1.

INTRODUCTION TO TESTING OF TURBOGENERATOR

Testing is an activity, which basically evaluates a component, and or a product (built up of component assemblies) as to whether it has the technical capability that has been built into it by way of design, materials, and technological processes employed while manufacturing and workmanship. As such, testing activities can broadly be classified in to a number of categories as follows: - Type tests. - Routine tests. - Process tests.

TESTING OF TURBOGENERATOR Advantages of testing: Provides quality assurance. Meets the requirements of legal & contract requirements. Reduction in rework cost. Ensures process capability & develops checklist. Increases confidence levels in manufacture. Provides data for optimization of design. Helps in building of Safety & general O&M manual. Establishes control over raw materials. Important points for testing Have an approved procedure. Tabulate test levels / stages. Check the testing equipment before use. Calibrate the test equipment & instruments. Ensure interlocks of the equipment

Log the results in proper formats. Analyse failure & submit a comprehensive report for repair / replacement.

PERFORMANCE TESTS ON TURBOGENERATOR: With the increasing trend on standardization every country has its National Standards covering a wide range of subjects, In India, the Indian Standards are valid and

applicable. The machines produced at Hyderabad fully conform to Indian and also International Standards, and many machines are being exported to various countries. The performance tests on turbo generators include the following Measurement of Insulation resistance.

 Measurement of ohmic resistance of windings in cold state. Applied H.V. tests. Measurement of vibrations and mechanical losses. Measurement of no load characteristics. Measurement of short circuit characteristics. Determination of excitation on load and checks of voltage rise (regulation). Measurement of leakage and potier reactances. Measurement of losses and determination of efficiency. Heat run tests. Retardation test.

TEST PROCEDURE During manufacturing of Turbo-generators the following stage tests are to be carried out on individual components to ensure quality of the product and to reduce last minute delay during acceptances tests. The standards for these tests will differ from plant to plant. 1.Stator Checking up of Resistance temperature detectors while core building. Ring flux test. Tan delta measurement on stator winding after impregnation. H.V. test on coils during manufacturers and assembly.

 Capacitance measurement. 2.Rotor H.V. test on excitation connecting leads. H.V. & inter- turn insulation tests on field coils during the winding process. Impedance measurement field coils. 3. Over-speed test. Over-speed test involves mechanical running of the rotor at the prescribed % over-speed for the stipulated period of time. It is later subjected to a very close mechanical inspection to investigating into the effects of over speed if any. The rotor is balanced to the required levels as per standards. This brings us to measurement of characteristics and losses of the generator.

Measurement or determination of efficiency of the machine is an important step. For determination of efficiency, losses measurement on the drive system is to be done and derive machine losses by subtracting drive motor losses.

4.Determination of efficiency Having measured the losses, the efficiency can be estimated from the formula. Efficiency =(input losses / input = output / (Output + losses) Tolerance on guaranteed efficiency is 0.1 (1-efficiency) when measured by summation of losses method.

5.Measurement for leakage & potier reactance Leakage reactance is measured on the stator alone when winding is completed. The procedure involves supplying the winding from a 3-phase variable voltage source and measuring currents voltage and power at the stator terminals. Depending on the source capacity upto 0.25In may be passed. Potier reactance as per accepted standard practices is taken as 0.6 to 0.65 of total leakage reactance. It can alternatively be calculated from the zero power factor test measurements.

6. Line-to-Line sustained short circuit test The negative phase sequence reactance is can be determined from the line-to-line sustained short circuit test.

Negative phase sequence reactance (X2) = P / 3. (Ik2)2 where P = Power measured and Ik2 is negative phase sequence current measured during line-to-line sustained short circuit test.

7.Line to line and to neutral sustained short circuit test From this test zero phase sequence reactance can be determined. Zero phase sequence reactance (Xo) = Vo / Io. Where Vo = Voltage from measured in open phase voltage and Io is current measured in line to neutral during line to line sustained short circuit test.

8.Retardation test for determination of Moment of Inertia The machine speed and time are noted during free coasting down of the machine. Moment of inertia =(4 x 365000 x P x T )/ N2 Kg-m2 where: P = Power input in kW to keep machine at rated speed. N = Rated Speed in rpm. T time in seconds from curve. (Tangent drawn at rated rpm)

2.

THEORY OF SYNCHRONOUS GENERATOR

THEORY: A synchronous generator is the core of any generating power plant. A synchronous generator is a rotating electromagnetic device that converts mechanical energy into electrical energy by taking the mechanical input from a prime mover (Gas turbine or Steam turbine) and magnetic energy from excitation.

The different electromagnetic or active parts of a generator are as follows: Stator core Stator coils/ bars Stator winding Output leads, brushings and conductors Rotor excitation leads Rotor coils Rotor winding

2.1.Stator core The stator core serves the two fold function of providing the mechanical support for the stator coils and carrying effectively the electromagnetic flux generated by the rotor winding. In order to minimize hysterisis and eddy current losses the entire core is built of thin laminations.

Each lamination layer is made up from a number of individual segments.

2.2.Stator coils/ bars The stator coils are the individual entities, which are placed in the slots of the stator core and finally connected to each other as per a pre-designed scheme to form a three phase winding. The prime purpose of the stator bars is to carry the load current at minimal winding losses. These coils are provided with high voltage stresses. Depending upon the size and rated voltage of the machine different types of stator bars are designed. 2.3.Stator winding The stator winding is a short pitch; two-layered type made 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 the losses, the bars are composed of separately insulated stands transposed by 360 degrees. To minimize the stray losses in the end winding, the standards of the top and bottom bars are separately brazed and insulated from each other. 2.4.Output leads, brushings and phase connectors Output leads are taken out from the exciter end of stator from the top and supported on an insulated glass fabric plate. Six terminals are brought out, three for phase and three for neutral connections. The phase connections are connections between the stator winding phase bars /coils to the output lead brushings. 2.5.Rotor excitation leads

The excitation leads provide electrical connection between rotor winding and output from brush less exciter. 2.6.Rotor winding: The construction of the rotor winding consists of placement of pre-formed rotor coils as per the winding scheme in the slotted rotor body, providing necessary insulation both in the straight position and overhang, making connections of the excitation leads, wedging of the straight part and mounting of the retaining rings.

CLASSIFICATION GENERATORS

OF

SYNCHROUS

Synchronous generators are classified into two main categories based on their design as: Smooth cylindrical rotor machines and salient pole machines. Generators driven by steam or gas turbines have cylindrical/ round rotors with slots into which distributed field windings are placed. These round rotor generators are usually referred to as turbo generators and they usually have 2 or 4 poles. Generators driven by hydraulic turbines have laminated salient pole rotors with concentrated field winding and a large number of poles.

PRINCIPLE OF OPERATION: The mechanical power of the prime mover rotates the shaft of the generator on which the field winding is

installed. When the field winding is excited using dc voltage, then a rotating dc flux is produced which when cut by the stator winding, a 3-phase voltage is generated owing the principle of Electromagnetic Induction. Faradays law of

DESIGN CRITERIA: Any generator design should be in accordance with the international standards like IEC and National standards like IS, BS etc. Various inputs required for the designing purpose of a generator is MVA, MW, PF, Voltage, frequency, speed, Type of cooling, type of excitation system etc. The main parameters during design to be considered are: Stator core- outer diameter, inner diameter, and no. of slots, each slots size and size of copper. Rotor- barrel

diameter, length, no. of slots, slot size and copper size. The criteria of the design should be in such a way as to ensure maximum efficiency, short circuit ratio (SCR) and sub transient reactance as per the standard stipulations and any other customer commitments.

The generators are classified as gas turbine generators or steam turbine generators depending on their drive. Generators driven by gas turbines are usually installed with a minimum civil foundation on base frame as for the gas turbine a perfect and proper civil structure is not very necessary and can be installed outdoors. Gas turbine generators can be either open circuit air-cooled or closed circuit air-water cooled. The terminals are usually at the top of the generator on the exciter side for the on word

connection to bus ducts through a GAC (Generator Auxiliary Compartment).

SYNCHRONOUS GENERATORS- LOSSES AND COOLING: All electrical machines produce heat owing to various losses generated inside the machine (like the I2R losses of stator copper winding). These losses are categorized as fixed and variable. Friction and windage losses, which include hysterisis and eddy current losses, are all considered to be fixed losses while the rotor copper losses, are treated as variable losses. Friction and windage losses are dependent upon speed and as synchronous machines run at constant speed, these losses are constant. As the magnetic flux passes through stator laminations, hysterisis and eddy current losses result in

and are dependent on the magnitude of flux. As long as machine is delivering power at a constant voltage, which is normal case, these losses in the laminations are fixed. The stator copper losses and rotor copper losses vary in square proportion to the stator and rotor currents respectively. These currents vary in accordance with the load and thus in turn the losses also vary and hence termed as variable losses.

As the synchronous machine has to deliver the output continuously, the heat generated inside the machine has also to be taken away at the same rate so that the machine can operate at a stable temperature

continuously; ensuring a longer life for the insulation system which in turn ensures a longer life of operation of the generator itself. Thus cooling forms one of the basic

requirements of any generator and the effective working of any generator considerably depends on the cooling system. The insulation used and the cooling employed is interrelated. Various methods of cooling employed are: Air-cooling Hydrogen cooling and Water-cooling

Generally Upto 125 MVA air-cooling is employed. Hydrogen cooling is employed in the machines i.e., above 125MVA; as it is more efficient compared to aircooling.

For still higher ratings like above 500MVA, Watercooling is employed. Air cooled generators are the simplest in design and either open air ventilating cooling system or a close air close water circuit (CACW) cooling can be employed. Open circuit air-cooling depends on the ambient temperature unlike the CACW cooling and this open aircooling is employed for the Gas turbine generators where there is scarcity of water.

