Documente Academic
Documente Profesional
Documente Cultură
BACHELOR OF TECHNOLOGY
In
By
Mr.J.P.Balaji (HOD)
We take this opportunity to record our gratitude to all those who helped us in
successful completion of the project.
Finally, we wish to express our profound thanks to all the employees, in charges
and workmen without whose support, completion of this project would have been
impossible.
ABSTRACT
INTRODUCTION
Introduction
Principle of operation
Stator
Rotor
STATOR
Stator
Stator frame
Stator core
Preparation of laminations
Compounding operation
Deburring operation
ROTOR
Rotor
Rotor shaft
Rotor winding
Construction
Conductor material
Insulation
INSULATION SYSTEM
VPI system
Process of VPI
1. General
2. Preheating
3. Impregnation
4. Post curing
5. Electrical testing
Gas turbines
Steam turbines
Compressors
Turbo generators
Heat Exchangers
Pumps
Pulverizers
Switch Gears
Oil rigs
BHEL Hyderabad is the only one in Asia that has the latest type of insulation system called the
Vacuum Pressure Impregnation System.
INTRODUCTION:
TURBO GENERATOR
A turbo generator is a turbine directly connected to electrical generator for the generation of
electric power. An electrical generator is a machine which converts mechanical energy to
electrical energy.
PRINCIPLE OF OPERATION:
Turbo generator or A.C. generators or alternators operates on the fundamental
Principles of FARADAYS LAWS OF ELECTROMAGNETIC INDUCTION. In them the
standard construction consists of armature winding mounted on stationary element called stator
and field windings on rotating element called rotor. The stator consists of a cast-iron frame,
which supports the armature core, having slots on its inner periphery for housing the armature
conductors. The rotor is like a flywheel having alternating north and south poles fixed to its outer
rim. The magnetic poles are excited with the help of an exciter mounted on the shaft of alternator
itself. Because the field magnets are rotating the current is supplied through two slip rings. As
magnetic poles are alternately N and S, they induce an e.m.f and hence current in armature
conductors. The frequency of e.m.f depends upon the no.
of N and S poles moving past a conductor in 1 second and whose direction is given by Fleming
s right hand rule.
STATOR
Stator Frame
Stator Core
Stator Windings
End Covers
ROTOR
Rotor Shaft
Rotor Windings
Bearings
Cooling System
Excitation System
STATOR
S TATOR
STATOR FRAME:
The stator frame is of welded steel single piece construction. It supports the laminated core and
winding. It has radial and axial ribs having adequate strength and rigidity to minimize core
vibrations and suitably designed to ensure efficient cooling. Guide bars are welded or bolted
inside the stator frame over which the core is assembled. Footings are provided to support the
stator foundation.
S TATOR 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 e
current losses core is made of thin laminations. Each lamination layer is made of individua
sections. The ventilation ducts are imposed so as to distribute the gas accurately over the c
and in particularly to give adequate support to the teeth.
The main features of core are
1. To provide mechanical support.
2. To carry efficiently electric, magnetic flux.
3. To ensure the perfect link between the core and rotor.
THE PURPOSE OF STATOR CORE
To support the stator winding
To carry the electromagnetic flux generated by rotor winding.
So selection of material for building up of core plays a vital role. The losses in the core are of
two types.
Hysterysis Loss: Due to the residual magnetism in the core material.
Hysterysis loss is given by
Wh max 1.6
Eddy Current Loss: Due to the e.m.f induced in the core of the stator. Eddy current loss is
given by
We max2 f2 t2
In order to reduce the hysterysis loss, silicon alloyed steel, which has low hysterysis constant is
used for manufacture of core. The composition of silicon steel is
Steel - 95.8%
Silicon 4.0%
Impurities - 0.2%
From the formula it is seen that eddy current loss depends on the thickness of the laminations.
Hence to reduce the eddy current loss core is made up of thin laminations which are insulated
from each other. The thickness of the laminations is about 0.5mm. The silicon steel sheets are of
COLD ROLLED NON-GRAIN ORIENTED (CRANGO) type as it provides the distribution of
flux throughout the laminated sheet.
PREPARATION OF LAMINATIONS:
For high rating machines each laminations is build of 6 sectors (stampings), each of 60 cut
according to the specifications. Press tools are used in the manufacture of laminations. Press
tools are mainly of two types.
