Beruflich Dokumente
Kultur Dokumente
First of all I am thankful to training coordinator Er. Satish Kumar Singh for
providing me with an opportunity to undergo my training at BHEL Haridwar.
Special thanks to Mr. Rajendra Kumar (project coordinator) who has guided
me at every step & my discussion with them was truly enlightening. Their
dedication & sincerity towards the project helped me a lot in the
completion of project report & gave it the present attractive look.
Last but not the least I would again like to express my sincere thanks to all
project guides for there constant friendly guidance during the entire stretch
of this report. Every new step I took was due to their persistent enthusiastic
backing and I acknowledge that with a deep sense of gratitude.
CONTENTS:
INTRODUCTION.
BHEL - An Overview.
TURBO-GENERATOR
REFERENCES
INTRODUCTION
BHEL was established more than 50 years ago when its first plant was setup in
Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India.
A dream which has been more than realized with a well recognized track record of
performance it has been earning profits continuously since 1971-72 and will
achieve a turnover of Rs 134,000 crore for the plan year 2012, showing a growth of
50% in the plan. Bharat Heavy Electricals Limited is country‟s „Navratna‟
company and has earned its place among very prestigious national and
international companies. It finds place among the top class companies of the world for
manufacture of electrical equipments.
BHEL caters to core sectors of the Indian Economy viz., Power Generation's &
Transmission, Industry, Transportation, Telecommunication, Renewable Energy,
Defense, etc. BHEL has already attained ISO 9000 certification for quality
management, and ISO 14001 certification for environment management and
OHSAS - 18001 certification for Occupational Health and Safety Management
Systems. The Company today enjoys national and international presence featuring
in the “Fortune International -500” and is ranked among the top 10 companies in
the world, manufacturing power generation equipment. BHEL is the only PSU
among the 12 Indian companies to figure in “Forbes Asia Fabulous 50” list.
Probably the most significant aspect of BHEL‟s growth has been its
diversification .The constant reorientation of the organization to meet the varied needs
in time with a philosophy that has led to total development of a total capability
from concepts to commissioning not only in the field of energy but also in industry and
transportation.
In the world power scene BHEL ranks among the top ten manufacturers of power
plant equipments not only in spectrum of products and services offered, it is right
on top. BHEL„s technological excellence and turnkey capabilities have won it
worldwide recognition. Over 40 countries in world over have placed orders with
BHEL covering individual equipment to complete power stations on turnkey basis.
BHEL - A BRIEF PROFILE
BHEL has:-
BHEL today is the largest Engineering Enterprise of its kind in India with
excellent track record of performance, making profits continuously since
1971-72.
Power
Industry
Transportation
Transmission
Defenses etc.
The greatest strength of BHEL is its highly skilled and committed 60,000
employees. Every employee is given an equal opportunity to develop
himself and grow in his career. Continuous training and retraining, career
planning, a positive work culture and participative style of management all
these have engendered development of a committed and motivated
workforce setting new benchmarks in terms of productivity, quality and
responsiveness.
POWER SECTOR -
Power generation sector comprises thermal, gas, hydro and nuclear power plant
business .BHEL supplied utility sets accounts to 87,646 MW 65% of the total
installed capacity of 1,38,175 MW in the country , as against nil in 1969 -70.
As part of India‟s largest Solar Power-based Island Electrification Project in India,
Bharat Heavy Electricals Limited (BHEL) has successfully commissioned two
Grid-Interactive Solar Power Plants of 100 KW each in Lakshadweep.
With this, the company has commissioned a total of eleven Solar Power Plants in the
Lakshadweep islands, adding over 1 MW of Solar Power to the power
generating capacity of the coral islands in the Arabian Sea.
Custom made hydro sets of Francis, pelton and kaplan types for different head
discharge combination are also engineering and manufactured by BHEL.
In, all 700 utility sets of thermal, hydro, gas and nuclear have been placed on the
company as on date. The power plant equipment manufactured by BHEL is based on
contemporary technology comparable to the best in the world and is also
internationally competitive.
INDUSTRY SECTOR -
BHEL is a major contributor of equipment and system to important industries like
-
Cement
Petrochemicals
Fertilizers
Steel papers
Refineries
Mining and telecommunication
BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for
reactive power management on long transmission lines). Presently a 400 kV
FACTS (Flexible AC Transmission System) projects is under execution.