EXCITATION SYSTEM: In all industrial countries, the electrical power demand is ever increasing, doubling itself approximately per decade. This automatically demands for the design, development and construction of increasingly large capacity turbo generators. Such large capacity alternators

should be highly reliable in operation and this calls for a reliable and sophisticated mode of excitation system. The excitation system consists of a small generator coupled to the main alternator through the excitation leads running through the shaft. Conventional D.C Excitation Systems with a D.C. exciter enjoyed an unchallenged position till recently was adopted universally for all alternators. With the growth in unit size of large capacity D.C. exciters capacity became necessary. Due to problems in communication it became inevitable to design of large capacity D.C. exciters at low speeds leading to increase in the systems. Moreover, the D.C. excitation suffered from problems like power cabling, problems associated with commutator and brush gear and maintenance.

With the advent of high power solid state semiconductor devices, significant strides were made in the

development of new excitation systems and thus in order to liquidate the communication and brush gear problems of the D.C, the A.C exciters were introduced. A.C excitation: Systems are classified into two types as: High Frequency Excitation System was developed. At present this is the system, which is widely used owing to its reliability, good transient performance and least maintenance. The system also doesnt suffer from the problems of communication, brush gear and power cabling. However, the main disadvantage of the system is that the rotor is not accessible and thus fast deexcitation, in case of any fault on rotor winding, is not possible.

Static Excitation System was developed contemporarily as an alternative to brush less excitation system. This system makes use of generators upto 160 MVA. The system has got an excellent transient response. But the system is not free from the power cabling, slip rings, brush gear and moreover the equipment and thus the layout of the cubical are not compact.

3. CONSTRUCTIONAL FEATURES OF TURBOGENERATOR

The turbo generator is designed for continuous

operation with voltage variations +/- 5% of the rated voltage and a frequency variation of +/- 1%. In general, the machine is designed for the altitudes of 1000 meters and above sea level and below an ambient temperature of 600 maximum, with cooling water temperature of 380 maximum at the inlet. The generator consists of the following components: 3.1 Stator: Stator Frame End Covers Stator Core

Stator Windings

3.2 Rotor Rotor Shaft Rotor Windings Rotor Retaining Rings Slip Rings

3.3 Bearings 3.4 Ventilation and Protection System 3.5 Cooling System 3.6 Insulation 3.7 Vacuum pressure impregnation system 3.8 Exciter 3.9 Base frame

Photo 2.1 Turbo generator

3.1. Stator 3.1.1. Stator Frame The stator frame is of welded construction, supports the core and the windings. In consists of air duct pipes and radial ribs, which provide rigidly to the frame. Footings are provided to support the stator on the skid. The stator frame should be rigid due to the various forces and torque during operation. The welded stator frame consists of the two end plates, axial and radial ribs. The arrangement and dimensioning of the ribs are determined by the cooling air passages, the required mechanical

strength and stiffness. The end covers are Aluminum alloy castings. The stator frame is fixed to the skid with the help of hexagonal bolts. The skid is temporarily fixed to the concrete foundation through bolts.

3.1.2. Stator Core Stator core is stacked from the insulated electrical sheet laminations and in the stator frame from insulated dovetailed guide bars. Axial compression is from clamping fingers, clamping plates and non-magnetic clamping bolts which are insulated from the core. In order to minimize the hysteresis and eddy current losses of the rotating magnetic flux, which interacts with the core, the entire core is built up of lamination, each layer of which is made from a number of individual segments. The segments are punched from the silicon steel. In the

outer circumference the segments are stacked in insulated trapezoidal guide bars, which hold them in position. The guide bar is not insulated to provide for grounding the core. The laminations are hydraulically compressed and heated during the stacking procedure. The complete stack is kept under pressure and fixed in the frame by means of cells.

The core packed into the stacking frame is pressed firmly together between the end plates of the machine frame and fixed in this position by welding the axial ribs of the core and end of the plates of frame. End fingers on the inside diameter of the end plates transmit the pressure to the teeth of the core. The compressive force produced prevents the laminations and teeth from vibrating. An eye is welded to each end plate for

attaching suitable lifting gear with adequate lifting capacity for transporting the complete machine. All the forces that occur during normal operation or on short circuits are transmitted from the stator yoke to the frame via the seating plates and into the foundation.

3.1.3. Stator Winding The winding is a double layer multi turn lap winding. The half coils are made up of electrolytic copper strips insulated with mica based epoxy insulation of suitable thickness to give a long and uninterrupted service. Each strip is staggered to 360degrees and it passes through all the sides of the coil. This process is called transposition. The purpose of transposition is to avoid the circulation currents due to eddy current and also to avoid corona losses. The straight parts of the half bar are coated with

conductive varnish to prevent corona discharges in the slot. The end winding is specially shaped to form a basket with an inviolate shaped over hang of the bars. The straight portion of the winding is secured by means of wedges driven into the slot position. The resistance thermometer elements are placed in the core teeth at carefully selected points to measure the temperature rise of the machine. Epoxy glass laminated brackets support the end winding. Epoxy glass laminated spacers to give a rigid structure to withstand the short circuit forces of the three-phase winding are connected to the connecting strips, which are also insulated and secured in position. Six output terminals are brought out from the rings of the insulated covers.

Fig 3.1 Wound Stator

3.1..4 End Covers The end covers are the castings of the aluminum alloy and are bolted to the side plates of the stator frame. The inlet passage is specially designed with built in guide vanes, which ensure uniform distribution of the air to the

fan. Air ceiling is provided around the shaft and at the parting plane of the top and bottom parts of the end covers so that suction of oil vapor from the bearings does not take place.

3.1.5. Location of Bars A semi-conducting wrapper of graphite paper in the slot protects the bar. The stator winding is protected against the effects of current forces in the slot section. To ensure tight seating of the bar at the slot bottom, a slot bottom-equalizing strip of stress path is inserted. A top ripple spring is arranged between two compression strips to exert a continuous pressure on the bars. The bars are shaped so that, cone shaped end windings are obtained. In order to reduce the stray losses a small cone taper of

(13-20deg) is used. On the wide sides of the bars spacers of insulating material are inserted at regular intervals.

3.1.6. Enclosure The enclosure consists of the inner and outer components. The inner components comprises of the winding covers, which from an angular enclosure of top and bottom parts and is designed as required for particular degree of protection, as indicated in the dimension drawing or in the Technical data. The ventilating circuit is of the double-ended symmetrical arrangement.

3.1.7. Electrical Connections of Bars and Phase Connection Brazing makes electrical connection of Bars: Electrical connection between the top and bottom bars, one top bar being brazed to the associated bottom bar. The coil connections are wrapper depends on the machine voltage. After tapping, an insulating varnish is applied.

3.1.8. 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 type. The phase connectors are wrapped with resin rich mica type, which contain synthetic resin having very good penetration properties. The phase connectors are then cured at a certain

temperature, with the shrinking tapes contracting so that a void free insulation is obtained.

3.1.9. Output leads The beginning and ends of three phase windings are solidly bolted to the output leads with flexible. The output leads consist of flat copper sections with mica insulation. To prevent eddy-current losses and

inadmissible temperature rises: the output leads are brought put.

Photo 3.2. Phase connectors and rings

3.2. ROTOR: The rotor is forged from a homogeneous steel ingot of specially alloy steel properly heat treated to meet the required mechanical, metallurgical and magnetic

properties. Axial slots are milled through out the active

length of the rotor body to accommodate the conductors. The slots are dovetailed at the top of housing the wedges.

3.2.1. Rotor shaft The rotor shaft is forged from a vacuum cast steel ingot. The high mechanical stresses resulting from the centrifugal forces and short circuit torque call for high quality heat-treated steel. The rotor consists of an electrically active portion and two shafts end.

Approximately 60% of the rotor body circumference has longitudinal slots, which hold the field winding. Slot pitch is selected so that 1800 displace the two solid poles. The rotor wedges act as damper winding within the range of winding slots. The rotor teeth at the ends are provided with the axial and radial holes, enabling the

cooling gas to be discharged into the air gap after, intensive cooling of the end windings.

3.2.2. Rotor Winding The field winding consists of several series connected coils inserted into the longitudinal slots of the rotor body. The coils are wound so those 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. The individual conductors are bent to obtain half turns. After insertion into the rotor slots, these turns are combined to form full turns of the series connected turns of one slot constituting one coil. The individual coils of the rotor winding are electrically series connected so that one north and one south magnetic pole are obtained.

3.2.3. Rotor Slot Wedges To protect the winding against the effects of the centrifugal force, the winding is secured with wedges. The slot wedges are made from an alloy high strength and good electrical conductivity, and are also used as damper wedged bars. The retaining rings act as short circuit rings to induced current in the damper windings.

3.2.4. Cooling of Rotor Windings Each turn is subdivided into four parallel cooling zones. One cooling zone includes the slot from the center to the end of the rotor body, while another covers half the end winding to the center of the rotor body. The cooling air

for the slot portion is a limited into the slot bottom ducts below the rotor winding. The hot gas at the end of the rotor body is then discharged into the air gap between the rotor body and stator core through the radial openings in the conductors and in the rotor slot wedges. The cooling air for the end windings is drawn from below the rotorretaining ring. It rises radically along the individual coils and is then discharged into the air gap. 3.2.5. Rotor Retaining Rings The rotor retaining rings with stand the centrifugal forces due to the end windings one end of each ring is shrunk on the rotor body, while the other end of the ring overhangs the end winding without contact on the shaft. The shrunk on the hub at the free end of the retaining serves to reinforce the retaining ring and secures the end winding in the axial director at the same time. The shrink

seat of the retaining ring is silver plated, ensuring a low contact resistance for the induced current. To reduce the stray losses and have high strength, the rings are made of non-magnetic core worked materials.

