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ELECTRICAL ENGINEERING
ABSTRACT
BHEL is the largest engineering and manufacturing enterprise in India in the energy related infrastructure sector today which manufactures turbo generators (2-pole and 4-pole) ranging up to 150 MHz. The manufacturing process of turbo generator is mainly divided into stator section and rotor section where stator frame, stator core, stator windings, end covers are received from the stator building section and rotor with rotor windings and rotor retaining rings is received from rotor section and assembled at the assembly section. Each and every process is carried out in a sequential process. Turbo generators are designed with the Closed circuit air cooling with water or air coolers mounted in the pit. The layout of the manufacturing plant is such that it is well streamlined to enable smooth material flow from the raw material stages to finished goods. The raw material that are produced for manufacture are used only after thorough material testing in the testing lab and with strict quality checks at various stages of productions. Latest technologies like vacuum press impregnated micalastic high voltage insulation, polyester fleece tape impregnation for outer corona protection are implemented to produce high quality insulation for turbines, outstanding performance and long lasting lifetime.
INDEX Chapter 1.1-2 ABOUT THE COMPANY: BHARAT HEAVY ELECTRICALS LIMITED. Chapter 2.3-4 2. Introduction 2.2 History of Turbo Generators 2.3 Principle of operation 2.4 Synchronous generators classification based on the medium used for generation 2.5 Components of Turbo Generator 2.5.1 Stator 2.5.2 Insulation 2.5.3 Rotor Chapter 3..5-14 3. Stator 3.1 Stator frame 3.2 Stator core 3.2.1 The purpose of stator core 3.3 Preparation of laminations 3.3.1 Compounding operation
3.3.2 Blanking & notching operation 3.4 The different operation in manufacturing of laminations 3.4.1 Deburring operation 3.4.2 Varnishing 3.5 Assembly of core 3.6 Stator windings 3.6.1 Slot discharges 3.6.2 Manufacture of stator coils 3.6.3 Process of taping 3.7 Stator end covers 3.7.1 Phase connectors 3.7.2 RTDs Chapter 4.14-15 4. Assemble of windings 4.1 Winding holder assembly 4.1.1 Assembly of HG rings 4.1.2 Identification of RTD slots 4.2 Bottom bars Laying 4.2.1 Pressing of bottom bars 4.2.2 Inter layer inserts & RTDs assembler 4.2.3 Stiffner assembler 4.3 Top bars laying 4.3.1 Pressing of top bars
4.4 Connecting rings assembly Chapter 5..16-17 5. Insulation system 5.1 BHEL insulation system for Turbo Generators 5.2 BITUMEN system & life extension 5.3 Various insulation system & practices Conclusion and Future scope REFERENCES.35
CHAPTER 1
Transmission & Distribution network up to 400kV AC & DC, Supplied over 25,000 Motors with Drive Control System Power projects. Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants etc., supplied Traction electric and AC/DC Locos to power over 12,000 Km Railway network. Supplied over one million Valves to Power Plants and other Industries. This is due to the emphasis placed all along on designing, engineering and manufacturing to international standards by acquiring and assimilating some of the best technologies in the world from leading companies in USA, Europe and Japan, together with technologies from its-own R & D centers. BHEL has acquired ISO 9000 certification for its operations and has also adopted the concepts of Total Quality Management (TQM). BHEL presently has manufactured Turbo-Generators of ratings up to 560 MW and is in the process of going up to 660 MW. It has also the capability to take up the manufacture of ratings unto 1000 MW suitable for thermal power generation; gas based and combined cycle power generation as-well-as for 13 diverse industrial applications like Paper, Sugar, Cement, Petrochemical, Fertilizers, Rayon Industries, etc. The Turbo generator is a product of high-class workmanship and quality. Adherence to stringent quality-checks at each stage has helped BHEL to secure prestigious global orders in the recent past from Malaysia, Malta, Cyprus, Oman, Iraq, Bangladesh, Sri Lanka and Saudi Arabia. The successful completion of the various export projects in a record time is a testimony of BHELs performance. Bharat Heavy Electrical Limited (BHEL) is, today, a name to reckon with in the industrial world. It is the largest engineering and manufacturing enterprises of its kind in India and is one of the leading international companies in the power field. BHEL offers over 180 products and provides systems and services to meet the needs of core sections like: power, transmission, industry, transportation, oil & gas, nonconventional energy sources and telecommunication. A wide-spread network of 14 manufacturing divisions, 8 service centers and 4 regional offices besides a large number of project sites spread all over India and abroad, enables BHEL to be close to its customers and cater to their specialized needs with total solutions-efficiently and economically. An ISO 9000 certification has given the company international recognition for its commitment towards quality. With an export presence in more than 50 countries BHEL is truly Indias industrial ambassador to the world.
