Presentation

MANUFACTURING AND
DESIGN OF
INSULATION SYSTEM
FOR
AIR COOLED TURBO
GENERATOR
BY V.P.I PROCESS
Profile of B.H.E.L
 Bharat Heavy Electrical Limited (BHEL) is today
the largest engineering enterprise of India with
an excellent track record of performance
 BHEL manufactures over 180 products and
meets the needs of core-sectors like power,
industry, transmission, transportation (including
railways), defense, telecommunications, oil
business, etc.
 Products of BHEL make have established an
enviable reputation for high quality and reliability
preface
 Power is the basic necessity for
economic development of a country.
 production of electrical energy its
per capital consumption deemed as
an index of standard of living.
 An AC generator works on the
principle of ‘Electro Magnetic
Induction’.
 Turbo generators are machines
which can generate high voltages
and capable of delivering KA of
currents
 the designer should be cautious in
designing the winding insulation.
 insulation design plays a major role
on the life of the Turbo Generator
Introduction
 First half we discuss about
manufacture of a stator
 The latter half we stress more on
insulation design by V.P.I process
 Defination of insulation
manufacture of generator
 generator manufacturing can be
broadly divided into three main
parts:
 1. Stator manufacture
 2. Rotor manufacture
 3. Exciter manufacture
fLowchart of various stages I a generator
manufacture
STATOR MANUFACTURE
PROCESS:
 Stator core construction and
 Coil construction and their assembly.
Stator core construction
 1.PREPARATION OF STATOR
LAMINATIONS
 a RECEPTION OF SILICON STEEL
ROLLS
 b SHEARING
 c BLANKING AND NOTCHING:
 i) Compound notching
 ii) Individual notching
 d. DEBURRING OPERATION
 e VARNISHING: sheets are dried at a
temperature of around 260 – 350 oC
The laminations are subject to various

tests
xylol test
mandrel
hardness
I.R
. STATOR CORE ASSEMBLY
 A TRAIL PACKET ASSEMBLY
 B NORMAL CORE ASSEMBLY
 i) Stepped packed assembly
 ii) Normal packet assembly

 a)In process pressings (venky ko

pooch)
 b) Fitting of clamping bolts:
STATOR WINDING INSULATION
SYSTEM FEATURES
 Strand Insulation
 Turn Insulation
 Ground wall Insulation
 CLASSIFICATION OF
INSULATING MATERIAL:
Picture of above shit
Stator Winding
 The most prime part of a winding is
insulation
MANUFACTURE OF STATOR
COILS:
A)For resin poor process
 Reception of copper
conductors:
 Transposition
 Putty operation:
 Stack consolidation:
 Bending:
 Final taping:
 FOR RESIN RICH PROCESS
 The coil manufacture is same as in
case of resin poor but differ in a few
stages
 Putty work:
 Final taping
 Final baking:
 10.1 ADVANTAGES OF RESIN POOR SYSTEM OF
INSULATION:
 It has better dielectric strength

 Heat transfer coefficient is much better
 It gives better capacitance resulting in less dielectric losses
due to which the insulation life will be more
 The cost will be less and it is latest technology
 Reduction in time cycle and consumption for MW also less
and it gives high quality
 DISADVANTAGES OF RESIN POOR SYSTEM OF

INSULATION:
 If any short circuit is noticed, the repairing process is

difficult and need of excess resin from outside.
 Dependability for basic insulating material on foreign supply
 Assembly of stator:
 Reception of stator core:
 Winding holder’s assembly
STIFFNER ASSEMBLY
 Eye formation
 Connecting rings assembly:
 Phase connectors:
• 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
• DISADVANTAGES OF RESIN RICH SYSTEM OF

INSULATION:
 It is a very long procedure
 Due to fully manual oriented process, the cost is more
 It is possible to process stator bars only.
 Even though the advantages and disadvantages of both
the process are explained above, resin poor process is
the best of all, as the resin content used is almost only
35% compared to resin poor process and also show good
insulation properties justified in the later sections.
THE VPI PROCESS
 INTRODUCTION TO VACUUM
PRESSURE IMPREGNATION
SYSTEM (VPI )
 Drawback of earlier VPI SYSTEM
Vacuum Pressure Impregnation of
resin poor insulated jobs
 1. Preheating
 Lifting and shifting
 Vacuum cycle
 Vacuum drop test
 Heating the resin
 Resin admission.
 Resin settling
 Pressure cycle
 Aeration
 Post curing cycle
 Cleaning
FACILITIES AVAILABLE IN VPI
PLANT IN BHEL
 Steam furnace for preheating
 Size of chamber: 2 * 2 * 6.5 M
 Maximum temperature: 160°C
 Electrical power consumption:
75KW
 Work place: 1425
 Work centre: 3215
 Stream inlet: 200-250°C
 Impregnated tubs for keeping
jobs
 For vertical impregnation: As
per respective tech. Document.
 For horizontal impregnation:
As per respective tech. Document
 Specifications of plant:
 Impregnation medium
 Epoxy resin (class F solvent free) and hardener mix in 1:1
ratio as per TG34967
 Epoxy resin (class F solvent free) and hardener mix in 1:1
ratio as per TG34931
 Horizontal impregnation chamber

