MANRAJ MEENA ELECTRICAL ENG.
Nov 27, 2014
MANRAJ MEENA ELECTRICAL ENG. MNIT ,JAIPUR
MANUFACTURING PROCESS OF TURBO GENERATOR
History of development in BHEL
History:- Our countries first heavy electrical manufacturing plant was established in Bhopal in 1964.The main aim of establishing BHEL was to meet the growing power requirement of the country.
1971-72:- The company has been earning profits continuously since 1971-72.
RANK :- India’s laregest and world’s 7th largest manufacture of power plant equipments .
MAHARATNA:- maharatna status ,february 2013. 2013-14:- Today BHEL has 15 Manufacturing
Divisions ,9 Service Centers, 4 Power Sector Regional offices, 2 repairing centers .
Employees:- More than 50,000 employees are working in BHEL.
LOCATION OF BHEL PLANTS
NEW DELHI
KOLKATA
VARANASI
GOINDWAL
HARIDWARRUDRAPUR
JAGDISHPURJHANSI
BHOPAL
HYDERABAD BANGALORE
RANIPETTIRUCHIRAPALLY
•Electronics Division (EDN), Bangalore•Heavy electrical Plant (HEP), Bhopal•Industrial Valves Plant (IVP),Goindwal•Heavy Electrical Equipment Plant,Haridwar•Central Foundry Forge Plant,Haridwar•Heavy Power Equipment Plant,Hyderabad•Insulator Plant (IP), Jagdishpur•Centralised Stamping Unit & Fabrication Plant , Jagdishpur•Transformer Plant, Jhansi•Boiler Auxiliaries Plant (BAP), Ranipet•Component Fabrication Plant (CFP), Rudrapur•High Pressure Boiler Plant (HPBP), Tiruchirapalli•Seamless Steel Tube Plant (SSTP), Tiruchirapalli•Power Plant Piping Unit, Thirumayam•Heavy Plates & Vessels Plant (HPVP), Visakhapatnam
BHEL Projects Covered BHEL has Supplied over
2,25,000 MVA Transformer capacity until today.(2012-13)
Bhel has supplied more than 1,25,000 MW generating capicity equipments till today.( approx 55%)
The plant also have the capacity and technology to manufacture 800MW generators.
As announced BHEL is planning for 600 MW Solar Module Factory.
BHEL HARIDWAR
1.CENTRAL FOUNDRY AND FORGE PLANT
(CFFP)AREA:- 1.0 sq. Km
.
2.HEAVY ELECTRICALS EQUIPMENT PLANT
(HEEP)AREA:- 0.845 sq. Km
INTRODUCTION TO HEEP
Block-1:- (Electrical Machine Final Assembly) Block-2:- (Gas & Steam Turbine Fabrication Block) Block-3:- (Gas & Steam Turbine Manufacturing
Block) Block-4:- [CIM (Coil & Insulation
Manufacturing)Block] Block-5:- (Heat Exchangers Fabrication Block) Block-6:- (Stampings Block) Block-7:- (Wooden Packing works Block) Block-8:- (Heat Exchanger Tubes Block)
Block-1 (Electrical Machine Final Assembly)
Mainly Block-I is designed to manufacture Turbo Generators.
Products
Stator frameStator core
Rotor & Rotor Windings
Exciter
Block-1 (Electrical Machine Final Assembly)
The block-1 consists of 4 bays:- Bay-I (36*482 meters), Bay-II(36*360 meters) Bay-III (24*360 meters ) Bay-IV (24*360 meters ).
Bay - I &Bay- II Machining of the all major components is carried
out here . The boring and facing of stators are done on CNC horizontal boring machine
Block-1 (Electrical Machine Final Assembly)
Bay - III and Bay – IV Machining of the other small components is carried
out here. For handling and transporting the various
components over-head crane facilities are available. There is also a number of self-propelled electrically driven transfer trolleys for the inter-bay movement of
components.
Block-1 (Electrical Machine Final Assembly)
There are 3-different assembiles in block-1 .
ASSEMBLIES
STATOR ASSEMBLY
ROTOR ASSEMBLY
EXCITOR ASSEMBLY
Block-1 (Electrical Machine Final Assembly)
STATOR ASSEMBLY- stator parts are assembled here by using different
machine. Stator winding is done by placing stator on rotating installation.
ROTOR ASSEMBLY :- Rotor winding coils are assembled in rotor slots. The
pressing of overhang portion is carried out on special ring type hydraulic press, where as slot portion is pressed manually with the help of rotor wedges.
EXCITOR ASSEMBLY:- different excitor parts are assembled here, either
manully or using different machine. BHEL imports with german company SIEMENS.
