LARGE AC MACHINES

BHEL

21/04/2008

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

TYPE OF CONSTRUCTIONS
1) LINE F MOTORS These are pedestal mounted motors (stator OD >1180 mm) with Sleeve bearings. The enclosures may be CACA, CACW & SPDP type TETV Totally Enclosed Tube Ventilated CACA Closed Air Circuit Air cooled CACW Closed Air Circuit Water cooled SPDP Screen Protected Drip Proof

H-MODULE MOTORS
These are end shield mounted motors (stator OD 1000 to 1400 mm) with Antifriction / Sleeve bearings. The enclosures may be CACA, CACW & SPDP type.

H-MOFLEX MOTORS These are pedestal mounted motors (stator OD >1330 mm) with Sleeve bearings. The enclosures may be CACA, CACW & SPDP type.

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

LINE- F (PEDESTAL MOUNTED MOTOR)

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

LINE F
SERIES MOTOR

EXPLODED
VIEW

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

VENTILATION ARRANGEMENT (INTERNAL CIRCUIT) OF LINE-F MOTOR

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

VENTILATION ARRANGEMENT OF LINE-F MOTOR

1. 2. 3. 4. 5. 6.

Cooler Seal between Stator & Outer Enclosure Winding Cover Outer Enclosure Fan Seal of the shaft gland

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

LINE- F MOTOR STATOR

1.
2. 3. 4. 5.

Air Guide
Stator Yoke Eyes for Transport Seating Plate Winding

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

LINE- F MOTOR STATOR CORE

1.
2.

End Wall of Frame with End Finger

Opening for Ventilating the Overhang Supporting Web Ventilating Duct Core Packet Rib

3. 4. 5. 6.

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

BRUSHLESS EXCITER
MAIN SUB ASSEMBLIES
A.C. EXCITER - The AC exciter is a 3-ph alternator which has the armature housed in the rotor and the salient poles with the field windings are mounted on stator. ROTATING RECTIFIER SYSTEM - The rectifier (diode ckt.) mounted on rotor SOLID STATE PROTECTION SYSTEM To protect diodes from abnormal conditions like voltage surges etc. EXCITER ROTOR stacked laminations shrunk on to the main shaft.

Mush Winding housed in rotor core

Rectifier Diode Module Protection Module

EXCITER STATOR Stator body is a shell constructed by rolled mild steel Exciter poles are directly bolted on yoke and of laminated construction The field wdg. (fed through AVR) is made up of round enameled copper and all field coils are connected in series

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

BRUSHLESS EXCITER ARRGT.

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

BRUSHLESS EXCITER CONNECTION DIAGRAM

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

H MODULE CACA MOTOR

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

EXPLODED VIEW

OF
H-MODULE

SCIM

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

H- MOFLEX SERIES MOTOR

BHEL

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

ENCLOSURE & BASEFRAME

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

ROTORS

1. SHAFT 2. FAN 3. SC RING 4. CORE 5. WINDING BARS 7. DBL LAYER WDG

10. EXCITER 11. DAMPER WDG 12. FIELD WDG

SCIM SYN

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

CYLINDRICAL ROTOR

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

SALIENT POLE ROTOR

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

BEARINGS
ROLLING ELEMENT BEARINGS
BALL AND ROLLER BEARING ON DRIVE END ROLLER BEARING ON NON DRIVE END

SLEEVE BEARINGS
ENDSHIELD MOUNTED SLEEVE BEARINGS PEDESTAL MOUNTED SLEEVE BEARINGS

RING LUBRICATED
FORCED OIL LUBRICATED HIGH PRESSURE JACKING

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

PEDESTAL MOUNTED SLEEVE BEARING ASSEMBLY

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

DIN BEARINGS

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

TERMINAL BOXES
&

ACCESSORIES

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

TERMINAL BOX
TYPES
1) PHASE SEGREGATED TYPE (PSTB) SUITABLE FOR FAULT LEVEL OF 500 MVA FOR 0.25 SEC AND NOMINAL CURRENT UP TO 450 AMPS A) DIRECT TERMINATION TYPE

