Sie sind auf Seite 1von 51

INDUSTRIAL TRAINING

REPORT
ON BHEL

SUBMITTED BY:
DERIL SIMON
ELECTRICAL ENGG.
FINAL YEAR-2006
ROLL NO:-02EE48
PREFACE

It is matter of great happiness for me that within a short span of 45 days, I am


presenting my vocational training report with the expertise in "production unit BL-
1, Machine shop BL-1, Electrical maintenance”. Needless to say that the report
covers most of the thing, which strictly speaking is, based on the experience what I
get in BHEL. Hardwar, effort has been made to such a way as to give proper
sequence & a very simple & a very simple & integrated structure for everybody to
understand with ease. In order to make the treatment of certain application
explicityl understand ably, through pictures, required samples, & needed circuitry
are presenting to the report where are required to better construct.

In the first section of report you have to find the historical & gorgeous
look of BHEL, Haridwar. The second section deals with overall information of
production (Generators & Motors), Machine shop BL-1.

Apart this I have done my all celebrities & effort to give the concise & untreatable
from to the report.

I shall fell grateful if readers by pointing out mistakes give suggestions &
information in the report in the report extended his hand of participation.

SANJULI
HARIDWAR
(02EE43, 6th sem)
30, July, 2005

,
ACKNOWLEDGEMENT

I have a great pleasure in acknowledgement the hellos


received from all those who favored me with it in giving shape to
the present position of the report. I owe a deep intellectual dept to
various authors, engineers & technicians who through their rich &
varied contribution have greatly improve my training purpose.

I am under a great depth of gratitude to our coordinator.


Mr. D kayal, Additional General Manager for his valuable
support& guidance at various steps of training. I am also sincerely
thankful to the suggestions & hello rendered by Mr. D Pant.
CONTENTS INSIDE

• BHEL - OVERVIEW

• HEEP – OVERVIEW

• MANUFACTURING FACILITIES

• BLOCK-1 PRODUCTION UNIT

I. BAY-1
II. BAY-2
III. BAY-3
IV. BAY-4

• REFRENCES
BHEL – AN OVERVIEW

The first plant what is today was an BHEL, was established nearly 39 year ago at
Bhopal and was the genesis of the heavy electrical equipment industry in India
BHEL is today, the largest engineering enterprise of its kind in India, with a well-
recognized track record of performance, making profits continuously since 1971-72
it achieved a sales turnover of Rs. 6347cr. With a per- tax profit of Rs. 294cr. In
2000-2001.

B.H.E.L caters to core sectors of the Indian Economy viz. power, Industry,
Transportation, transmission, Defense, etc.

The wide network of BHEL’s manufacturing division nine service centers and four
Power Sector Regional Centers and about 150 project sites enables the company to
be closer to its customers and provide them with suitable product, system and
services and competitive prices. Having attained ISO 9000 certification, BHEL is
now embarking upon the total quality management.

The company’s inherent potential coupled with its strong performance over the
year, has resulted in it being chosen as one of the “Nirvana” poses, which are to be
supported by the Government in their endeavor to become future global players.

BUSINESS SECTORS:-

To provide a strong market orientation, BHEL’s operation is organized


around three business sectors, viz, Industry and International.

POWER SECTOR:-
Power sector comprises thermal, nuclear, gas and hydro power plant
business. Today, BHEL supplied sets account for nearly 64737 or 65% of the total
installed capacity of 86,636 M Win in the country as again nil till 1979-70.

BHEL has proven turnkey capabilities for executing power project form concept to
commissioning; it possesses the technology and capability to produce thermal
power plant equipment up to1000 MW rating and gas turbine generator sets up to a
unit rating of 240MW. Cogeneration and combined cycle plant have been
introduced to achieve higher plant efficiencies. To make efficient use to the high
ash content coal available in India, BHEL supplies circulating fluidized bed boilers
to both thermal and combined cycle power plants.

BHEL manufactures 235 MW nuclear turbine generator sets and commenced


production of 500 MW nuclear turbines generators sets.

Custom made hydro sets of Francis; Pelton and Kaplan types for different head-
discharge combinations are also engineered and manufactured by BHEL. In all,
more than 700 utility sets of thermal, hydro, gas and nuclear have been given on
contract to BHEL 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 internationality competitive.

INDUSTRY SECTOR:-

BHEL is major contributor of equipment and industries like cement,


fertilizers, refineries, petrochemical, steel, paper and telecommunication. The range
of system & equipment supplied include captive power plant, high speed industrial
drive turbine industrial boilers and auxiliaries, waste heart recovery boilers, gas
turbines, heart exchanges & pressure vessels, centrifugal compressors, electrical
machines, pumps, valves, seamless steel tubes, process control, etc.

BHEL is a major producer of large size thyristor devices; it also supplies


digital distributed control system for process industries and control &
instrumentation for power plant and industrial application. BHEL is the only
company in India with the capability to make simulators for power plants, defiance
and other applications.

TRANSMISSION:-

BHEL also supplies a wide range of transmission products systems up to


400 KV class. These include high voltage power & distribution transformers,
instrument transformers, dry type transformers, SF6 switchgear, capacitors and
insulators etc. for economics transmission of bulk power over long distances; high
voltage direct current (HVD) systems are supplied. Series and shunt compensation
systems have also been developed and introduced to minimize transmission losses.

TRANPORATATION:-

A high percentage of trains operated by Indian railways are equipped


with BHEL’s traction control equipment including the metro at Calcutta. The
company supplies broad gauge electric locomotives to Indian railways and diesel
shunting locomotives to various industries. 5000/4600 hp AC/DC locomotives
developed and manufactured by BHEL have been leased to Indian railway. Battery
powered road vehicles are also manufactured by the company.

RENEWABLE ENERGAY:-

Technologies for exploiting non-conventional and renewable sources of


energy include wind generators, solar-power based pumps, lighting and heating
system. BHEL manufactures wind electrical generator of unit size up to 250 KW
for wine farms to meet the growing demand for energy.

BHEL has commenced manufactures of large Desalination plant to help augment


the supply of drinking water to people.

HUMEN RESOURCE DEVELOPMENT: -

The prized asset of BHEL is its 62.507 employees. The human Resources
Development Institute and other training institute of the company help are not only
keeping their skills updated and finely honed but also add new skills when
required. Continuous training and retraining, a positive work culture and
participative workforce style of management have led to the development of a
committed and motivated workforce and enhanced productivity and quality levels.
HEEP :AN OVERVIEW
Over the years, BHEL as emerged as world-class engg. & Industrial
giant, the best of its kind in entire south East Asia. Its business profile cuts across
various sectors of engg/power utilities & industry. The company today enjoys
national & international presence featuring in the "fortune international-500" & is
rank among the top 12 companies in the world, manufacturing power generation
equipment. BHEL has now 14 manufacturing divisions , 8 service centers & 4
power sectors regional centers besides a large nos. of projects site spread over India
& abroad.
The company is embarking upon an ambitious growth path though
clear vision; mission & committed values to sustained & augment its image as a
world class enterprise.

VISION:-

A world class, innovative, competitive & profitable engg. Enterprise


providing business solutions.

MISSION:-

To be the leading Indian engg. Enterprise providing qualities


products system& services in the field of energy, transportation, infrastructures &
other potential areas.

VALUES:-

* Meeting commitments made to external & internal customers.


* Foster learning creativity & speed of response.
* Respect for dignity & potential of individuals.
* Loyalty & pride in the company.
* Team playing.
* Zeal to excel.
* Integrity &fairness in all matters.