BHEL HARIDWAR units manufacture includes the following. Gas turbines Steam turbines Compressors
Pumps
Pulverizers
BHEL is the only one in Asia that has the latest type of insulation system called the Vacuum Pressure Impregnation System.
INTRODUCTION
CHAPTER 2
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.
2.4 SYNCHRONOUS GENERATORS CLASSIFICATION BASED ON THE MEDIUM USED FOR GENERATION:
Turbo generators in Thermal, nuclear, Gas station High speed 3000 rpm Min poles 2 poles Horizontal construction Cylindrical rotor Hydro generators in hydel plants low speed 1000 to 500 rpm more poles 6 or more vertical construction salient rotor
The following auxiliaries are required for operation: Bearings Cooling System Oil Supply System Excitation System
STATOR
CHAPTER 3
3.2 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. 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.
3.4.2 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.
Fig: assembled core The core building or assembling method depends on the insulation system used. 1. For resin rich insulation system the laminations are stacked in the frame itself. 2. For resin poor insulation system (VPI) cage core of open core design is employed.
There are two types of coils manufactured in BHEL, Hyderabad. Diamond pulled multiturn coil (full coiled): Roebel bar (half coiled). 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.
(a) Remove insulation at the ends of the strips. (b) Test for inter-strip and inter-halves shorts. 7.Set the universal former as per standards. Check the setting of universal former for (a)Length of straight part also mark diagonals/former walls inside for cross check. (b)Check for marking made by template. 8.(a) Place the bar on former. (b) Form the overhang bends as per standards. Remove clamps and inserts overhand insulation to both roebel halves with an application of araldite mixture. (d) The bar is allowed to cure by giving supply to heating clamps. 9.Remove heating clamps and take out the bar halves from former. (b)Round off sharp edges of straight part and dress up overhang halves insulation of both halves with out damage to copper strip insulation and to copper stacks.
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. 6.Provide End Corona protection taping. 7.Provide overhang with protective tape (Polyester glass tape) 8.Test for inter-strip shorts.
ASSEMBLE OF WINDINGS
CHAPTER 4
Each individual bars subjected for pressing at 60 kg/cm2 horizontal & vertical in order to
obtain predetermine the dimensions up to 30 minutes. This process is carried out for all the bottom bars before laying to the respective slots. By following above procedure first bar is layed in to the respective slots when the bar is center to the core centre by measuring pitch dimensions on both sides. Similarly next bar is layed in to the respective bar by following procedure. After laying the every two bars the over hangs are reinforced with glass mat at three different locations on both sides and tying the bars with neoprene glass view. Similarly the above procedure is following for all the eliminating bars. After completion bottom bars laying the bars reinforced end wedges and middle wedges. Then the bottom bars are subjected to D.C high voltage.
4.2.2 Inter layer inserts & RTDS assembles: All the inter layer inserts & RTDS are
assembled as per drawing required i.e. inter layer inserts are assembled in each and every slots except RTDS slots. In RTDS slots only RTDS are assembled before laying top bars.
check the pitch dimensions on both sides. Similarly the next bar is assembled in to respective slots by following the above procedure. After laying every two bars the over hangs are reinforced by inserting glass mat at 3 different locations on the both sides. By following the above procedure all the top bars are layed in to the slots by full filling the drawing requirements then the top bars are reinforced wedging with HGW over layer and placing glass mat under the wedges. All the respective wedges are driven by matching with respective ventilation holes of the pores. Similarly all the wedges are driven in all respective slots by blocking the top bars.
After completion top bars laying top bars are subjected to D.C. high voltage. 4.4 Connecting rings assembly: All connecting rings assemble as per the drawing requirements, and then the phase groups are processed by jointing, bracing and insulation. After completion of jointing bracing and insulation once again it is subjected to D.C. high voltage. Termination of desired RTDS on one side for monitoring the post curing temperature.
INSULATION SYSTEMS
CHAPTER 5
RESIN POOR
1.Epoxy resin content is about 8%. 2.This method follows Thermo Setting Process. 3.There is a need for addition of resin from outside. 4.Time required for this cycle is less. 5.Repairing is very difficult.