B) WITH TAIL CABLE ARRANGEMENT

2) 3) PHASE SEPARATED TYPE SUITABLE FOR FAULT LEVEL OF 750 MVA AT 11 KV FOR 0.25 SEC AND NOMINAL CURRENT UP TO 1200 AMPS ELASTIMOLD CONNECTOR - SUITABLE FOR FAULT LEVELOF 750 MVA AT 11 KV FOR 0.25 SEC AND NOMINAL CURRENT UP TO 1500 AMPS ROD TYPE FOR NOMINAL CURRENT > 1500 A FLAME PROOF TB FOR Exd & Exp MOTORS. SUITABLE FOR FAULT LEVEL OF 500 MVA FOR 0.25 SEC.

4) 5)

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

PHASE SEGREGATED BOX WITH DIRECT TERMINATION

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

PHASE SEGREGATED BOX WITH TAIL CABLE

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

PHASE SEPARATED TRMINAL BOX

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

ELASTIMOLD TRMINAL BOX

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

NEUTRAL TERMINAL BOX WITH CTs

04 02

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

CABLE DETAILS REQUIRED FOR SELECTION OF CABLE GLANDS & ELASTIMOLD MODEL
Parameter
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Cable size Number of runs per phase Conductor material Type of Insulation Number of core Cable overall diameter Cable type Type of armouring Dia./ thickness of armour Cable dia. over armour Cable dia. under armour Individual core dia. over insulation Individual core dia. bare Type of shielding Dia. of individual core over shielding mm Copper or Aluminium PVC, PILC or XLPE etc. 3 core or 1 core Mm Armoured / Unarmoured Round wire or strip wire mm mm mm mm mm

Detail required
mm2

To be filled up by customer

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

CT DETAILS REQUIRED FOR ORDERING CTs

Parameter Detail required To be filled up by customer

1 CT Ratio 2 Rated voltage 3 Rated frequency 4 Minimum knee point voltage Vk 5 Class of insulation 6 Accuracy class 7 Maxm. resistance of secondary winding 8 Maximum excitation current at Vk/2 9 Short time thermal current rating Volts Hz Volts E or better PS Ohms

Mili Amperes KA. for 1.0 second

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

INSTRUMENT TERMINAL BOXES

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

ACCESSORIES
RESISTANCE TEMPERATURE DETECTORS (RTDs) A) B) FOR STATOR WINDING FOR BEARINGS - 4 Nos. per phase, PT100, Simplex, 3 Wire - 2 Nos., PT100, Duplex, 3 Wire

CALIBRATION CURVE FOR RTD/BTD - PT100 Rating : 2510 KW, 6.6 kV, 4 P , SPDP, Cage Rotor Asyn. Motor. Frame : 1TC4640 W.O.No. : 47056A423-11 Customer : M/s. NTPC KORBA NTPC DOC NO.: 2140-133PVE-N-006
160

150

RESISTANCE( OHMS)

140

130

120

110

100 0 20 40 60 80 TEMPERATURE(DEG. C) 100 120 140 160

Curve No. AM 47056-11-06

AME DIVISION

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

ACCESSORIES
DIAL TYPE THERMOMETERS (DTTs)
FOR BEARINGS FOR HOT / COLD AIR Technical Specification Dial Size Case & Bezel Window Pointer Model Sensor/Stem Material Capillary Connection Range Accuracy

Contd.

- 2 Contacts, Contact rating 5A at 220 V AC / 0.5A at 220 V DC - 2 Contacts, Contact rating 5A at 220 V AC / 0.5A at 220 V DC

: 4", 6 : SS 304 / Doe -cast Aluminium weather proof : Sheet Glass or Safety Glass : Micro zero or Center Zero adjustable : Capillary Type : SS 316 (Dai 6mm, 8mm, 10mm) : SS 304, Copper, PVC coated etc. (Having Dia. 4.5 mm and 6mm) : 1/4", 3/8", 1/2", 3/4" and 1" BSP, NPT adjustable/Fixed : 0 to 150 C : + 1% of F.S.D.

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

ACCESSORIES

Contd.