TRANSPORTATION—
TELECOMMUNICATION-
BHEL also caters to telecommunication sector by way of small, medium and large
switching system.
HEAVY ELECTRICAL EQUIPMENT PLANT
(HARIDWAR)
MISSION
The leading Indian engineering enterprise providing quality products systems and
services in the fields of energy, transportation, infrastructure and other potential
areas.
VALUES
Meeting commitments made to external and internal customers.
Foster learning creativity and speed of response.
Respect for dignity and potential of individuals.
Loyalty and pride in the company.
Team playing
Zeal to excel.
Integrity and fairness in all matters.
ESTABLISHMENT AND DEVELOPMENT STAGES:
MAIN PRODUCTS:
Steam Turbines
Hydro Turbines
Gas Turbines
Turbo Generators
Medium Size Motors.
DIFFERENT BLOCKS AT HEEP-
PLANT FACILITES:
No. Compressors of
3 no Satellite exchange
INTRODUCTION---
MACHINE SHOP.
T/G ROTOR WINDING.
H/G IRON ASSEMBLY.
EXCITER.
T/G STATOR WINDING.
TOTAL IMPREGNATION TECHNIQUE.
T/G IRON ASSEMBLY.
T/G MAIN ASSEMBLY.
L.S.T.G ROTOR WINDING.
L.S.T.G STATOR WINDING.
L.S.T.G MAIN ASSEMBLY.
TEST BED.
TURBO GENERATOR
1. THRI
2. TARI
3. THDI
4. THDD
5. THDF
6. THFF
1st LETTER = (here-T)
= 3-phase turbo generator
COMPONENTS OF T.G. :-
STATOR -
1. Stator frame
2.Stator core
3.Stator winding
4.End covers.
ROTOR -
1. Rotor shaft
2. Rotor windings
3. Rotor retaining rings
BEARINGS
COOLING SYSTEM
EXCITATION SYSTEM
STATOR
STATOR FRAME
STATOR CORE:-
The stator bar consists of hollow (in case of 500 MW generators) solid
strands distributed over the entire bar cross-section, so that good heat
dissipation is ensured. In the straight slot portion the strands are
transposed by 540 degrees. The transposition provides for mutual
neutralization of the voltage induced in the individual strands due to
slot cross field and end winding flux leakage and ensure that minimum
circulating current exists. The current flowing through the conductors is
thus uniformly distributed over the entire cross section so that the current
dependent losses will be reduced.
The alternate arrangement of one hollow strand and two solid
strands ensures optimum heat removal capacity and minimum losses. The
electrical connection between top and bottom bars is made by connecting
sleeve.
B. Corona Protection:-
This section is present in BAY-1. Two no. core pits with core
building and pressing facilities are available in this section. The section is
also equipped with optical centering device, core heating installation and
core loss testing facilities.
Cooling:-
Heat losses arising in the generator are dissipated through hydrogen. The
heat dissipating capacity of hydrogen is eight times to that of air.
ROTOR
The moving or rotating part of generator is known as rotor. The axial length
of shaft of the rotor is very large as compared to its diameter in case of
turbo generators. It is coiled heavily (field coils) as it has to support large
amount of current and voltage. Rotor revolves in most generators at a speed
of 3000rpm. Field coils are wound over it to make the magnetic poles and to
maintain magnetic strength the winding must carry a very high current. As
current flows heat is generated, but the temperature has to be maintained
because as temperature raises problems with insulation becomes more
pronounced. With good design and great care this problem can be solved.
ROTOR SHAFT:-
The rotor shaft is cold rolled forging 26N1 or MOV116 grade and it is
imported from Japan and Italy.
Rotor shaft is a single piece. The longitudinal slots are distributed over its
circumference. After completion, the rotor is balanced in the various planes
and different speed and then subjected to an over speed test at 120% of
rotor speed. The rotor consists of electrically active portion
and two shaft ends approximately 60 % of rotor body circumference
have longitudinal slots which hold the field winding. Slots pitch is
selected so that the two solid poles are displaced by 180 degree the
rotor wedges act as damper winding within the range of winding slots. The
rotor teeth at the rotor body are provided in radial and axial poles enabling
cooling air to be discharged.