HEAVY ELECTRICALS EQUIPMENTS PLANT (HEEP):-


At hardwar, against the picturesque back ground of shivalik hills, 2 important
manufacturing units of BHEL are located viz. HEEP& central foundry forge plant
(cfpp).T he hum of the construction machinery woke up shivalik hills during early
60s & sowed the seeds of one of the greatest symbol of indo soviet collaboration -
HEEP of BHEL.Following is the brief profile of HEEP:-

1. ESTABLISHMENT & DEVELOPMENT STAGES

* Established in 1960 under the indo soviet agreement of 1959 &1960 in the area
of scientific, technical &industrial cooperation.
*DPR-prepared in 1963-64 construction started from October 1963.
* Initial production of electric motors started from January 1967.
* Major cunstruction/erection/commisioning completed by 1971-72 as per original
DPR scope
* Stamping unit added later during 1968 -72.
* Annual manufacturing capacity for thermal sets was expanded from 1500 MW to
3500MW under LSTG project during 1979-85(sets up to 500MW, extensible to
1000/1300MW unit size with marginal addition facilities with the collaboration of
M/s KWU-SIEMENS, Germany.)
* Motor manufacturing technology updated with siemens collaboration during
1984-87.
* Facilities being modernized continually through replacment/reconditoning -
retrofitting, technological/ operational balancing.

2. HEEP PRODUCT PROFILE

*THERMAL & NUCLEAR SETS


(Turbines, generators, condensers & auxiliaries of unit capacity up to 1000 MW)
*HYDRO SETS INCLUDING SPHERICAL & DISK VALUS
(Kaplan, Francis, pelton, reversible turbines of all size & matching generators &
auxiliaries maximum runner dia- 6600 mm.)
*Electrical Machines
(For various Industrial applications, pump drives & power station auxiliaries, Units
capacity up to 20000 KW AC/DC)
*CONTROL PANELS
(For thermal/ Hydro sets & Industrial drives)
*LARGE SIZE GASS TURBINES
(Unit rating 60-200 MW)
*LIGHT AIRCRAFT
*DEFENCE PRODUCTS

3. HEEP: FACILITIES & INFRASTRUCTURE

Modernization & regular updation/upgradation of facilities & other infrastructure is


a continuous endeavourer at HEEP, BHEL. After initial setting up of the plants
during the year 1964/72, in collaboration with the soviet union, the plants facilities
& infrastructure have since been continuously upgraded under various investment
project viz, stamping unit project, LSTG project, motor project, Governing
component project, TG facilities Modernization, TG facilities augmentation,
quality facilities augmentation, EDP project, gas turbine project. Facilities have
also been added and establishments have been created for new products in defense
& aviation projects. Additionally, R&D facilities have also been created under
generators research institute, pollution control research institute, HLT
modernization and other such schemes.

To day the plants has unique manufacturing and testing facilities, computerization
Numerically controlled machines- tools, blades shop, heavy duty lathes, milling
machines, boring machines, machining centers and many more. The over speed
vacuum balancing tunnel created for rotors up to 1300 MW (320 T, 6.9 M- dia
bladed rotor, 6 rpm. up to 4500 rpm) is one of the eight of its kind in the entire
world.

The total spectrum of sophisticated, unit and other facilities at Heep, Haridwar are
the state of the art in manufacturing processes and can be utilised for a verity of
products manufactures.
MANUFACTURING FACILITIES

HEEP Haridwar plant is equipped with most modern and sophisticated


machine tools, facilities and test equipment to manufacture and test
generators up to 1000 MW rating, which include:

• Most modern micalastic insulation plant for stator bars


• Overspeed and vacuum balancing tunnel
• Koellmann rotor slot milling machine upto maximum barrel length of
7000 mm, barrel dia. of 1800 mm and rotor weight of 225 tons
• Two computerised test beds to test large size generators upto 1000
MW
• Wotan CNC horizontal boring machine
• Center lathe machine up to max. length of 16 m and dia. of 3.15 m
• Insulation life endurance test assessment facility

Besides these, HEEP has also set up a Generator Research Institute with
an objective to develop basic know-how and know-why through
experimental studies for reliable, efficient and optimum design of
generators and improve their performance in service.
FORWARD

Business mission of BHEL is ---"To be the leading Indian engineering


enterprise providing quality products, systems and services in the fields of
energy, transportation, industry, infrastructure and other potential area". In line
with this mission, HEEP _ one of the major manufacturing units of BHEL, strives
to achieve Technological Excellence in all area of its operations. Manufacturing &
Engineering facilities and infrastructure at HEEP are comparable to any World -
class enterprise of its kind.

To be at par with advanced global competitors and to meet the changing


needs of different products, the Modernization and Technological up gradation of
facilities is a continuous endeavor at HEEP. Keeping pace with the the State - Of -
The - art, manufacturing facilities have been augmented to include a host of CNC
machine - tools, incorporating computer - aided manufacturing. Plans are in hand
to introduce Computer Integrated Manufacting, Flexible Manufacturing Systems,
Electro - chemical machining in near future. Also Computer - aided engineering
and design has become a way of life for the Engineering professionals at HEEP.

This publication on "Directory of Manufacturing and Engineering


Facilities" will serve the facility planners and users as a reference guide and present
the vivid picture of Engineering and Manufacturing Potential & Capabilities of this
unique plant.

(M. K. Mittal)
Executive Director
BHEL, HARDWAR
BLOCK-1 PRODUCTION UNIT

* BAY-1

INTRODUCTION, LSTG ROTOR WINDING &


STATOR WINDING(T.G), OVERSPEED BALANCING
TUNNEL.

* BAY-2

MOTOR IRON ASSEMBLY, HEAVY ROTOR ASY.,


STATOR WINDING AND IMPREGNATION PLANT.

* BAY-3

MEDIUM ROTOR IRON ASSEMBLY,


COMMUTATOR SECTION,FIXTURE AND
BUSBAR,TEST STAND.

* BAY-4

SMALL SIZE MOTOR, POLE SECTION, T.R.C.


ROTOR COIL SECTION.
INTRODUCTION

From the Electrical point of view the main stress is given on the
manufacture and maintenance of turbo (large) generators and hydro generators as
well as A.C & D.C motors in block-1 with the largest manufacturing techniques
being employed for their production. This block is also significance its better
production and quality control performanceblock-1 has the tremendous part of all
block present in BHEL with accordance to manufacturing techniques. The largest
machine shop of India is also available of this block. There are many achievements
are established by this block.

Block-1 was established by BHEL


HEEP (Heavy Electrical Equipment
Plant, Hardware). Inaugurated by sh. D.
sanjivayya, Union Minister for
Industry, Smt. Suchetra Kripalani, 3rd
Jan. 1967, Chief Minister, Uttar
Parades, Presided 13 Paush-Saka 1888.

ELECTRICAL MACHINES BLOCK (BLOCK-1)

Block-1 is designed to manufacture Hydro generators, Turbo


generator & large & medium size AC & DC electrical M/Cs. Equipment layout
plan is as per drawing no. 003 appended in section-3. The block consist of 4-bays:
Bay-1(36*482 meters), Bay-2(36*360 meters) & Bay -3&4 of size 24*360 meters
each. For handling & transporting the various components overhead crane facilities
are available, depending upon the products manufactured in each Bay. These are
also a number of self propelled electrically-driven transfer trolleys for the inter bay
movement of components/assemblies.

Convention bay wise brood distribution of products is as follows:--

LSTG Area Large size turbo generators.


Bay-1 Hydro generators their exciter; PMG & large size turbo
generator.
Bay-2 Turbo generator, their exciter & heavy electrical motors
Bay-3 Medium size electrical motors
Bay-4 Small & miscellaneous components for all electrical M/Cs.

Testing facility for turbo generator & heavy motors are available in Bay-2 &
for medium size electrical motors in Bay-3.their is a special test bed area for
testing of capacity of 500 MW unit size & above .

