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TECHNOLOGY
B.E.(ELECTRICAL)
I take this opportunity with much pleasure to thank all the people who
have helped me through the course of journey through producing this
report.
I sincerely thank my thesis supervisor Mr. A.K. Dhiman for his guidance,
help and motivation.
ANISH GUPTA
B.E.(ELECTRICAL)
3RD YEAR
PEC UNIVERSITY OF TECHNOLOGY
BHEL- Corporate Profile
In the late fifties Bharat Heavy Electrical Established Limited , better known
BHEL, is today the largest engineering and manufacturing enterprises of its kind in
India . the first plant of BHEL was established nearly 47 years ago in August 1956
at Bhopal and was the genesis of heavy electrical equipment industry in India.
The organization is engaged in engineering, development and manufacture of a
wide variety of electrical and mechanical equipments for generation, tansmission
and utilization of energy and electric power. The company provides product, system
and services for the energy sector as well as for industry and transportation. It has a
well recognized track record of performance, making profit continuously since
1971-72. It achieved a sales turnover of Rs. 5625 crores 1999-2000 and NAV per
share Rs. 135. A vast reservoir of manufacturing skills – the 80000- strong BHEL
family comprises a formidable team of engineers, scientists, managers, and trained
technicians. In the world power scene BHEL ranks among the top 12
manufacturers. It is the largest engineering and manufacturing enterprises of its
kind in India. It has a well recognized track record of performance making profit
continuously since 1971-72. It offers services from project feasibility studies trough
after – sales services, thus meeting all customer requirements. More than 456
countries ranging from USA and USSR in the west to Australia and New Zealand in
the east are BHEL‘s customers. Its operations are spread over 14 manufacturing
units, 4 power sectors regional centers, over 150 project sites and service centers,
and 15 regional offices, which enable the company to be closer to its customer and
provide them with suitable products, system and services at competitive prices.
Having attained ISO 14001 and TQM (total quality management) BHEL is now on
its journey towards ISO 18001 (OHSAS).
3. High Pressure Boiler Plant & Seamless & Steel tubes plant Tirichi.
Thermal Sets:
Turbine generator sets along with all Auxillaries of thermal power plant of
the utilities are supplied for rating of 30, 60, 110, 120, 200, 210 & 500 MW
capacities.
Hydro Sets:
Heat Exchangers:
Surface condensers.
Low pressure heaters for re-generative feed heating systems.
High pressure heaters.
Chimney and gland steam-condensers for all operating conditions.
Coolers, condensers, separators and seal oil regulators, tanks, for upto 300
atm on channel sides of any material.
Try type de-areators for TG sets.
Steam operated air ejectors.
Boiler Auxiliaries:
Fans-Axial reaction fans of single stage and double stage for clean air
application with capacity ranging from 25m^3/sec to 800m^3/sec with
pressure ranging from 120 to 1480 meters of gas column. Axial impulse fans
single and double suction radial fans etc are also.
Air heaters-Ljungstrong regenerative air-heaters for boiler and process
furnaces in a broad range of size and capacities.
Gravimetric feeders.
Pulverizes- slow and medium speed coal pulverizes upto a capacity of 100
tones/ hour.
Electro static precipitators- of any capacity with efficiency upto 99.5% for fly
ash removal in power plants.
Mechanical separators.
Steam generators for utilities; range- 30MW to 500MW using coal, oil,
natural gas or a combination of these fuels.
Steam generators for industrial applications; range- 6tonnes/hour to
300tonnes/hour using coal, oil, natural gas, industrial gases, wood, bio gases
or a combination of these fuels.
Waste heat recovery boilers.
Recovery boilers for paper industry; range- 100tonnes/day to 1000 tons/day
of dry solids.
Pressure vessels.
Fluidized bed boilers.
Pumps:
Diesel electric oil rigs for onshore drilling for depths upto 9000m complete
with matching draw-works and hoisting equipments.
Christmas tree valve and well head assembly.
Compressors:
Centrifugal compressors of varying size for industrial applications range
covers MCL series (pressure upto 40kg/cm^2 and capacity upto
350,000NM^3/hr) amd BCL series (pressure upto 800kg/cm^2 and capacity
upto 50,000 NM^3 /hr) and package SRL series (pressure ratio upto 40 and
capacity upto 240,000 NM^3/hr).
Transformers:
Electrical Machines:
Hot finished and cold drawn seamless steel tubes with a range varying from
outer diameter of 14mm to 159mm and wall thickness 12.5mm in carbon
steel and low alloy steels to suit ASTM/AP and other international
specifications.
Capacitors:
Power capacitors for industrial use from 2to 20KVAr at 400V.
Capacitors for high voltage installation.
Coupling/ CVT capacitors for high voltage upto 400KV.
Electrolytic and paper capacitor for motor start and motor run duties.
Transportation Equipments:
Traction motors.
Traction generators/ alternators.
Auxiliary machines.
Field diverting inductive shunts.
Eddy current clutches.
Transformers/ rectifiers.
Electronic control equipments.