Various Steps Involved In Rotor Machining:-
SHAFT MACHINING:-
SLOTTING:-
Two types of machines do slotting, air cooled and liquid cooled. Slotting is
done diametrically. First the shaft is made to rest on two horizontal plates
and is firmly attached to them with the help of chains which
exerts load and with the help of jack so that it handles the vibrations
produced during the slotting process.
Now the centre is marked and slotting is done. After slotting is
done through one side the shaft is rotated to the diametrically opposite end
of the slotted portion and then again slotting of that portion is
done. It is done in diametrically opposite ends so as to prevent bristling of
slot due to mechanical vibrations.
ROTOR WINDING :-
Rotor winding involves coiling of rotor. It is a two pole rotor.
Rotor coils are made of pure copper + 0.2% silver, which has high
tensile as well as temperature bearing properties. The coil doesn’t
deform even at high temperatures as on adding silver the thermal stresses are
eliminated. Rotor winding is also known as field winding which is
wound in longitudinal slots in rotor.
To protect the rotor windings against the effects of centrifugal force and the
secured in slots with wedges.
Slot wedges are made of copper-nickel-silicon alloy featuring high
temperature resistance and high strength.
There is retaining ring, which protects the rotor from the impact of
centrifugal force on end windings.
Comprehensive tests such as ultrasonic examination and liquid penetration
examination are carried out in the coils.
To ensure low contact resistance, retaining rings are coated with nickel,
aluminum and silver by three step flame-spraying process.
ROTOR WINDING:-
The winding consist of several coils inserted into the slots and
the series connected such that two coils group to form one pole. Each
coil consist of several series connected turns each of which consist of
two half turns connected by brazing in end section. The individual turn of
coil are insulated against each other by interlayer insulation. L-
shaped strip of laminated epoxy glass fiber with nomex filter are used
for slot insulation.
The field winding consists of several series connected coils into the
longitudinal slots of body. The coils are wound so that two poles are
obtained. The solid conductors have a rectangular cross-section.
These coils are formed arranging together the 14 no. of strips which makes a
half of the coil which means that total 28 strips are used to make single coil of
the field winding.
Depending upon the type of cooling there are 8 solid and 6 hollow strips in each
half of the coil.
Nitrogen test is also performed for cleaning and leakage purposes and
finally impregnating it through vacuum impregnation technique.
The vacuum impregnation technique is the latest technique to
insulate the windings of stator and not used in rotors of any of the
generators being used in the power plants nowadays.
The process above is discussed is also known as transposition, which
involves the bending of the strips used in forming the coil of either rotor
or stator.
Conductor material:-
Insulation:-
The insulation between the individual turns is made up of layer of glass fiber
laminate the coils are insulated from the rotor body with L-shaped strip of glass
fiber laminate with nomex interlines to obtain the required leakage path between
the coil and rotor body, thick top strips of glass fiber laminate are inserted below
wedge. The top strip are provided with axial slots of same cross-section and
spacing and used on the rotor winding.
The cooling air in generator is cold by two axial flow fans located at
the rotor shaft one at each end augment the cooling of the winding.
The blades of fan have threaded roots for screwed into the rotor shaft.
Blades are drop forged from aluminum alloy. Threaded root fastenings
permit angle to be changed. Each blade is screwed at its root with a
threaded pin.
BEARINGS -
Leads are run in axial direction from the radial bolt of the exciter
coupling. They consist of low semi-circular conductors insulated from each
other and from the shaft by a tube.
The field current leads are coupled with exciter leads through a
multi contact plug in which allows unobstructed thermal expansion of field
current.
ROTOR ASSEMBLY:-
Rotor winding assembly and rotor assembly and rotor assembly like
rotor retaining ring fitting. All these four assemblies are carried out in a
ROTOR ASSEMBLY SECTION present in BAY-1. This section is also in a
dust-proof enclosure with no. of rotators, rotor bars laying facilities and MI
heating and mounting of retaining rings.
MACHINE SECTION:-
VENTILATION SYSTEM-
COOLING SYSTEM -
BLK-I
EXCITATION SYSTEM:-
EXCITER:-
EXCITER ROTOR
1. rectifier wheels
2. three phase main exciter
3. three phase pilot exciter
4. Metering and supervisory equipment.
(a) Completely eliminates brush gear, slip rings, field breaker and excited bus or cable.
