Documente Academic
Documente Profesional
Documente Cultură
Submitted to the
Department of Electrical Engineering
in partial fulfillment of the requirements for the degree of
Bachelor of Technology
in
Electrical Engineering
JSS Academy of Technical Education, NOIDA
U.P. Technical University
SUBMITTED BY:
Puneet Kapoor
(1109120122)
VII-EE-B
SUBMITTED TO:
ACKNOWLEDGEMENT
Training has an important role in exposing the real life situation in an industry. It was
a great experience for me to work on training at BHARAT HEAVY
ELECTRICALS LIMITED through which I could learn how to work in a
professional environment.
Now, I would like to thank the people who guided me and have been a constant
source of inspiration throughout the tenure of my summer training.
I am sincerely grateful to MR. RAJ SINGH (Manager) at HRDC, BHEL Haridwar
who allowed me to pursue my summer training at the plant and rendered me his
valuable assistance, constant encouragement and able guidance which made this
training actually possible.
I wish my deep sense of gratitude to MR. SANJAY KUMAR (Asst. General
Manager) whose affectionate guidance has enabled me to complete this training
successfully. I wish my deep sense of gratitude to Dr. V. K CHANDNA (HOD: EE
Department) whose guidance and encouragement made my training successful.
Puneet Kapoor
CONTENTS
Topic
Page No.
1. BHEL An Overview.
11
I.
II.
III.
TURBO-GENERATOR.
12
13
COMPONENTS OF TURBO-GENERATOR.
14
a)
STATOR
1) STATOR CORE.
2) STATOR WINDING.
3) END COVERS.
b)
ROTOR
1)
IV.
EXCITATION SYSTEM.
19
a) EXCITER.
V.
VI.
VII.
VIII.
20
TEST STANDS.
26
26
TESTING.
26
a)
b)
4. CONCLUSION
27
5. REFERENCES
27
1. BHEL AN OVERVIEW
Bharat Heavy Electricals Limited (BHEL) owned by Government of India, is a
power plant equipment manufacturer and operates as engineering and manufacturing
company based in New Delhi, India. Established in 1964, BHEL is India's largest
engineering and manufacturing company of its kind. The company has been earning
profits continuously since 1971-72 and paying dividends uninterruptedly since 197677.
BHEL caters to core sectors of the Indian Economy viz., Power Generation's &
Transmission, Industry, Transportation, Telecommunication, Renewable Energy,
Defense, etc. The wide network of BHEL's 14 manufacturing division, four power
Sector regional centres, over 150 project sites, eight service centres and 18 regional
offices, enables the Company to promptly serve its customers and provide them with
suitable products, systems and services efficiently and at competitive prices. BHEL
has already attained ISO 9000 certification for quality management, and ISO 14001
certification for environment management.
POWER GENERATION
Power generation sector comprises thermal, gas, hydro and nuclear power plant
business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65%
of the total installed capacity of 99,146 MW in the country, as against nil till 1969-70.
BHEL has proven turnkey capabilities for executing power projects from concept to
commissioning, it possesses the technology and capability to produce thermal sets
with super critical parameters up to 1000 MW unit rating and gas turbine generator
sets of up to 240 MW unit rating. Co-generation and combined-cycle plants have been
introduced to achieve higher plant efficiencies. to make efficient use of the high-ashcontent coal available in India, BHEL supplies circulating fluidized bed combustion
boilers to both thermal and combined cycle power plants.
The company manufactures 235 MW nuclear turbine generator sets and has
commenced production of 500 MW nuclear turbine generator sets.
Custom made hydro sets of Francis, Pelton and Kapian types for different head
discharge combination are also engineering and manufactured by BHEL.
In all, orders for more than 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.
The Company has proven expertise in Plant Performance Improvement through
renovation modernisation and uprating of a variety of power plant equipment besides
specialised know how of residual life assessment, health diagnostics and life
extension of plants.
