Professional Documents
Culture Documents
REPORT
ON BHEL
SUBMITTED BY:
DERIL SIMON
ELECTRICAL ENGG.
FINAL YEAR-2006
ROLL NO:-02EE48
PREFACE
In the first section of report you have to find the historical & gorgeous
look of BHEL, Haridwar. The second section deals with overall information of
production (Generators & Motors), Machine shop BL-1.
Apart this I have done my all celebrities & effort to give the concise & untreatable
from to the report.
I shall fell grateful if readers by pointing out mistakes give suggestions &
information in the report in the report extended his hand of participation.
SANJULI
HARIDWAR
(02EE43, 6th sem)
30, July, 2005
,
ACKNOWLEDGEMENT
• BHEL - OVERVIEW
• HEEP – OVERVIEW
• MANUFACTURING FACILITIES
I. BAY-1
II. BAY-2
III. BAY-3
IV. BAY-4
• REFRENCES
BHEL – AN OVERVIEW
The first plant what is today was an BHEL, was established nearly 39 year ago at
Bhopal and was the genesis of the heavy electrical equipment industry in India
BHEL is today, the largest engineering enterprise of its kind in India, with a well-
recognized track record of performance, making profits continuously since 1971-72
it achieved a sales turnover of Rs. 6347cr. With a per- tax profit of Rs. 294cr. In
2000-2001.
B.H.E.L caters to core sectors of the Indian Economy viz. power, Industry,
Transportation, transmission, Defense, etc.
The wide network of BHEL’s manufacturing division nine service centers and four
Power Sector Regional Centers and about 150 project sites enables the company to
be closer to its customers and provide them with suitable product, system and
services and competitive prices. Having attained ISO 9000 certification, BHEL is
now embarking upon the total quality management.
The company’s inherent potential coupled with its strong performance over the
year, has resulted in it being chosen as one of the “Nirvana” poses, which are to be
supported by the Government in their endeavor to become future global players.
BUSINESS SECTORS:-
POWER SECTOR:-
Power sector comprises thermal, nuclear, gas and hydro power plant
business. Today, BHEL supplied sets account for nearly 64737 or 65% of the total
installed capacity of 86,636 M Win in the country as again nil till 1979-70.
BHEL has proven turnkey capabilities for executing power project form concept to
commissioning; it possesses the technology and capability to produce thermal
power plant equipment up to1000 MW rating and gas turbine generator sets up to a
unit rating of 240MW. Cogeneration and combined cycle plant have been
introduced to achieve higher plant efficiencies. To make efficient use to the high
ash content coal available in India, BHEL supplies circulating fluidized bed boilers
to both thermal and combined cycle power plants.
Custom made hydro sets of Francis; Pelton and Kaplan types for different head-
discharge combinations are also engineered and manufactured by BHEL. In all,
more than 700 utility sets of thermal, hydro, gas and nuclear have been given on
contract to BHEL 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 internationality competitive.
INDUSTRY SECTOR:-
TRANSMISSION:-
TRANPORATATION:-
RENEWABLE ENERGAY:-
The prized asset of BHEL is its 62.507 employees. The human Resources
Development Institute and other training institute of the company help are not only
keeping their skills updated and finely honed but also add new skills when
required. Continuous training and retraining, a positive work culture and
participative workforce style of management have led to the development of a
committed and motivated workforce and enhanced productivity and quality levels.
HEEP :AN OVERVIEW
Over the years, BHEL as emerged as world-class engg. & Industrial
giant, the best of its kind in entire south East Asia. Its business profile cuts across
various sectors of engg/power utilities & industry. The company today enjoys
national & international presence featuring in the "fortune international-500" & is
rank among the top 12 companies in the world, manufacturing power generation
equipment. BHEL has now 14 manufacturing divisions , 8 service centers & 4
power sectors regional centers besides a large nos. of projects site spread over India
& abroad.
The company is embarking upon an ambitious growth path though
clear vision; mission & committed values to sustained & augment its image as a
world class enterprise.
VISION:-
MISSION:-
VALUES:-
* Established in 1960 under the indo soviet agreement of 1959 &1960 in the area
of scientific, technical &industrial cooperation.
*DPR-prepared in 1963-64 construction started from October 1963.
