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PRESENTATIONON

INDUSTRIAL TRAININGTAKEN AT

BHARAT HEAVY ELECTRICALS LIMITED,

HARIDWAR

BHEL AT A GLANCE --INTRODUCTION - -

ESTABLISHED MORE THAN 50 YEARS AGO IN BHOPAL

CATERS TO CORE SECTOR OF INDIAN ECONOMY.

THE WIDE NETWORK INCLUDES BHEL's 14 MANUFACTURING DIVISION, 8 SERVICE CENTER ,4 POWER SECTOR REGIONAL CENTERS, OVER 150 PROJECT SITES AND 18 REGIONAL OFFICES

COMPANY CONTRIBUTES MORE THAN 75% OF THE NATIONAL GRID, SHARE OF 45% COMES FROM BHEL-Hardwar.

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ACHIEVEMENTS -- INDIA’S “NAVRATNA” COMPANY

ENJOYS PLACE IN “ FORTUNE 500 COMPANIES”

RANKED AMONG TOP 12 COMPANIES IN THE WORLD MANUFACURING POWER GENERATION EQUIPMENTS

ONLY PSU AMONGST 12 INDIAN COMPANIES TO FIGURE IN “ FORBES ASIA FABULOUS 50” LIST

HAS EARNED ISO 9000 , ISO 14001 AND OHSAS 18001

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BHEL HARIDWAR -- HAS TWO UNITS HEEP AND CFFP

Heavy electrical equipment plant

Central foundry forge plant

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HEAVY ELECTRICAL EQUIPMENT PLANT --

ESTABLISHED UNDER THE INDO- SOVIET AGREEMENT IN 1959-60

STARTED MANUFACTURING THERMAL SETS IN 1967

NOW MANUFACTURES THERMAL SETS OF 210, 250, 500 MW TURBO GENERATORS & TURBINES WITH ALL ASSOCIATIVE EQUIPMENTS

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FACILITIES ( PLANT PREMISES ) --

DIVIDED INTO EIGHT BLOCKS

BLOCK 1 (ELECTRICAL MACHINES BLOCK) –

TURBO GENERATORS, EXCITERS AND AC , DC MOTORS ARE MANUFACTURED

MAJOR FACILITIES -- Machine Shop, assembling, painting section, packing & preservation, over speed balancing, test bed, test stand etc.

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CONVENTIONAL BAYWISE DISTRIBUTION --

BAY-1 ROTOR SHAFT MACHINING

SHAFT SLOTTING

ROTOR WINDING

OVERSPEED AND BALANCING TUNNEL

LSTG

BAY-2 EXCITER SHAFT MACHINING

STATOR BODY MACHINING

STATOR WINDING

TOTAL IMPREGNATION

TEST BED

BAY-3 ROTOR SUPPORT BEARING

SHAFT SEAL BODY

DC MOTOR WINDING

BAY-4 COOLING FANSMACHINING

ARRANGEMENT AND OTHER PARTS

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TURBO GENERATOR --

INTRODUCTION— COMMONLY KNOWN AS ALTERNATOR.

WORKS ON THE PRINCIPLE OF E.M.I.

PRODUCES A THREE PHASE ALTERNATING E.M.F OF CONSTANT FREQUENCY.

GENERALLY HAVE LARGE AXIAL LENGTH AND SHORT DIAMETER WITH CYLINDRICAL ROTOR.

HIGH SPEED GENERATOR .

SPEED– 3000 rpm

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TYPES OF TG

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COMPONENTS OF T.G.--

STATOR— 1. STATOR FRAME.

2. STATOR CORE. 3. STATOR WINDING

4. END COVERS ROTOR— 1. ROTOR SHAFT 2. ROTOR WINDINGS 3. RETAINING RING COOLING SYSTEM EXCITATION SYSTEM

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Manufacture process for TG

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STATOR FRAME--

HOUSES ARMATURE CONDUCTORS.