Compounding tools.
Blanking and slot notching tools.
LAMINATIONS ARE MANUFACTURED IN TWO DIFFERENT WAYS
COMPOUNDING OPERATION:
In this method the stamping with all the core bolt holes, guiding slots and winding slots is
manufactured in single operation known as Compounding operation and the press tool used is
known as Compounding tool. Compounding tools are used for the machines rated above 40 MW.
Deburring operation:
In this operation the burrs in the sheet due to punching are deburred. There are chances of
short circuit within the laminations if the burrs are not removed. The permissible is about 5
micrometer. For deburring punched sheets are passed under rollers to remove the sharp burs of
edges.
Varnishing:
Then depending on the temperature withstand ability of the machine the laminations are
coated by varnish which acts as insulation. The lamination sheets are passed through conveyor,
which has an arrangement to sprinkle the varnish is obtained. The sheets are dried by a series of
heaters at a temperature of around 260-350 C. Two coatings of varnish are provided in the above
manner till 12-18mm thickness of coat is obtained.
The prepared laminations are subjected to following tests:
Xylol test - To measure the chemical resistance.
Mandrel test - When wound around mandrel there should not be any
cracks.
Hardness test - Minimum 7H pencil hardness.
IR value test - For 20 layers of laminations insulation.
ASSEMBLY OF CORE:
The stator laminations are assembled as separate cage without stator frame. The entire core
length is made in the form of packets separated by radial ducts to provide ventilating passages
for the uniform cooling of the core. The thickness of each lamination is 0.5mm and the thickness
of lamination separating the packets is about 1mm. The lamination separating each packet has
strips of nonmagnetic material that are welded to provide radial ducts. The segments are
staggered from layer to layer so that a core of high mechanical strength and uniform permeability
to magnetic flux is obtained. Stacking mandrels and bolts are inserted into the windings slot
bores during stacking provide smooth slot walls.
Fig: assembly of core
To obtain the maximum compression and eliminate under setting during operation, the
laminations are hydraulically compressed and heated during the stacking procedure when certain
heights of stacks are reached. The complete stack is kept under pressure and located in frame by
means of clamping bolts and pressure plates.
The clamping bolts running through the core are made of nonmagnetic steel and are
insulated from the core and pressure plates to prevent them from short circuiting the laminations
and allowing the flow of eddy currents. The pressure is transmitted from the clamping plates to
the core by clamping fingers. The clamping fingers extend up to the ends of the teeth thus,
ensuring a firm compression in the area teeth.
STATOR WINDINGS:
Stator winding is the one which induces emf and supplies the load. Stator winding is placed
in the slots of stator core. Due to the advantages of generation and utilization of 3 phase power
we use three phase windings for generation. So number of slots must be a multiple of 3 (or 6 if
two parallel circuits are required).
Generally two layer lap winding, chorded to about 5/6 pitch which practically eliminates 5th
and 7th harmonics from the flux wage or open circuit induced emf wave is used. The stator coil is
made up of number of strips instead of single solid piece to reduce the skin effect.
Generally diamond pulled multiturn coils are used for low capacity machine. In this coils are
pulled in a particular shape similar as diamond thats why they are called so.
In large capacity machines we use ROEBEL bars. These coils were constructed after
considering the skin effect losses. In the straight slot portion, the conductors or strips are
transposed by 360 degrees. The transposition is done to ensure that all the strips occupy equal
length under similar conditions of the flux. High purity (99%) copper conductors/strips are
used to make the coils. This results in high strength properties at higher temperatures so that
deformations due to the thermal stresses are eliminated. The high voltage insulation is provided
according to the resin poor mica base of thermosetting epoxy system. Several half overlapped
continuous layers of resin poor mica tape are applied over the bars. The thickness of the tape
depends on the machine voltage.
Slot discharges occur if there are gaps within the slot between the surface of the insulation and
that of the core. This may cause ionization of he air in the gap, due to breakdown of the air at the
instances of voltage distribution between the copper conductor and the iron.
Within the slots, the outer surface of the conductor insulation is at earth potential, in the
overhanging it will approach more nearly to the potential of the enclosed copper. Surface
discharge will take place if the potential gradient at the transition from slot to overhang is
excessive, and it is usually necessary to introduce voltage grading by means of a semi-
conducting (graphite) surface layer, extending a short distance outward from the slot ends.