* Initial production of electric motors started from January 1967.
* Major cunstruction/erection/commisioning completed by 1971-72 as per original
DPR scope
* Stamping unit added later during 1968 -72.
* Annual manufacturing capacity for thermal sets was expanded from 1500 MW to
3500MW under LSTG project during 1979-85(sets up to 500MW, extensible to
1000/1300MW unit size with marginal addition facilities with the collaboration of
M/s KWU-SIEMENS, Germany.)
* Motor manufacturing technology updated with siemens collaboration during
1984-87.
* Facilities being modernized continually through replacment/reconditoning -
retrofitting, technological/ operational balancing.
To day the plants has unique manufacturing and testing facilities, computerization
Numerically controlled machines- tools, blades shop, heavy duty lathes, milling
machines, boring machines, machining centers and many more. The over speed
vacuum balancing tunnel created for rotors up to 1300 MW (320 T, 6.9 M- dia
bladed rotor, 6 rpm. up to 4500 rpm) is one of the eight of its kind in the entire
world.
The total spectrum of sophisticated, unit and other facilities at Heep, Haridwar are
the state of the art in manufacturing processes and can be utilised for a verity of
products manufactures.
MANUFACTURING FACILITIES
Besides these, HEEP has also set up a Generator Research Institute with
an objective to develop basic know-how and know-why through
experimental studies for reliable, efficient and optimum design of
generators and improve their performance in service.
FORWARD
(M. K. Mittal)
Executive Director
BHEL, HARDWAR
BLOCK-1 PRODUCTION UNIT
* BAY-1
* BAY-2
* BAY-3
* BAY-4
From the Electrical point of view the main stress is given on the
manufacture and maintenance of turbo (large) generators and hydro generators as
well as A.C & D.C motors in block-1 with the largest manufacturing techniques
being employed for their production. This block is also significance its better
production and quality control performanceblock-1 has the tremendous part of all
block present in BHEL with accordance to manufacturing techniques. The largest
machine shop of India is also available of this block. There are many achievements
are established by this block.
Testing facility for turbo generator & heavy motors are available in Bay-2 &
for medium size electrical motors in Bay-3.their is a special test bed area for
testing of capacity of 500 MW unit size & above .
Block-1 has specially only for T.G. & H.G. of the specifications as:-
Therefore the block has their own importance in whole of the HEEP family
of BHEL Hardwar.
The internal positional diagram of block-1 are attached, in which that the
block-1 has four bay (Sections), into which there are many heavy & medium
machines are positioned are also the T.G.& H.G. section are present there.
*BAY-1
LARGE SIZE TURBOGENERATOR (LSTG AREA):--
Two number core pits core building & pressing facilities are available in this
section .The section is also equipped with optical centering device, core heating
installation & core loss testing facility.
The section is located in a dust proof area enclosure & equipped with one number
winding platform two number rotating installation for assembly of windings,
resistance bracing M/Cs & high voltage transformer are also available in this
section.
This section is also in a dust proof enclosure & is equipped with number of
rotators, rotor bar laying facilities & MI heating heating installation for heating &
mounting of retuning rings. Rotor winding assembly & rotor assembly like
retuning ring fitting, four assemblies are carried out in this section.
This section consists of milling M/C for long preparation, installation for insulation
of tension bolts for stator & preparation of stator winding before assembly.
(e.) Test bed section:
This section is equipped with bed plates, height blocks, supporting blocks &
12MW drive motors. LSTG & exciter are assembled & tested in this section.
HYDROGENERATORS:--
This section is equipped with large size rotor slot milling M/C , lathe convention as
well as CNC vertical boring , CNC horizontal boring M/C , drilling & double
column planning M/C . Small size milling, slotting M/C & a shaper are also
available for manufacturing small components.
The major component M/C in this section are stator frames upper & lower brackets
, rotor spider , rotor shaft, pole end plates , thrust bearing disc ,collar of hydro
generator & rotor shaft of LSTG.
This section is equipped with two centering columns & set of welding for carrying
out iron assembly of hydro generators stators.
Two truck mounted brazing installation are available in this section for resistance
brazing of bar head joints of stator winding bar of hydro generators.
This section is equipped with rotators, hydraulic presses & wedge driving press for
the assembly of rotor winding for turbo generator.
