Manufacturing of Turbo Genrators

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A Presentation on

Presented by:Akshay Dhaka

B-Tech, Final Year(ECE)

www.powerpointpresentationon.blogspot.com


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So, what is special about the holy cityHaridwar:-The City Of Gateway To

GODPlaces of interests in Haridwar: Chandi devi Mansa devi Maya devi Har-ki-pauri

Daksh mahadevtemple

Bharat mata mandir

Sati kund Sapt rishi ashram


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BHELAn Overview

In 1950s: At Bhopal with British collaboration30MW &120MW hydrogen cooled.

In 1960s: At Haridwar with Russiancollaboration

100MW & 200MW hydrogen cooled. In1970s: At Hyderabad with Germany

collaboration60MW air cooled.


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Complex is situated atthe foot hills of Shivalikrange Haridwar districtof Uttaranchal state.


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Principle ofoperation:The a.c

generators workson the principle

ofELECTROMAGNETIC

INDUCTION.


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Stator is the stationary,outer part of generatorwhich is used for housingthe rotor.

Rotor is the rotating partof the generator whichrotates in b/w themagnetic field provided bystator.


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End Plates (2 nos per generator) End Packets Ventilation stampings Insulating stampings ( b/w the core) Insulating studs ( b/w the sheets) Core bas Baskets (3 nos) Compressing rings

Hydraulic press Heating units.


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Stator

Stator frameIt is made up of steel iron with weldingprocess.

Stator core Silicon steel laminations are used. Ventilation is used in b/w the packets.

In a typical 350 MW generator-116packets

are used (55,47,36 Si sheets in each

packets)


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Copper bar VPI windings are used. Two types of bars are used in

stator.1. Upper

2. lower

Upper and lower bars are further divided into3 categories:

a) Normal bar b) Mid-phase bar c) Phase bar


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With 3 types of bars we get total 6 terminals, whichare connected in star to get 3 phases and a neutralpoint.

These bars are connected according to

SLOT-PITCH.

Finally upper and lowerbars are connected through

BRAZING.


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These rotor shaft are brought from theGermany.

Slots are made over it.

For a typical 500MW generator:- 2 groups of 14 main slots are cut.(diametrically opposite )

Damper slots are then made over it. Finally cross pole slots are made over theshaft.


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Main slots 38 degrees from centre line, then each

slots are at 8 degrees apart. Between two slots, distances are:

a) 50.9mm at front.b) 36.7mm at rear.c) 196.5mm depth.

Damper slots 22 deg. from centre line.Cross pole slots Breadth 10.5mm, Depth 110mm.


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2 pole, 3000rpm, 50Hz. Total slots=(14+14=28). 11 conductors in each slot. F type insulation is used in b/w two coils of 2mm

thickness. Diametrically opp. slots are connected in series. Holes are provided for passing hydrogen. Liners are placed over the slot portion wdg. To keep

them intact at one position. Returning rings are provided in the overhead portionfor keeping the wdg. intact at one position.


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After the manufacturing of both the stator androtor, these are assembled together at theassembly bed.


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It is the process by which theelectrical conductivity of any materialincreases at around 100 times.


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Uses VPI technology.( Vapour pressure impregnation)

Uses resins in the tank.

Explosion proof software controlled

oven with rotator facility.


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Rotor withdrawal during initial inspectionnot required.

Possibility of loosening and fastening ofcore eliminated.

Big savings in spares' cost.

Additional revenue of approx 3750 lakhs.


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Improved Heat transfer during operation.

Manufacturing cycle time reduces by 4-5months.

Mechanically firm binding b/w core and

winding components, better suitedagainst thermal stress.


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Electrical tests. Open circuit test. Short circuit test. Milivolt test.

Partial discharge test.Mechanical tests. Vibration test. Temperature test.

tan test ( Software operated ).


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Atlast, after all the manufacturingprocesses and testings, the journey of theGenerator starting from Germany to the

BHEL has come to an end.

Now its time for the generator to say Bye-Bye to BHEL(HARIDWAR)


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Documents

Manufacturing of Turbo Genrators