The manufacturing products and capacity of this are as under—

PROJECT TYPE MAX. UNIT


CAPACITY

1. Turbo I) Air cooled Up to 1000


Generator II) h2 cooled M.W
III) Water cooled

2. Hydro Generators I) Umbrella Up to 250


II) C.M.Umbrella M.W
III) Suspension
IV) Horizontal

3. Motors I) A.C. Motor 35 M.W


II) D.C.Motor 12 MW 70 rpm

The manufacturing M/Cs by Block-1 in India till 2001 is as follows:-


A.C.Motor—3690
D.C.Motor – 5549
Turbo Generators – 46 (Projected in India)
Hydro Generators – 50 (Projected in India)

Block-1 has specially only for T.G. & H.G. of the specifications as:-

T.G. 500MW 250MW 235 MW 210MW


(NPC) (THRI, THW)
Cooling THDF THRI THW
Method
159 MW 80 MWX Frames 6
TARI
H.G. UPTO 250 A.C.Motors: up to 10400 kW
MW D.C.Motors: up to 12500 kW

Therefore the block has their own importance in whole of the HEEP family
of BHEL Hardwar.
The internal positional diagram of block-1 are attached, in which that the
block-1 has four bay (Sections), into which there are many heavy & medium
machines are positioned are also the T.G.& H.G. section are present there.

The bayside description of the above are visualize here as accordance to


me.

*BAY-1
LARGE SIZE TURBOGENERATOR (LSTG AREA):--

Following facilities are available in different section of this area:-

(a.) Stator core assembly section:

Two number core pits core building & pressing facilities are available in this
section .The section is also equipped with optical centering device, core heating
installation & core loss testing facility.

(b.) Stator winding section:

The section is located in a dust proof area enclosure & equipped with one number
winding platform two number rotating installation for assembly of windings,
resistance bracing M/Cs & high voltage transformer are also available in this
section.

(c.) Rotor assembly section:

This section is also in a dust proof enclosure & is equipped with number of
rotators, rotor bar laying facilities & MI heating heating installation for heating &
mounting of retuning rings. Rotor winding assembly & rotor assembly like
retuning ring fitting, four assemblies are carried out in this section.

(d.) Bar preparation section:

This section consists of milling M/C for long preparation, installation for insulation
of tension bolts for stator & preparation of stator winding before assembly.
(e.) Test bed section:

This section is equipped with bed plates, height blocks, supporting blocks &
12MW drive motors. LSTG & exciter are assembled & tested in this section.

HYDROGENERATORS:--

Following facilities are available in the various sections: ---

(a.) Machine section:

This section is equipped with large size rotor slot milling M/C , lathe convention as
well as CNC vertical boring , CNC horizontal boring M/C , drilling & double
column planning M/C . Small size milling, slotting M/C & a shaper are also
available for manufacturing small components.

The major component M/C in this section are stator frames upper & lower brackets
, rotor spider , rotor shaft, pole end plates , thrust bearing disc ,collar of hydro
generator & rotor shaft of LSTG.

(b.) Iron assembly section:

This section is equipped with two centering columns & set of welding for carrying
out iron assembly of hydro generators stators.

(c.) Stator winding section:

Two truck mounted brazing installation are available in this section for resistance
brazing of bar head joints of stator winding bar of hydro generators.

(d.) Rotor winding section:

This section is equipped with rotators, hydraulic presses & wedge driving press for
the assembly of rotor winding for turbo generator.

(e.) Rotor assembly section:

This section is equipped with bed plates & induction heating facilities for assembly
of rotors of turbo generator. Assembly of retaining ring is carried out in this
section.
TURBO GENERATOR:--
Modern feature of direct cooling by water &
hydrogen are incorporated in the 210 MW turbo generators, thus evolving an
economical & reliable design. This high efficiency M/c, together with a fast acting
excitation system & dependable auxiliary service has a proven record & withstood
the test of time by prolonged trouble free Operation over the years. All the
materials that go into the manufacture of this M/c are subjected to rigorous tests as
per international standards. Each sub assembly or component undergoes a series of
stage wise tests .Each unit that rolls off the assembly line is fully assembled &
tested at the plant test bed as per the standards of the standards of the international
electro technical commission.

HYDROGEN AND WATER COOLED TURBOGENERATORS OF


200-235 MW RANGE (TYPE: THW):--

SALIENT DESIGN FEATURES

• Stator winding directly water-


cooled
• Rotor winding directly
hydrogen cooled by gap pickup
method
• Resiliently mounted stator core
on flexible core bars
• Thermo reactive resin rich
insulation for stator winding
• Top ripple springs in stator
slots
• Enclosed type slip rings with
forced ventilation
• Ring/thrust type shaft seals
• Two axial fans for systematic
ventilation and four Hydrogen 210 MW THW TYPE GENERATOR AT ROPAR THERMAL
coolers POWER STATION

• Static excitation
HYDROGEN AND WATER COOLED TURBOGENERATORS OF
500 MW RANGE (TYPE: THDF):--

SALIENT DESIGN FEATURES

• Stator winding directly water-


cooled
• Rotor winding directly hydrogen
cooled (axial)
• Leaf spring suspension of stator
core
• Micalastic insulation system
• End shield mounted bearings
• Support ring for stator over hang
• Magnetic shunt to trap end
leakage flux
• Ring type shaft seals with double
flow
• Multistage compressor and
vertical coolers on turbine end 500 MW TURBOGENERATOR ON TEST BED
• Brushless/static excitation

• Integral coupling of rotor

STATOR:--

The stator body is a totally enclosed gastight, explosion -proof fabricated structure,
suitably ribbed & stayed internally & ensure high rigidity. These are so designed
that the tubes may be cleaned without removing hydrogen from the generator
.Hydrogen coolers with a sufficient surface area , are mounted limitedly in the
stator frame for cooling the hydrogen

The stator core is built from high alloy low loss electro-technical
steel segmental stampings which are varnished on both sides. Segments of
insulating material are inserted at frequent intervals to provide additional insulation
& to localize shorts circuits .The stampings are assembled & pressed on core bars
forming several packets .The packets are separated from each other by steel spacers
of special profile to form ventilating ducts providing a gas passages to cool the
stator core . In order to reduce the losses in the end packets, copper screening
plates are provided at either end of the core & cooled by hydrogen passing through
radial ducts provided between the core end plate & end packets.
The stator winding employs direct cooling by distilled water
which permits the use of high value of current density in this M/c .The stator
winding over hang fixing is designed to withstand sudden short ckts at the
terminal .Each coil side consist of solid & hollow conductors through which the
cooling water passes . For distributing water through the stator coils, ring type
water headers insulated from the body, are provided on the turbine end. The
winding is designed for double star connection. Three line & 6 neutral terminals
are brought out thus enabling split phase differential protection to be provided.

HYDROGEN COOLED TURBOGENERATORS OF 140-260 MW


RANGE (TYPE: THRI):--

SALIENT DESIGN FEATURES

• Stator core and rotor winding


directly hydrogen cooled
• Indirect cooling of stator
winding
• Rigid core bar mounting
• Micalastic insulation system
• End shield mounted bearings
• Top ripple springs in stator
slots
• Ring type shaft seals
• Symmetrical ventilation.
• Brushless/static excitation

• Integral coupling of rotor 210 MW THRI TYPE GENERATOR STATOR

ROTOR:--
The rotor is of the cylindrical type, the shaft & rotor body being forged in one
piece from nickel chrome molybdenum vanadium steel. Longitudinal slots are
milled in the body to house the field winding .The field winding is made of cooled
rolled electrical copper which has a small percentage of silver . Slot portion of the
winding are held against centrifugal forces by means of duralumin wedges & the
overhang portion, by retaining rings of floating type. Retaining rings are made
from high tensile nonmagnetic alloy steel forgings. An end damper winding is
provided, which safeguards the asymmetrical & asynchronous operative conditions
of the M/c.