This section is equipped with bed plates & induction heating facilities for assembly
of rotors of turbo generator. Assembly of retaining ring is carried out in this
section.
TURBO GENERATOR:--
Modern feature of direct cooling by water &
hydrogen are incorporated in the 210 MW turbo generators, thus evolving an
economical & reliable design. This high efficiency M/c, together with a fast acting
excitation system & dependable auxiliary service has a proven record & withstood
the test of time by prolonged trouble free Operation over the years. All the
materials that go into the manufacture of this M/c are subjected to rigorous tests as
per international standards. Each sub assembly or component undergoes a series of
stage wise tests .Each unit that rolls off the assembly line is fully assembled &
tested at the plant test bed as per the standards of the standards of the international
electro technical commission.
• Static excitation
HYDROGEN AND WATER COOLED TURBOGENERATORS OF
500 MW RANGE (TYPE: THDF):--
STATOR:--
The stator body is a totally enclosed gastight, explosion -proof fabricated structure,
suitably ribbed & stayed internally & ensure high rigidity. These are so designed
that the tubes may be cleaned without removing hydrogen from the generator
.Hydrogen coolers with a sufficient surface area , are mounted limitedly in the
stator frame for cooling the hydrogen
The stator core is built from high alloy low loss electro-technical
steel segmental stampings which are varnished on both sides. Segments of
insulating material are inserted at frequent intervals to provide additional insulation
& to localize shorts circuits .The stampings are assembled & pressed on core bars
forming several packets .The packets are separated from each other by steel spacers
of special profile to form ventilating ducts providing a gas passages to cool the
stator core . In order to reduce the losses in the end packets, copper screening
plates are provided at either end of the core & cooled by hydrogen passing through
radial ducts provided between the core end plate & end packets.
The stator winding employs direct cooling by distilled water
which permits the use of high value of current density in this M/c .The stator
winding over hang fixing is designed to withstand sudden short ckts at the
terminal .Each coil side consist of solid & hollow conductors through which the
cooling water passes . For distributing water through the stator coils, ring type
water headers insulated from the body, are provided on the turbine end. The
winding is designed for double star connection. Three line & 6 neutral terminals
are brought out thus enabling split phase differential protection to be provided.
ROTOR:--
The rotor is of the cylindrical type, the shaft & rotor body being forged in one
piece from nickel chrome molybdenum vanadium steel. Longitudinal slots are
milled in the body to house the field winding .The field winding is made of cooled
rolled electrical copper which has a small percentage of silver . Slot portion of the
winding are held against centrifugal forces by means of duralumin wedges & the
overhang portion, by retaining rings of floating type. Retaining rings are made
from high tensile nonmagnetic alloy steel forgings. An end damper winding is
provided, which safeguards the asymmetrical & asynchronous operative conditions
of the M/c.
The rotor winding is provided with a lateral gap pick up system of cooling
in the slot part, ensuring uniform temperature distribution of the winding. The
overhang part is provided with axial cooling .The slip rings are steel forgings
which are shrunk on to the steel hub covered with mica, built up in positions. These
are arranged side by side outside the generator bearing at the exciter end. The
surfaces of the slip rings are spiral grooved & the brushes staggered to increase the
life of the slip ring & brushes.
BEARING AND SHAFT SEALS:--
The generator bearing at the end is of pedestal type with high rigidity & is provided
with a spherically seated shelf adjusting bush .The bearing bush is lined with anti-
friction metal & is automatically lubricated by the oil supplied by the lube oil
system . For checking the oil flow, sight windows are provided on the drain pipes.
In order to prevent the escape of hydrogen where the shaft leaves the casing,
shafts seals of the thrust type are provided at each end. For improving the
reliability during all regimes of operation, the shaft seals design incorporates high
pressure oil for pressing the seal liner against the shaft collar. In order to prevent
the circulation of shaft currents, oil seals & the bearings on the exciter end are
insulated from earth.
In this section the turbo-generator rotor of siemens Germany design are assembled.
This section assembles TG rotor of the following ratings:
a). 500 MW hydrogen cooled rotors.
b). 210/250 MW hydrogen cooled rotors.
c). 80 to 135 MW air cooled rotor.