RESIN RICH
1.Epoxy resin content is about 40%. 2. This method also follows Thermo Setting Process. 3. Further addition of resin is not required from outside. 4.Its a very long process and time consuming. 5.Repairing is easy. 6.Over all cost is more.
CHAPTER 6
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.
Improves resistance to moisture and chemicals. Increases mechanical resistance to winding surges.
Variant-01 Variant-02
Preheating Vacuum to be maintained 60 for 605C for 5 C 3hrs 12hrs 0.4mbar 0.2mbar/0.4mbar
Variant-03
603C for 12hrs <0.2mbar
(both together shall not exceed 50hrs including rising time) 0.2mbar for 9hrs Stopping vacuum pumps 0.4mbar for 17hrs for 10min shall check 17hrs vacuum drop. The vacuum drop shall not exceed by 0.06mbar for 10min 80min 80min 4bar 3hrs 4bar 3hrs At1405C for 32hrs
6.4 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.
Fig: VPI Resin tub 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.
drying and the heating of the resin in the storage tank are to be synchronized. The heating of resin in the tank and pipeline is to be maintained as at preheating temperature.
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.
TESTING
CHAPTER 10
10.1 ROUTINE TETSTS ON TURBO GENERATOR MECHANICAL RUN AND MEASUREMENT OF VIBRATIONS AT RATED SPEED:
The machine is rolled and run at rated speed after ensuring the bearing oil and kept at rated speed for stabilization of bearing temperatures. The vibrations are measured at rated speed on both the bearing housings in Horizontal, Vertical and Axial directions. The temperature of stator is monitored by monitoring RTDs embedded in core, tooth and winding. The vibrations should be less than 5 microns and noise level should be in between 7590 db.
From the Open Circuit test, we will get Iron losses. The Open Circuit Characteristics is plotted on a graph paper from OCC results by selecting X-axis as field current and Y-axis as % rated voltage.
10.5 MEASUREMENT OF INSULATION RESISTANCE OF STATOR AND ROTOR WINDINGS BEFORE AND AFTER HIGH VOLTAGE TEST (Machine at rest):
Insulation Resistance of the stator and rotor windings is measured separately before and after high voltage test using Megger of 2500 V for stator & 1000 V for rotor windings. The Insulation Resistance values are taken at 15 sec and at 60 sec. The ratio of insulation resistance at 15 sec and 60 sec is known as Absorption Coefficient. Absorption Coefficient = IR at 60/IR at 15 .This Absorption Coefficient for High Voltage test should be > =1.3
10.6 HIGH VOLTAGE TEST ON STATOR AND ROTOR WINDINGS (MACHINE AT REST):
The High Voltage is applied to windings by increasing gradually to required value and maintained for one minute and reduced gradually to minimum. The transformer is switched off and winding is discharged to earth by shorting the terminal to earth using earthing rod connected to earthen wire. The test is conducted on all the phases and rotor winding separately. When High Voltage test is done on one phase winding, all other phase windings, rotor winding, instrumentation cables and stator body is earthed. High Voltage test levels : Stator winding = (2 Ut +1) KV Rotor winding = (10 * Up) V Where Ut = Rated voltage of the machine under test Up = Excitation voltage
CHAPTER 11
CONCLUSION :
The Vocational training at BHEL HARIDWAR helped us in improving our practical knowledge and awareness regarding Turbo Generator to a large extent. Here we came to know about the technology and material used in manufacturing of turbo generators. Besides this, we also visualized the parts involved or equipments used in the power generation. Here we learnt about how the electrical equipments are being manufactured and how they tackle the various problems under different circumstances. At least we could say that the training at BHEL Hyderabad is great experience for us and it really helped us in making or developing our knowledge about turbo generator and other equipment used in power generation.
FUTURE SCOPE:
The technology research and investigations division of BHEL is currently investigating the technical and logistical merit of performing offline quadratic-rate partial discharge tests on the stator winding insulation of its hydro & turbo generators. A series of laboratory based insulation research studies on stator bars have been conducted to gain a better
understanding of the various partial discharge phenomena involved. Results thus far obtained from these tests have provided valuable insight into the discharge activity of operation.
REFERENCES: www.indiamart.com www.eriks.co.uk www.seimens.com www.bhel.com A text book of electrical technology by B.L.THERAJA. A text book of electrical machines by P.S.BIMBRA. BHEL Internal material.