final ppt for bhel
TRANSCRIPT
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MANUFACTURING PROCESS OF 500 MW TURBO GENERTOR STATOR WINDING BAR
Tushar Shukla(0803221054)
AT BHEL HARIDWAR
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INTRODUCTIONINTRODUCTIONIn 1956 India took a major step towards the establishment of its heavy engineering industry when BHEL, the first heavy electrical Manufacturing unit of the country was set up at Bhopal.
BHEL's Heavy Electrical Equipment Plant (HEEP) was set up in technical collaboration with USSR, for the manufacturing of power plant equipment.
More than 40 percent of the country's electrical energy is generated from the power equipment supplied by BHEL, Haridwar.
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MANUFACTURING BLOCKS:
BLOCK I : Electrical Machine Block
BLOCK II : Fabrication Block
BLOCK III : Turbine Blade Block
BLOCK IV : Coil & Insulation Manufacturing Block BLOCK V : Fabrication And Forge Block
BLOCK VI : Stamping And Dies Manufacturing Block
BLOCK VII : Woodworking Block
BLOCK VIII : Heat Exchanger Block
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COIL & INSULATION MANUFACTURING SHOP
(BLOCK-IV)Block-4 is a feeder block for insulating items, winding with class-B Bituminous insulation and sheet metal components for all the products of Block-1 i.e. Turbo-generators, Hydro-generators, A.C. and D.C. machines
There are three BAYS in this block each bay manufactures stator bars and coils for different machines
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Sections in Block IV 1) Assembly Section
It is equipped with small size• Drilling machines• Welding sets• Hydraulic testing equipment
for manufacturing turbo-generator mechanical assemblies.
2) Stator Bar Winding Section It is equipped with• Conductor cutting, insulation
and transposition section.• Stack consolidation section,
forming and lug brazing sections.
• Insulation taping sections with automatic taping facilities in air-conditioned3) Impregnation Section
It is equipped with• Impregnation tank• Ovens for impregnation of DC pole coils.
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Layout of CIM, Block-IV
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Types of GeneratorsThe generator may be classified based upon the cooling
system used in the generators such as: THRI, TARI, THDI, THDD, THDF, THFF, and THW
Stands for type of
generator
• T- Turbo Generator
• H- Hydro Generator
Stands for the cooling media for
Rotor
• H- Hydrogen gas
• A- Air
Stands for the type of cooling for
Rotor
• R- Radial• D- Direct• F- Forced• I- Indirect
Stands for type of
cooling for Stator
• I- Indirect• D- Direct• F- Forced
Stands for cooling
media used for Stator coil
• W- Water
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Set Type Upper Ordinary
Upper Terminal
Lower Ordinary
Lower Terminal
Total Bars
No. of Bus Bars
500MW THDF
42 6 42 6 96 6
210MW THW
54 6 54 6 120 9
250MW THRI
48 12 48 12 120 9
No. of Bars in current products
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For making ONE bar
FOURTY SOLID CONDUTOR ARE USED
TWENTY HOLLOW CONDUTOR ARE USED
LENGTH OF UPPER BAR & LOWER BAR =10,500mm
FOR 500 MW TOTAL 96 BARS ARE USED
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COPPER CUTTING TRANSPOSITION CROSS OVER INSULATION STACK MACHINE IST TEST FORMING LUG MOUNTING LUG BRAZING
Manufacturing process a of bar:
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NITROGEN TEST THERMAL SHOCK TEST HELIUM TEST BODY INSULATION IMPERGNATION BAKING FINISHING HV TEST DISPATCH FOR LAYING IN STATOR
Cont…
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INSULATION CLASSIFICATION:
Class Y
•Upto 90 °C
•Cotton, Silk, or Paper.
Class A
•Upto 105 °C
•Reinforced Class-Y materials with impregnated varnish.
Class E
•Upto 120 °C
•Cotton lamination & Paper lamination.
Class B
•Upto 130 °C
•Inorganic material is hardened with adhesives.
Class F
•Upto 150 °C
•Class-B materials that are upgraded with adhesives.
Class H
•Upto 180 °C
•Made of inorganic material glued with silicone resin.
Class C
•> 180 °C Upto 220 °C
•Made of 100% inorganic material
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2-Pole machine with the following features:
Direct cooling of stator winding with water.Direct hydrogen cooling for rotor.Micalastic insulation system.Spring mounted core housing for effective transmission of
vibrations.Brushless Excitation system.Vertical hydrogen coolers
500 MW Turbo generators at a glance
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Important dimensions & weights:Heaviest lift of generator stator : 255 Tons Rotor weight : 68 Tons Overall stator dimensions [L*B*H] : 8.83m*4.lm*4.02m Rotor dimensions(Dia. and length) : 1.15m and 12.11m Total weight of turbo generator : 428 Tons
Salient technical data:
Rated output: 588 MVA , 500 MW Terminal voltage: 21 KV Rated stator current: 16 KA Rated frequency: 50 Hz Rated power factor: 0.85 Lag Efficiency: 98.55%
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Picture Of Bars
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THANK YOU