After the rotor shaft matching, the shaft is received in this section for further
assembly work:-
The following assembly is done here:-
a). Field lead assly.
b). Lying of winding.
c). Retaning ring mounting.
d). Fan blade assembly.
Then the rotor is sent for final machine, balancing & testing & despatch.This entire
cycle taken around 4.5 months to complete.
a). Field lead assembly . Science the siemens design rotor is brushless type,
therefore adequate arrangement is made to provide leads for carrying the
D.Csupply to the winding. The consist of the field lead core bar , current carrying
bolts , field lead bar & connecting piece along with various insulation & wedge
.
b). Laying of winding siemens rotor are 2 pole, 3000 rpm synchronous m/c having
D.C concentric winding. There 28 slots cut on 2/3 periphery which houses the
winding bar. There are 9 turns per slot in 500 MW (F.L current 4040A d.c 340V).
Due to non uniform distribution on the circumference, different moment of inertia
is obtained in main axis of the rotor shaft, causing 2f oscillations. To reduce this
vibration the deflection of pole axis & neutral axis is compensated by transverse
slotting of poles. Solid poles are also provided with additional longitudinal slots to
hold the copper bar of damper windings.
The turns of coils are trapezoidal in shape & have two semicircular
ducts for cooling (hydrogen at 3.5 bars). The conductor is made up of copper with
silver content 0.1% for higher mechanical strength at higher temperature
. The body insulation is made of glass fiber lamination having
nomex filler .To prevent the windings from centrifugal force the winding is secured
in slots by copper-silicon-nickel alloy wedges which also act as damper windings.
The rotor overhang is braced from centrifugal forces by the means
of retaning ring on each T- side & E-side. One end of the ring is heat shrunk (at
360 degree centigrade ) on the rotor body (interface value 4.0 mm) while the other
end over hangs the winding contacting the shaft .Material of retaning ring is X8 Cr
Mn N1818K alloy steel .
c). After completion of winding & fitting of RR the rotor is sent to machine shop
for machining of T grooves on compressor hub 515 nos. fan blade are arranged in
5 stages & arc fitted in these T grooves .
d). The rotor shaft is again sent to m/c shop for final machining before balancing.
4. Now the rectangular hollow copper conductor. to be used for parallel sides
slots each slots have 7/9 copper bars (for 500 MW) concentric multiturn
coils are allow based in the slots which are a multiple of four. The slots
pitches are chosen to avoid undesirable harmonies in the field form
.
5. After placing the copper bars into each slot there end connection will be
joint with the gas welding or magnates bronze or stalling is driven into the
mouth of each slot for the purpose of keeping the winding in place. Ultimate
there are two terminals will be remain open to give the field current into
them to side of exciter.
7. The end connectors of the field winding must be rigidly supported by end
bells because of the large centrifugal forces due to high speed of rotation the
end bells are used made of non-magnetic austenitic steel (mn-18%, cr-3%,
c-0.5%) in order to reduce the leakage flux. The end bells are mechanically
strong and have an ultimate strength of1150 MN/M2 Atypical end bell and
Overhang arrangement.
8. After this the rotor will packed with polythene cover due to dust and not
atmosphere.
It has two dust free stands for stator winding of turbo generator and
an installation for heating stator bars. This section is used for stator winding of
capacity 250MW, 500 MW T.G. Are as follows:--
1. Core
2. Stator bars
3. Support rings
4. Header
5. Bus bar
Except these component there are some additional auxiliary are required for
testing and cooling purpose and these are:
6. Air system
7. Gas system
8. Primary water system
The cores are mounted as that they will form the required no. of slots (48 slots
for 500 MW) and 1 coil for 2 slots.
2. STATOR CORES:--
The stator core is built up segmental laminations of
type. The use of grain oriented steel laminations with direction of flux being
along the grains in the armature core and perpendicular in teeth result in
lower core loss but it is usual to use cold rolled non-oriented steel. The
desired no. of core is placed into the vertical stands stator body with the
technological arrangements. The stator body is a stand with the help of
umbrella like vertical stands which under ground into this section of Bay-1
and having depth of 10 MT. Approximate.
The stator cores are laminated with impregnation (varnished) then pointed
with on insulated point. Every core has air gap and no. of holes for cooling
purpose after placing all the cores the stator body will form the slotted
shape.