3.6.2 MANUFACTURE OF STATOR COILS:
1.Tape the bar with Resin poor fine mica paper tape on straight part of bar taking copper foil
outside the tape.
3.Tape the straight part of bar with conductive polyester fleece tape with starting and ending
shall be on straight part of bar.
4.Tape with mica splitting tape with accelerator taking Ocp layer into and leaving.
5.Tape the straight part of bar with polyester Conductive fleece tape.
The stator end covers are attached to end flanges of stator frame and also rest on the foundation
plate. The end covers are made up of non-magnetic material (Aluminium castings) to reduce
stray load and eddy current losses.
The phase connectors consist of flat copper sections, which results in low specific current
loading. The phase connectors are wrapped with resin rich mica tape. After curing the
connectors are attached to the pressure plate with clamps and bolts.
The temperature measurements on the generator are made with RTDs. They are placed at various
sections of the core and winding. When making measurements with RTDs the resistance element
is exposed to the temperature to be measured.
The RTD works on the principle of the change in electrical resistance of a conductor due to
temperature. R= Ro (1+ T) ;Where Ro = reference resistance at room temperature; R=
temperature coefficient of resistance ; T = temperature difference in C.
ROTOR
ROTOR:
Rotor is the rotating part of alternator. It is used to support field winding placed in slots on the
rotor.
Solid rotors are manufactured from forged alloy steel with suitable alloying elements to achieve
very high mechanical and superior magnetic properties. This type of rotor can withstand even
upto speed of 3000 rpm. Rectangular or trapezoidal rotor slots are accurately machined to close
tolerances on slot milling machine.For indirectly cooled generator rotors, ventilation slots are
machined in the teeth.
For directly cooled rotors, sub slots are provided for cooling Generator rotors of 1500 RPM are
of round laminated construction. In this case rotor is made up of two parts (1) core, (2)
lamination. The outer diameter of core and the inner diameter of laminations are equal. So for
inserting the core inside the laminations the laminations are first red heated at medium
temperature for 15 hours in BELL FURNACE. After that the core is shrunk fitted inside the
laminations. Thus punched and varnished laminations of high tensile steel are mounted over
machined shaft and are firmly clamped by end clamping plates.
ROTOR SHAFT :
Rotor shaft is a single piece solid forming manufactured from a vacuum casting. It is forged from
a vacuum cast steel ingot. Slots for insertion or the field winding are milled into rotor body. The
longitudinal slots are distributed over the circumference such that two solid poles are obtained.
To ensure that only a high quality product is obtained, strength tests, material analysis and
ultrasonic tests are performed during the manufacture of rotor. The high mechanical stresses
resulting from the centrifugal forces and short circuit torques call for a high quality heat treated
steel. After completion, the rotor is balanced in various planes at different speeds and then
subjected to an over speed test at 120% of the rated speed for two minutes.
Approximately 60% of rotor body circumference has longitudinal slots which hold the field
winding. Slot pitch is selected so that the two solid poles are displaced by 180 degrees. The rotor
wedges act as damper winding within the range of winding slots. The rotor teeth at the ends of
rotor body are provided with axial and radial holes enabling the cooling air to be discharged into
the air gap after intensive cooling of end windings.
ROTOR WINDINGS :The rotor windings consist of several coils inserted into the slots
and series connected such that two coil groups form one pole. Each coil consists of several series
connected turns, each of which consists of two half turns connected by brazing in the end
section. Thickness of each strip can be made upto 10.5 mm but here in BHEL we make only upto
5.3 mm. The rotor bearing is made of silver bearing copper ensuring an increased thermal
stability. For ventilation purpose the slots are provided on the coil and on inter strip insulation
layer both.
The individual turns of coils are insulated against each other by interlayer insulation. L-shaped
strips of laminated epoxy glass fiber fabric with nomex filter are used for slot insulation.
Fig: rotor winding.
The slot wedges are made of high electrical conductivity material and thus act as damper
windings. At their ends the slot wedges are short circuited through the rotor body. The inter
space between the overhang is called slot through.
CONSTRUCTION
The field winding consists of several series connected coils inserted into the longitudinal slots of
rotor body. The coils are wound so that two poles are obtained. The solid conductors have a
rectangular cross section and are provided with axial slots for radial discharge or cooling air. All
conductors have identical copper and cooling duct cross section. The individual bars are bent to
obtain half turns. After insertion into the rotor slots, these turns are brazed to obtain full turns.