The rotor winding is provided with a lateral gap pick up system of cooling
in the slot part, ensuring uniform temperature distribution of the winding. The
overhang part is provided with axial cooling .The slip rings are steel forgings
which are shrunk on to the steel hub covered with mica, built up in positions. These
are arranged side by side outside the generator bearing at the exciter end. The
surfaces of the slip rings are spiral grooved & the brushes staggered to increase the
life of the slip ring & brushes.
BEARING AND SHAFT SEALS:--

The generator bearing at the end is of pedestal type with high rigidity & is provided
with a spherically seated shelf adjusting bush .The bearing bush is lined with anti-
friction metal & is automatically lubricated by the oil supplied by the lube oil
system . For checking the oil flow, sight windows are provided on the drain pipes.

In order to prevent the escape of hydrogen where the shaft leaves the casing,
shafts seals of the thrust type are provided at each end. For improving the
reliability during all regimes of operation, the shaft seals design incorporates high
pressure oil for pressing the seal liner against the shaft collar. In order to prevent
the circulation of shaft currents, oil seals & the bearings on the exciter end are
insulated from earth.

LSTG ROTOR WINDING

In this section the turbo-generator rotor of siemens Germany design are assembled.
This section assembles TG rotor of the following ratings:
a). 500 MW hydrogen cooled rotors.
b). 210/250 MW hydrogen cooled rotors.
c). 80 to 135 MW air cooled rotor.

After the rotor shaft matching, the shaft is received in this section for further
assembly work:-
The following assembly is done here:-
a). Field lead assly.
b). Lying of winding.
c). Retaning ring mounting.
d). Fan blade assembly.

Then the rotor is sent for final machine, balancing & testing & despatch.This entire
cycle taken around 4.5 months to complete.

DETAILS OF ASSEMBLY WORK OF LSTG

a). Field lead assembly . Science the siemens design rotor is brushless type,
therefore adequate arrangement is made to provide leads for carrying the
D.Csupply to the winding. The consist of the field lead core bar , current carrying
bolts , field lead bar & connecting piece along with various insulation & wedge
.
b). Laying of winding siemens rotor are 2 pole, 3000 rpm synchronous m/c having
D.C concentric winding. There 28 slots cut on 2/3 periphery which houses the
winding bar. There are 9 turns per slot in 500 MW (F.L current 4040A d.c 340V).
Due to non uniform distribution on the circumference, different moment of inertia
is obtained in main axis of the rotor shaft, causing 2f oscillations. To reduce this
vibration the deflection of pole axis & neutral axis is compensated by transverse
slotting of poles. Solid poles are also provided with additional longitudinal slots to
hold the copper bar of damper windings.
The turns of coils are trapezoidal in shape & have two semicircular
ducts for cooling (hydrogen at 3.5 bars). The conductor is made up of copper with
silver content 0.1% for higher mechanical strength at higher temperature
. The body insulation is made of glass fiber lamination having
nomex filler .To prevent the windings from centrifugal force the winding is secured
in slots by copper-silicon-nickel alloy wedges which also act as damper windings.
The rotor overhang is braced from centrifugal forces by the means
of retaning ring on each T- side & E-side. One end of the ring is heat shrunk (at
360 degree centigrade ) on the rotor body (interface value 4.0 mm) while the other
end over hangs the winding contacting the shaft .Material of retaning ring is X8 Cr
Mn N1818K alloy steel .

c). After completion of winding & fitting of RR the rotor is sent to machine shop
for machining of T grooves on compressor hub 515 nos. fan blade are arranged in
5 stages & arc fitted in these T grooves .

d). The rotor shaft is again sent to m/c shop for final machining before balancing.

LSTG (Large Scale Turbo Gen.) ROTOR


WINDING ASSEMBLY:-
This section has facilities for rotor winding of LSTG for turbo generator.
This is the second last section of bay – 1, which is used for high-speed approx.
3000 rpm rotor winding. The LSTG has two-dust proof stand into an A.C. glass
block. Both the stands can bear the weight of rotor approximate 68 tons and having
a length of 12 mt. Long the rotor is bring to here after there slotting and well
grinded, finish .

The grinding (cutting of slots) of rotor


(parallel slots) also done into the bay-1
thereafter it will be come here for winding.

Firstly the rotor will lying down on to


the rotor stands into the A.C. cabinet. Then
the winding procedure will do as describe:--
1. Before doing the winding each slots will be cleaned and dust free.
2. The insulating material known as text lire is put into the slot in each side.
3. Thereafter one another strip of thick glass textiles are used to avoid the
unnecessary vibration of rotor to field winding (glass textiles ).

Fig-Conductor with insulation & passed


for hydrogen

4. Now the rectangular hollow copper conductor. to be used for parallel sides
slots each slots have 7/9 copper bars (for 500 MW) concentric multiturn
coils are allow based in the slots which are a multiple of four. The slots
pitches are chosen to avoid undesirable harmonies in the field form
.
5. After placing the copper bars into each slot there end connection will be
joint with the gas welding or magnates bronze or stalling is driven into the
mouth of each slot for the purpose of keeping the winding in place. Ultimate
there are two terminals will be remain open to give the field current into
them to side of exciter.

6. An additional sets of winding with placed on to the poles known as damper


surface of rectangular copper conductor.

7. The end connectors of the field winding must be rigidly supported by end
bells because of the large centrifugal forces due to high speed of rotation the
end bells are used made of non-magnetic austenitic steel (mn-18%, cr-3%,
c-0.5%) in order to reduce the leakage flux. The end bells are mechanically
strong and have an ultimate strength of1150 MN/M2 Atypical end bell and
Overhang arrangement.

8. After this the rotor will packed with polythene cover due to dust and not
atmosphere.

The rectangular copper conductor are manufacture a in to block-


4. The conductors are of special type. Each conductors have the ventilating
ducts which is inclined cut of the middle portion due to proper H2 is passed into
there.

After the proper winding a fan cooling arrangement is also done


into this section. At the turbine side there are many small blades of generally
made up chromium nickel-steel or chromium molybdenum steel is used. The
blade are placed as that there are a small gap to every blade with a spacers of
same metal.
The LSTG section is devoted only 250-500 MW rotor winding
only. This section is providing the winding for THRI & TARI type turbo gen.
This section has four brazing M/s for brazed of end connections of winding.
After the winding the technological requirement will be removed. Thereafter
the rotor will send to the checking department to check the proper connection
and avoid ness of short circuit into any portion. After passed this department the
rotor will go out on to the over speed balancing tunnel for tested of proper
balance and with stand to vibration & centrifugal forces.

Assist by: -- Senior technician


Mr. R. S. Prem
(LSTG Winding Section)

LSTG STATOR WINDING :--

It has two dust free stands for stator winding of turbo generator and
an installation for heating stator bars. This section is used for stator winding of
capacity 250MW, 500 MW T.G. Are as follows:--

Weight of wound stator -- 278 MW tons


Weight of wound rotor -- 62 T
Length of stator body -- 8.83 ml
Length of rotor shaft -- 12.1 Mt
No. Of slots in stator -- 48
No. Of slots in rotor -- 28

The main components of 500 MW stator winding may be:--

1. Core
2. Stator bars
3. Support rings
4. Header
5. Bus bar

Except these component there are some additional auxiliary are required for
testing and cooling purpose and these are:

6. Air system
7. Gas system
8. Primary water system

The constructional details of these components are as:--


1. CORES:--
The stator core is shown as under. These cores are of segmental
laminations and compress to them as per the requirement.

The cores are mounted as that they will form the required no. of slots (48 slots
for 500 MW) and 1 coil for 2 slots.

2. STATOR CORES:--
The stator core is built up segmental laminations of
type. The use of grain oriented steel laminations with direction of flux being
along the grains in the armature core and perpendicular in teeth result in
lower core loss but it is usual to use cold rolled non-oriented steel. The
desired no. of core is placed into the vertical stands stator body with the
technological arrangements. The stator body is a stand with the help of
umbrella like vertical stands which under ground into this section of Bay-1
and having depth of 10 MT. Approximate.