1. SUPPORT RINGS:- Support rings are used to support the stator cores.
These are the vertical and oval shaped iron rings with epoxy glass insulated
to each are placed into stator body.
2. HEADER: - header is the round shape hollow pipe. This positioned on the
header of stator body. The header is the
silver color pipe into which distilled
water flow for cooling of stator winding.
The pipe is of Teflon tube. The distilled
water circulating through the stator with
radial cooling arrangement
. Fig-Retaining ring
3. BUSBARS:- The bus bar is the 3 phase
output connection from the 3 winding of
stator.
COOLING ARRANGEMENT:--
The problem of cooling of turbo-
alternators is one of the most complex problem in electrical engineering
since being high speed M/Cs their dimensions is much smaller than of H.G.
in fact the problems associated with cooling arise because T.G. are
characterized by long core lengths and small diameters. According to
various methods cooling the T.G. are classified.
a. THRI -T.G. Radial, indirect cooling
b. TARI - T.G. Air Radial, indirect cooling.
c. THW - T.G. Hydrogen water cooled.
d. THDF – T.G. Hydrogen direct cooling.
When the problem of increasing generator rating was talked in became clear
that the air-cooled M/C did not provide the necessary scope for progress. Not
only in circulating the requisite quantity of air through the M/C but also
because the high fan power required to circulate the air. Thus air circulating
fan power required for this duty is high and on this score alone the air cooled
generator can be ruled out when it becomes necessary to increase gen. Rating.
Evidently to push-up gen ratings an alternative-cooling medium had to be
found. That medium was hydrogen. Following are the advantage of utilizing
H2. :-
a) Increased efficiency: This because the density of H2 is only 0.07 times the
density of air and therefore the power required to circulate H2 should be about
1/14 of the air.
The unique combination of lead discharge and water conduct system at any
hydroelectric site make the design of the turbine and generator custom built for
each project.
Based on the unit rating and speed selected for the turbine. The generator is
designed to suit the specific requirements of rational inertia over speed system
requirements, special design technique have to be used taking into account the
transport limitations too site.
This section of BAY-1 is mainly to assemble the various iron arrangements of
Hydro generator. Since the hydro generator is having more poles than T.G. therefore its
rotor diameter will also large. Hence there are many iron accessories are needed to
assemble H.G. in this section the assembly of rotor and stator iron assembly will formed.
To cover the large area of rotor used the iron spider. This spider is a spider
shape hollow iron body on to which the solid rotor wedge and rotor segment will
wear then the we climbed the upper and lower guide bearing on both side of rotor.
Thereafter welding will be done.
After completing the wedging the places will fit on the rotor body with
proper insulation.
Similarly the large dia of stator cover by iron pieces and jointed to than on
the site due to their large shape and heavy weight.
This selection is prescribed only for rotor winding and the PMG machines for
H.G. site to develop the D.C. current through rectifier. So first we concentrate on
H.G. rotor winding.
The forged steel construction is used for high speed M/sc. The earliest
construction. Particularly of relatively low outputs (below 40 MVA) consisted
of a body shaft extension made as a single forging.
This cheapest form of rotor body construction is the punched segmental rim
carried on a fabricated steel spider. The communication use 1.8 mm thick and are
in the form of over lapping segments tightly bolted. The spider is therefore relived
of all required to transmitorque to the rim. The advantages of a segmental rim are
that it is copy to transport and assemble at site.
After choice of specific rotor frame; we mounted the poles on it. The poles are
clamp or fixed etc. to rim in different ways. They can halt to the yoke either
dovetail or the T-head type of construction is used for fixing the pole to the yoke.
The cross sections of the poles may be rectangular or circular. The circular
pole has the following advantages.
1) The length of means turn of the winding is smallest with circular pales.
2) The whole of the winding surface is uniformly exposed etc. air and therefore
ventilation is better.
3) The field coils with circular poles are circular in shape and therefore they
can’t the easily deformed by centrifugal forces.
ROTOR WINDING OR FIELD WINDING:--
The coils are supported by v block in order to with stand centrifugal forces
alternatively; a canted coil construction may be used. In this arrangement, the
construction of turn is such that the necessity of support for the coils.