The series connected turns of one slot constitute one coil. The individual coils of rotor are
connected in a way that north and south poles are obtained.
INSULATION
The insulation between the individual turns is made of layer of glass fiber laminate.
The coils are insulated from the rotor body with L-shaped strips of glass fiber laminate with
nomex interlines.
To obtain the required leakage paths between the coil and the rotor body thick top strips of glass
fiber laminate are inserted below top wedges. The top strips are provided with axial slots of the
same cross section and spacing as used on the rotor winding. Insulation b/w overhang is done by
blocks made of HGL.
To protect the winding against the effects of centrifugal forces, the winding is secured in the
slots with wedges. The slot wedges are made of copper alloy featuring high strength and good
electrical conductivity. They are also used as damper winding bars. The slot wedges extend
beyond the shrink seats of retaining rings. The wedge and retaining rings act on the damper
winding in the event of abnormal operations. The rings act as short circuit rings in the damper
windings.
The spaces between the individual coils in the end winding are filled with insulated members
that prevent coil movement. Two insulation plates held by HGL high glass laminate plates
separate the different cooling zones in the overhangs on either sides.
The centrifugal forces of the rotor end winding are contained by single piece rotor retaining
rings. Retaining rings are made of non-magnetic high strength steel in order to reduce stray
losses. Each retaining ring with its shrink fitted. Insert ring is shrunk on to the rotor body in an
overhang position. The retaining ring is secured in the axial position by snap rings.
The rotor retaining rings withstand the centrifugal forces due to end windings. One end of each
ring is shrunk fitted on the rotor body while the other end overhangs the end windings without
contact on the rotor shaft. This ensures an unobstructed shaft deflection at the end winding.
ROTOR FANS
The cooling air in generator is circulated by two axial flow fans located on the rotor shaft one at
each end. To augment the cooling of the rotor winding, the pressure established by the fan works
in conjunction with the air expelled from the discharge parts along the rotor. The blades of the
fan have threaded roots for being screwed into the rotor shaft. The blades are drop forged from
an aluminium alloy. Threaded root fastenings permit angle to be changed. Each blade is secured
at its root with a threaded pin.
BEARINGS
VENTILATION AND COOLING
INSULATION SYSTEMS
BHEL INSULATION SYSTEM FOR TURBO GENERATORS:
BHEL had Bitumen insulation system for low & medium rating TGS and switched over to resin
rich Thermo setting type as a step towards increasing reliability and upgrading technology.
Micalastic system has been adopted for high rating machinery.
The experience with Bitumen system has been generally satisfactory & practically
negligible service failure has been reported on these sets.
Mechanical damage most commonly associated with this system ie., tape separation, due
to thermal expansion of the winding during normal or abnormal temperature eyeing is not
met any of sets.
Though outage due to insulation failures has been considerably low, yet these machinery
would need to be attended to have life extension above their estimated life of 25 years.
Major inspection of the machine condition is by checking the healthiness of windings &
life of bar insulation.
Rehabilitation, if needed, requires restoration of varnish, removal of bitumen & cleaning,
tightening of fasteners/supports, modification of busbars, use of new wedges & other
winding components.
Large & medium range motors are provided with following insulation system.
1.Resin flux Insulation System : This system is used on earlier designs & where duplicate or
spare motors to suit the customer requirements are required. In the coming years this system may
become absolute.
2.Resin Rich micalastic Insulation System : The system provides use of Resin rich polyester
backed epoxy micafolium on straight portion & resin rich polyester backed epoxy mica paper
tape on overhang with a final layer of polyester shrink tape. The system is highly productive
during coil manufacture and housing.
3.Resin poor Micalastic Insulation System: Resin poor micalastic system is adopted for large
range Ac Induction and synchronous machines. Theses are designated to meet specific customer
requirement hence for unique in nature to each other. The main insulation consists of resin poor
epoxy mica paper tape all over the oil periphery with varying number of layers on straight and
overhang portions.
The brief comparison of Resin poor over Resin rich is as follows:
1.Epoxy resin content is about 8%. 1.Epoxy resin content is about 40%.
2.This method follows Thermo Setting 2. This method also follows Thermo Setting
Process. Process.