The stator cores are laminated with impregnation (varnished) then pointed
with on insulated point. Every core has air gap and no. of holes for cooling
purpose after placing all the cores the stator body will form the slotted
shape.
1. SUPPORT RINGS:- Support rings are used to support the stator cores.
These are the vertical and oval shaped iron rings with epoxy glass insulated
to each are placed into stator body.

2. HEADER: - header is the round shape hollow pipe. This positioned on the
header of stator body. The header is the
silver color pipe into which distilled
water flow for cooling of stator winding.
The pipe is of Teflon tube. The distilled
water circulating through the stator with
radial cooling arrangement
. Fig-Retaining ring
3. BUSBARS:- The bus bar is the 3 phase
output connection from the 3 winding of
stator.

4. STATOR WINDING: -- The stator winding of T.G. is a double-layer


winding of T.G. is a double-layer winding with the pitch of winding so
adjusted as to reduce the 5th and 7th harmonies. A generator designed for
high voltages no doubt require a high level of slots insulation but permits
used of similar size of conductors. The conductors are used of copper these
are hollow and solid of two types. The hollow conductors used to flow of
water and coolant.

The advantages of lesser number of parallel ckts smaller positional


forces blow conductor lesser conductor sub division and case in coil
formation and installation. The generation voltages used are 20-25 KV for
250-500 M/Cs.

The electro magnetic forces developed in turbo alternators under short


circuit conditions are very high on account of large pole pitch and high
armature mmf per pole. The problem of bracing the overhang to with stand
electromagnetism forces. Hardwood blocks with glass fiber cord or type
along with nonmagnetic metallic brackets are used for bracing the overhang.

COOLING ARRANGEMENT:--
The problem of cooling of turbo-
alternators is one of the most complex problem in electrical engineering
since being high speed M/Cs their dimensions is much smaller than of H.G.
in fact the problems associated with cooling arise because T.G. are
characterized by long core lengths and small diameters. According to
various methods cooling the T.G. are classified.
a. THRI -T.G. Radial, indirect cooling
b. TARI - T.G. Air Radial, indirect cooling.
c. THW - T.G. Hydrogen water cooled.
d. THDF – T.G. Hydrogen direct cooling.

The BAY-1 is specially designed to manufacture only THRI and


TARI type T.G. therefore. I will describe only both type of cooling.

1. AIR COOLED TURBO GENERATOR :--


This type of cooling of
T.G. by air used for small units. Therefore this method of cooling is applicable
only for rating of 30MW-60MW generator. The various methods used for air
cooling of T.G. are:--
a) One sided axial ventilation: M/Cs for power output up to 3MW permit.
b) Two sided axial ventilation: M/Cs rating up to 12MW.
c) Multiple inlet system: this method is more applicable than above two
because of long core lengths of T.G. Therefore multiple units supplied
cooled air.

AIR COOLED GENERATORS UPTO 200 MW RANGE (TYPE:


TARI)

SALIENT DESIGN FEATURES

• Stator core and rotor winding


direct air-cooled
• Indirect cooling of stator winding
• Horizontally split casing design of
stator
• Vertically side mounted coolers in
a separate housing
• Micalastic bar type insulation
system
• Separately assembled stator core
and winding for reducing the TARI 108/41 GAS TURBINE GENERATOR
manufacturing cycle
FOR FARIDABAD
• Brushless/static excitation system

2 HYDROGEN COOLING AND HYDROGEN COOLED T.G. :--

When the problem of increasing generator rating was talked in became clear
that the air-cooled M/C did not provide the necessary scope for progress. Not
only in circulating the requisite quantity of air through the M/C but also
because the high fan power required to circulate the air. Thus air circulating
fan power required for this duty is high and on this score alone the air cooled
generator can be ruled out when it becomes necessary to increase gen. Rating.
Evidently to push-up gen ratings an alternative-cooling medium had to be
found. That medium was hydrogen. Following are the advantage of utilizing
H2. :-

a) Increased efficiency: This because the density of H2 is only 0.07 times the
density of air and therefore the power required to circulate H2 should be about
1/14 of the air.

b) Increase in rating: H2 has a heat transfer coefficient 1.5 times on its


thermal conductivity is 7 times that of air. Consequently when H2 is used as a
coolant, the heat is more rapidly taken up from the M/C parts and given out.
Therefore heat generated is more
effectively removed and the active
materials can be loaded more than
is possible with air-cooling.

c) Increase in Life: The life

of M/C is mainly the life of winding in


insulation and air pockets in
insulation can be sources of such high
local temperature that there is always
the risk of insulation breakdown and
free, due thermal conductivity of H 2.
Fig—Hydrogen channel
d) Elimination of fire hazard:
The outbreak of fire inside the M/c
is impossible us H2 does not
support burning.

e) Smaller size of coolers: the size


of coolers requires cooling the gas
core smaller in size. When
hydrogen is used as a coolant.
Fig—Rotor fan

3 DIRECT COOLING AND DIRECT COOLED T.G. :

The direct cooling is the process of


dissipating the armature and field
winding losses to a cooling medium
circulating within the winding
insulation wall. Machine cooled in this
manner are also called “super charged
inner cooled “or “conductor cooled “by
various manufacture. In this method the
coolant is in indirect contact with
conductor copper or is separated only
by material having negligible thermal
resistance. The direct cooled method has their own advantage. It is dear how the
cooling progress does.
Fig—Hydrogen cooler

COOLANT USED FOR DIRECT COOLING:--

The coolants normally used are H2 water and oil.

HYDROGEN GENERATOR IRON & UNIT ASSEMBLY:

The unique combination of lead discharge and water conduct system at any
hydroelectric site make the design of the turbine and generator custom built for
each project.

Based on the unit rating and speed selected for the turbine. The generator is
designed to suit the specific requirements of rational inertia over speed system
requirements, special design technique have to be used taking into account the
transport limitations too site.
This section of BAY-1 is mainly to assemble the various iron arrangements of
Hydro generator. Since the hydro generator is having more poles than T.G. therefore its
rotor diameter will also large. Hence there are many iron accessories are needed to
assemble H.G. in this section the assembly of rotor and stator iron assembly will formed.

To cover the large area of rotor used the iron spider. This spider is a spider
shape hollow iron body on to which the solid rotor wedge and rotor segment will
wear then the we climbed the upper and lower guide bearing on both side of rotor.
Thereafter welding will be done.

After completing the wedging the places will fit on the rotor body with
proper insulation.

Similarly the large dia of stator cover by iron pieces and jointed to than on
the site due to their large shape and heavy weight.

HYDRO GENERATOR ROTOR WINDING SECTION:--

This selection is prescribed only for rotor winding and the PMG machines for
H.G. site to develop the D.C. current through rectifier. So first we concentrate on
H.G. rotor winding.

THE H.G. ROTOR BODY IS USED HERE:--

1. Machined with its shaft from a forcing


Built up from discs shrunk on a shaft.
3. Fabricates from accost steel spider mounted on shaft and carrying laminar
ring of segmental plates

The forged steel construction is used for high speed M/sc. The earliest
construction. Particularly of relatively low outputs (below 40 MVA) consisted
of a body shaft extension made as a single forging.

Another type of construction employs thick roller steel discs, 120-180 in


length either struck on to shaft or slighted to each other and formed into a solid ring
axial through bolts.

This construction is cheeps and is used for generator running at 60 rpm.

This cheapest form of rotor body construction is the punched segmental rim
carried on a fabricated steel spider. The communication use 1.8 mm thick and are
in the form of over lapping segments tightly bolted. The spider is therefore relived
of all required to transmitorque to the rim. The advantages of a segmental rim are
that it is copy to transport and assemble at site.

After choice of specific rotor frame; we mounted the poles on it. The poles are
clamp or fixed etc. to rim in different ways. They can halt to the yoke either
dovetail or the T-head type of construction is used for fixing the pole to the yoke.
The cross sections of the poles may be rectangular or circular. The circular
pole has the following advantages.

