A

Mini Project Report

on

VACUUM PRESSURE IMPREGNATION AND MANUFACTURING OF TURBO

GENERATOR
Submitted in partial fulfillment of the requirement for the award of
degree of
BACHELOR OF TECHNOLOGY
in
ELECTRICAL & ELECTRONICS ENGINEERING
by
G.RAJA SHEKAR 16M65A0204
G.NAVEEN 15M61A0219
G.PREETHAM 15M61A0225
D.ANIL 14M61A0215
D.AJAY JADEJA 15M61A0214
T.UPENDAR RAO 15M65A0222
Under the Guidance of
Mrs. J. NANDANA , M. Tech.
Assistant Professor

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

SWARNA BHARATHI
INSTITUTE OF SCIENCE AND TECHNOLOGY
(Approved by AICTE, New Delhi , Affiliated to JNTUH, Hyderabad & Accredited by NAAC)

KHAMMAM – 507002
2017-18
 DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

SWARNA BHARATHI
INSTITUTE OF SCIENCE AND TECHNOLOGY
(Approved by AICTE, New Delhi, Affiliated to JNTUH, Hyderabad & Accredited by NAAC)

KHAMMAM - 507002

CERTIFICATE
This is to certify that, the mini project work entitled “VACUUM PRESSURE
IMPREGNATION AND MANUFACTURING OF TURBO GENERATOR” is a bonafide

record of work carried out by

G.RAJA SHEKAR 16M65A0204
G.NAVEEN 15M61A0219
G.PREETHAM 15M61A0225
D.ANIL 14M61A0215
D.AJAY JADEJA 15M61A0214
T.UPENDAR RAO 15M65A0222

We hereby accord our approval of it as a mini project report carried out

and presented in a manner required for its acceptance in partial
fulfillment for the award of B.Tech in Electrical & Electronics Engineering
by JNTUH , Kukatpally, Hyderabad during academic year 2017-18.

GUIDE HEAD OF THE DEPARTMENT

Mrs. J. NANDANA Mr. T. CHARAN SINGH

M.Tech, M.Tech, (Ph.D.)

Assistant Professor Associate Professor

PRINCIPAL

EXTERNAL EXAMINER Prof. PANNALA KRISHNA MURTHY

M. Tech., Ph. D.
 ACKNOWLEDGEMENT

We offer our sincere thanks to Mrs. J. NANDANA, M.Tech, Assistant

Professor . for providing us both time and amenities to make this project, a
success with
in the schedule.

We would like to express our sincere gratitude to our Head of The

Department Mr. T. CHARAN SINGH , M.Tech., (Ph.D). who took immense
interest by giving us initiative and support.
We express our sincere gratitude to Prof. S. PULLAIAH ,
Chairman, Prof. S. V. SURYANARAYANA , Director, Prof. K.
RAMA RAO , Director , Prof. PANNALA KRISHNA MURTHY ,
M.Tech., Ph.D. Principal and MANAGEMENT MEMBERS for providing
excellent academic environment in the college.

We have been greatly helped by all our faculty and Lab Technicians
during design and discussion phase of the project. We wish to thank them all
for their kindness. We extend our thanks to our parents and all people, who
have helped us a lot directly or indirectly in the completion of our project.
 DECLARATION

We declare that the mini Project Work entitled “VACUUM PRESSURE

IMPREGNATION AND MANUFACTURING OF TURBO GENERATOR”

recorded in this report does not form part of any other work on which a

degree has been awarded earlier. We further declare that this Project Report

is based on our work carried out at the SWARNA BHARATHI INSTITUTE OF

SCIENCE & TECHNOLOGY, Khammam, in the second semester of third year

B.Tech course.