3.2.6. Slip Rings These are made of forged steel and shrunk on either side of the rotor between the end cover and the bearing. The mica splitting is used to insulate the slip rings from the rotor body. The excitation to the rotor winding is taken from these slip rings. The connection leads are suitably insulated and taken through slots milled on the surface of the rotor. Wedges are provided to keep the leads in position. A helical groove is machined on the outer

surface of the slip rings to have better dissipation of heat, thus minimizing the brush wear.

3.2.7. Rotor Fan The generator cooling air circulated by the two axial flow fans located on the rotor shaft at either end. To augment the cooling of the rotor winding the pressure established by the fan works in conjunction with the air expelled from the discharge ports along the rotor shaft. The blades are screwed into the rotor shaft. The blades are forged from an aluminum alloy. Threaded root fastening permits the blade permits the blade angle to be changed.

Photo 3.3 Rotor over hang Portion

3.2.8. Rotor Balancing The rotor is balanced with the help of sophisticated balancing machine. The balancing weights are provided in the hubs under retaining rings and in the fans. The rotor is dynamically balanced and subjected to an over speed of 20% for 2min.

3.2.9. Field Connections The field connections provide the electrical connection between the rotor winding and the exciter.

3.2.10. Terminal Lugs

Consists of a copper conductor of rectangular crosssection. One end of the terminal lug is brazed to the rotor winding, while the other end is screwed to the radial bolt.

3.2.11. Radial Bolt The field current lead located in the shaft bore is connected to the terminal lug through a radial bolt. The radial bolt is made from steel and screwed into the field current lead into the shaft bore.

3.3 BEARINGS The generator rotor is supported at two-journal bearing. The bearings consist of a bearing pedestal and bearing shell is split into two halves to facilitate assembly. The bearing pedestals are iron castings and the bearing shells are the steel castings. The bearing pedestals are

providing with a spherical seating surface and bearing shell rests into with its outer spherical surface. The inner surface of the bearing shell is provided with spherical grooves and cast with Babbitt metal.

3.3.1. Bearing Oil Supply The oil required for the bearing lubrication and cooling is obtained from the turbine oil supply system supplied to the lubricating groove in the bottom-bearing sleeve. The upper bearing sleeve consists of a wide overflow groove through which oil is distributed over the shaft journal and fed to the lubricating pump.

3.3.2. Bearing Temperatures One double-element resistance temperature detectors monitor the temperatures of each bearing. The resistance

temperature detector is screwed in the position on side of the low bearing sleeve from outside with the detector extending to the Babbitt liner.

3.4. VENTILATION AND PROTECTION EQUIPMENT:

3.4.1. Ventilation Arrangement The turbo generator is cooled by air circulated by means of two axial fans. Air coolers cool the air after circulation. The air is drawn through suction ducts by axial fans mounted on either side of the rotor. The warm air flows out through the exhaust at the bottom of the stator frame.

3.4.2. Space heaters

These heaters are used to circulate warm air inside the turbo generator and during outages to prevent

condensation of the moisture inside the machine. They are of strip type and robust design. The heating elements are enclosed in a steel sheet with specific rating of 15W per sq. inch of the surface. They are so designed that they may be fixed in the suction ducts of the turbo generator. The heaters are completely covered in order to prevent the accidental contact with the heat units. 3.4.3. Resistance Temperature Detectors The resistance temperature detectors are made up of Platinum resistance elements. The detectors are placed in a groove cut in a rectangular glass laminate and embedded in different positions like stator teeth, stator core, and slots. There are 12 active and three spare elements distributed in different locations in 3 different

planes, 5active plus 3 spare elements are placed in stator slots, 4 active are placed in stator core, 3 are placed in teeth to measure the hot and the cold air temperatures. The resistance thermometers are fixed in the exhaust hood of the stator frame and the end covers. The leads from these resistance thermometers are brought out and connected to the terminal board. The leads coming from the spare elements are brought up to the terminal board and left inside the machine. These resistance temperature detectors operate on the principle that the resistance of the elements will change depending on the temperature coefficient of the element. The change in resistance can be accurately measured in a bridge circuit. A graph is drawn showing the variation of resistance with temperature, which is used to know the temperature rise

under different operating conditions of the turbo generator.

3.4.4. Fire Detectors For the protection of turbo generator against any possible fire hazards 12 fire detectors relays are provided on either side of the stator winding. These relays have a set of normally open contacts. The set of contacts will close when the temperature surrounding the first relay exceeds 80deg Celsius. The other relay set of contacts close when the temperature exceeds 1000. These contacts are wired up to the terminal board provide on the stator frame for the resistance temperature detectors. Both the sets of contacts are used for automatic fire alarm shutting down of the turbo generator system and for the release of CO2 gas from the Carbon dioxide system.

3.5. Insulating systems are of two types: 1.Resin rich system of insulation 2.Resin poor system of insulation

3.5.1. Resin rich system

Conductor cutting and material used is same as

resin poor system. Transposition is done same as that of resin poor

system. Stacking of coils is done. In this case high resin

glass cloth is used for preventing inter half shorts. Putty work.

Nomex is used as transposition pieces. Putty

mixture is a composition if mica powder, china clay and SIB 775 Varnish.
-

Straight part baking is done for 1hour at a

temperature of 160OC and a pressure of 150kg/ sq.cm Then bending and forming is done. Half taping with resin rich tape is done for over

hangs and reshaping is done. done. Initial taping is done and final tapings is done with To ensure no short circuits half testing of coils is

resin rich tape to about 13-14 layers.

-

Final baling is done for 3hrs at a temperature of

160OC in cone furnace. Gauge suiting is done.

Conductive/ graphic coating (643) and semi-

conductive coating 642 are done. High voltage testing is done at four times that of rated voltage and tan testing, inter half testing are done. Finally glass taping followed by epoxy gel coating is carried out. inter strip,

Advantages of resin rich system of insulation: Better quality and reliability is obtained. In case of any fault (phase-ground/ phase- phase short) carrying the repair process is very easy. Addition of excess resin will be avoided because of using resin rich mica tape.

3.6. VACUUM PRESSURE IMPREGNATION Siemens electrical machines quality is highly dependent on the vacuum pressure impregnation insulation system. All the high voltage machines, pole coils irrespective of size and shape are being impregnated under vacuum and pressure of self developed Siemens patent resin systems. The stringent quality tests on the resin mixtures and strictly following the vacuum pressure impregnation and systematic cooling and heating cycle of resin mixture and sophisticated automatic control systems made the insulation systems for better and better quality for more than 30 years, made Siemens pioneers in this field. The insulating materials used by Siemens for wedges are resin poor and accelerator treated. For eg. Main insulation tapes, mica paper tapes, overhang protective

tapes, shrink tape and glass mates HM693 are treated with accelerator. After impregnation, they become hard experiments were conducted for voltage endurance at room temperature and at evaluated temperature

continuously for more than 3 years. Though the mica tape can withstand 20kv per mm, the extrapolation has been done at 4kv/mm and life expectancy is around 100yrs. With an operation stress level of less than 4kv/mm, factor of safety is considerable. The Vaccum pressure impregnation system was brought by Dr.Meyer with the collaboration of westinghouse in the year 1956. The resins used were of polyester. Siemens developed the present Vaccum pressure impregnation system with epoxy resin and treated accelerator on tapes. The mica tapes used for Vaccum pressure impregnation systems are ROGS 275, ROGS 275.1 and ROV 292. ROGS 275

tapes are with glass cloth baking upto 13.8 kV voltage levels ROV 292 mica paper tapes are with polyester fleece above and more penetration of resin. ROGS 275.1 tape is special glue varnish for tropical countries like India and Brazil to resist higher humidity. The glue being used for main insulation tape is X2026 and for conductor insulation is X2027.

The resin used for Vaccum pressure impregnation is ET 884, a mixture of epoxy resin E1023 (lekuther m x 18) and hardener H1006 in 1:1.2 ratio by weight. In kwu, the components are mixed in 1:1 ratio.

E1023: The resin is in drums of 220 kgs weight. It is in crystal form at temperature of 14 or 20deg.C the container is resin is available in drum the reason is faster

heating in furnace, the resin in liquid state shall not come out of the container. The drums are kept in oven and heated up to 1000 C for about 18hrs. If the resin is not fully in liquid condition, can be heated up to 1250C the storage tank is filled with resin first depending on the volume and ratio of mixture at a temperature of 600 C through hose pipes. Resin filling is being done by

creating 0.2 bar vacuum in the tank.

RESIN MIXTURE: The mixing ratio of resin to harden is 46:54 parts.

The resin mixture required for the siemens Impregnation tank is 27000lts. A job of 1.9m height and 4.5m dia can be impregnated.

Size of the tanks - Main impregnation tank = 4.5m pie x 3.0m ht. - There are 3-inch vessels for different sizes jobs impregnation. (a) (b) (c) Vessel (1) 3.8m pie x 2.25m ht. Vessel (2) 3.0m pie x 2.3m ht. Vessel (3) 2.0m pie x 2.3m ht.

3 Storage tanks of each resin capacity 9000 litres are in the operation for storing. The resin mixture cooling and heating cycle is by circulating the resin through the heat exchangers. Oil heated by water is being used for heat exchangers. The Vaccum pressure impregnation cycle is as per WIV 114.1 standard. Job preheating 70oc 12 hrs.