1) The length of means turn of the winding is smallest with circular pales.
2) The whole of the winding surface is uniformly exposed etc. air and therefore
ventilation is better.
3) The field coils with circular poles are circular in shape and therefore they
can’t the easily deformed by centrifugal forces.
ROTOR WINDING OR FIELD WINDING:--

In hydroelectric generators, the iso-called “strip on edge” winding is used


for the field coils. The field coils are formed forma fiat copper trip wounded guises
with interterm insulation on the machine-operated former.
The coil may have a smooth surface or may have some of the turns made of
a wider copper strap so that they perfect out sick and act as cooling fins. The
cooling fins substantially increase the external bare copper area the rib lowering the
temperature rise.

The coils are supported by v block in order to with stand centrifugal forces
alternatively; a canted coil construction may be used. In this arrangement, the
construction of turn is such that the necessity of support for the coils.

DAMPER WINDING:--

In order to dam pout the oscillations damper windings are used which are
housed in the pole shoes. There damper winding consist of heavy copper coils, one
in each slot or hale, riveted at the ends to common bars at each and so as to form
short circuited grid or the rods may be brazed to copper and bars attached us the
pole and plates. In most cases copper rods in the pole shoe as adequate without
inter polar cage connection.

Within the damper rods are completely buried in iron. The inductance is
reduced and the of damper winding current is improved.

Special attention must be paid to connecting bars lying in the inter polar
region as this portion has no either support except the support of ends in the pole
shoe.

PMG SECTION:--

The PMG (permanent magnet generator) is the special type


of A.C. generator trough we can exciter the field of H.G. without any external
source of power. The PMG is used for low power requirement of 210-250 MW
H.G. sometimes it is known as pilot exciter. In PMG the permanent magnets
mounted on the rotor shaft and a three phase winding on the stator. The P.M. of the
pilot exciter produces the field current of the exciter. The exciter supplies the field
current of the main machine. Thus the use of pilot exciter makes the excitation of
the main generator completely independent of external supplies
EXTENDING LIMITS WITH LATEST TECHNIQUES

BHEL possesses very strong engineering base, R&D infrastructure, very precise
CNC & conventional machine tools, sophisticated technologies and capabilities to
produce hydro-generators of capacity up to 300 MW based on customer’s
requirements as per national / international standards.

BHEL has the latest hardware and computer software for design development of
large capacity (> 250 MW) and large size hydro-generators.

• Latest computational techniques for design analysis and integrated


manufacturing like CAD, FEM, CAM etc. are used.
• Use of solid modeling, finite element modeling and further down stream
applications for solution of design structure, heat transfer, electro-magnetic
applications etc. for optimization.
• The computer software is also used for thermal network solutions and
ventilation system, which are vital parameters for large capacity machines.

CONSTRUCTION:--

The rotor of PMG is on the same shaft of H.G. but is it is


covered with proper insulation by stamping of cores of permanent magnets. This is
the solid formation like as squired cage rotor.

The stator design is very tedious and length process due to field winding.
The stepwise construction details are as: -

1 Laying of power bars.


a) First check the surface is dust free and no shade edges.
b) Placed and plast as-co-lite piece within every slots.
c) Now placed support ring.
d) Glass textulite piece.
e) Distance spacers to cover up the air gap an unnecessary distance.
f) Glass bring and binding the position.
g) Filling the space of plast semi conductor polish to reduce vibration.

2. Laying of upper bars:


a) Spacer of 3 mm thick of glass textulite.
b) Joint spacer
c) Copper jointer for both head.
d) Slot bearing
e) Brazing with brazing M/s. The brazing alloy as in ,it consists of ban
Cu p5.
f) Testing the braze surface with a subsonic detector M/c. which detect
the planning of surface.
g) Placed the head insulator (male & female)
h) Hardliner of Epoxy kilt to fill the air gap.
i) Than bind the glass tape
j) Finally coursed with PVC transparent cover (hex glass or glass
maiden.
k) Stand for bus bar. As in fig. 29 and ceramic paper paper

Guidance by--
Mr. A.k.Shrivastava

OVER SPEED BALANCING TUNNEL:--

The dynamic balancing of turbo generator’s rotors is done on this


installation. The T.G. rotor after winding is fitted between two head and then
moving it to its rated speed. Then check with the help of CNC control display
where the rotor is misbalance and how much quality. This procedure also detects
the vibration of rotor under rated speed.

If any type of misbalancing bis measured here then marked it and charge
it to the responsible section.

The OSBT is the largest tunnel for balancing of rotor of T.G. into allover
BHEL.

EXPANDING POSSIBILITIES

BHEL undertakes complete turnkey


operations – ranging from systems
design through manufacture and
coordinated supply of equipment to
erection and commissioning. The post-
commissioning services include
optimal planning and supply of spares,
maintenance, overhauling /revamping
and up rating for optimisation of
generator.

BHEL has the capabilities to undertake


the manufacture of any type of hydro-
generator specified by the customer.
The hydro-generators have been
designed for:

• Underground or surface stations


• Attended or unattended power
stations
• Additional synchronous
condenser mode of operation
• Reversible pump storage
operation
• Operation in seismic areas
• Optimum excitation system
• Parameters based on power
system studies

• Special features like hot air


bleeding for heating of power
station from heat given out by
generator etc.

BAY-2
TURBO-GENERATORS AND HEAVY MOTORS
The following are the main sections:--

(a) Machine section:-

This section is equipped with large size CNC & conventional M/C tools such as
lathes, vertical boring, horizontal boring M/C ,rotor slot milling & radial
drilling M/C for machining stator body , rotor shaft end shields & bearing
etc.for turbo generator.

(b.) Iron assembly section:-


This section has facility for stator core assembly of T.G & heavy electrical
motor. 1000T & 200 T umbrella type presses for pressing the cores &
transformer for induction heating of armature cores of large size electric are
available in this section. The facilities in this section also include one 250 KW
induction brazing M/C for brazing of squirrel cage induction motor. For this
purpose one 250 KW medium frequency induction brazing M/C is available.

IRON ASSEMBLY (LSTG) - Two numbers core pits with two numbers
hydraulic pressing & heating arrangement for pressing the core are available in
this section.

(c.) Stator winding:-

This section has 2 nos. of rotators along with one no. of winding platform for
the winding for the assembly of the stator winding of T.G. The winding
assembly is carried under dust free atmosphere. Assembly of stator winding of
heavy motor & exciter is also carried out in this section in clean atmosphere.

(d.) Armature section:-

This section is equipped with installation like bandaging M/Cs, tensioning


devices, magnetic putty application M/C & 45 KW MF brazing M/C for laying
windings. In large size DC armature.Rotors/Armatres up to 16 Ton weight are
balanced on the dynamic balancing M/C available in this section.

(e.) Armature/stator/impregnation section:-

It has impregnation & drying ovens for large DC armatures including vacuum
pressure impregnation facilities for total impregnation of AC & DC motor.

(f.) General assembly section:-

General assembly of large size AC & DC motors is carried in this section.

T.G. EXCITER IRON ASSEMBLY:-

This section has facilities for shame core assembly of turbo generator and
heavy electrical motor including 1000 tones umbrella type press for pressing
the cores and transformer of inductions heating of retaining rings and armature
cores of large size electric motor. The umbrella type stands for core pressing is
done here and into Bay-1 as describe first .The procedure involve into core
assembly may be describe as:

i. Hold down the T.G. stator vertically


with the help of umbrella type stands.
Place the stator bars with all around the stator.
Now placed the lower supporting core.
iv. Now placed the cores in such a manner
that two core will overlap to each other in ratio of ¾: ¼ with butt
joint.
v. This process known as bracing of
cores. After bracing the cores that we done the punching operation.
vi. Therefore, all the cores will tightly fit in
the same manner and finally cover the last layer by upper supporting
ring.

