic EMF in the stator winding. The magnitude of emf is
given by following formula
E = 4.44* ø *ƒ*N volt
Where
ø = strength of magnetic field
ƒ = frequency in hertz
N = number of turn in stator winding
ƒ = frequency = P*n / 120 where, P = number of poles n = number of revolution per second of
rotor
How Turbo Generator Works:
As shown in the figure, when high pressure
steam is passed through the turbines it
expands in the passage between various stages
of blades. The expansion exerts force on the
blades causing the turbine to rotate.
• In power plants all the rotating shafts are
coupled with each other, the rotation of
turbine also results in rotation of generator
shaft as well as Exciter shaft.
• The rotation of exciter shaft causes the
magnetic field created by PMG(permanent
magnet generator, which is a 16 pole unit)
mounted on the exciter shaft to rotate.
• The rotating magnetic filed is cut by the
conductors placed in the pilot exciter(which
encapsulates the PMG and contains field
windings) produces 3phase AC current.
• The output 3 phase AC current is converted into variable DC current with help of
AVR(automatic voltage regulator.

• The DC current is fed to the main 3 phase exciter which is having 6 poles. The current passed
through main exciter creates magnetic field.

• The magnetic field is cut by the conductors placed in the rotating armature (mounted on the
shaft). This create 3 phase AC current in the armature windings.

• The 3 phase AC produced in the armature is rectified in the diode wheels, which coverts it into
DC current.

• The DC current is passed into TG rotor using DC lead assembly (conductors and contact pins).

• A similar arrangement is there in TG to receive the DC current from excite r(here it is called as
filed lead core bars and contact pins)
 Stator:
• The generator stator is a tight construction supporting and
enclosing stator winding, core and hydrogen cooling medium.
Hydrogen is contained within frame and circulated by fans
mounted at either end of rotor. The generator is driven by direct
coupled steam turbine at the speed of 3000 rpm. The generator is
designed for continuous rated output. Temperature detector and
other device installed or connected within machine, permit the
windings core and hydrogen temperature, pressure, and purity in
machine.
• It consists of stator frame and stator core.
 Stator Frame -
 Stator body is a totally enclosed gas tight fabricated structure
made up of high quality mildsteel and austenitic steel. It is
suitably ribbed with annular rings in inner walls to ensure high
rigidity and strength and it also help to reduce vibration and to
withstand the gas thermal pressure.
 .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.
 It supports the laminated core and winding the stator comprises
an inner frame and outer frame.
  Stator Core -

 Stator core is made up of thousands of laminated

high silicon sheets/stampings stacked together to
form a cylindrical structure. This form of structure
helps in minimizing eddy current losses.

 The sheets are coated with insulating varnish and

have slots in the inner portion and several holes for
ventilation purpose.

 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 core and rotor.
 Rotor:
• Rotor revolves in most modern generator at speed of
3000 revolutions per minute. It is also as
electromagnet and to give it necessary magnetic
strength, the winding must carry a very high current.

• The passage of current through windings generates

heat. But the temperature must not be allowed to
become too high, otherwise difficulties will be
experienced with insulation.

 Rotor Shaft –
 TG Rotor shaft is produced form high strength alloy
steel forging. The dimensions of the rotor i.e.
diameter and length depends upon the rating of TG.
The straight portion of the shaft is known as barrel. It provides location (slots, 28 no’s) for rotor
coils (bars), cooling vents etc.

At both ends of the shaft there are provisions for coupling with the turbine and exciter.

The flat place between barrel and coupling ends there is place for placing journal bearings which
supports the load of rotor shaft.

In case of THRI type TG shaft has defined locations for installing rotor blades, and in case of THDF
and THFF only turbine end of shaft is having location for blades mounting. No's of slots are
machined on shaft, the white portion is for mounting of rotor blades. The adjacent location is for
bearing.
Ventilation and Cooling System:
 Ventilation System –

 The machine is designed with ventilation system having rated pressure.

 The axial fans mounted on either side of rotor ensure circulation of hydrogen gas.

 The rotor is designed for radial ventilation by stem. The end stator is packets and core
clamping and is intensively cooled by through special ventilation system.

 Design of special ventilation is to ensure almost uniform temperature of rotor windings

stator core. Embedded resistance temperature detector do continuous monitoring of
hydrogen temperature at part of generator.
 Cooling System
• Stator Cooling System

 The stator winding is cooled by distillate water which is fed from one end of the machine by Teflon
tube and flows through the upper bar and returns back through the lower bar of a slot.

 Turbo generator requires water cooling arrangement over and above the usual hydrogen cooling
arrangement. The stator is cooled in this system by circulating demineralized water trough hollow
conductors. The cooling was used for cooling of stator winding and for the use of very high quality
of cooling water.

 For this purpose DM water of proper specifying resistance is selected. Generator is to be loaded
within a very short period. If the specific resistance of cooling DM water goes beyond present value.
The system is designed to maintain a constant rate cooing water flow through the stator winding at
a nominal inlet with temperature of 40 degree centigrade.

 As it is look working, the cooling water is again cooled by water which is also demineralized to avoid
contamination with any impure water in case of cooler tube leakage the secondary DM cooling
water is in turn cooled by Clarified water taken from clarified water header.
 • Rotor Cooling System

 The rotor is cooled by means of gap pickup cooling, where in the hydrogen gas in the air gap is
sucked through the scoops on the rotor and is directed to flow along the ventilating canals milled
on the sides of the rotor coil, to the bottom of slot where it takes a turn and comes out on the
similar canal milled on the other side of the rotor coil to the hot zone of the rotor.

 Due to the rotation of the rotor, a positive section as well as discharge is created due to which a
certain quantity of a gas flow and cools the rotor.

 The method of cooling gives uniform distribution of temperature. Also this method has an
inherent of eliminating the deformation of copper due to varying temperature.
Conclusion:
• Training at B.H.E.L. has proved to be quite faithful. It proved an opportunity for encounter
with such huge machine like turbo-generators.

• The architecture of B.H.E.L., the way various units are linked and the way working of whole
plant is controlled make the students realize that Engineering is not just structural
description but greater part is planning and management.

• It provides an opportunity to learn techniques. Used at proper place and time can save a lot of
labour.