(b) Eliminates the hazard of changing brushes and leads.
(c) Carbon dust is no longer produced and hence the operation is fully dust free.
(d) Brush losses are eliminated.
(e) Operating costs are reduced.
(f) The system is best suited for atmospheres contaminated with oil, salt, chemical etc.
and where sparking may be a fire hazard
(g) The system is simple and requires practically no maintenance except for an occasional
inspection. Maintenance costs are thus reduced.
(h) Ideally suited for locations where maintenance is likely to be rare due to continuous
demand on the m/c.
(i)Brush-less system with shaft mounted pilot exciter is of self generating type and the
excitation is unaffected by system faults and disturbances.
(j) Reliability is better.
(k) Ideally suited for large sets.
(l) Increasingly popular system the world over.
The three phase pilot exciter is a 16 poles revolving-field unit. The frame
accommodates the laminated core with the three phase winding. The rotor consists of
hub with mounted Poles. Each pole consists of 12 separate permanent magnets which
are housed in a non-magnetic metallic enclosure. The magnets are braced between
the hub and the external pole shoe with bolts. The rotor hub is shrunk on to the free
shaft end.
Also known as thyristor voltage regulator. It converts the three phase ac generated by
the permanent magnet exciter in to the variable dc to excite the stator of the main
exciter.
The field ground fault detection system detects the high-resistance and low -resistance
ground fault in the exciter field circuit. It is very important for safe operation of a
generator, because a double fault causes magnetic unbalances with very high currents
flowing through the faulted part, resulting in its destruction with in a very short time.
The field ground fault detection system consists of two stages.
If the field ground fault detection system detect a ground fault, an alarm is activated
at R< 80 kΏ. If the insulation resistance between the exciter field circuit and ground
either drops to R< 5 kΏ the generator electrical protection is tripped. The generator is
automatically disconnected from the system and de-excited.
The three phase main exciter is a six-pole revolving armature unit. Arranged in the
stator frame, the poles with field and damper winding. The field winding is arranged on
the laminated magnetic poles. At the pole shoe, bars are provided. Their ends being
connected so as to form a damper winding between two poles. A quadrature-axis coil
is fitted for inductive measurement of the exciter current. 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 rotor
winding are secured with steal bands. The connections are made on the side facing the
rectifier wheels. The winding ends are run to a bus ring system to which the three
phase leads to the rectifier wheels are connected. After full impregnation with
synthetic resin and curing, the complete rotor is shrunk onto the shaft. A journal
bearing is arranged between main exciter and pilot exciter and has forced oil
lubrication from the turbine oil supply.
RECTIFIER WHEELS
The main component of the rectifier wheels are the silicon diodes which are arranged
in the rectifier wheels in a three-phase bridge circuit. The contact pressure for the
silicon wafer is produced by a plate spring assembly. The arrangement of the diodes is
such that this contact pressure is increased by centrifugal force during rotation. Two
diodes are mounted in each aluminum alloy heat sink and connected in parallel.
Associated with each heat sink is a fuse which serves to switch off the two diodes if one
diode fails.
For suppression of the momentary voltage peaks arising from commutation, each
wheel is provided six RC networks consisting of one capacitor and one damping
resistor each, which are combined in a single resin encapsulated unit.
The insulated and shrunken rectifier wheels serves as dc buses for the negative and
positive side of the rectifier bridge. This arrangement ensures good accessibility to all
components and a minimum of circuit connection. The two wheels are identical in their
mechanical design and differ only in the forward directions of the diodes.
The direct current from the rectifier wheels is fed to the leads arranged in the
center bore f the shaft via radial bolts. The three phase alternating currents is obtained
via copper conductors arranged on the shaft circumference between the rectifier
wheels and the three-phase main exciter. The conductors are attached by means of
banding clips and equipped with screw on lugs for the internal diode connections. One
three-phase conductor, each is provided for the four diodes of a heat sink set.