For ventilation of cores the core is formed as such that same air gap
will be remain between them with a special silicon sheet bar and welded it by
arcing M/c.

Similar produce will adopt for exciter iron assembly but in core of
exciter we used the small brushing umbrella stand. This section is done the iron
assembly of T.G. of 250 MW to 500 MW and the same exciter.

Information by:
Mr. Ramla Khan Verma
(Sr. Tech T.G. & Exciter
Assembly)

HEAVY MOTOR WINDING:

This section is dedicated to motor winding of A.C. stator of rating 3


MW to 10 MW. Stator winding is generally done as the following procedure:-

a) First of all placed the stamping, cores into stator body with
proper impregnation of each cores.
b) Put down the glass insulation into each slots (Sam 8).
c) Put the copper conductor into each slots with proper
insulation of glass tape on it.
d) Distribute the RTD into each slot to detect the temperature
into running condition of motor.
e) Now make connection for input supply for a MW M/s the
designing dimensions are as:
Slots, 8 poles and 1 pole – 3 coils
f) Now brazing is done of all three phases by brazing machine
machine.
g) The entire end we rubbed the magnate kilt (iron powder) to
increase the flux into motor.
h) After doing the proper connections the machine will check
by means of short circuit of winding etc.

Information by:
Mr. O.L.Verma
(Sen. Tech. Heavy motor
winding section)

TURBO GENRETOR:-

This section has two fully A.C. &covered stand for the stator winding
of turbo generator of 210 MW capacity. The winding done here is same as
that of LSTG stator winding the stamped stator is laying here horizontally
and then winding, should be done. The cooling the generator is water hence
it is a THW T.G.

The difference make here with 500 MW T.G. is:-

a) The bars profile is different make than 500 MW T.G.


b) The thickness of the conductor bar for 210 MW T.G. is
28-29 mm.
c) Distilled water-cooling for bars.
d) The winding type used there is single bar layer lap
winding.

Guidance by:
Er. Y.K.Sharma
(T.G.Stator winding 210 MW)
HEAVY ROTOR ASSEMBLY SECTION:-
SQUIRREL CAGE MOTOR SLIP RING ROTOR

This section is provide the facility of assembled the rotor for A.C.
This section has a250 ton horizontal press for pressing the rotor’s stamping
cores. The stamping is manufactured by Block-6. The cores are stamped
together without and insulation and supported to the entire periphery by the
iron bars of rectangular type. After the formation of solid rotor it will fitted
into the horizontal press machine and press a definite pressure after pressing
check the outer surface of rotor that there is no any sharp edge of cores will
be remain out of the diameter. This section is assembled rotor of rating 3
MW-10MW. Assist by:-
Mr. B.R.C.Tyagi
(Sen. Tech., Heavy rotor iron
assy.)

BRUSHLESS EXCITERS:--
--: MERITS :--

• Eliminates sliprings, brushgear,


field breaker and excitation
bus/cables
• Eliminates all the problems
associated with transfer of current
via sliding contacts
• Simple, reliable and ideally suited
for large sets
• Minimum operation and
maintenance costs
• Self generating excitation
500 MW BRUSHLESS EXCITER
unaffected by system faults or
disturbances of shaft mounted
pilot exciter

• Increasingly popular system the


world over

*(BAY-3)
MEDIUM SIZE MOTOR:--
Facilities available in the various sections are as follows:

(a.) Machine section – This section is equipped with medium size tools for
machining components for medium size AC & DC machines & smaller
components of turbo generator & hydro generators.

(b.) Iron assembly section – Umbrella type double column & four column
presses are available in this section for assembly & pressing of cores of
medium size electrical motors.

(c.) Commutator section – Commutators for DC M/Cs are manufacture in a


dust free enclosure in this section, having ovens for static & dynamic
forming, installation for brazing of risers & hydraulic presses for pressing
commutators.

(d.) Hydro generator pole core section – This section is equipped with
core building installation, horizontal press & special straightening plate for
the assembly of hydro generator pole cores.

(e.) Rotor assembly section – This section is equipped with static &
dynamic balancing installation bearing assembly installation & rotor
assembly facilities for the medium size M/Cs .

(f.) Winding section – This section is equipped with bandaging M/Cs,


brazing installation, rotators for rotors & stators for winding/stators
armatures /slip-ring rotors.

(g.) General assembly section – Final assembly of medium size of motors is


carried out in this section. Final assembly of medium size motors is carried
out in this section. Panting booth is available in this section for final
panting of motors.

H-MODULE HIGH VOLTAGE AC MOTORS:--

H-module is a modular family of motors that can be flexibly


adapted:

• For degrees of protection and cooling arrangements


• For various types of construction
• For noise control requirements
• For every application
Constructional Features

The motors are provided with rolling contact/sleeve bearings depending upon the
load and operating conditions. Rolling contact bearings are sealed by means of a V-
section axial shaft-sealing ring that rotates with the shaft. Sleeve bearings are used
when the limit for rolling contact bearings are exceeded or when specified by the
customer. The terminal boxes are made short circuit proof by the cast-resin
bushings and strong bolts to enable them to withstand short circuit current of 110
kA for 0.2 seconds. A pressure-relief flap provides the short circuit safety for the
terminal boxes. Slipring motors are additionally provided with a rotor terminal box
permitting the connection of starting resistors.

Field proven MICALASTIC insulation provides high interturn dielectric strength.


The rigid end turns provide high switching withstand capability and reversal
withstand strength.

Synchronous motor

The motors are suitable for


 open circuit cooling
 air/water cooling
 air/air cooling with separately driven fan
 Air/air cooling with shaft mounted fan

MOTOR IRON ASSEMBLY:--


In this section we give the unwound shape of A.C. rotor. The section has
umbrella type double and four column presses are installed for assembly and
pressing the iron cores of medium size electrical motors. The unwound rotor is
formed with the help of silicon steel core are stamped with each other by the help
of an iron cage.

The procedure iron assemblies of medium size motors may be write as:-
i. Prepare the fabricated rotor, which is brought from block – 5.
ii. Now, fit it on to umbrella type stand and fitted the winding
holder one upper and down head.
iii. Now stamped the cores vertical in or horizontally and pressed
them tightly.
iv. Now checked the outer surface of the unwound rotor that no
sharp edge is remaining of cores.

Now squirrel cage rotor will ready doing winding on it.


The squirrel cage further may be of two types as per the requirement and it is.

i) Single cage rotor


ii) Double cage rotor

The single cage rotor has single brucing of copper instead of it double cage rotor
has double brucing. The double cage is inner cage and single cage is outer cage.
The double cage rotor use to getting the high starting torque. The melting coin of
the external cage is high than inner cage (cu).
After select the appropriate rotor will be used as slip ring and simple motor by
exerted internal resistance.

Information by:
Mr.Bhupendra Singh
(Sn.Tech.Medium motor Iron Assy.)

MEDIUM MOTOR WINDING:--

This section is designed to do the wound shape of medium size motor


about ratings 66 KV and 800A from the previous section. To do the wound shape
of rotor first of all selects the required size of the copper conductor. The conductor
is hard copper bar; this bar is plane at one side and round the other side which is
placed in to the stamping slots. After going the proper winding check the short
circuit of windings.
L-SERIES HIGH VOLTAGE AC MOTORS:--
These motors are medium size motors .The motors can be designed to specific
customer's requirements. The motors are suitable for indoor and outdoor
applications, in strongly contaminated, damp surroundings and corrosive
atmosphere. The salient features of these machines are

• Robust construction and non vibrating frames.