The job is kept in an oven for a period of 12hrs at a temperature of 70OC. 6 nos thermocouples are inserted on the back of the core and measured the temperature. Job insertion in the impregnation tank at 70oc The lid of the impregnation tank in open condition. The vessels are kept clean. Resin is available is wiped out by methylene. Traces of resin shall not be allowed on the inner side of the tank. It reacts with humidity and scale formation will takes place. These component and obstruct the filters also. The resin at the time of cleaning is carefully removed by wiping with rubber sheets. Keeping the vessel in slant position on the ground also cleans the inner vessels. After ensuring the perfect cleaning, the tank should allowed for further operation. The job is inserted in the tank the temperature monitoring thermocouples are placed on the back of the

core. The lid is allowed to come down by hydraulic motor. Silicon grease is applied on the surface of tank where the lid is touching. A rubber gasket is also provided on the rim not to allow any leakage. Air pipes are closed and vacuum pumps will be started.

Vacuum creation 0.35 torr for 2 hrs: The job temperature is to be maintained always above 65OC , if found less, tank can be heated up. In practice, the vacuum can be created in 2 hrs. Siemens adept before starts of 2nd shift (3.0 pm), they create 0.35 torr vacuum and it will be continued till next day morning 1st shift (6.00 am) min. requirement is 2hrs.

During this time the resin cooling is being carried out to reach 10deg.C and heated up automatically to 70deg.C.

IMPREGRATION: The resin mixture is to be heated to 70deg.C. Everyday morning a 20ml sample will be taken to laboratory tests. Viscosity will be measured at 70deg.C. It should not be more than 45 CD +10%. Anew resin will beat 15 CP. New resin and hardener mixture is to be added if the viscosity is more. The resin filling is being completed in 25 minute. At this time, the vacuum reduces to 0.5 Torr 1 Torr level. The resin is to be allowed to settle for 15 min. The level of resin is above 100mm over the job. Pressuring 3 bar With the hydrostatic pressure of the resin, only surface of the insulation can be filled with resin. To have an effective penetration up to the end of a barrier, pressure

is to be created to 3 bar (2 bar over atm. Pressure of 1 bar).

Gelling time: The polymerization of resin and accelerator take place at this time. At 65OC, the time required is 170 min. The insulation gets hardened. Curing 14 hr at 140 O C The resin is to be pumped back to the storage tank. The job is to be removed from the tank and allowed for dripping. It is kept in oven at 140deg.C for min of 14 hrs.

The accelerator B1057.1 is to be placed at 4 corners of the oven. In curing process the accelerator vapors will react with surface resin and cures.

CHARACTERISTICS SYSTEM: 1) 2) 3)

OF

VPI

INSULATION

Higher mechanical bond Void free insulation High dielectric strength, low dissipation factor,

hence longer electrical life. 4) 5) Better heat transfer Higher thermal stability, ensures class-F under

running conditions 6) 7) Less maintenance Cost effective

8)

Low inflammability, hence limited damage

during abnormal operations. 9) High resistance to oil, acid, alkali and moisture.

10) Manufacturing cycle is less 11) Frame size is small, machine cheaper. 12) Elastic response to thermo-mechanical stress, machine suitable peak load operation

VACUUM PRESSURE IMPREGNATION PROCESS: Four stages of Vacuum pressure impregnation cycle 1) vacuum drying:

temperature : 60oc +/- 3oc pressure duration : 0.2 millibar : ~ 16-18 hrs

drying check: 0.06 mbar drop in 10min 2) Imprgnation: : 60oc +/- 2oc

resin temperature resin filling resin level

: ~ 20 min : ~ 100 mm above

settling time : ~ 10 min resin (epoxy bisophenol a) & hardener ratio 1:1

3)

Pressurisation:

N2 pressure : ~ 4 bar rising : ~ 80 min

holding time : ~ 2 hrs capacitance measurement to ensure effective

peneteation and gelling 4) Post curing:

temperature of job : 140oc +/- 5oc duration : ~ 20 hrs

INSULATING MATERIALS USED IN THE STATOR WINDING: USAGE A foam insulation for slot bottom layer of stator coil Slot bottom insulation Inter layer insert MATERIAL DESCRIPTION Semi conductive foam fleece Semi conductive fleece Glass mat (compressible)

Top insulation Spacers in overhang Bandage ring spacers Slot wedge Fillers for Slot Merge spacer Slot Merge spacer Stiffeners between top & bottom layers Interlacing for ring and stiffeners Typing of spacers b/w collector rings Insulation of rings Shrink and protection layer Adhesive varnish for tape ends

-do-do-doGlass mat (Hard) -do-doGlass mat (repressed in a hydraulic fixture) Glass Sleeve

Glass tape Fine mica paper glass tape Polyester shrink tape Adhesive varnish

Bandage rings Terminal boards

Polyester resin + glass ravings Glass mat (hard) Table 3.1 List of

insulating materials

Photo 3.4 Wound Stator at VPI Plant

Photo 3.5 Impregnation Plant

3.7.EXCITER 3.7.1. Design Features The exciter consists of Rectifier wheels Three-phase main exciter Three-phase pilot exciter

The three-phase pilot exciter has a revolving field with permanent-magnet poles. The three-phase ac is fed to the field of the revolving-armature main exciter via a stationary regulator and rectifier unit. The three-phase ac induced in the rotor of the main exciter is rectified by the rotating rectifier bridge and fed to the field winding of the generator rotor through the dc lead in the rotor shaft. A common shaft carrier the rectifier wheels, the rotor of the main exciter and the permanent magnet rotor of the pilot exciter. The generator and exciter rotors are thus

supported on a total of three bearings. Mechanical coupling of the two-shaft assemblys results in coupling of the dc leads in the central shaft bore through the multi contract electrical contact system.

3.7.1.1. Rectifier wheels: The main components of the rectifier wheels are the silicon diodes, which are arranged in the rectifier wheels in a three-phase bridge circuit. A plate spring assembly produces the contact pressure for the silicon water of the diodes. One diode each is mounted in each light metal heat sinks and then connected in parallel. Associated with each diode is a fuse, which serves to switch off the diode from the circuit if it fails. Each arm of the diode bridge is provided with one RC block. The three-phase connection between the armature and diodes is obtained

through copper conductors arranged on the shaft circumference between the rectifier wheels and the main exciter. One conductor is provided for each arm of the diode bridge. The conductors originate at a bus ring system of the main exciter.

3.7.1.2. Three-phase pilot exciter It has a frame, which accommodates the laminated core with the three-phase winding. The rotor consists of a hub with mounted poles. Each pole consists of separate magnets, which are housed in non-magnetic metallic enclosure.

3.7.1.3. Three-phase Main Exciter It is a revolving armature unit, the frame poles with the field and the damper winding. The field winding is

arranged on the laminated magnetic poles. The rotor consists of stacked laminations, 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 the end turns of the winding are secured with the steel brands. The winding ends are run at bus ring system to which the three-phase leads leading to the rectifier wheels are also connected. After full

impregnation with epoxy resin and curing, the complete rotor is shrunk onto the shaft.

3.8. Skid The skid is interim fixed to the concrete through foundation bolts. The stator frame is fixed to the skid

with the help of hexagonal bolts. Footings are provided to support the stator on the skid.

Photo 3.6 Exciter

4. TESTING OF TURBOGENERATOR

4.1. Objectives of testing

Testing is the most important process to be conducted on a machine after it is designed. The testing of machine is necessary primarily to establish that the machine performance complies with the customer specifications. Tests ensure that the piece of equipment concerned is suitable for and capable for performing duty for which it is intended.

Testing is done under condition simulating closely as possible to those, which will apply when the set is finally installed with a view to demonstrate to purchasers representative its satisfactory operation. Test provides the experimental data like efficiency, losses, characteristics, temperature limits, etc. for the use of design office, both as confirmation of design

forecast and also as basic information for the production of future designs.

Introduction With ever increasing rating of the modern turbo generators and reliability of service expected, testing at manufacturers works has become of paramount importance. The machine performance is evaluated from the results of the equivalent tests.

(a)

Advantages of testing

- Provides data for optimization of design - Provides quality assurance - Meets the requirement of legal and contract requirements. - Reduction in rework cost.

- Ensures process capability and develops checklist. - Increases confidence levels in manufacture. - Establishes control over raw materials. - Helps in building of safety and general operation and manual.

4.2. TYPES OF TESTS Tests on turbo generators are classified under the following headings, which is also the order in which these are performed during the course of manufacture. 1.Tests on the materials and components during the manufacture so as to control the quality of the materials in process also known as Process tests. 2. Performance tests on the machine to prove the performance of the generator in accordance with the required standard.

4.3. TESTS DURING MANUFACTURE/ PROCESS TESTS: Tests on rotor winding Tests on stator coils. Balancing and over speeding of rotor.

4.3.1.Rotor winding The rotor coils and their insulation are subjected to a high stress when in normal operation. Thus a thorough inspection of these is necessary before putting them in the rotor slots as otherwise any replacement of the faulty insulation or cell would necessitate

removing the coil binding rings and the wedges, which is a cumber job. A series of graded voltage tests are

conducted on the rotor cell and coils dusting assembly and also when finished to test its electrical strength against likely creep age to ground or inter turn breakdown.

4.3.2.Tests On The Rotor Coils 1. Between turns: The rotor coils turns are made up of a number of turns which are formed in halves and then assembled with their inter turn insulation and boned with an adhesive in the steam heat press. Although the normal working voltage per turn is very small, a turn to test of 240 volts is done to exercise quality control. 2.Top turn trough: The insulation the top and bottom of the rotor slot provides adequate and safe creep age distance between

copper and rotor steel, in case of slotted copper 500 volts for one minute to test the top trough. 3. Collecting leads: A high voltage equivalent to the shipping test plus 1500v is applied to the collector leads when fitted in bore with studs of seals fitted but before connecting to the windings.