ANTI-CONDENSATION HEATERS (SPACE HEATERS)

PLUG IN TYPE - 2 Nos, 600 W Each, 240V, 1Ph AC

COIL TYPE

- 3-4 Nos., 950 W Each, 240V, 1Ph AC

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

ACCESSORIES
SPEED SWITCH
For motors driving high inertia loads. Features 1. Speed dependent contact actuation by eddy current torque results in instant response even to small speed changes. 2. Rotor and actuating stator mounted on sealed prelubricated bearings for smooth operation over long service periods.

Contd.

3. Spring steel contacts with Silver-Cadmium alloy tips for wear

free circuit interruption. 4. Actuation speeds from 30-3000 RPM in 6 ranges. 5. High repeat accuracy. 6. Setting easily adjustable at site. 7. Heavy duty flexible coupling.

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

ACCESSORIES
WATER FLOW INDICATOR
For motors with Water Cooler (CACW) Principle of Operation

Contd.

With rise of flow, the flapper of the Flow Relay is

pushed up angularly. Markings on the glass coinciding with the flapper gives indication of liquid Flow. The return of flapper, in case of reduction of flow is by gravity in case of horizontal installation or by return springs provided in case of vertical installation. With the help of eccentric pivots, a spindle, which is taken out through a rubber seal, is made to move proportionally to angle of tilt. The spindle end operates one or two Microswitches provided inside the switch box mounted on the flow relay. Microswitch : 5 A at 230V AC/ 0.25 A at 220V DC.

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

ACCESSORIES
WATER LEAKAGE DETECTOR

Contd.

For motors with Water Cooler (CACW)

Principle A low AC voltage is applied between the probe electrode and the tank wall (or reference electrode in case of insulated tank). When the liquid comes in contact with the electrode tip, a conductive path is established between the sense electrode and the tank wall/reference electrode. This current is sensed, amplified and made to operate a relay whose contacts in turn can be used for annunciation/control.

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

INSULATION
RESIN POOR (VPI) MICALASTIC INSULATION SYSTEMS Normally used for Large Range Motors (Stator OD > 1000 mm) or as per customer requirements.

RESIN RICH MICALASTIC INSULATION SYSTEMS Used for Medium Range Motors (Stator OD<1000 mm).

HYBRID INSULATION It is the feature of H-Series machines, but can be used in Line-7 & Line-F series machines also.

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

TESTING(IS4029)
ROUTINE TESTS - CONDUCTED ON ALL MACHINES
1) MEASUREMENT OF RESISTANCE OF WINDINGS OF STATOR AND WOUND ROTOR. 2) INSULATION RESISTANCE TEST 3) RES. AND I.R. OF RTDs,BTDs AND SPACE HEATERS. 4) NO LOAD TEST 5) LOCKED ROTOR READINGS OF VOLTAGE, CURRENT AND POWER INPUT AT A SUITABLE REDUCED VOLTAGE. 6) REDUCED VOLATGE RUNNING UP TEST. 7) OPEN CKT. VOLTAGE TEST. 8) 9) 10) P.I. AND HIGH VOLTAGE. VIBRATION MESUREMENT(IS12075) SHAFT VOLTAGE MEASUREMENT ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

TESTING(IS4029)
TYPE TESTS CONDUCTED TO PROVE THE DESIGN
1) FULL LOAD TEST TO DETERMINE EFFICIENCY, POWER FACTOR AND SLIP. 2) TEMPERATURE RISE TEST 3) MOMENTARY OVERLOAD TEST. 4) NOISE LEVEL OF MOTOR(IS 12065) 5) OVER SPEED TEST etc.

SPECIAL TESTS (FOR SPECIFIC REQUIREMENT)

1) 2) 3) 4) 5) 6) TAN DELTA ON ASSEMBLED MOTOR NOISE SPECTRUM LOCKED ROTOR TEST AS PER JEC-37 IP55 II NUMERAL PRESSURISATION TEST RETARDATION TEST etc. ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

VFD INDUCTION MOTORS

ALSO CALLED VVVF THAT IS VARIABLE VOLATGE VARIABLE FREQUENCY DRIVES TYPES 1) CONSTANT POWER (V CONSTATNT, F VARIED) 2) CONSTANT TORQUE (V/F IS KEPT CONSTANT)