 Diameter: 4000mm
 Cylindrical length: 9000 mm
 Operating over pressure: 6 bar
 Operating vacuum: 0.15 mbar
 Operating temperature: 90°C
 Loading weight of impregnation object: maximum of 120
tonnes
 Maximum leakage rate: less than 1mbar/lit/sec.
 Moving load: 140 tonnes.
 Static load: 170 tonnes
 Pressure medium for impregnation
 Pressure medium: dry nitrogen
 Operating pressure: 6 bar.
 Nitrogen storage capacity: 52cubic meter at 25
bar.
 Resin storage capacity
 Total storage: 5*9000L+1*3000L
 Operating parameters of each tank
 Operating vacuum: 0.5mbar
 Operating over pressure: 0.5bar
 Operating temperature: 80°C
 Resin filters(stainless steel washable)
 Filter fineness: 150microns
 Output (maximum): 1000lits/min
 Vacuum system
 Root pumps: 2No.s, 5.5KW each
 Suction capacity: 2000cubic meter/hr
 Vacuum pumps(4No.s, 7.5KW each)
 Suction capacity: 250 cubic meter/hr
 This system is provided with separator filter with activated carbon filters, to protect
the vacuum pumps from resin and hardener vapours.
 Refrigeration system
 The resin inside the tanks has to be stored at 10±2°C. this can be stored for
indefinite period with a brine chilling/refrigeration system.
 The brine storage capacity: 1*25000L+1*26000L
 Composition of brine: 40%Mono Ethylene glycol and 60%water
 Heating and cooling system
 The heating of resin in the storage tanks and the impregnation chamber is by
circulating the heated brine through the heat exchangers, to heat by saturated
steam. The hot brine is cooled to about 40°C by circulating water through coolers
and then the brine is chilled to -10°C and stored in the tanks.
 Post heating of job
 Explosion proof steam drier and electrical heating superposed.
 Size: 7*4.5*4.5M
 Maximum weight of job: 80 tonnes
 Indirectly heated hot air circulating oven (gas fired)
 Size: 9*4.5*4.5M
 Maximum weight of job: 170 T/120T with facility for rotation.
DATA COLLECTION OF SAMPLES

INDO-BHARAT-II ROTOR
RESIN POOR SYSTEM RESIN RICH SYSTEM
• The insulation tape used in this system

• The insulation tape used in this is 7%
has 40% resin. of 40% resin.
• This method follows thermosetting • Same as in resin poor.
process.
• There is a need for addition of resin • Further addition of resin is not
from outside. required from outside.
• Reduction in time cycle for this • It is very long process and
process time consuming while at processing
stage.
• No tests are carried out while at • Tests are being carried out Stage.
processing
• Processing of bars along with stator
and with conductors and
• Processing of stator bars is
processing of exciter Coils only possible in resin rich
along with exciter is possible. systems.
• Repairing work is easy.
• The cost of repair is more • The total cost in this process is more.
• The overall cost is less

compared to resin rich
system.
JUSTIFICATION
 Justification can be done by two tests

 HV and TAN δ tests
PRESENT INSULATION
SYSTEMS IN THE WORLD
 1. Vacuum pressure impregnation
(VPI) of individual coils and bars
 2. Global VPI of complete stators
 3. Hydraulic molding of individual
coils and bars using resin-rich tapes
 4. Press curing of individual coils
and bars, also using resin-rich tapes
 Westinghouse Electric Co.: Thermalastic™
 General Electric Co.
:Micapals I anII™,EpoxyMicaMat™, Micapal
HT™, and hydromat™
 Alsthom, GEC Alsthom, Alstom Power:
Isotenax™, Resitherm™,
Siemens AG, KWU: Micalastic™
 ABB Industrie AG: Micadur™,

 Toshiba Corporation: Tosrich™ and
Tostight- I™
 Mitsubishi Electric Corporation
 Hitachi, Ltd.: Hi-Resin™, Hi-Mold™, and
Super Hi-Resin™
 Summary of Present-Day Insulation

Systems
A NEW hype IN INSULATION
SYSTEM
 MICALASTIC
 The MICALASTIC Insulation in
ITAIPU™
 Manufacturing and Design
 Fitting of Roebel Bars into Slots:
 Thermal Stability
CONCLUSION:

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MANUFACTURING AND

The laminations are subject to various

 a)In process pressings (venky ko

 It has better dielectric strength

 DISADVANTAGES OF RESIN POOR SYSTEM OF

 If any short circuit is noticed, the repairing process is

• DISADVANTAGES OF RESIN RICH SYSTEM OF

 Horizontal impregnation chamber

• The insulation tape used in this system

• The overall cost is less

 Justification can be done by two tests

 ABB Industrie AG: Micadur™,

 Summary of Present-Day Insulation

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