4.3.3.Tests on stator coils As per the standards the stator winding has to be subjected to a shipping pressure test of (2 x line voltage +1kv). This power frequency voltage applied for one minute. In order that machine when found with stands this final voltage test and any faulty coil is eliminated during various stages of coil manufacture and

winding. Because of the continued application of HV tests overstress the winding insulation, the voltage is reduced in various stages. 1.Tests between parallel strips This is a test of strip insulation provided for eddy emf, on low voltage at the order of 350V for 3 seconds is applied.

2.Coils in manufacturing and Winding Sections: When the coils are first tested, a voltage of 8kV in excess of shipping pressure test is applied, and this voltage tests are repeated.

3.Tests on Thermocouples: 1000V Megger test is applied to the thermocouples.

4.3.4. Balancing and over speeding of rotors 1.Balancing: One of the most important preliminaries to testing is that of balancing the rotors. Before over speeding, the rotor is dynamically balanced, in cold as well as hot conditions. A set of run up and run down is taken sure those critical speed is well away from the running speed.

2.Over Speeding: In order to check the soundness of all parts and fitting on rotor assembly, the rotor is run at an over speed of 14% for five minutes or 30% for one minute.

4.4. PERFORMANCE TESTS/ TESTS ON COMPLETED MACHINE:

The machine is assembled and erected at the heavy rotating plant test bay for test.

1. Dry out insulation resistance of rotor & stator windings

-

Before starting with running tests, the stator

windings are dried out by circulating current in the winding from an external dc source Input of power is so controlled as to limit the temperature of the end windings to a maximum of 800C by thermometer. - Progress of dry out is observed by one minute insulation resistance reading with 1000v Megger. With the application of heat, the insulation resistance will initially drop and then will rise again over a period of time and finally becomes approximately constant temperature. Ration of ten-minute reading

i.e. polarization index, when more than 2 gives an indication of good dry out. Insulation resistance readings of rotor winding to ground are taken.

2.Resistance of machine windings Measurement of cold winding resistance, both for stator and rotor must be very accurate basis of Calculating copper under cold and hot conditions For determining the rise in temperature of rotor winding by resistance method at the end of temperature test. since it forms the

All precautions are taken to ascertain correct temperature of the winding white measuring cold resistance. Since the winding resistance of turbo generator is quite low: a modified form of wheat stone bridge i.e. Kelvins double

bridge does away with the necessity of accounting for the resistance of loads. Resistance between phases for stator and between slip rings for is recorded along with the cold winding temperature at the time of

measurement.

3.Phase sequence test: The phase sequence test is to check the agreement of the terminal markings that have been specified using the Phase Sequence Indicator.

4.Zero excitation rated speed run By wattmeter method when condition is steady. From the result of above test after deducting drive motor in gear losses, friction and wind age losses of the machine under test are computed. These losses are for rated speed.

Bearing oil quantities with inlet temperatures of oil can yield calculations for bearings loss. From a previous data on seal face losses determined from a prototype test, the total friction loss in the bearings and seals can be difference. Since bearing loss is computed for design office use by the difference. Since bearing loss goes to oil, any heat carried out on the unexcited machine will give temperature rise due to wind age.

4.4. PERFORMANCE TESTS The performance tests on the turbo generator are classified as: - Type tests - Routine tests - Heat run tests

4.4.1. TYPE TESTS These are specially requested tests form the customer. They are not performed on all machines i.e., they are specific to machine. They include - Mechanical measurement of leakage reactance of stator winding - Measurement of residual voltage of stator winding at rated speed
-

Line to line sustain short test and determination of

negative sequence reactance [X2]

-

Line-to-line and neutral sustain short circuit test and

determination of negative sequence reactance [XO]

-

Retardation test for determination of GD2

4.4.1.1 Measurement of leakage reactance of stator winding

- This test is done on the stator winding with out rotor, generally before assembly on test bed for running test. - Purpose To determine total leakage reactance To determine potier reactance To determine armature leakage reactance

To determine leakage reactance, a search coil of adequate number of turns is installed securely with in the stator bore with a flexible and well-insulated copper wire. The coil span shall be of full pitch with all four sides as closely in contact with fore as possible if one side of the coil is on the top of slot no

one, the other side of the coil shall be on the top of the slot number n.

where, n = [total no. of slots / total no. of poles] + 1 After connecting meters, variable voltage is applied to the stator windings such that the stator current reaches to 30% of rated current or maximum capacity of thyristor set which ever is less and meter reading are noted down.

(a) (b)

Evaluation of leakage reactance The different leakage reactances are evaluated

as follows: i) Base impedance [Xn] = En / 3In ohms where En = rated line to line voltage In = rated line current ii) Total armature leakage reactance [XL] = (Z2 R2)

where Z = U/ 3I, R = P/ 3 I2 U = voltage measured during the test I = current measured during the test P = power measured during the test As the value of R i.e., stator winding resistance per phase is negligible compared to Z, measurement of P is not required. XL = Z = U/ 3 I ohms % XL = 100(XL / XN) iii) Potier reactance % XP = a ( % XL) where a = 1 for salient pole machine and 0.63 for cylindrical pole machine

Figure 4.1 Single line diagram of measurement of leakage reactance

4.4..1.2 Measurement of residual voltage of stator windings at rated speed After the open circuit test, the machine is gradually deexcited and the residual voltages of stator windings are measured at rated speed, across the three phases.

4.3.2.1.3. Line-to-line sustained short circuit test and determination of negative sequence reactance The line-to-line sustained short circuit test is carried out by short circuiting and two line terminals of the stator winding using current transformer with the machine driven at rated speed and excited. The following

parameters are recorded at three values of the short current limited to 30% at rated current.
-

Short

circuit

current

(IK2),

through

current

transformer
-

Voltage between the open line terminal and one of

the short circuit terminals Uk2, through potential transformer. - Active power p.

Evaluation of negative sequence reactance (X2)

(i)

X2 = P / 3. (I K2)2 ohms

where P = power measured during the test IK2 = line-to-line short circuit current measured during the test %X2 = 100(X2/Xn)

4.4..1.4. Line- to-line and to neutral sustained short circuit test: The line-to-line and neutral short circuit test is carried out by short-circuiting two line terminals and shorted to the neutral using current transformer. The machine is driven at rated speed and excited. The following values are recorded at several values of short circuit current.

- Neutral current (Io), through the current transformer

-

Voltage between the open line terminal and neutral

(V0) through potential transformer 1.Evaluation of zero sequence reactance Zero sequence reactance is calculated as follows: XO = VO / IO ohms where VO = line to neutral voltage

IO = line to neutral current measured during the test % Xo = 100 (Xo / Xn) Note: Minimum time is taken for the test because serious overhang winding heating may result, if current is sustained for a longer time or raised to too high a value.

4.4..1.5.Redardation test for determination of GD2 (Gravitational deterioration) The machine along with the drive system is run at rated speed and drive motor input power is noted. Then speed is increased by 1hz corresponding rpm over the rated speed and at the stage, the machine is tripped by opening the in-comer circuit breaker of drive system. Time and speed are noted with an interval of 5 seconds upto 30 seconds, with an interval of 10 seconds upto 1minute and so on till the machine comes to stand still.

1.Evaluation of GD2 GD2 is calculated as follows: Time versus speed curve is plotted on a graph paper, taking X axis as time and Y-axis as speed. A tangent is drawn at rated speed point on the curve, which meets the

time axis at point T2.T1 is the point corresponding to rated speed. GD2 = (365000*P*T) /N2 Where, P = Mechanical losses in kW T = Time in seconds = (T2 -T1) N = Rated rpm of the machine GD2 of machine = GD2 measured GD2 of drive system (known) kg-m2

4.5. ROUTINE TESTS These tests are carried out on each generator to ascertain that it is electrically and mechanically sound. These tests are carried out on different machines and are classified as

4.5.1. Static tests 1. Measurement of insulation resistance of stator & rotor windings before and after high voltage test (machine at rest). 2. High Voltage test on stator & rotor windings (machine at rest). 3. Measurement of Polarization Index of stator winding. 4. Measurement of d.c resistance of stator & rotor windings in cold condition. 5. Measurement of d.c resistance and insulation resistance of resistance temperature detectors and thermocouples.

4.5.2. Running tests

1. Mechanical run and measurement of vibrations at rated speed. 2. Measurement of mechanical losses, short circuit characteristic and losses. 3. Measurement of mechanical losses, open circuit characteristic and losses. 4. Measurement of shaft voltage. 5. Checking of phase sequence. 6. Measurement of Rotor Impedance (rotor inside stator).

4.5.1. Static tests 4.5.1.1. Measurement of insulation resistances of stator and rotor windings before and after high voltage test: Equipment: a) b) Megger (1000V/ 2500V) Earthing rod and earthing wire/ cable.

- Insulation resistances of the stator and rotor windings are measured separately before and after high voltage test using 2500V Megger for stator and 1000V for rotor winding. These values are taken at 15 seconds and at 60 seconds. Absorption coefficient of insulation is found out as, Insulation resistance at 60 seconds Absorption -----------------------------------------coefficient =

Insulation resistance at 15 seconds - This value for H.V. test should be approximately 1.5

4.5.1.2. Minimum insulation resistance value The minimum value of insulation resistance (Rm) at 60 seconds recommended as:

Rm = (KV + 1) megaohms.