MADE OF CYLINDRICAL SECTION WITH TWO END SHIELDS WHICH ARE GAS TIGHT AND PRESSURE RESISTANT.

TESTING ON THE FRAME HYDRAULIC TESTING

PNEUMATIC TESTING

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STATOR FRAME

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STATOR CORE --

STACKED FROM INSULATED ELECTRICAL SHEET LAMINATIONS MADE OF SILICON STEEL.

SHEETS ARE LAYERED IN THE FORM OF BUTT JOINTS, GROUP OF LAYERS FORM THE PACKETS.

PACKETS ARE ALLIGNED BY THE STUDDS

IMPOSED VENTILLATION DUCTS FOR COOLING AFTER EACH PACKET

DOVETAIL BARS AND HEADER ARE USED.

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STATOR CORE

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ROTOR --

MOVING OR ROTATING PART OF GENERATOR, HOUSING THE FIELD WINDING

CYLINDRICAL TYPE CONSTRUCTION IS USED HENCE LARGE AXIAL LENGTH COMPARED TO DIAMETER.

WINDING CARRIES VERY HIGH CURRENT

REVOLVES AT A SPEED OF 3000 RPM.

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ROTOR

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STEPS IN ROTOR MACHINING--

SHAFT MACHINING

SLOT CUTTING

ROTOR WINDING

ROTOR SLOT WEDGES

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PARTS OF ROTOR

1. ROTOR SHAFT

2. ROTOR WINDING

3. ROTOR WEDGES

4. RETAINING RING

5. FANS

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1. ROTOR SHAFT --

CHROMIUM, MOLYBDENUM, NICKLE & VANADIUM MAIN CONSTITUENT OF ROTOR STEEL.

LONGITUDINAL SLOTS & CROSS SLOTS.

180 DEGREE DISPLACED MAGNETIC POLES.

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ROTOR SHAFT

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2. FIELD WINDING --

SERIES CONNECTED COILS INTO LONGITUDINAL SLOTS.

WOUND TO HAVE TWO POLES.

CONDUCTORS HAVE RECTANGULAR CROSS SECTION.

28 STRIPS OF COIL USED TO MAKE SINGLE COIL OF FIELD WINDING

FINISHING OF COIL

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3. ROTOR RETAINING RINGS --

CENTRIFUGAL FORCES OF THE END WINDINGS ARE CONTAINED BY RRR.

SECURED IN THE AXIAL POSITION BY SNAP RINGS.

PLACED OVER THE ROTOR BY FITTING.

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ROTOR RETAINING RING --

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4. ROTOR FANS --

The cooling air in generator is cold by two axial flow fans.

located at the rotor shaft one at each end augment the cooling of the winding.

The blades of fan have threaded roots for screwed into the rotor shaft.

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EXCITER --

FUNCTION IS TO PRODUCE NECESSARY DC FOR TURBO GENERATORS FIELD WINDING

AC EXCITER WITH ROTATING ARMATURE AND STATIONARY FIELD

AC VOLTAGE IS RECTIFIED TO DC AND FED TO GENERATOR FIELD WINDING

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EXCITER COMPONENTS--

1. DIODE WHEEL (RECTIFIER)

2. PMG OR PILOT EXCITER

3. SLIP RING

4. AVR

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EXCITER

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EXCITER

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CONCLUSION

Improved practical knowledge and awareness abt. TG

Got to know about the technology and material used in manufacturingof  turbo generators.

Turbo Generator and exciter are manufactured in HEEP part

Manufacturing process mainly divided into Stator Section And Rotor Section

Each and everyprocess is carried out in a sequential process.

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Turbo generators are designed with the Closed circuit air cooling withwater or air coolers mounted in the pit.

Raw material are usedonly after thorough material testing in the testing lab.

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REFERENCES

Manuals Provided by Manager of Block-1

Electrical machinery by Dr. P.S. Bimbhra

www.wikipedia.org

www.bhel.com/

www.google.com

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THANK YOU

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ANY QUERIES ?