COOLING SYSTEM
The exciter is air cooled. The cooling air is circulated in a closed circuit and recooled in two
cooling sections arranged along side the exciter. The complete exciter is housed in an
enclosure draw the cool air in at both ends and expels the warmed air to the compartment
beneath the base plate. The main exciter enclosure receives the cool air from the fan
after it passes over the pilot exciter. The air enters the main exciter from both ends and
is passes in to the ducts below the rotor body and discharged through radial slots in the
radial core to the lower compartment. The warm air is then returned to the main
enclosure via the cooler section
SUPERVISION OF EXCITER
The most essential measuring and supervisory devices at the exciter are:
1. Temperature monitoring system: The exciter is provided with devices for monitoring
the temperatures of the cold air after the exciter cooler and the hot air leaving the rectifier
wheels and main exciter.
2. Fuse monitoring system: The indicator flags of the fuse on the rectifier wheels may be
checked during operation.
3. Ground fault detection system: Two slip-rings are installed on the shaft between the
main exciter and the bearing. One is connected to star point of the three-phase winding of
the main exciter and the other to the frame. These slip-rings permit ground fault
detection.
MACHINE SECTION:-
1. ANNEALING PROCESS:-
2.WINDING PROCESS:-
The joint in the copper coil shall be located in the straight part
of longer side.
If required heating by gas torch of copper profile at corner
zone at temperature between 100-150 degree centigrade is
allowed. This is to make easier bending.
3.BRAZING:-
4. PRESSING:-
6. SEPARATION:-
** Again press the coil as in pt.5 & take out the coil from the press.
7. PICKLING:-
Send the coil for pickling to block 4 & check the quality of
pickling.
Press the coil again after pickling then remove pressure and take
out.
Prepare end half turn as per drawing with template.
Braze item 2 & 3 corresponding to the variant with end half turn
with brazing alloy
Ag 40 Cd.
8. FINISHING:-
9. INSULATION:-
This section is equipped with electric drying ovens, Air drying booths, Bath for
armature / rotor impregnation. Rotors / armatures of AC and DC motors are
impregnated in this section.
BABBITING SECTION:-
This section is equipped with alkaline degreasing baths, hot and cold rinsing
baths, pickling baths, tinning bath, and electric furnaces and centrifugal
Shot Blasting
babbitting machines, Babbitting of bearing liners for Turbo generators,
Turbines, Hydro generators, AC motors and DC motors is carried out in this
section.
TEST STAND:
Turbo-generators Test Bed -The Test Bed for Turbo-generators and Heavy motors
is equipped with one no. 6 MW drive motor and a tests pit for
carrying out testing of Turbo-generators and Heavy motors. Open circuit, short
circuit, temperature rise, hydraulic and hydrogen leakage test etc., are carried
out here for Turbo-generators. AC motors up to 11 MVA capacity and DC
machines up to 5000 amps and 850 volt can also be tested. Two DC
drive motors of 2200 KW and one of 1500 KW are available for type testing of
motors. Data logging equipment is also available.
It is equipped with a 12 MW drive motor and two number test pits. Open
circuit ,short circuit , sudden short circuit , temperature rise , hydraulic &
hydrogen leakage tests are carried out here Large size Turbo-generators.
This test bed can presently test Tgs of unit capacity up to 500 MW. With
certain addition in facilities (Higher capacity Drive motor and EOT cranes and
modification in controls and auxiliary systems), Turbo-generators of unit size up
to1000 MW can be tested.
PURPOSE -
To check any leakage of gas from stator and rotor as if there is any
leakage of gas used for cooling such as hydrogen then it may cause an
explosion.
Testing of stator frame involves two types of testing:
Insulation Classification:
Thermal classification of insulation depends upon the temperature withstand
capacity of the insulation.
Class- Y upto 90‟c
Class- A upto 105‟c
Class- E upto 120‟c
Class- B upto 130‟c
Class- F upto150‟c
Class- H upto 180‟c
Class- C > 180‟c and upto 220‟c
Type of generators:
The generator may be classified based upon the cooling system used in the
generator such as:
THRI
TARI
THDI
THDD
THDF
THFF
Each conductor must be capable of carrying rated current without over heating.
The stator winding consists of two layers made up of individual bars. Windings for the
stators are made of copper strips wound with insulated tape which is
impregnated with varnish, dried under vacuum and hot pressed to form a solid
insulation bar. These bars are then placed in the stator slots and held in with
wedges to form the end turns.