- Where KV is voltage in kilovolts to be applied for test. - In practice a fairly high value is obtained. - With dry winding its value will be somewhere in the vicinity of 2 or even more. With damp winding it will decrease to somewhere near 1. Absorption coefficient

value of 1.8 and 1.7 may be satisfactory, while a value below 1.5 indicates a damp machine. - The winding is discharged to earth after each measurement.

4.5.1.3. Measurement of polarization index of stator winding The polarization index of stator winding, all the three phases together is measured using 2500V Megger after high voltage test. The insulation resistances are noted at 1minute and at 10 minutes from starting of measurement.

The polarization index is evaluated as follows: Insulation resistance value at 10 minutes

Polarization Index (P.I) = ------------------------------------------------Insulation resistance value at 1 minute The minimum allowable PI value is 2.0.

4.5.1.4. High voltage test on stator and rotor windings Equipment: 1. 50 Hz A.C. High Voltage transformers and its induction regulator / input autotransformer. 2. Potential transformer (35 or 100kV / 100V) 3. Voltmeter. 4. Binding wire. 5. Earthing rod and earthing wire / cable. When H.V. test is done on one-phase winding, all other phase windings, rotor winding, instrumentation cables and stator body are earthed.

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/ cable. The test is conducted on all the phases and rotor winding separately.

High voltage test levels: Stator winding: (2Ut + 1) kV = 23 kV for 11 kV machine. Rotor winding: (10 Ue) volts. (with minimum of 1500 V and maximum of 3500V). where, Ut
=

Rated voltage of the machine (kv).

Ue = Excitation voltage. 1. Stator winding:

Testing of stator winding involves the testing of connecting rings after the assembly and stator bars during assembly. Up = (2 Un + 1) Where, Up is the final test voltage after the test run and Un is the rated voltage of the generator.
-

The connecting rings are tested for 1.2 UP for 1

minute. If there is sparking due to less distance between the live joints, the same can be done with 1.1 UP. If the connecting rings are assembled after laying bars, they are tested along with the bars. - The high potential is given to copper and the core is earthed. The output voltage of the high voltage tester is continuously increased to test the voltage level, held for 1 minute and subsequently decreased to initial level.

After the bottom bars are laid they are tested for 1

minute with 1.1 UP. Individual strips are of each bar are tested with 220V ac for any possible inter half shorts and inter bundle shorts.

After the top bars are laid, High voltage testing is

carried out with 1.1 UP for 1 minute and they are tested for inter half and inter bundle shorts. Inter half shorts test with 220V ac is carried out after connecting the top and bottom bars without the connecting rings.
-

High voltage testing of the individual phases with

1.05 UP is carried out for 1 minute after the completion of the winding . When one phase is under test the other phases are earthed.

- Resistances of individual phases are measured . - During high voltage testing all the instrumentation cables assembled in the machine are to be earthed. - Insulation resistance of each phase is to be measured after each high voltage test. - Whenever bunch brazing is employed for

connecting top and bottom layers, only inter half shorts test is to be carried out.

2. Rotor winding The rotor winding must be tested at various stages of its manufacture and assembly. - The output of the high voltage test equipment is connected to the output lead or to the winding as the case may be and shaft is earthed. The voltage is continuously increased to test voltage level,

maintained for 1 minute and subsequently decreased to initial value. - To test for inter turn shorts the required voltage is applied across the total winding of both the poles and voltage across the winding corresponding to each pole is measured and recorded.
-

The final test voltage UP is ten times the rated

voltage subjected to a maximum of 3.5 kV and manimum of 1.5 kV.

-

Before assembly of rotor bars HV test is carried

with UP + 2000V for one minute. Then both the poles against earth are tested with UP + 1500 V for one minute.
-

After the assembly of the rotor bars HV test is

carried with UP + 1500 V for one minute initially pole against pole and then against earth.

After the assembly of two coils HV test is carried

with UP + 1500 V for one minute initially pole against pole and then against pole and then against earth.
-

Before the wedging is complete, winding against

shaft is tested with UP+900V for one minute. After wedging the complete winding against shaft is tested with UP+800V for one minute.
-

After pressing and curing the insulation under the

retaining ring, high voltage testing of the winding against shaft is carried out with UP + 600V for 1 minute. Then d.c winding resistance is measured.
-

After mounting the retaining ring high voltage

testing of the winding against the shaft with UP+400V is carried out for one minute.

After over speeding and balancing at standstill HV

testing of the winding against the shaft with UP+200V ac is carried out for one minute.
-

HV testing of the winding is carried out at 3000 rpm

with 500V ac for one minute. Then the winding is tested against the shaft with UP for one minute. - The insulation resistance value of the winding is measured after each high voltage.

Figure no: 4.3 Single Line Diagram of H.V Testing of Stator Winding

4.5.1.5. Measurement of D.C resistance of Stator and condition Equipment: Rotor windings in cold

a) leads. b)

Digital micro ohmmeter and its measuring

Thermometer (Hg in glass)

D.C resistances of stator and rotor windings are measured separately using digital micro ohmmeter. The instrument terminals are connected to the machine terminals and proper range in meter is selected. The stabilized reading is recorded. Ambient temperature from Hg in glass thermometer is recorded. The stator resistance temperature detectors values are noted and average value of stator winding temperature is evaluated.

1.4.1. Evaluation of resistance at 20OC:

Evaluation of resistances at 20OC (R20) is done by

using formula:
-

R20 = {Rt (235+20)} / (235 + T) milli ohms Where, R20 = Resistance at 20OC in milli ohms T= The average temperature of the stator winding

in degrees centigrade. Rt = Measured resistance of the winding in milli ohms - Variation in maximum and minimum values of d.c resistance of 3 phases of stator windings up to 5% is acceptable.

4.5.1.6. Measurement of D.C resistances and insulation resistances of Resistance temperature detectors The d.c resistances and insulation resistances of resistance temperature detectors are measured using multimeter and megger respectively and recorded.

4.5.1.7. Measurement of Capacitance and Tan of stator winding a) The capacitance measurement of stator winding is done using schering bridge and standard capacitor. For a 3 phase synchronous machine, the windings are symmetrical and the value of capacitance is arrived by measuring in arrangements I & II. Arrangement I:

H.V. application to one of the phases and remaining phases are connected to body of stator. This gives the value of Cg+2 Cm, where Cg is capacitance of winding with respect to ground and Cm is with respect to other winding capacitance). Arrangement II: H.V. application to all the phases. This gives the value of 3Cg.. (mutual

b) Equipment: a) 50 Hz A.C. high voltage transformer

(T90, 0 - 35kV) b) c) d) Standard capacitor (100 / 1000 pF). Schering bridge Isolation shunt box

e) f) g)

Connecting H.T. cables. Earth wire with earthing rod. Voltmeter. h)Megger (1000V). i)Null Indicator (galvanometer).

j)

1- phase supply source for null indicator.

c) Test preparation: i) The stator body is isolated from ground by

placing insulation packing between the body and the base. ii) Connections to the Schering Bridge,

standard capacitor, Null indicator and transformer are done as per figure 4.4 for the selected arrangement.

iii)

Measurements are taken at voltages 0.2Un to

1.0Un in steps of 0.2Un.

iv)

The H.V. supply is switched on and raised

to the required value. The bridge is balanced with the proper selection of variable resistances (R3+S) & the capacitance C4 and readings are recorded. After all measurements, voltage is reduced to zero, supply is switched off and windings are discharged to earth. e) Formula used: i) Capacitance: Cx = Cn x R4 x (R3+100) -------------------------N x (R3+S) F.

ii) Percentage of tan % tan = ( x R4 x C4 x 10-4 ) x 100 where, C4 & Cn are in F.

R3, R4, N & S are in .

Figure 4.4 Single line diagram of Schering bridge for measurement of capacitance and tan

4.5.2. RUNNING TESTS

These tests are run after assembly of machine on test bed. Equipment: a. b. c. d. e. f. g. h. i. j. k. monitor. l. 50 Hz A.C High voltage test equipment. D.C motor drive system. Bearing lubrication system. Cooling water system. Current transformers 2 nos. Potential transformers 2 nos. D.C current shunts 2 nos. AC/DC Power analyzer. Phase sequence indicator. Multimeter for continuity checks. Vibration monitor. Resistance temperature detectors

m. n. o.

Meggers. Micro ohmmeter. Connecting leads/copper strips and

earthing cables rods etc.

4.5.2.1 . Mechanical run and measurement of vibrations at rated speed The turbo-generator under test is assembled separately without coolers and enclosures (if any), on a test foundation frame using its own bearings and coupled to a calibrated d.c drive motor with gearbox of suitable capacity (1900kW/ 1300kW/ 750kW). The brushless Exciter and Permanent magnet generator are mounted on the overhang of the generator rotor. Testing of turbogenerator, brushless exciter and permanent magnet generator are done separately. The power to the drive

motor and the field of

the generator are drawn

independently from the thyristor converters suited in electrical machine controlled rooms and controlled from test gallery independently.

Before running the machine ensure: - Lubricating Oil is flowing through bearings and the gear box. - All the instruments are working - Roll the machine and check all the parameters. Slowly raise the speed to one-sixth rated speed. Observe slow roll vibrations, temperature and oil flows. Raise the speed to one-third rpm slowly and record the vibrations, temperature and oil flows. - The vibrations are measured at rated speed on both the bearing housings (pedestals) in horizontal,

vertical and axial directions with the help of vibration meters, which are internally connected to the monitor and the vibrations, are noted in the form of graphs. - The temperature of stator is monitored by monitoring resistance temperature detectors

embedded in core, tooth and winding. Now raise the speed to two third the rpm by observing all the parameters, critical speed and record them. The machine is rolled and run at rated speed after ensuring the bearing oil and left at rated for stabilization of bearing temperatures.

