Documente Academic
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Project Incharge:
Mr. Satish k. Singh
Submitted By:
BHEL, Haridwar Ajay Jangir
ACKNOWLEDGEMENT
Engineer is a boon for this modern era because of leaps and bound advancement in
modern technology. So it is a very important to impart a practical knowledge and t
heoretical knowledge. I am very grateful that I got the opportunity to have training
from BHEL, Haridwar. Which is the no.1 industry in India.
et and outlet of water are brazed. The water box is also known as contact slew. The
contact slew is brazed with the help of copper aluminium alloy rod. This rod is br
ought to touch to hot contact slew and after melting it fill the spaced, in this manne
Micalastic system :
In case of poor resin system the insulated bars are heated under vacuum and t
he impregnated (dipped) in heated resin so that all the air gap are filled, layer
by layer, with resin. Then extra resin is drained out and the bar are heated and
baked under pressed condition in closed fixture.
The bar already laid in closed fixture and full fixture is impregnated (dipped) i
n resin and then fixture with box is baked under given temperature for given d
uration.
Insulation:
The bar is insulated with the given number of layer to built the wall thickness
of insulation subject to the generating voltage of machine.
Finishing:
The baked and dimensionally correct bars are sanded-off to smoothen the edg
es and the surface is calibrated, if required, for the dimension.
Manufacturing process:-
1- Stator-
The stator is assembled as six parts. It is made up of steel with 4.5% of silica. Silic
a decreases hysteresis loss. The sheets are cut at 30 degree angles. The sheets then
are punched with man drill holes, support rod slots and slots for the conductors. Th
is process is called notching and the cutting part as shearing. The sheets are then va
rnished after blanking or smoothening of the surface. This is to increase the insulati
on. A bunch of these sheets are stacked together and compressed onto each other s
o that air gaps are eliminated. These stacks are then assembled with a small air gap
differentiating each stack. This ventilates the machine and keeps it cool. After the a
ssembly of the stator shell, the inside of the slots are varnished. The sheets of the c
ore are varnished with xylor, at a temperature of 30-400 degrees Celsius. It is heate
d, coated then cooled. After the core is assembled , the winding is placed in the stat
or. The winding type depends upon the power required and the current required to
be produced. The core and the winding are separated by an insulation called HGL.
This prevents the shorting of the core and winding .The winding in the front and ba
ck are also separated by this material and they are joined as per the winding require
d (lap or wave) using glass-o-flex, a pink ribbon like material. The windings are in
sulated. These windings are then painted to obtain a the stator, where the power is
generated. The windings are always inserted from the exciter end, one is clockwise
and the other anti-clockwise.
2-The Rotor-
The rotor comprises of following component:
Rotor shaft -1
Rotor winding -2
Rotor wedges and other locating parts for winding -3
Retaining ring -4
Fans -5
Field lead connections -6
The rotor is carved out with the slots into a cylindrical shape from a large block o
f metal using Lathe heavy machines. The rotor consists of 2 ends –
•The turbine coupling end
•The exciter end
The turbine end has a coupling shaft which is circular in shape and has slots.
The exciter end has an input lead and an output lead which are used to give the roto
r DC input for the excitation of the rotating field.
The ends of each rotor consist of bearings. These bearings are placed so as to supp
ort the shaft. The bearing consists of oil which is used to support a thin film over th
e surface. This lubricates and decreases friction and losses. The bearing has top end
and bottom end and is stationary. The top end is used to supply the oil. After the c
onstruction, the winding is fitted into the slots. The slots and windings are separate
d by HGL or hard glass lamination which insulates the core from the cable. The rot
or is constructed so as to obtain brushless excitation. The complete rotor along wit
h the excitation mechanism is mounted on the shaft and is balanced for synchronou
s speed. For better balancing weight removal is done as that is a better option to ad
ding weight to the system. The rotor ends are provided with induction motor fans
which are used for cooling of the rotor winding. The winding is made up of 99.99
% copper.
WORKING PRINCIPLE:-
One end of the alternator is coupled to the turbine and other end is coupled through
the exciter. The whole assembly is on the shaft. Turbine act as a prime mover, the
permanent magnet of the exciter creates a permanent magnetic field, which is cut b
y the rotor conductors. Making the formation of 3-phase power, this 3-phase power
is fed to the thyristor controlled switches for rectification. The 3-phase power is fe
d to main exciter, after that this 3-phase power is given to the diode wheel so it is
produce the dc power. The dc power is given to the main alternator field without br
ushes and slip ring. Then alternating field is produce by the cut of rotor conductors
making the production of emf by the FARADAY’S LAW.
Cooling of the Alternator:-
The machine needs to be cooled to avoid damage and for greater life. Heating caus
es insulation failure. Hence, cooling is a very important factor that needs to be take
n care of. For cooling, the stator and rotor are provided with a ventilation to cool it
down. Air gaps are provided throughout the machine. But for very high power mac
hines natural cooling is insufficient so a cooling system is provided. For collection
of hot air, a large chamber is provided. This air is cooled and recycled into the gen
erator. The rotor of the alternator consists of fans powered by induction motors. Th
ey suck in the air and push it through to the cooling chamber. Another method is al
so used which is called hydrogen cooling. Hydrogen acts as ac coolant and the cha
mber is shut completely is filled with hydrogen. Hydrogen cools itself. The chamb
er is emptied each time the machine is stopped.