DAMPER WINDING:--
In order to dam pout the oscillations damper windings are used which are
housed in the pole shoes. There damper winding consist of heavy copper coils, one
in each slot or hale, riveted at the ends to common bars at each and so as to form
short circuited grid or the rods may be brazed to copper and bars attached us the
pole and plates. In most cases copper rods in the pole shoe as adequate without
inter polar cage connection.
Within the damper rods are completely buried in iron. The inductance is
reduced and the of damper winding current is improved.
Special attention must be paid to connecting bars lying in the inter polar
region as this portion has no either support except the support of ends in the pole
shoe.
PMG SECTION:--
BHEL possesses very strong engineering base, R&D infrastructure, very precise
CNC & conventional machine tools, sophisticated technologies and capabilities to
produce hydro-generators of capacity up to 300 MW based on customer’s
requirements as per national / international standards.
BHEL has the latest hardware and computer software for design development of
large capacity (> 250 MW) and large size hydro-generators.
CONSTRUCTION:--
The stator design is very tedious and length process due to field winding.
The stepwise construction details are as: -
Guidance by--
Mr. A.k.Shrivastava
If any type of misbalancing bis measured here then marked it and charge
it to the responsible section.
The OSBT is the largest tunnel for balancing of rotor of T.G. into allover
BHEL.
EXPANDING POSSIBILITIES
BAY-2
TURBO-GENERATORS AND HEAVY MOTORS
The following are the main sections:--
This section is equipped with large size CNC & conventional M/C tools such as
lathes, vertical boring, horizontal boring M/C ,rotor slot milling & radial
drilling M/C for machining stator body , rotor shaft end shields & bearing
etc.for turbo generator.
IRON ASSEMBLY (LSTG) - Two numbers core pits with two numbers
hydraulic pressing & heating arrangement for pressing the core are available in
this section.
This section has 2 nos. of rotators along with one no. of winding platform for
the winding for the assembly of the stator winding of T.G. The winding
assembly is carried under dust free atmosphere. Assembly of stator winding of
heavy motor & exciter is also carried out in this section in clean atmosphere.
It has impregnation & drying ovens for large DC armatures including vacuum
pressure impregnation facilities for total impregnation of AC & DC motor.
This section has facilities for shame core assembly of turbo generator and
heavy electrical motor including 1000 tones umbrella type press for pressing
the cores and transformer of inductions heating of retaining rings and armature
cores of large size electric motor. The umbrella type stands for core pressing is
done here and into Bay-1 as describe first .The procedure involve into core
assembly may be describe as:
For ventilation of cores the core is formed as such that same air gap
will be remain between them with a special silicon sheet bar and welded it by
arcing M/c.
Similar produce will adopt for exciter iron assembly but in core of
exciter we used the small brushing umbrella stand. This section is done the iron
assembly of T.G. of 250 MW to 500 MW and the same exciter.
Information by:
Mr. Ramla Khan Verma
(Sr. Tech T.G. & Exciter
Assembly)
a) First of all placed the stamping, cores into stator body with
proper impregnation of each cores.
b) Put down the glass insulation into each slots (Sam 8).
c) Put the copper conductor into each slots with proper
insulation of glass tape on it.
d) Distribute the RTD into each slot to detect the temperature
into running condition of motor.
e) Now make connection for input supply for a MW M/s the
designing dimensions are as:
Slots, 8 poles and 1 pole – 3 coils
f) Now brazing is done of all three phases by brazing machine
machine.
g) The entire end we rubbed the magnate kilt (iron powder) to
increase the flux into motor.
h) After doing the proper connections the machine will check
by means of short circuit of winding etc.
Information by:
Mr. O.L.Verma
(Sen. Tech. Heavy motor
winding section)
TURBO GENRETOR:-
This section has two fully A.C. &covered stand for the stator winding
of turbo generator of 210 MW capacity. The winding done here is same as
that of LSTG stator winding the stamped stator is laying here horizontally
and then winding, should be done. The cooling the generator is water hence
it is a THW T.G.
Guidance by:
Er. Y.K.Sharma
(T.G.Stator winding 210 MW)
HEAVY ROTOR ASSEMBLY SECTION:-
SQUIRREL CAGE MOTOR SLIP RING ROTOR
This section is provide the facility of assembled the rotor for A.C.