4.5.2.2. Measurement of mechanical losses, short circuit characteristic and losses

- The

machine

is

prepared

for

short

circuit

characteristic using current transformers and shorting links as shown in figure 4.5
-

The machine is run at rated speed and drive motor

input voltage and current are noted and m/c is excited gradually in steps, at 20%, 40%, 60%, 80%, 90% and 100% In (In = Rated current of machine).

At each step the following parameters are noted: 1) Stator current (Ia & Ib) 2) Rotor current (If) corresponding to stator current. 3) Drive motor voltage (Vd) and current (Id) corresponding to stator current.

4) Resistance temperature detectors readings at rated stator current (100% In). 5) Bearing vibrations at rated stator current (100% In).

The excitation is reduced and cut off. The speed is reduced and the machine is cooled at lower speed. The temperatures resistance are checked from machine detectors readings. The

temperature

machine is stopped when it is sufficiently cooled down. (The stator winding temperatures to be less than 60OC).

From the above data, the characteristic curves are plotted as follows:
a)

% In versus If.

b)

% In versus machine looses in kW.

Figure 4.5 Single line diagram for short circuit characteristics

4.5.2.3. Measurement of mechanical losses, open circuit characteristic and losses: - The machine is prepared for open circuit as shown in the figure 4.6.
-

The machine is run at rated speed and drive motor

input voltage and current are noted and m/c is excited gradually in steps, at 20%, 40%, 60%, 80%, 100% and 120% En (En = rated voltage of machine). At each step the following parameters are noted:

1) Stator voltages (Vab,Vbc,Vca) 2) Rotor current (If) corresponding to stator voltage. 3) Drive motor voltage (Vd) and current (Id) corresponding to stator voltage. 4) Resistance temperature detectors readings at rated stator voltage (100% En). 5) Bearing vibrations at rated stator voltage (100% En). The excitation is reduced and cut off. The speed is reduced and the machine is cooled at lower speed. The temperatures are checked from machine

resistance temperature detectors. The machine is stopped when it is sufficiently cooled down. (The stator winding temperatures to be less than 60OC).

From the above data, the characteristic curves are plotted as follows:
c)

%En versus If. % En versus machine looses in kW.

d)

Figure 4.6 Single line diagram for open circuit characteristics

4.5.2.4. Measurement of shaft voltage Phase voltage of generator is measured using multimeter or a high input impedance a.c voltmeter across the two ends of the rotor when machine is in open circuit test condition at 100%En.

4.5.2.5. Checking of phase sequence: Phase sequence of generator is checked using a phase sequence indicator across potential transformer output

terminals when machine is in open circuit condition at 100%En.

4.5.2.6.. Measurement of rotor impedance (Rotor inside stator): Equipment: a) 50Hz (Power frequency) A.C source. b)AC/DC Power analyzer. c) Current transformer (50A/5A or 100A/5A) d)Connecting leads. Connections are made as per the figure 4.7 A variable 50 Hz A.C. voltage of single phase is applied across the slip rings /input leads and readings of voltage and current are noted down from 50V to 200V in steps of 50V. This test is done at 1/3, 2/3 and at rated speed.

Evaluation of impedance: Using formula does evaluation of impedance: Z = V /I ohms where Z = impedance in ohms V = voltage in volts I = current in amperes

Impedance measurement: - At rated rpm (Rotor inside stator). - At standstill (Rotor inside stator). - At standstill (Rotor outside stator).

Figure 4.7 Single line diagram for measurement of Rotor impedance

4.6. EVALUATION OF EFFICIENCY Efficiency of Turbogenerator Introduction:

Among some of the parameters, which decide the quality of the machine, like Short circuit ratio (S.C.R.), reactance & time constants, moment Of inertia, efficiency, Efficiency of a machine is put under guarantee clause by most of the customers. An efficient machine adds in economy in performance and brings exclusive respect to the manufacturer. Most of the manufacturers brand their product on efficiency. The demand is more inclined towards efficiency. Product efficient machine or loose the market has become todays endeavor. Efficiency is defined as The ratio of output to input expressed in the same units, generally it is expressed as a percentage. The output of the machine always losses of the machine subtracted from the input.

Thus %Efficiency = 100{(output) / (output + losses)} The Total loss consists of the following component losses 1.Excitation Circuit Losses:
a.

Field I2R loss: The I2R loss in the field winding.

b. Main rheostat loss: The loss in the rheostat in the main exciting winding.
c.

Electrical loss in the brushes: The summation of

I2R losses in the brushes and the connectors and brush contact loss. d. Exciter loss: All the losses of exciter mechanically driven from the main shaft which forms part of the complete unit and is used solely for exciting the machine, together with the losses in the rheostat in the field circuit of such an exciter. 2.Losses independent of Current:

a. Core loss: Core loss at no load, rated speed and rated terminal voltage. b. Bearing friction loss: only losses in the bearing supplied with the equipment will be included. c. Total windage loss: The total windage loss in the machine and exciter, if any, including the power absorbed in the fans forming an integral form of the machine. d. Brush friction loss: The brush friction including that of the exciter if mechanically driven.

3. Direct load loss: The I2R loss in primary windings determined from the winding. 4. Stray load loss: current and the resistance of the

a)

Stray load loss determined from the primary

windings determined from the current in the conductors. b) Stray load loss in the conductors.

4.6.1. EVALUATION OF EFFICIENCY: After completion of routine tests, efficiency of the machine evaluated. The following sequence of calculation is followed. 1.Open circuit characteristics is plotted on a graph paper from open circuit characteristics results by selecting X axis as field current and Y- axis % of rated voltage. Values of field current at 80%,100&,115%,130%En are taken from the curve. 2.Short circuit characteristic is plotted from S.C.C

results by selecting X axis as field current and Y axis

as % of rated current. Values of field at 100% In are taken from the curve. Turbo generator looses: ref. Fig. 4.8. Air gap line for open circuit characteristics is drawn and field current for air gap line at 100%En is obtained.

Copper loss characteristic is plotted from S.C.C results by selecting X axis, as %of rated current and Y axis as losses in kW. The value of copper loss (kW 100%In is taken from the curve. Iron loss characteristic is plotted from O.C.C results by selecting X axis, as %of rated current and Y axis as losses in kW. The value of iron loss (kW fe) at 100%En is taken from the curve. Drive motor with gearbox losses:
cu1

) at

From calibration curves of drive motor used testing following data is taken: Drive motor iron losses at voltage Vd = kw1

Drive motor copper losses at current Id = kw2 Drive motor loss kw1+Kw2 Drive motor iron losses at 100% In Drive motor copper losses at 100% In Drive motor loss at 100% In (kw6) Drive motor iron losses at 100 En Drive motor copper losses at 100% En Drive motor loss at 100% En (kW9) = kw4 = kw5 = kw4+k5 = kw7 = kw8 = kw7+kw8 (kw3) =

3. Mechanical losses of the Turbo generator + Drive unit:

i). Average mechanical losses (kW mechanical.) = Average of mechanical losses before Short circuit characteristics and open circuit characteristics (kw average mechanical) ii) Losses at 100% In i.e. 100%In mech. = kW average mech. + (kW6 kW3) iii) Losses at 100% En i.e. 100%En mech. = kW average mech. + (kW9 kW3)

4. Machine losses: a. Mechanical losses (Pmech) = kW avg mech. kW3 b. Stator copper losses at 100% In (Pcu1) = kWcul kW 100%In mech.

c.

Stator iron losses at 100% En (Pfe) = kWfe kW

100%En mech. d. Excitation losses: This shall be taken as 5% of rotor copper losses. e. Brush drop losses: In case of machine with conventional excitation system with slip rings on rotor, the brush drop losses are calculated taking voltage drop of 1.0 volt each polarity multiplied by the rated excitation current. For brushless excitation system, this loss is non-existent. To obtain field currents of the turbo generator at 25%, 50%, 75% & 100% loads all the data required from the test results are fed to the computer program. The output gives field currents, rotor copper losses and excitation losses. After obtaining the machine losses including exciter mechanical losses (if any),

stator copper losses, stator iron losses, rotor copper losses, excitation losses, brush drop losses (if any); all the losses are added to get total loss. Percentage efficiency (%) is evaluated as follows: %Efficiency = 10 0 X losses 4.6.2. Evaluation of short circuit ratio (S.C.R): From the test data S.C.R is calculated using formula: Field current at 100% En from open circuit test Short circuit ratio = ---------------------------------------------------------Field current at 100% In from Short circuit test Output -----------------------Output + total

4.6.3. Evaluation of % inherent regulation: From the test data % inherent regulation is calculated using formula: Eo - En % Inherent regulation = ----------- X 100 En where, Eo = Open circuit voltage at full load

estimated field current En = Rated voltage

4.7. TESTING OF BRUSHLESS EXCITER:

This test procedure covers the procedure for routine tests on brushless exciter and permanent magnet generator.

4.7.1.Tests conducted on brushless exciter: Open circuit characteristic. Measurement of D.C. resistance of armature

windings and main pole winding.

4.7.2.Tests Generator

conducted

on

Permanent

Magnet

- Measurement of output voltage at rated speed. - Checking of phase sequence and measurement of frequency. - Measurement of load characteristic. - Measurement of insulation resistance value before high voltage tests.

- Measurement of D.C. resistance of stator winding.

SETUP: The brushless exciter mounted on the overhang of the generator rotor shaft but electrically not connected to the generator rotor. The rotor shaft is mechanically coupled to a calibrated D.C drive motor with its gearbox and is run at rated speed. The exciter is excited from a separate DC source and output will be taken through the slip rings to a water load resistance. The source of electrical power is derived from the thyristor converters located in an independent machine room and the operation is controlled from the test gallery. Output terminals of the machine under test are connected to the outlet boxes of the test pit, which in turn connects

to the terminals in the control gallery where the measurement is done.