- Industrial Fans
- Seamless steel Tubes
- Fabric Filters
- Valves
- Pumps
- Electrical Machines
- Piping Systems
- Power, Distribution & Instrument Transformers
- Reactors
- Synchronous Condensers
- Switchgear
- Control gear
- Distributed Digital Control for Power
Stations
- Bus Ducts
- Rectifiers
- Porcelain Insulators
- Ceralin
Drive Turbine
Manne Turbines
Industrial Heat Exchangers
Centrifugal Compressor
- Industrial Valves
- Reactors
- Columns
- Pressure Vessels
- Pumps
RATING (MW)
500
250
210/200
3
NO. OF
SETS
30
9
138
TOTAL
CAPACITY (MW)
15000
2250
28570
120/125/130
195
110
100
70/67.5
60
30
TOTAL
(THERMAL)
20
1
38
6
6
14
5
267
2420
195
4180
600
410
840
150
54615
GAS
FRAME SIZE/
SCOPE
9
6
5
3
V 94.2
6FA
STG
GEN
TOTAL (GAS)
NO. OF
SETS
5
17
13
6
2
3
24
4
74
TOTAL
CAPACITY (MW)
730
580
309
48
286
207
1190
87
3437
NUCLEAR
RATING (MW)
NO. OF
SETS
2
10
12
TOTAL
CAPACITY (MW)
1000
2200
3200
TOTAL (THERMAL+GAS+NUCLEAR)
353
61252
HYDRO
402
755
18735
79987
500
220
TOTAL
(NUCLEAR)
GRAND TOTAL
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
Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the area
of Scientific, Technical and Industrial Cooperation.
DRR prepared in 1963-64, construction started from October '63
Initial production of Electric started from January, 1967.
Major construction / erection / commissioning completed by 1971-72 as per original
DPR scope.
Stamping Unit added later during 1968 to 1972.
Annual Manufacturing capacity for Thermal sets was expanded from 1500 MW to
3500 MW under LSTG. Project during 1979-85 (Sets up to 500 MW, extensible to
1000/1300 MW unit sizes with marginal addition in facilities with the collaboration of
M/s KWU-Siemens, Germany.
Motor manufacturing technology updated with Siemens collaboration during 1984-87.
S.No.
Area/ Block
Major Facilities
Products
1.
Block I
Turbo Generator,
(Electrical
Generator exciters,
Machines)
2.
Block II
(Fabrication
assemblies/
equipments
Block)
Block III
(Turbines &
turbine bladders,
special tooling.
Auxiliary Block)
polishing etc.
4.
Block IV
(Feeder Block)
generators, hydro
generators insulation
electroplating, impregnation,
insulating components
5.
Block V
Fabricated parts of
hydraulic manipulators
6.
Block VI
Fabricated parts of
(Fabrication)
work, assembly
7.
Block- VI
Wooden packing,
spacers etc.
8.
9.
Wooden packing,
working)
grinding , packing
spacers etc.
Block VIII
LP Heater ejectors
10.
Services plat
Power generation
Producer gas
generators
Acetylene Plat : A fully
Acetylene gas
Compressed air
Nitrogen gas
Power supply
11.
Motor transport
Transport service
Telephone service
internal communication
3 no Satellite exchange
13.
Testing of turbine
instrumentation. It consists of
models
HRDC
Training to
Employees, VTs
Apprentices,
Contractors &
carpentry work
Customers
15.
Engineering
of all products
Computer Center
IT services
Lab.)
sample components
Testing of components
Hardwar is in extreme weather zone of the Western Uttar Pradesh of India and
temperature varies from 2oC in Winter (December to January) to 45oC in Summer
(April-June); Relative humidity 20% during dry season to 95-96% during rainy
season.
10
INTRODUCTION
Block-I is designed to manufacturing Turbo Generators, Hydro generators and
large and medium size AC and DC Electrical machines.
The Block consist of 4 bays: Bay-1 (36*482 meters), Bay-2 (36*360 meters) and
Bay-3 and Bay-4 of size 24 *360 meters each. For handling and transporting the
various components over-head Crane facilities are available, depending upon the
products manufactured in each Bay. There are also a number of self-propelled
electrically-driven transfer trolleys for the inter-bay movement of components
/assemblies.