Diesel electric shunting locomotives (350 HP to 700 HP).
Battery operated passenger vans.
Electric trolley buses.
Castings & Forgings:
Sophisticated heavy castings and forgings of creep resistant alloy steel and
other grades of alloy steels and meeting stringent international specification.
Thyristor Equipment:
BHEL- Haridwar
HEEP was set up in technical collaboration with M/S Prommash-export of USSR, for
the manufacture of power plant equipments. AC/DC motors of various sizes were
available with associated control equipment and started production in Jan 1976. In
1976 BHEL entered in to collaboration with M/S Kraftwerk Union A.G. of Germany
for design, manufacture, erection and commissioning of large size steam turbines
and turbo generators of unit rating upto 1000MW.
CFFP established in technical collaboration with M/S Creusot Loire of France and
became operational in 1976. It was established for production of highly
sophisticated alloy steel castings and forgings. CFFP has produced international
creep resistant steel , heat resistant steel , armour steel etc. it supplies casting for
steam turbines , turbo generators press ring , hydro turbines coupling blades.
Together, the two plants contribute significantly to the BHEL energy is generated
from the power equipment supplied by BHEL Haridwar. The Pollution Control
Research Institute has also been set up at BHEL Haridwar with the help of United
Nations Development Program (UNDP). The main objective of the institute is to
evolve industrial pollution control technologies with respect to air, water, noise,
and solid waste in order to avoid unintended side effects of economic growth of
country. BHEL Haridwar possesses very strong engineering base, R&D
infrastructure, very précised CNC and conventional machine tools.
Tool Room:
Die and stamping shop.
ICIM-39-270-270-20 mainframe computer along with satellite micros
& PC’s CAD/CAE stations.
Micalastic insulation systems.
Large size turbo generators test bed (upto 500MW IG).
Radio remote control for EOT cranes in certain areas.
Service plants (oxygen, nitrogen, PGP Acetylene, compressed air,
central refrigeration).
Pollution control research institute.
Generator research institute.
Metal research and testing: Various types of modern inspection and
quality control equipment/ devices and testing/ calibration facilities
(NDT, outline inspection, scanning, electron microscope,
spectroscope, electrical insulation spectrograph/ spectrometer,
industrial X ray/ gamma ray apparatus etc.
HEEP
Heavy Electrical Equipment Plant of BHEL, Haridwar involves in the
manufacturing of the power equipments such as turbines and AC/DC machines. It
comprises of following main blocks:
Electrical Machines Block (Block-I):
It is designed to manufacture hydro-generator, turbo-generators and large &
medium sized AC/DC electrical machines. There are number of self-propelled
electrically driven transfer trolleys for the inner bay movement of component/
assemblies.
Fabrication Block (Block-II):
It is the feeder block for various products- steam turbine, turbo generators,
hydro generators, electrical machines, apparatus and control gears, aircraft and
medical lines. This block has facilities for compressed air, oxygen, acetylene
and carbon-dioxide gas pipelines.
Turbine & Auxiliary Block (Block-III):
It manufactures turbines, hydro turbine, and gas turbines and turbine blades.
Special toolings for all products are also manufactured in the Tool Room
located in the same block. The block is equipped with the facilities of EOT
cranes, compressed air, steam, OSBT, indicating stands for steam turbine
rotors, one test stand for testing 210MW steam turbine and two separate test
stands for testing of governing assembly of steam and hydro turbine.
Manufacturing of motor stator coil, DC armature coil , main pole coil , inter
pole coil , equalizer coil etc.
Also manufacture heavy duty generator stator bar with new CNC machines
i.e. Robot bar center.
BAY-III: Insulation detail shop:- Manufacturing of hard insulation and machining
of hard insulation part (glass textile) such as packing, washer, insulation box,
wedges etc.
Bar: It is quite difficult to manufacture, handle and wind the coil in stator slot of
generator of higher generation capacity because of its bigger size and heavy weight.
That is why we make coil in two parts- bottom (lower) and top (upper) part.
Insulation classification:
Thermal classification of insulation depends upon the temperature withstand
capability of the insulation.
Class Temperature
Y Upto 90 C
A Upto 105 C
E Upto 120 C
B Upto 130 C
F Upto 150 C
H Upto 180 C
C >180 C & upto 220 C
Types of generators:
The generators may be classified based on the cooling system used in the generators
such as: THRI, TARI, THDD, THFF, and THW.
T= Ist alphabet signifies the type of generator i.e. turbo or hydro generator.
H/A=IInd alphabet stands for the cooling media used for the cooling of rotor i.e.
hydrogen gas or air.
R/D/F/I=IIIrd alphabet signifies the type of cooling of rotor e.g. radial, indirect,
forced, direct, etc.
I/D/F=last alphabet stands for the type of cooling of stator e.g. indirect, forced,
direct, etc.
W=cooling media used for cooling the stator coil e.g. water.