• Shaft heights and mounting feet as per IEC and Indian standards.
• Dust protected long life bearings.
• Degree of protection IP54 and IP55.
• Large size, phase segregated terminal boxes.
• Rotors dynamically balanced at rated speed.
• Non vibrating bars and inductively brazed S.C. rings to withstand heavy
stress during starting.
• Uniform cooling inside the motor to avoid hot spots.
• Low noise levels.
• Magnetic slot seals for high efficiency, high power factor & low noise.
• Highly reliable class-F insulation system.

Constructional features

The machines have closed circuit cooling with a concentric tube nest cooler, which
is integral with the frame and with shaft-mounted external and external fan. The
external fan is located in the fan casing on the non drive-end and forces the
atmospheric air through the cooling tubes of stator frame.The two internal fans in
the main compartment cause primary air to circulate in two symmetrical sub-
circuits. Circulation is intensified by the radial ducts in the laminated rotor-core.
The primary air circulates through the end windings and the ducts in the core packs
and carries the heat to the cooling tubes.

The stator winding of HV machines is double layer lap windings and is provided
with MICALASTIC® VPI insulation complying with class-F insulation
requirements. The insulation system is based on integrated mica employing a
special synthetic resin impregnation process. The insulation possesses high di-
electric strength, high resistance to moisture, aggressive gases & vapours, excellent
mechanical stability and long life.

The shafts have two bearings ( drive-end and non drive-end ) and a cylindrical
shaft extension at the drive-end. The bearings are either grease lubricated rolling
contact bearings or journal bearings with or without forced oil lubrication. Solid
shafts are used in 2-pole machines and ribbed shafts in machines having 4 or more
poles. The laminated rotor core is pressed on to the shaft, clamped and secured
against axial displacement, and carries the squirrel cage winding.

The winding bars are firmly seated in the slot of the rotor core and are connected to
the cage rings by induction brazing. The rotor is dynamically balanced with a half
parallel key inserted in the key way of the shaft extension.

COMMUTATOR SECTION:--

As the name refer commutator section is provide commutator for D.C.


machine. This section is manufactured the commutator for motor of rating up to
few hundred volt. The procedure of production of commutator is as follows:-

a) First of all, we will take a copper profile which ordered from Block-4.The
copper profile is special type of copper segment which has a tunnel and one its end
and smooth on other end.
b) The tunnel or slitting is formed by slitting machine on the flat copper bar.
The slitting is done, 50, to fix the riser on one head of bars. The riser holds the
winding connection this process of placing rising is known as brooding or rising.
c) After this tinning is done, to fix perfectly the riser on to segment.
d.) Now the grinding is done to remove the zigzag surface of riser.
e) Now Baking is done on to 150-160 0C Temp. For 8 hrs. To remove the
moisture.
f) Now doing the cold pressing.
g) Now formed and duck till joint by the M/c on to the solid round frame of iron
the riser sides on top.
h) Now clinning by brushes or air pressure.
i) Now checking the segment by high voltage test.
j) Now placed the circular segment in to bush type fixture and put the fixture
into oven of 160-1500C than cold pressing
k) Now confirm the H.V. test segment to segment.
l) Now being the mutual fitting.
m) After this we will doing credit turning by lathe machine.
n) Now cleaning and heating at 1800C.
o) After cold pressing we are doing the dimming and forming for smoothing the
quarter surface of commutater body, then cold pressing.
p) Now coining into bush.
q) Ultimately we will do the tapping of bottom side.
*(BAY-4)

SMALL AND MISCELLANEOUS


COMPONENTS:-
Facilities available in the various sections are as follows: -

(a.) Machine section – The M/Cs section of bay-4 is equipped with small &
medium size CNC & conventional tools like center lathes, milling, radial
drilling cylindrical grinding, slotting, and copy.

(b.) Maching of main components is carried out in bay-2 & 3 while small
components are machined in Bay-4.

(c.) Iron assembly of AC motors stator & rotor is carried out manually &
pressing is done on hydraulic presses in Bay-2 & 3.

(d.) Winding of stator is done on rollers support. The phase connections are
made by resistance brazing M/C & the stator is tested for phase resistance
& high voltage. Wound stators are totally impregnated under vacuum &
pressure.

(e.) Rotor assembly – After assembly of rotor core the rotors bar are driven &
short ckt rings are mounted & brazed by induction heating. Then static &
dynamic balancing of rotor is done on balancing installation.

(f.) General assembly - The coolers, headers, end shields, terminal boxes etc.
are assembled manually to complete the assembly of motors.

.
TURBO GENERATOR ROTOR COIL (T.R.C.) (210MW) SECTION:-

It is mainly designed to manufacturing the T.G. rotor coils of 210 MW rating. It


has block type hydraulic press installed for forming and drilling halt coils, installed
for soldering and installed for straightening and cutting conductors for turbo coils.
The rotor coils formation procedure is as follow: -

(a) First of all we are taking the copper then we do opt blanking &
straightening.
(b) Now making
(c) Now form the excel channel milling and removing the extra bars.
(d) Now its hard board array (0.5 mm both side) as in Sam (12)
(e) Now doing the angular array and then final milling.
(f) Now handing to form the coil shop on bounding machine (fig. 44)
(g) Radial drilling by radial drilling machine.
(h) Former drilling
(i) Now we are doing the over hand debarring (as in fig 4.5)
(j) Now doing the strip polishing 3,9,11 by wire brush.
(k) Now insulate bottom (varnish-VLY556) 13 layers and a proxy impregnated
glass tube bar (1x28.5,13 layers 1mm)
(l) Rapping of all the copper bars by making a seat of strips for 31/4 hrs.
Technical response:
Mr. Aggrawal
(Sen. Tech. T.R.C.)

MANUFACTURING PROCESS:--

Stator Bar Winding Section - In this section following process is carried out:

-- Stator Winding Bar of TG With Resin Rich - Thermo-reactive Insulation


System- The self insulated hollow and solid conductors are straightened, cut to size
and skinned at the ends on special machine. After manual transposition the slot
portion is stack consolidation in Electrically heated hydraulic press and then tested
for inter strand short circuit. The bars are shaped on formers, coil lugs are brazed
by resistance brazing & bars are tested hydraulically. Bars are insulated with resin
rich tape, baked, pressed in the moulds as per the regimes and finally subjected to
electrical test.
-- Stator Winding Bar of TG With Resin Poor thermo-reactive Insulation
System - Same process is used as for Resin Rich system up to the forming stage.
After which the bars are insulated with resin poor tape, impregnated under vacuum
& pressure & subsequently cured in oven followed by Electrical Testing.
-- Hydro generator bars - Stator winding bars of HG with Resin Rich
Thermo-reactive Insulation System: Same process is followed as in case of TG.
-- Stator Winding Bars of HG with Respire System: The process followed is
similar to that of TG bars expect that in case of Resiflux insulated bare, the slot
portion is taped with resin rich tape & over-hang with flexible tape.

Armature winding & Stator coil section - In this section following processes are
followed:

-- Pole coils - The coils are wound on wooden or steel formers on semi-
automatic insulation & winding m/c. After inter turn testing the body insulation,
coils are impregnated & backed as per the technological regimes & subjected to
Electrical Tests. Coils are also encapsulated on pole cores epoxy resin.

-- AC Stator Coil - Conductors are wound & turn insulated on semi- automatic
insulation & winding machines. These are pulled to boat shapes, diamond shapes,
formed in wooden formers or on semi-automatic pulling & forming machining.
The straight portion is pressed on electrically heated presses. The coils are body
insulated. For epoxy coils with Resin rich system, straight portion is consolidation
on electrically heated presses & after cleaning the ends the coils are subjected to
electrical testing.

TRAINING & DEVELOPMENT:--

• 35 number employees exposed to 141 courses in HRDC during the year.


R EFERENCES

FOR GREAT THANKS—

• Shri S. P. GUPTA

• Shri D. N. LAL

• Shri A. K. VISHWAKARMA

• Shri HUSSIEN

• Shri R. K. DHIMAN

Das könnte Ihnen auch gefallen