ADVANTAGES Eliminate Inefficient Mechanical System

1) Lower Stress On System 2) Lower Stress On Motor

3) Four Quadrant Operation

4) Step-less Control For Wide Speed Range 5) Efficient Operation( Low Energy Losses)

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

DESIGN FEATURES OF AC MACHINES

LOW NOISE
MAGNETIC NOISE MINIMISED BY APPROPRIATE SELECTION OF SLOT COMBINATION SKEWING OF STATOR/ROTOR SLOTS USE OF MAGNETIC PUTTY ON STATOR SLOT OPENING AERODYNAMIC NOISE MINIMISED BY STREAMLINED AIRFLOW PASSAGES LOW NOISE PROFILED FANS STRUCTURE BORNE NOISE NOISE ABSORBING MATERIALS ON THE JOINT FACES USE OF SILENCERS

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

DESIGN FEATURES OF AC MACHINES

LOW VIBRATION
DYNAMIC BALANCING OF ROTORS TO GRADE G-2.5 OF ISO-1940 TO ACHIEVE LOW BEARING VIBRATIONS
HIGH SPEED FLEXIBLE ROTORS BALANCED AT RATED SPEED TO EVEN FINER GRADES TO ACHIEVE LOW SHAFT VIBRATIONS VIBRATION LEVELS COMPLY TO CATAGORY GOOD OF ISO-10816

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

DESIGN FEATURES OF AC MACHINES

BEARING INSULATION
NDE BEARING INSULATED IF SHAFT VOLTAGE > 350 mV FOR MEDIUM RANGE MOTORS
NDE BEARING INSULATED FOR ALL LARGE RANGE MOTORS

ELECTRICAL MACHINES GROUP, BHEL, BHOPAL

DESIGN FEATURES OF AC MACHINES

DESIGN CONSIDERATIONS
LOAD DETAILS VARIATION IN SUPPLY VOLTAGE LOCKED ROTOR WITHSTAND TIME THERMAL WITHSTAND CHARACTERISTICS FREQUENCY OF STARTING VOLTAGE DIP DURING STARTING

LOAD DETAILS
LOAD TORQUE vs SPEED CURVE LOAD INERTIA VALUE TYPE OF COUPLING & ITS DETAILS

VARIATION IN SUPPLY VOLTAGE

MOST COMMON VALUES ARE IN THE RANGE 5% TO 10%

STARTING & PULLOUT TORQUE VARIES AS (VOLTAGE)2

STARTING CURRENT DEPENDS ON VOLTAGE DURING RUNNING VARIATION EFFECTS MOTOR STABLE OPERATION, CURRENT, TEMPERATURE RISE, EFFICIENCY ETC.

THERMAL WITHSTAND CURVES

SAFE LOADING LIMITS & ITS DURATION SETTING OF LOCKED ROTOR RELAY EFFECT ON MOTOR WINDING INSUATION SPEED SWITCH FOR HIGH INERTIA DRIVES
1000

10000

T IME(SEC.) LOCKED ROTOR CURRENT = 500% FLC FULL LOAD CURRENT = 742.0 AMPS

LOCKED ROTOR WITHSTAND TIMES : HOT = 20.0 SEC COLD = 38.0 SEC

100

10

3 4 CURRENT (P.U.)

FREQUENCY OF STARTING
NORMAL VALUE IS 1 HOT, 2 COLD, 3 EQUALLY SPACED STARTS PER HOUR
DEPENDS ON TEMPERATURE RISE OF STATOR / ROTOR WINDING PER START STRESSES DURING STARTING & INSULATION LIFE NOT MUCH CONCERN FOR SLIP RING & VFD CAGE MOTORS

VOLTAGE DIP DURING STARTING

VOLTAGE DIP DUE TO HIGH STARTING CURRENTS AT DOL

EFFECT ON OTHER MOTORS / EQUIPMENTS NEARBY

VOLTAGE DIP SHOULD NOT EXCEED MUCH TO KEEP THE INPUT VOLTAGE AT MOTOR TERMINALS MINIMUM STARTING VOLTAGE PULL OUT TORQUE SHOULD BE 205% FLT FOR MOTOR SMOOTH RUNNING EVEN AT 70% VOLTAGE FOR SOME TIME

THANKS