TG TEST BED:-
New LSTG [Large Scale Turbo Generator] TEST BED has been put up with indige
nous know –how in record time testing Turbo Generator of rating 500MW and abo
ve up to 1000MW. It caters to the most advanced requirement of testing by employ
ing on line computer for data analysis.
Circuit –Breakers:-
Current interruption in a high-voltage circuit-breaker is obtained by separating two
contacts in a medium, such as SF6, having excellent dielectric and arc quenching p
roperties. After contact separation, current is carried through an arc and is interrupt
ed when this arc is cooled by a gas blast of sufficient intensity. Gas blast applied o
n the arc must be able to cool it rapidly so that gas temperature between the contact
s is reduced from 20,000 K to less than 2000 K in a few hundred microseconds, so
that it is able to withstand the transient recovery voltage that is applied across the c
ontacts after current interruption. Sulphur hexa fluoride is generally used in present
high-voltage circuit-breakers (of rated voltage higher than52 kV)In arc assisted op
ening interruption principle arc energy is used, on the one hand to generate the blas
t by thermal expansion and, on the other hand, to accelerate the moving part of the
circuit breaker when interrupting high currents. The over pressure produced by the
arc energy downstream of the interruption zone is applied on an auxiliary piston lin
ked with the moving part. The resulting force accelerates the moving part, thus incr
easing the energy available for tripping.
COOLING SYSTEM:-
Cooling system is a very important part of the alternator. Mainly two types of cooli
ng process is occur such as-
Radial cooling -1
Axial cooling -2
Since the cooling system is divided three part such as-
Hydrogen cooling -1
Water cooling -2
Air cooling -3
Cooling system is used because dissipating the heat generated by various losses
and to prolong the life of insulating material. In small generator natural cooling
is adequate. In these machines cooling by natural sources is sufficient, but in la
rge generators natural cooling is in sufficient, so in these generator air, water &
hydrogen is done. Force air cooling is used for large machine. In this scheme air
is first passed through cleaning filter and then forced through the machine for c
ooling purpose. Air cooling system is better and necessary in 500MW & 600M
W generator.
EXCITATION SYSTEM:-
Turbo generator is a doubly excited machine. Because it’s field winding is excit
ed by dc source and it’s armature winding is connected to ac source. For dc exci
tation we need use the use of exciter. Hence there are three types of dc excitatio
n-
DC exciter -1
Static excitation -2
Brushless exciter -3
In our BHEL organization brushless exciter is widely use because slip ring and
brushes is absent and it is provide less losses so that it’s efficiency is high so we
use the brushless exciter. The brushless exciter is used for generating the dc fiel
d which is used to fall on alternator of rotor. When the dc field is fall on the roto
r and the rotor is directly connected to the turbine so that the turbine is rotate th
e rotor, the alternating field is generated by the rotor then due to the induction t
he alternating emf is generated in the stator core. These emf is received by the s
tator terminal those are called ac voltage.
The brushless exciter has mainly two parts such has-
Pilot exciter -1
Main exciter -2
In pilot exciter permanent magnet is used, which produce the permanent magnet
ic field. Three phase power from pilot exciter is fed to thyristor controlled brid
ge to main exciter. After rectification the controlled dc output is supplied to stat
ionary field winding of main exciter.
ELECTRICAL GENERATOR PROTECTION:-
Generator may be endangered by short circuit, ground fault, over voltage, under
excitation and excessive thermal stresses. The following protective equipment i
s recommended such as –
Differential protection -1
Stator ground fault protection -2
Rotor ground fault protection -3
Under excitation protection -4
Over current protection -5
Load unbalance protection -6
Rise in voltage protection -7
Under frequency protection -8
Reverse power protection -9
10-Over voltage protection
CONCLUSION:-
Bharat heavy electrical limited is the largest engineering and manufacturing ent
erprises of kind in the public sector in India. The sector is an important part in t
urbo generators. The stator is assembled by the laminated sheets. We use the U
NIVERSAL FORM FICTURE type bar which assemble all the straight part and
the over hang at a time. The universal from facture type bar is more flexible an
d its life time more. We use the bar transposition for stator winding which is mo
re advantages. BHEL has acquired the latest technology in the insulation system
, the VACCUM IMPREGINATION system of insulation, which has various ad
vantages like cost reduction with improve quality. Thus designed an manufactur
ed start of turbo generator is used mostly in paper, sugar, cement, petrochemical
, fertilizer, Rayon, industries. The architecture of BHEL, the way various units a
re linked and the way working of whole plant is controlled make the students re
alize that engineering is not just structural description but greater part is plannin
g and management.
It has allowed us and an opportunity to get and exposure imple
mentation of theoretical fundamental.