FIG:- EXCITOR FOR 800 MW TURBO GENERATOR
Block-1 (Electrical Machine Final Assembly)
TEST BED:-
General assembly of Turbo Generator is done in the test bed.Rotor is inserted in the stator and assembly of end shields, bearings etc.are carried out to make generator ready for testing. Turbo Generators are tested as per standard practices and customer requirements.
New LSTG test bed have the facilites for testing
the turbo generator of ratings upto 1000 MW.
Block-1 (Electrical Machine Final Assembly)
TURBO GENERATOR
500 MW Turbo generators at a glance(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 : 98.5%
IMPORTANT DIMENSIONS &WEIGHTS
500 MW TURBO GENERATOR :- Heaviest lift of generator (stator) : 255 Tons Rotor weight : 68 Tons stator dimensions :- 4.l2M(dia)x 8.83M(length) Rotor dimensions : 1.15M (dia )x 8.5 M( length) Total weight of turbo generator : 428 Tons
Transport through 24-Axle carrier beam railway wagon specially designed and manufactured at Haridwar.
COMPONENTS OF T.G.
STATOR – Stator frame Stator core Stator winding End covers
ROTOR – Rotor shaft Rotor winding Rotor retaining rings.
BEARINGSCOOLING SYSTEMEXCITATION SYSTEM.
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.
Basic purpose of stator frame to provide the support for stator core and to act as a pressure vessel for hydrogen gas in hydrogen –cooled T.G.
STATOR CORE The stator core is made of
insulated steel laminations. The thickness of the laminations and the type of steel are chosen to minimize eddy current and hysteresis losses
To remove the heat, a large number of space segments, are made along whole length of the core to pass the cooling agent through it and keep the stator core cool.
The stator core is then mounted in the stator frame.
STATOR WINDING
The stator has a three phase, double layer, short pitched and bar type of windings having two parallel paths. Each slots accommodated two bars.
Each bar consists of solid as well as hollow conductor with cooling water passing through the latter.
Alternate arrangement hollow and solid conductors ensure an optimum solution for increasing current and to reduce losses.
ROTOR SHAFT» Cylendrical rotor with 2 poles, speed 3000 rpm» Rotor shaft is a single piece forging manufactured from
a vacuum casting.» On 2/3 of its circumference( approximately) longitudinal
slots are provided to accommodate field winding
FIG:- FINISHED ROTOR
ROTOR WINDING
The winding consist of several coils inserted into the slots and the series connected such that two coils group to form one pole.
The conductors are made up of copper with silver content of approx. 0.1% for high strength at high temperature so that coil deformations due to thermal stresses are eliminated.
ROTOR RETAINING RINGS
It is the highly stressed component of T.G. The centrifugal forces of the end windings are
contained by rotor retaining rings. Retaining rings are made of non-magnetic high
strength steel in order to reduce the stray losses.
BEARINGS
Bearing require to rotate with minimum friction and vibration.
The turbo generators are provided with
pressure lubricated type bearing to ensure higher mechanical stability and reduced vibration in operation.
Jounral bearings are most commonly used in turbo generators.
COOLING SYSTEM
STATOR COOLING SYSTEM:- The stator winding is cooled by
demineralised water Water is fed from one end of the machine
by Teflon tube and flows through the upper bar and returns back through the lower bar of a slot.
Turbo generator requires water cooling arrangement over and above the usual hydrogen cooling arrangement.
COOLING SYSTEM
ROTOR COOLING SYSTEM:- Hydrogen is used as a cooling medium
in large capacity generator, generally in views of high heat carrying capacity and low density.
Cooling medium is required to circulate inside the generator in order to pick up the genrated heat,rotor fans are used for this purpose .
EXCITATION SYSTEM
STATIC EXCITATION:- • All components are static or stationary• Dc is directly supplied to the field of the main generator
through slip rings• the power supply to the rectifiers is from the main generator
EXCITATION SYSTEM
BRUSHLESS EXCITATION SYSTEM:- 1.)Pilot excitior 2.) Main excitior
Advantages of brushless excitation
No need of slip rings and brushes. Eliminates all the problem associated with
transfer of current via sliding contacts. Simple reliable and ideally suited for large
sets. Minimum operation and maintenance costs. Self generating excitation unaffected by
system faults or disturbances of shaft mounted pilot exciter.
Brush losses are eliminated
CONCLUSION
Practical training at BHEL Haridwar provided important knowledge in the field of construction of turbo- generators and their components.
Training at B.H.E.L. has proved quite faithful. It proved an opportunity for encounter with such huge machine like turbo-generators.
THANK YOU