PROJECT ASSOCIATES

G.RAJA SHEKAR 16M65A0204

G.NAVEEN 15M61A0219
G.PREETHAM 15M61A0225
D.ANIL 14M61A0215
D.AJAY JADEJA 15M61A0214
T.UPENDAR RAO 15M65A0222

Date:
Place: Khammam
 ABSTRACT
Electricity is the basic necessity for the trade and industry development

of a country. The production of electrical energy and its per–capital use is

deemed as an index of the standard of living in a nation in the present day

civilization. Development of heavy or large scale industries, as well as medium

scale industries, agriculture, transportation, etc., totally depend on electric

power resources of engineers and scientists to find out ways and means to

supply required power at cheapest rate. The need for immediate increase in

the country’s power production in vital. So, we have to utilize the available

resources in better possible manner

Since generator principle is based on the induction of EMF In a

conductor placed in a varying magnetic field. There should be a proper

insulation between magnetic field and the conductor. In this project studied

about the major generator of capacity in MW there is a problem arise with

insulation of stator and rotor. After completion of manufacturing

requirements of stator core, stator winding coils, rotor core and rotor winding

coils. For the purpose of providing protection against THERMAL,

MECHANICAL, VOLTAGE AND ENVIRONMENTAL stresses which are the

factor causing to reduce the service lift of the electrical machines we move on

to the stage of ( VPI ) plant there as we said earlier in the above jobs are

dumped into the varnish container after completion of VPI plant the job's are

move on to the stator and rotor assembly with stator frame with the help of

ball bearing there are attached to the end covers and conduct various test on

generator as per the requirement of application.

 INDEX

Chapter No DESCRIPTION Page No

1 INTRODUCTION 1
1.1 Technical Superiority Of The Total VPI 2
Insulation System
2 IN SULATION SYSTEM FOR STATOR AND ROTOR 5
WINDINGS
2.1 Insulation System For Stator Winding 5
2.2 Insulation System For Rotor Winding 8
2.2.1 Insulation For Field Winding 12
2.3 Rationalization Of VPI Insulation System 13
3 CONSTRUCTIONAL FEATURES OF 15
TURBOGENERATOR
3.1 Stator 16
3.1.1. Stator Frame 16
3.1.2. Stator Core 16
3.1.3. Stator Winding 17
3.1.4. End Covers 19
3.1.5. Location of Bars 19
3.1.6. Enclosure 19
3.1.7. Electrical Connections of Bars and 20
Phase Connection
3.1.8. Phase Connectors 20

3.1.9. Output leads 20

3.1.10. Insulating materials used in the 21
stator winding
3.2 ROTOR: 22
3.2.1.Rotor shaft 22
3.2.2. Rotor Winding 22
3.2.3. Rotor Slot Wedges 24
3.2.4. Cooling of Rotor Windings 24
3.2.5. Rotor Retaining Rings 24
3.2.6. Slip Rings 24
3.2.7. Rotor Fan 25
3.2.8. Rotor Balancing 25
3.2.9. Radial Bolt 25
3.3 BEARINGS 26
3.3.1. Principle Of Operation 26
3.3.2. Bearing Oil Supply 27
3.3.3. Bearing Temperatures 27
3.4 VENTILATION AND PROTECTION 27
EQUIPMENT
3.4.1. Ventilation Arrangement 27
3.4.2. Space heaters 27
3.4.3. Resistance Temperature Detectors 27
3.4.4. Fire Detectors 28
3.5. EXCITER 28
3.5.1. Design Features 28
a. Rectifier wheels 29
b. Three-phase pilot exciter 29
c. Three-phase Main Exciter 29
3.6. Skid 30
CONCLUSION 31
REFERENCE 32
 LIST OF FIGURES

Figure No Description Page No

Generators Manufactured With Total VPI Micalastic
1.1 2
Insulation System
1.2 Increasing Trend Of Total VPI Generators 2
2.1 pre – shaped coil 5
soft glass mat spacers fitted in between end faces
2.2 6
of the coils
2.3 Accelerator treated glass sleeves 7
2.4 Rotor slot Insulation 8
2.5 Rotor End Winding 9
2.6 End corona protection 10
2.7 Stator Winding Insulation System 11
Glass fiber laminate are inserted below the slot
2.8 12
wedges
2.9 Moulded insulation cover 13
3.1 Turbo Generator 15
3.1.1 Stator Winding 18
3.2 Phase connectors and rings 20
3.2.1(a) Rotor shaft 23
3.2.1(b) Laminated Rotor before winding 23
3.3 Rotor over hang Portion 25
3.4 Overhang Brushless Exciter (Stator and Rotor) 30
3.5 Conventional Brushless Exciter 30

LIST OF TABLES

Table No Description Page No

1 3.1: Insulating materials used in the stator winding 22