Equipment: - D.C. motor drive system - Bearing lubrication system - D.C. voltmeters - D.C. current shunts - Phase sequence meter - Water load resistance bank - Current Transformers - A.C Ammeters - A.C. voltmeters - Frequency meter - Vibration probes and Vibration monitor

- Megger - 50Hz A.C High voltage test kit - Micro ohmmeter 4.7.1. Test Procedures Of Brush less Exciter 4.7.1.1..Open Circuit Characteristics The machine is prepared for open for open circuit characteristic and resistance ( =500ohms) is connected across the slip rings. This is to allow a minimum current to pass through the diodes for voltage measurement. The machine is run at rated speed and the field winding is excited gradually in steps up to rated output voltage. At each step, following parameters are noted: Va = Output voltage of the exciter Ia = Load current of the exciter From the above data characteristic curve is plotted as Va versus If.

4.7.1.2..Load Magnetization curve: - The machine is prepared for the load magnetization characteristic. A variable water load resistance is connected across the slip rings.
-

The machine is run at rated speed, load breaker is

closed and the machine is excited gradually in steps. The load resistance is maintained at R40 (R40: Turbo generator rotor resistance at calculated for 400C) by adjusting the water load resistance. - At each step, following parameters are noted: - Va : Output voltage of the exciter - Ia: Load current of the exciter - If: Field current of the exciter - And bearing vibrations at rated load.
-

Test is repeated for load resistances R70 and R100.

- From the above data curves (Ia versus If) are plotted at each load.

4.7.1.3. Measurement of insulation resistance and HV tests: - Before performing these tests, all the diodes are shorted by the copper wire. This is to protect the diodes during meggering and HV tests on armature windings. Rotor and stator bodies are properly earthed. IR values of the windings are measured with 500V or 1KV megger and values at 15 and 60 are noted before and after high voltage tests. - Minimum insulation resistance value:
-

The minimum value of insulation resistance (Rm) at

60 seconds is recommended as:

Rm = (kV+1) mega ohms - where kV = Voltage in kilo volts to be applied for H.V. test. High voltage test is done on individual windings using high voltage test kit by regulating primary voltage to the transformer. Slowly HV is reached and maintained for 1 minute and is reduced to zero. The earth rod then discharges the object and the IR values are taken. When this test is done on one winding, the other windings are earthed.

4.7.1.4. Measurement of DC resistances of Armature windings and main pole winding: After dynamic tests the machine is allowed for cooling and when it is sufficiently cooled, the DC resistances of all the three armature windings and main pole windings

are measured separately by the micro-ohmmeter. The ambient temperature is also recorded and the evaluation of resistances at 20OC is done by using the formula:

R20 = Rt (235+20)/(235+T) where, R20 = DC resistance at 20deg Rt = DC resistance of the winding at t deg T = Temperature of the winding in deg

4.7.2. Test Procedure of the permanent magnet generator (PMG) The permanent magnet generator is assembled along with the brushless exciter on the generator rotor shaft. The output is connected to a three-phase resistance load (variable in steps). As permanent magnet generator has

got permanently magnetized field poles, it starts generating voltage right from the start of mechanical run.

4.7.2.1.Measurement Of Output Voltage At Rated Speed The machine is run up to rated speed and the output voltages Vuv, Vvw, Vwu are measured. To counter check, voltage is also measured at speeds of 1/3, 2/3, and rated speeds.

4.7.2.2.Checking

Of

Phase

Sequence

and

Measurement of Frequency: When the machine is at 1000rpm of the rated speed, the three phases input terminals of the phase sequence meter are simultaneously touched with the output terminals if

permanent magnet generator. The sequence indicated by the meter is recorded. At rated speed, a frequency meter is connected across any two phases of the permanent magnet generator PMG output terminals and frequency is measured.

4.7.2.3.Measurement Of The Load Characteristic - Machine is run at rated speed and loaded using three-phase resistance bank in steps up to rated load current. - At each step, load currents and output voltages are noted. - Load magnetization curve is drawn as phase-tophase voltage versus load current.

4.7.2.4.Measurement Of insulation resistance value and HV tests: - Insulation resistance value of the stator winding is measured by 500V or 1KV hand operated/ motorized megger before and after HV test. - High voltage test is done on the stator winding using H.V test kit by regulating primary voltage to the transformer. Slowly high voltage is raised and maintained for one minute and then reduced to zero. Winding is discharged and values are taken. 4.7.2.5.Measurement Of DC resistance Of Stator Winding: After dynamic tests, the machine is allowed for cooling and when it is sufficiently cooled, digital microohmmeter measures the d.c resistances of all the three insulation resistance

phase windings separately. The ambient temperature is also recorded and the evaluation of resistances at 20deg is done as shown in the figure.

5. CONCLUSION

In this project a sincere effort has made for the testing of turbo generator of 90.59 MVA, 11kv,3000 RPM, 2-Pole Synchrous generator. The various active components of the generator were studied and attempt was made to acquaint us with the sophisticated design and technologies involved.

The present project gave us an opportunity to know above the manufacture of the turbo generator and its structural components viz., stator, rotor, brushless

excitation systems etc. and other auxiliary equipment. A study was also made on most update insulation technique latest technology of vacuum pressure impregnation (VPI) system used for generator stator.

The testing process employed here are on par with international satisfaction. Constant improvement in the design lead to betterment in efficiency and power standards, which ensure customer

generation. Breakthrough research works in the design and working of turbo generator leading to reduction in the cost per MW and increase in capacity. There are many improvements in the design and technologies of the auxiliary systems, which aid smoother and efficient of the generator.

6. BIBLIOGRAPHY

1.Stephen J.Chapman (Electrical Machinery Fundamentals) 5, 250-262, 299-308 (1999)

3. D.F.Warne (Electrical Engineers Reference Book) 5, 97-98,101-102 ( 2000)

4. B.H.E.L,Test Procedures (Routine tests on Turbogenerator) Ref.ETP1114, Revision: 01

5. BHEL Test Procedures (Type tests on Turbogenerator) Ref.RILJ/ETP1111, Revision: 00

7. APPENDICES PROFILE OF B.H.E.L BHARAT HEAVY ELECTRICALS LTD., (BHEL) is the largest engineering and manufacturing enterprise in India and one of the leading international companies in the field of power equipment manufacture. The first plant of BHEL was set up at Bhopal in 1956, which signaled the drawn of Heavy Electrical Industry in India. In the early sixties 3 more major plants were set up at Hyderabad, Haridwar and Tiruchanapalli, which all together from the core of the diversified product range, systems and services that BHEL offer today. The company has 14 manufacturing units, 4 power sector regional centers,

8 service centers and 18 regional offices besides project sites spread all over India and abroad. BHEL manufactures over 180 products under 30 major product groups and caters to core sectors of the Indian economy like Power generation and

Transmission,

Industry,

Transportation,

Telecommunication, Renewable energy etc. BHEL has acquired ISO 9000 & 14000 certification for its operation and has also adopted the concepts of Total Quality Management (TQM) and Environmental Management Systems.

Profile of B.H.E.L Hyderabad: BHEL, Hyderabad, a vital link to the chain of BHEL, manufactures variety of products such as Turbo Generators, Steam & Gas Turbines, Switchgear

equipment, Compressors, Heat exchangers, Pumps, Pulverizers, Oilrigs and so on. The Hyderabad unit of BHEL manufactures Turbo Generators of rating up to 200 MW for industrial applications and for power generation in Steam Power Plants. The Turbo Generators manufactured at BHEL, Hyderabad range from 4 MW to 200 MW. The largest capacity machines manufactured here (up to date) are: 164.5 MW hydrogen-cooled and 110MW air-cooled Turbo

Generators. The Turbo Generators are supplied with the turbines and matching excitation systems. BHEL, Hyderabad uses the latest type of insulation called Vacuum Pressure Impregnation (VPI) method of insulation (to optimize the design), which is unique of its kind in our country.

BHEL, Hyderabad started manufacturing 145KV to 420 KV class high voltages Air Blast Circuit Breakers in 1965 in collaboration with ASEA, Sweden. The collaboration was extended to include 72.5 KV to 140 KV Minimum Oil Circuit Breakers in 1967. To keep in place with the technological advancement in the developed countries and to meet the customer requirements, BHEL has developed collaboration with World leaders-SIEMENS, Germany in 1981 for the

manufacture of 145 KV to 420 KV Oil Circuit Breakers.

In general BHEL operations are organized around three business sectors namely POWER INDUSTRY including transmission, transportation and

telecommunications, RENEWABLE ENERGY and INTERNATIONAL OPERATIONS. This enables

BHEL to have a strong customer orientation to be sensitive to his needs and respond quickly to the changes in the market.

PRODUCT PROFILE OF ELECTRICAL MACHINES FROM BHEL HYDERABAD

ELECTRICAL MACHINES

GENERATORS

EXCITERS MATCHING TO GENERATORS TO 176 MW

H2 COOLED 3000 RPM STGs

AIR COOLED

2-POLE

4-POLE

STGs STGs GTGs Fr V,VI,VI-FA & IX

GTGs Fr I, III, V & VI

CONFORMANCE STANDARDS IEC IS BS ANSI VDE IEEE : 34.1 to 34.15 : 4722,5422,7132,7306,7816 : 4999,5000 : C50.10,C50.12,C50.13, C50.14 : 2056,2059 : 115

CHAPTER-6 APPENDICES