Conventional bay -wise broad distribution of products is as follows :
BAY1
ROTOR
SHAFT
MACHINI
NG
ROTOR SHAFT
SLOTTING
ROTOR
WINDING
OVER SPEED
AND
BALANCING
TUNNEL
BAY2
EXCITER
SHAFT
MACHINI
NG
STATOR BODY
MACHINING
STATOR
WINDING
TOTAL
TEST BED
IMPREGNATION
BAY--3
ROTOR
SUPPORT
BEARING
SHAFT SEAL
BODY
DC
MOTOR
WINDING
(EARLIER)
BAY--4
COOLING
FANS
MACHINI
NG
ARRANGEMEN
T AND OTHER
PARTS
MACHINE SHOP.
T/G ROTOR WINDING.
H/G IRON ASSEMBLY.
EXCITER.
T/G STATOR WINDING.
11
LARGE SIZE
TURBO
GENERATOR
S
I.
TURBO GENERATOR
12
LSTG AREA
THRI
TARI
THDI
THDD
THDF
THFF
1st LETTER = (here-T)
= 3-phase turbo generator
R= radial,
F= direct water cooling
D= direct axial gas cooling)
III.
COMPONENTS OF T.G. :-
STATOR
1.
Stator frame
2.
Stator core
3.
Stator winding
4.
End covers.
ROTOR
1.
2.
3.
Rotor shaft
Rotor windings
Rotor retaining rings
BEARINGS
COOLING SYSTEM
EXCITATION SYSTEM
STATOR
The generator stator is a tight construction supporting and enclosing stator winding,
core and hydrogen cooling medium. Hydrogen is contained within the frame and
circulated by fans mounted at either end of rotor. The generator is driven by a direct
coupled steam turbine at the speed of 3000 rpm.
14
The generator is designed for continuous rated output. Temperature detector or other
devices installed or connected within the machine, permits the winding core and
hydrogen temperature, pressure and purity in machine.
STATOR FRAME
The stator frame is used for housing armature conductors. It is made of cylindrical
section with two end shields which are gas tight and pressure resistant. The stator
frame accommodates the electrically active parts of stator i.e. the stator core and the
stator winding.
The fabricated inner cage is inserted in the outer frame after the stator has been
constructed and the winding completed.
STATOR CORE
The stator core is stacked from the insulated electrical sheet steel lamination and
mounted in supporting rings over the insulated dovetail guide bars. In order to
minimize eddy current losses core is made of thin laminations. Each lamination layer
is made of individual sections. The ventilation ducts are imposed so as to distribute
the gas accurately over the core and in particularly to give adequate support to the
teeth.
15
STATOR WINDING
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.
16
INSULATION OF BARS
A.
The voltage insulation is provided according to the proven resin poor mice base of
thermo setting epoxy system. Several half overlapped continuous layer of resin poor
mica tape are applied over the bars. The number of layers or thickness of insulation
depends on the machine voltage. To minimize the effect of radial forces windings
hold and insulated rings are used to support the overhang.
B.
Corona Protection:-
To prevent the potential difference and possible corona discharge between the slot
wall and the insulation, the section of bars are provided with outer corona protection.
The protection consists of polyester fluce tape impregnated in epoxy resin with carbon
and graphite as fillers. At the transition from the slot to the end winding portion of the
stator bars a semiconductor tape is impregnated.
17
C.
Resistance Temperature Detector:The stator slots are provided with platinum resistant thermometer to record and watch
the temperature of stator core and tooth region and between the coil sides of machine
in operation. All AC machines rated for more than 5 MVA or with armature core
longer, the machine is to be provided with at least 6 resistance thermometers. The
thermometer should be fixed in the slot but outside the coil insulation. When the
winding has more than one coil side per slot, the thermometer is to be placed between
the insulated coil sides. The length of resistance thermometer depends upon the length
of armature. The leads from the detector are brought out and connected to the terminal
board for connection onto temperature meter or relays. Operation of RTD is based on
the prime factor that the electric resistance of metallic conductor varies linearly with
temperature
END COVERS:-
The end covers are made up of fabricated steel or aluminum castings. They are
employed with guide vans on inner side for ensuring uniform distribution of air or
gas.
18
EXCITER:-
EXCITER ROTOR
19
rectifier wheels
three phase main exciter
three phase pilot exciter
Metering and supervisory equipment.