This section has a250 ton horizontal press for pressing the rotor’s stamping
cores. The stamping is manufactured by Block-6. The cores are stamped
together without and insulation and supported to the entire periphery by the
iron bars of rectangular type. After the formation of solid rotor it will fitted
into the horizontal press machine and press a definite pressure after pressing
check the outer surface of rotor that there is no any sharp edge of cores will
be remain out of the diameter. This section is assembled rotor of rating 3
MW-10MW. Assist by:-
Mr. B.R.C.Tyagi
(Sen. Tech., Heavy rotor iron
assy.)
BRUSHLESS EXCITERS:--
--: MERITS :--
*(BAY-3)
MEDIUM SIZE MOTOR:--
Facilities available in the various sections are as follows:
(a.) Machine section – This section is equipped with medium size tools for
machining components for medium size AC & DC machines & smaller
components of turbo generator & hydro generators.
(b.) Iron assembly section – Umbrella type double column & four column
presses are available in this section for assembly & pressing of cores of
medium size electrical motors.
(d.) Hydro generator pole core section – This section is equipped with
core building installation, horizontal press & special straightening plate for
the assembly of hydro generator pole cores.
(e.) Rotor assembly section – This section is equipped with static &
dynamic balancing installation bearing assembly installation & rotor
assembly facilities for the medium size M/Cs .
The motors are provided with rolling contact/sleeve bearings depending upon the
load and operating conditions. Rolling contact bearings are sealed by means of a V-
section axial shaft-sealing ring that rotates with the shaft. Sleeve bearings are used
when the limit for rolling contact bearings are exceeded or when specified by the
customer. The terminal boxes are made short circuit proof by the cast-resin
bushings and strong bolts to enable them to withstand short circuit current of 110
kA for 0.2 seconds. A pressure-relief flap provides the short circuit safety for the
terminal boxes. Slipring motors are additionally provided with a rotor terminal box
permitting the connection of starting resistors.
Synchronous motor
The procedure iron assemblies of medium size motors may be write as:-
i. Prepare the fabricated rotor, which is brought from block – 5.
ii. Now, fit it on to umbrella type stand and fitted the winding
holder one upper and down head.
iii. Now stamped the cores vertical in or horizontally and pressed
them tightly.
iv. Now checked the outer surface of the unwound rotor that no
sharp edge is remaining of cores.
The single cage rotor has single brucing of copper instead of it double cage rotor
has double brucing. The double cage is inner cage and single cage is outer cage.
The double cage rotor use to getting the high starting torque. The melting coin of
the external cage is high than inner cage (cu).
After select the appropriate rotor will be used as slip ring and simple motor by
exerted internal resistance.
Information by:
Mr.Bhupendra Singh
(Sn.Tech.Medium motor Iron Assy.)
Constructional features
The machines have closed circuit cooling with a concentric tube nest cooler, which
is integral with the frame and with shaft-mounted external and external fan. The
external fan is located in the fan casing on the non drive-end and forces the
atmospheric air through the cooling tubes of stator frame.The two internal fans in
the main compartment cause primary air to circulate in two symmetrical sub-
circuits. Circulation is intensified by the radial ducts in the laminated rotor-core.
The primary air circulates through the end windings and the ducts in the core packs
and carries the heat to the cooling tubes.
The stator winding of HV machines is double layer lap windings and is provided
with MICALASTIC® VPI insulation complying with class-F insulation
requirements. The insulation system is based on integrated mica employing a
special synthetic resin impregnation process. The insulation possesses high di-
electric strength, high resistance to moisture, aggressive gases & vapours, excellent
mechanical stability and long life.
The shafts have two bearings ( drive-end and non drive-end ) and a cylindrical
shaft extension at the drive-end. The bearings are either grease lubricated rolling
contact bearings or journal bearings with or without forced oil lubrication. Solid
shafts are used in 2-pole machines and ribbed shafts in machines having 4 or more
poles. The laminated rotor core is pressed on to the shaft, clamped and secured
against axial displacement, and carries the squirrel cage winding.
The winding bars are firmly seated in the slot of the rotor core and are connected to
the cage rings by induction brazing. The rotor is dynamically balanced with a half
parallel key inserted in the key way of the shaft extension.