These end turns are rigidly placed and packed with blocks of insulation material to
withstand heavy pressure.
The stator bar consists of hollow (in case of 500 MW generators) solid strands
distributed over the entire bar cross-section, so that good heat dissipation is
ensured. In the straight slot portion the strands are transposed by 540 degrees. The
transposition provides for mutual neutralization of the voltage induced in the
individual strands due to slot cross field and end winding flux leakage and ensure that
minimum circulating current exists. The current flowing through the
conductors is thus uniformly distributed over the entire cross section so that the current
dependent losses will be reduced.
The alternate arrangement of one hollow strand and two solid strands ensures
optimum heat removal capacity and minimum losses. The electrical connection
between top and bottom bars is made by connecting sleeve.
Class “F” insulation is used.
The no. of layer of insulation depends on machine voltage. The bars are brought
under vacuum and impregnated with epoxy resin, which has very good penetration
property due to low viscosity. After impregnation bars are subjected to pressure
with nitrogen being used as pressurizing medium (VPI process). The impregnated
bars are formed to the required shape on moulds and cured in an oven at high
temperature to minimize the corona discharge between the insulation and slot wall
a final coat of semiconducting varnish is applied to the surface of all bars within
the slot range. In addition all bars are provided with an end corona protection to
control the electric field at the transition from the slot to end winding. The bars
consist of a large no. of separately insulated strands which are transposed to reduce
the skin effect.
PROJECT:
MANUFACTURING PROCESS OF 600 MW
TURBO-GENERATOR STATOR WINDING BAR-:-
Transposition of conductor.
CONDUCTOR BARS
MFG PROCESS:
CUTTING:
This process is done by automatic 3-444CNC machine. In this process the pre
insulated copper conductor is cut into number of required length. Insulation is
removed from both ends of the conductor cut.
Cutting size of conductor :
solid: 28
600 MW upper: 10887 mm solid: 9.5*1.2
hollow: 14
lower: 11053 mm hollow: 9.5*4.4*1.3
4. Stack Consolidation :
The core part of the bar stack is pressed in press (closed box) under pressure
(varies from product to product) and temperature of 160 C for a given period. The
consolidated stack is withdrawn from the press and the dimensions are checked.
6. Forming :The straight bar stack is formed as per overhang profile (as per
design), The overhang portion is consolidated after forming.
7. Brazing of coil lugs :
For water cooled generator bars, the electrical connection contact and water box for
inlet and outlet of water are brazed.
After thermal shock test bar is tested for any leakage with the help of helium gas.
11. Insulation:
The bar is insulated with the given number of layers to build the wall thickness of
insulation subjected to the generating voltage of the machine.
b) Micalastic system: In case of poor resin system the insulated bars are heated under
vaccum and the impregnated (dipped) in heated resin so that all the air gaps are filled,
layer by layer, with resin. Then extra resin is drained out and bars are heated and
baked under pressed condition in closed box fixture.
VPI Micalastic system: The bars already laid in closed fixture and full fixture is
impregnated (dipped) in resin and then fixture with box is baked under given
temperature for given duration.
VIP Micalstic system: The individual (separate) bar is heated in vaccum and
impregnated in resin. Then bar is taken out and pressed in closed box fixture and then
baked at given temperature for given duration.
13. Finishing:
The baked and dimensionally correct bars are sanded-off to smoothen the edges and
the surface is calibrated, if required, for the dimension.
ii) ECP (End Corona Protection) coating: The grey semi-conducting varnish is
applied at the bend outside core end of bars in gradient to prevent from discharge
and minimize the end corona.
15. Testing:
a) Tan@ test: This test is carried out to ensure the healthiness of dielectric
(Insulation) i.e. dense or rare and measured the capacitance loss.
b) H.V. Test: Each bar is tested momentary at high voltage increased gradually to three
times higher than rated voltage.
16. Dispatched for Winding :
The bars preserved with polythene sleeves to protect from dust, dirt, oil, rain etc are
send to Block-I (Electric Machines Production Block - I, Turbo Generators and Hydro
Generators) for winding.
REFERENCES
B.H.E.L. MANUALS
B.H.E.L. Websites
Electrical machines – P.S. BIMBHRA.