MACHINE SECTION:-
The machine section of Bay-4 is equipped with small and medium size
CNC & conventional machine tools like centre lathes, milling, radial drilling,
20
cylindrical grinding, slotting, copy turning lathe, internal grinding and surface
grinding machines. Small-size and miscellaneous components for Turbogenerators, Hydro generators and Motors are machined in this section.
POLE COIL SECTION
COILING SECTION
21
Take out the softened copper rolls for pole coil winding.
Winding is done with the help of change plate & winding template so
ensure major working dimensions of change plate & winding template
with respect to tool drawing.
Adjust & set the winding machine as per the product standards using
gear rack, change plate & winding template. Ensure parallelity of
winding template with respect to machine platform. Maintain height of
winding template with platform. Wind the coil in anticlockwise
direction.
NOTE: 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. Carry out bright annealing of the coil. Take out the coil from the oven
after annealing.
5. FIXING:-
22
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
the coil.
9. Braze item 2 & 3 corresponding to the variant with end half turn with
brazing alloy
Ag 40 Cd.
10. FINISHING: Hang the coil on stand and separate out turns
23
Remove black spots, burrs the sharp edges and clean the coil turns with
cotton dipped in thinner.
Press the coil again and check the height of the coil under press to
check dimensions as per drawing.
11. Take out the coil from the press and send for insulation.
12. INSULATION: Hang the coil on stand and separate out the turn.
Clean each turn with cotton dipped in thinner.
Apply Epoxy varnish on both sides of each turn with brush uniformly
all over the leaving top & bottom turn.
Cut strips of Nomax paper as per contour of coil with technological
allowance 3 to 5 mm on either side.
Stick two layers of Nomax strips between each turn.
Coat varnish layer between two layers of Nomax also.
Let the excess varnish to flow out some time
13. BAKING AND PRESSING OF COIL: Place the coil on mandrel putting technological washer at top & bottom
of the coil.
Heat the coil by DC up to 100 +/-5o C , and maintain for 30 to 40
minutes.
Switch off the supply and elongate the coil and tight the pressing
blocks from sides.
Start heating coil again and raise temperature gradually in steps up to
130 +/- 5o C , with in 10 +/- 10 minutes.
Apply 110 tones pressure and maintain for 20 to 30 minutes. Then after
every half an hour, increases the pressure and temperature according to
product requirement.
Stop heating and then allow cooling the coil under pressure below 50o
C, and taking out the coil from the press.
14. CLEANING AND DRYING: Clean outer and inner surface of projected insulation by means of shop
made scrubber.
Flow dry compressed air after cleaning.
Check height and window dimensions as per drawing.
Check no gap between the turns.
24
Test the coil from inter turn test at 116 volts AC at a pressure of 480
tons in 5 minutes.
15. Coat the coil with two layers of epoxy red gel.
IMPREGNATION SECTION:-
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.
25
Turbo-generators Test Bed -The Test Bed for Turbo-generators and Heavy
motors is equipped with one no. 6 MW drive motor and a test 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.
VII. LARGE SIZE TURBO GENERATOR TEST STAND (LSTG):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.
HELIUM LEAK TEST
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.
VIII. Testing of stator frame involves two types of testing:
HYDRAULIC TESTING AND PNEUMATIC TESTING
Hydraulic testing involves in empty stator frame with attached end shields and
terminal box is subjected to a hydraulic test at 10 bar to ensure that it will be
capable of withstanding maximum explosion pressure.
The pneumatic testing involves filling of hydrogen in the sealed stator frame
and then soap water is used to check the leakage of welding.
26
4. CONCLUSION
The Vocational training at BHEL Hardwar helped me in improving my practical
knowledge and awareness regarding Turbo Generator to a large extent.
Here I came to know about the technologies and material used in manufacturing of
turbo generators. Besides this, I also visualized the parts involved or equipments used
in the power generation.
Here I learnt about how the electrical equipments are being manufactured and how
they tackle the various problems under different circumstances. At least I could say
that the training at BHEL Hardwar is great experience for me and it really helped me
in making or developing my knowledge about turbo generator and other equipment
used in power generation.
5. REFERENCES
1.
2.
27