COMMUTATOR SECTION:--
a) First of all, we will take a copper profile which ordered from Block-4.The
copper profile is special type of copper segment which has a tunnel and one its end
and smooth on other end.
b) The tunnel or slitting is formed by slitting machine on the flat copper bar.
The slitting is done, 50, to fix the riser on one head of bars. The riser holds the
winding connection this process of placing rising is known as brooding or rising.
c) After this tinning is done, to fix perfectly the riser on to segment.
d.) Now the grinding is done to remove the zigzag surface of riser.
e) Now Baking is done on to 150-160 0C Temp. For 8 hrs. To remove the
moisture.
f) Now doing the cold pressing.
g) Now formed and duck till joint by the M/c on to the solid round frame of iron
the riser sides on top.
h) Now clinning by brushes or air pressure.
i) Now checking the segment by high voltage test.
j) Now placed the circular segment in to bush type fixture and put the fixture
into oven of 160-1500C than cold pressing
k) Now confirm the H.V. test segment to segment.
l) Now being the mutual fitting.
m) After this we will doing credit turning by lathe machine.
n) Now cleaning and heating at 1800C.
o) After cold pressing we are doing the dimming and forming for smoothing the
quarter surface of commutater body, then cold pressing.
p) Now coining into bush.
q) Ultimately we will do the tapping of bottom side.
*(BAY-4)
(a.) Machine section – The M/Cs section of bay-4 is equipped with small &
medium size CNC & conventional tools like center lathes, milling, radial
drilling cylindrical grinding, slotting, and copy.
(b.) Maching of main components is carried out in bay-2 & 3 while small
components are machined in Bay-4.
(c.) Iron assembly of AC motors stator & rotor is carried out manually &
pressing is done on hydraulic presses in Bay-2 & 3.
(d.) Winding of stator is done on rollers support. The phase connections are
made by resistance brazing M/C & the stator is tested for phase resistance
& high voltage. Wound stators are totally impregnated under vacuum &
pressure.
(e.) Rotor assembly – After assembly of rotor core the rotors bar are driven &
short ckt rings are mounted & brazed by induction heating. Then static &
dynamic balancing of rotor is done on balancing installation.
(f.) General assembly - The coolers, headers, end shields, terminal boxes etc.
are assembled manually to complete the assembly of motors.
.
TURBO GENERATOR ROTOR COIL (T.R.C.) (210MW) SECTION:-
(a) First of all we are taking the copper then we do opt blanking &
straightening.
(b) Now making
(c) Now form the excel channel milling and removing the extra bars.
(d) Now its hard board array (0.5 mm both side) as in Sam (12)
(e) Now doing the angular array and then final milling.
(f) Now handing to form the coil shop on bounding machine (fig. 44)
(g) Radial drilling by radial drilling machine.
(h) Former drilling
(i) Now we are doing the over hand debarring (as in fig 4.5)
(j) Now doing the strip polishing 3,9,11 by wire brush.
(k) Now insulate bottom (varnish-VLY556) 13 layers and a proxy impregnated
glass tube bar (1x28.5,13 layers 1mm)
(l) Rapping of all the copper bars by making a seat of strips for 31/4 hrs.
Technical response:
Mr. Aggrawal
(Sen. Tech. T.R.C.)
MANUFACTURING PROCESS:--
Stator Bar Winding Section - In this section following process is carried out:
Armature winding & Stator coil section - In this section following processes are
followed:
-- Pole coils - The coils are wound on wooden or steel formers on semi-
automatic insulation & winding m/c. After inter turn testing the body insulation,
coils are impregnated & backed as per the technological regimes & subjected to
Electrical Tests. Coils are also encapsulated on pole cores epoxy resin.
-- AC Stator Coil - Conductors are wound & turn insulated on semi- automatic
insulation & winding machines. These are pulled to boat shapes, diamond shapes,
formed in wooden formers or on semi-automatic pulling & forming machining.
The straight portion is pressed on electrically heated presses. The coils are body
insulated. For epoxy coils with Resin rich system, straight portion is consolidation
on electrically heated presses & after cleaning the ends the coils are subjected to
electrical testing.
• Shri S. P. GUPTA
• Shri D. N. LAL
• Shri A. K. VISHWAKARMA
• Shri HUSSIEN
• Shri R. K. DHIMAN