Industrial Summer Training

BHEL HARIDWARPresentation By:Arun Kumar GuptaFinal Year ME-G0902740026

Training SectionsIntroductory Classroom

Sessions about BHEL.

Plant Visit and Self Observation.

Specific Work under Supervision.

Bharat Heavy Electricals Limited

• Largest power equipment manufacturer in India and 7th Largest in the world.

• Engaged in the Design, Engineering, Manufacture, Construction, Testing, Commissioning and Servicing of a wide range of products and services.

• Covers Power, Transmission, Heavy Industry, Transportation, Renewable Energy, Oil & Gas.

Presence

• 15 manufacturing divisions.• Two repair units.• Four regional offices.• Eight service centres.• Eight overseas offices.• 15 regional centres and • Currently operates at more than 150 project

sites across India and abroad.

.....and.....

• Ranked ninth most innovative company in the world by US business magazine Forbes.

• The only Indian Engineering company on the list.

Summer Training 2012

Study of AC and DC Motors

BHEL HARIDWAR

BHEL Ranipur• Started in 1960s with the

help of Russia and Czech.• BHEL has two plants here:– HEEP: Heavy Electrical

Equipment Plant.– CFFP: Central Foundry

Forge Plant.• Spread in about 5000

Acres.

Product Profile

DC Motors• A DC motor is an electric motor that runs

on direct current (DC) electricity• Main Parts:

Poles of Motors

Two Pole Motor Four Pole Motor

Armature

Actual Image of Armature

Output of the DC Motors

Manufacturing of DC Motor• SHAFT MACHINING:-

– It involves finishing of shaft by machining it with a central lathe machine.

– It is done in accordance to the engineering drawing design. Special care is taken to maintain the tolerance level.

• SLOTTING:- – Two types of machines do slotting, air cooled and liquid

cooled. – Slotting is done diametrically. First the shaft is made to rest

on two horizontal plates and is firmly attached to them with the help of chains which exerts load and with the help of jack so that it handles the vibrations produced during the slotting process.

• ROTOR WINDING :- – Rotor winding involves coiling of rotor.– Rotor coils are made of pure copper + 0.2% silver, which has

high tensile as well as temperature bearing properties.– The coil doesn’t deform even at high temperatures as on

adding silver the thermal stresses are eliminated.

• ROTOR SLOT WEDGES :- – To protect the rotor windings against the effects of

centrifugal force and the secured in slots with wedges. – Slot wedges are made of copper-nickel-silicon alloy featuring

high temperature resistance and high strength. – There is retaining ring, which protects the rotor from the

impact of centrifugal force on end windings.

– Comprehensive tests such as ultrasonic examination and liquid penetration examination are carried out in the coils.

– To ensure low contact resistance, retaining rings are coated with nickel, aluminium and silver by three step flame-spraying process.

AC Motors• An AC motor is an electric motor driven by

an alternating current.• Major Parts:

Types of AC Motors

• On the basis of types of Rotor Used:Induction Motor. Synchronous Motor.

Manufacturing of AC Motors

Image of Conductor Bars and their Cuts

• Stator Frame:– Stator body is a totally enclosed gas tight fabricated structure

made up of high quality mild steel and austenitic steel.– It is suitably ribbed with annular rings in inner walls to ensure

high rigidity and strength. The arrangement, location and shape of inner walls is determined by the cooling circuit for the flow of the gas and required mechanical strength and stiffness.

• Stator Core:– It consists of thin laminations. Each lamination made of

number of individual segments.– Segments are stamped out with accurately finished die from

the sheets of cold rolled high quality silicon steel.

Manufacturing of Stator

Manufacturing of Rotor• Rotor Shaft:

– The rotor shaft is a single piece solid forging manufactured from a vacuum casting.

• Rotor Winding:– After preliminary turning, longitudinal slots are milled on

horizontal slot milling machine. – The slot houses the field winding consists of several coils.

• Rotor Wedges:– For protection against the effect of centrifugal force the

winding is secured in the slots by slot wedge. – The wedges are made from duralumin, an alloy of copper,

magnesium and aluminium having good electrical conductivity and high mechanical strength.

• Retaining Ring:– The overhang portion of field winding is held by non-

magnetic steel forging of retaining ring against centrifugal forces.

AC motor Data Plate

Questions.....?

Thank You