Resin Systems:
Material check
Copper conductor 8*28mm[solid, for lower bar]
Hallow Copper conductor 8*4.6*1.5mm
Copper Conductor 8*1.3mm[solid, for upper bar]
1. Conductor Cutting
This process is done by automatic CNC machine. In this process
the pre insulated copper conductor is cut in to number of pieces
of required length. Insulation is removed from both ends of the
copper conductor cut.
LOWER BARS:
Solid conductors – length 10,200mm(10 no.s)- 1 bar
Hollow conductors – length 10,200mm(10 no.s)
UPPER BARS:
Solid conductors – length 10050mm( 20 no.s)- 1 bar
Hollow conductors – length 10050mm( 10 no.s)
We have to clean both sides of ends – 500mm.
CNC (Computerized Numeric Control)
Conductor Cutting Machine:
1. Copper storage
2. Bobbin ready to use
3. Tool rack
4. Bobbin revolving machine
5. Tension device
6. Conductor cutting
7. Drum for plastic waste
8. Control panel
9. Operator control desk
10. Waste glass dust collection
11. Conductor shifting table
2. Transposition
Transposition means changing/shifting of position of each conductor in
active core (slot) part. After cutting the required number of conductors,
the conductors are arranged on the comb and in staggered manner and
the bends are given to the conductors with the help of bending die at
required distance. Then the conductors are taken cut from, the comb and
die and placed with their ends in a line and transposition is carried out.
This process is repeated for making another half of the bar which would
be mirror image of the first half. The two halves of the bar are overlapped
over each other and a spacer is placed between the two halves.
Requirement: The main reason of doing transposition is to
generate equal emf in each bar. Also, it is done so that average distance of
each bar from the rotor is same so they cut same amount of flux and
thereby producing equal emf. If transposition is not done then the
conductors nearer to the rotor generates more emf and therefore, its life
is reduced and after sometimes nearly half of the conductors get damaged
due to heating.
LOWER BAR’S:
COMB OF SETTING: Die 1st Die 2nd Die 3rd
2200.2mm 3735.3mm 6586.2mm
UPPER BAR’S:
COMB OF SETTING: Die 1st Die 2nd Die 3rd
2109mm 3602.2mm 6496.2mm
IInd Pressing
Attach full slots separator between two half bar with NOMEX paper and tapped
with transparent film. After pressing remove the transparent film and calibrate
sand etc.
Radius Milling
In slot portion, corner of bar should be cleaned by Radius Miling Machine.
6. Forming
The straight bar stack is formed as per overhang profile( as per
design). The overhang portion is consolidated after forming.
Pickling
Pickling is the process of cleaning of component by chemical like:
PICKLING SOLUTION:-
Water- 100 parts by weight 140 Kg
Sulphuric acid -10 parts by weight 14Kg
Phosphoric acid-5 parts by weight 7 Kg
Hydrogen per oxide-5 parts by weight 7 Kg
These chemicals are heated upto 50-60 degree Celsius.
Dip the components in solution. 10-15 min after that, clean the
component with brass brush and water. Dip Ammonia solution for
neutralization of acidic property. Ammonia solution is the
combination of liquid Ammonia 10 parts by weight with 100 parts by
weight and clean with water and then dipping in Ethyl Alcohol. After
this dry the solution with nitrogen pressure before pickling all types
of components like bar, contact sleeves, bottom and top part of water
box, wedge plane and profile etc.
7. Brazing of Coil Lugs
For water cooled generator bars, the electrical connection contact and
water box for inlet and outlet of water are brazed.
LUG MOUNTING:
1. Stand by bars for setting of lug.
2. Set up the conductors in each row as per drawing.
3. Insert contact sleeve with the setting of plane row wise wedge then
tapper wedge fix up for tightening with copper thin strip as per
marking.
MAIN BRAZING:
1. Stand by bars of setting for brazing used Resistone for that area
which will not braze.
2. Heating the lug joint by two inductors at 65 C use brazing alloy L
Ag-15P by 4 persons.
3. Then cooled with air and water.
Deveering
20 no.s of hollow conductors should be deveered in lug braze with the
help of special machine. After deveering water flow is checked,
whether all hollow conductors are allowing equal amount of water or
if not, then may be due to improper hammering during lug brazing,
then the bar has to be repaired.
13. Finishing
The baked and dimensionally correct bars are sanded of to smoothen
the edges and the surfaces is calibrated, if require, for the dimension.
14. Conducting Varnish Coating
OCP (Outer Corona Protection) Coating:- The black
semiconducting varnish coating is applied on the bar surface on
the core length.
ECP (End Corona Protection) Coating:- The Grey semiconducting
varnish coating is applied at the bend outside core end of the
bars in gradient to prevent from discharge in minimize the end
corona.
15. Testing
Tan α test: - This test is carried out to ensure the healthiness
of dielectric (insulation) i.e. dense or rare and measure the
capacitance loss.
HV test: - Each bar is tested momentarily at high voltage
increased gradually to 3 times higher than rated voltage.
FORMULA USED:
Hv = 1.5(2un + 1)
Up = 2Un + 1
Un = working voltage