3.There is a need for addition of resin from 3. Further addition of resin is not required from
outside. outside.
4.Time required for this cycle is less.
4.Its a very long process and time consuming.
5.Repairing is very difficult.
5.Repairing is easy.
DR. MEYER brought the VPI system with the collaboration of WESTING HOUSE in the year
1956. Vacuum Pressure Impregnation has been used for many years as a basic process for
thorough filling of all interstices in insulated components, especially high voltage stator coils and
bars.
VPI is a process, which is a step above the conventional vacuum system. VPI includes
pressure in addition to vacuum, thus assuring good penetration of the varnish in the coil.
The result is improved mechanical strength and electrical properties. With the improved
penetration, a void free coil is achieved as well as giving greater mechanical strength.
With the superior varnish distribution, the temperature gradient is also reduced .
In order to minimise the overall cost of the machine & to reduce the time cycle of the
insulation system vacuum pressure Impregnated System is used.
The stator coils are taped with porous resin poor mica tapes before inserting in the slots of
cage stator, subsequently wounded stator is subjected to VPI process, in which first the
stator is vacuum dried and then impregnated in resin bath under pressure of Nitrogen
gas.
PROCESS:
1.General:
The jobs that are entering tank for Vacuum Pressurised Impregnation shall not have any
oil based coatings. Any such, rust preventive/ corrosion preventive viz., red oxide etc.,
shall be eliminated into the tank.
Resin in the storage tank shall be stored at 10 to 12C and measured for its
viscosity, viscosity rise.
Proper functioning of the impregnation plant and curing oven are to be checked
by production and cleared for taking up of job for impregnation
2.Preheating:
The job is to be loaded in the curing oven and heated. The temperature is to be
monitored by the RTD elements placed on the job and the readings are logged by
production. The time of entry into the oven, time of taking out and the temperature
maintained are to be noted. Depending on convenience of production the jobs can be
preheated in impregnation tank by placing them in tubs.
The impregnation tubs used for impregnation of jobs are to be heated in the
impregnated tank itself, when the jobs are preheated in the curing oven.
3. Impregnation:
By the time, the preheating of job is completed, it is to be planned in such a way that the
heating of tub and tank heating matches with the job. This is applicable when the job is heated in
the curing oven separately. The preheated job is to be transferred into the tub by crane handling
the job safely and carefully with out damage to the green hot insulation.
The warm tub with job is inserted into impregnation tank by sliding on railing, in case of
horizontal tank. The thermometer elements are to be placed at different places on the job. The
connection for inlet resin is to be made for collection of resin into tub. After ensuring all these
the lid of the impregnation tank is closed. In case of vertical tank the job along with tub is
slinged and inserted carefully into impregnation tank without damage to insulation.
The job is to be dried under vacuum. Drain out the condensed moisture/ water at the
exhausts of vacuum pumps for efficient and fast vacuum creation. Also check for oil replacement
at pumps in case of delay in achieving desired vacuum.
The resin is allowed into the impregnation tank tub if required from various storage
tanks one after the other up to a level of 100mm above the job generally, after which the resin
admission is stopped. After 10mins of resin settling the tank is to be pressurized by nitrogen.
While admitting resin from storage tanks pressurize to minimum so that nitrogen will not affect
resin to spill over in tank.
Pressurizing/gelling
The resin that is pressurized as per pressure cycle by which the opening of relevant valves
will allow the resin to come back to the storage tank. The job also shall be allowed for dripping
of residue of resin for about 10min. After dripping, withdrawal of resin in various storage tanks
is to be carried out.
The lid is then opened after taking precautions of wearing mask and gloves for the
operating personnel as a protection from fumes. The job is withdrawn from
impregnation tank by sliding on railing for horizontal and slinging on to crane for
vertical impregnation tanks.
4. Post curing: The job is post heated. The time for raising from job temperature to this
temperature as per relevant annexure. The time at which the heating is started, achieved and
maintained is to be logged.
5.Electrical testing:
All jobs that are impregnated till above process, are to be tested for electrical tests. After
ensuring that all the temperature/vacuum conditions stipulated for drying, impregnation and
curing operations have been properly followed, the job is to be released for this operation.
CONCLUSION
AND
FUTURE SCOPE
CONCLUSION :
REFERENCES:
www.indiamart.com
www.eriks.co.uk
www.seimens.com
www.bhel.com