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Presentation on Manufacturing Process Of Turbo Generator:

Presentation on Manufacturing Process Of Turbo Generator Presented by: NITIN GUPTA

Overview - B.H.E.L:

Overview - B.H.E.L BHEL is the largest engineering & manufacturing enterprise in India. Established 50 years ago. It is the 12th largest power equipment manufacturer in the world Earns profits continuously since 1971-72, & paying dividends since 1976-77

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Contribution of BHEL to various core sectors of Indian economy : BHEL Industry Power Generation International Business Transmission Renewable Energy Transportation

BHEL Haridwar Complex:

BHEL Haridwar Complex Situated in the foot hills of the Shivalik range in Haridwar district of Uttarakhand state BHEL Haridwar was founded in 1960 with Russian collaboration Plant is divided into two sections one is Heavy Electrical Equipment Plant(HEEP) and the other one is Central Foundry Forge Shop(CFFP)

HEEP Classification:

HEEP Classification

MANPOWER AT HARIDWAR:

MANPOWER AT HARIDWAR UNIT EXECUTIVES SUPERVISORS OTHERS TOTAL HEEP 1499 1513 4452 7464 CFFP 400 350 950 1700 Total 1899 1863 5402 9164

INTRODUCTION TO TURBO GENERAOR:

INTRODUCTION TO TURBO GENERAOR

Introduction To Turbo Generators:

Introduction To Turbo Generators A turbo generator is turbine directly connected to electric generator for the generation of electricity. Based on the operating principle of Faraday’s Law Of electromagnetic induction Basic equation for sizing of electrical machines P=K.As.Bδ.D 2 L .n s Depending on the cooling medium used there are various generator modules namely TARI, THRI, THDF

Generator Module Nomenclature:

Generator Module Nomenclature

TECHNICAL DATA :

TECHNICAL DATA

STATOR:

STATOR

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Stator Frame:- Consist of cylindrical steel frame and is the heaviest section in the generator It is used for holding the armature stampings & windings in position Provision of H 2 coolers for cooling of stator core and stator winding

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Stator Core:- Stator core is made from the insulated electrical sheet lamination The purpose of stator core is to carry magnetic flux and accommodates stator winding Stator core is made from silicon alloyed steel to reduce hysteresis losses. The core is laminated to minimize losses due to Eddy currents

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Stator Windings Stator winding is three phase layer lap winding Stator bar are transposed by 540 o Stator bar of THDF consist of hollow and solid strands The stator bars are insulated with Micalastic insulation. Bar of THDF Transposition Stator winding

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End Covers :- The end covers are made up of fabricated steel or aluminum castings. Accommodates generator bearings, coolers etc. The end covers are horizontally split to allow for assembly . Turbine end side (500 MW) Exciter end side ( 500 MW)

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BUSHINGS : The beginning and ends of the three phase windings are brought out from the stator frame through bushings located in generator terminal box Six bushings are used three for the phase and three for neutral Bushings Generator Terminal Box

ROTOR:

ROTOR

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Rotor:- The moving or rotating part of generator is known as rotor . It is coiled heavily (field coils) as it has to support large amount of current and voltage. The axial length of shaft of the rotor is very large as compared to its diameter in case of turbo generators. Solid rotors are manufactured from forged alloy steel with suitable alloying elements to achieve very high mechanical and magnetic properties .

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Constructional Features of Rotor :- Rotor consists of following parts: Rotor shaft Rotor winding Rotor Slot Wedges Retaining ring

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Rotor Shaft :- The rotor shaft is a single piece solid forging manufactured from a vacuum casting. Approximately 60 % of the rotor body circumference is with longitudinal slots , which hold the field winding . The main constituents of the steel are chromium, molybdenum, nickel and vanadium The shaft and body are forged integral to each other by drop forging process .

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Rotor Winding The slot house the field winding consists of several coils inserted into the longitudinal slots of rotor body The field winding consists of several series connected coils inserted into the longitudinal slots of rotor body. Rotor coils are made of pure copper + 0.2% silver, which has high tensile properties.

ROTOR SLOT WEDGE: :

ROTOR SLOT WEDGE: Rotor Slot wedges: To protect the winding from flying out of the rotor slot wedges are used The slot wedges are made of copper alloy They also act as damper winding bars

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Retaining Rings :- The centrifugal forces of the end windings are contained by piece rotor retaining rings. Retaining rings are made up of non-magnetic high strength steel in order to reduce the stray losses . These act as short circuit rings to the induced current to the damper system .

EXCITATION SYSTEM:

EXCITATION SYSTEM

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Excitation System :- The basic use of given exciter system is to produce necessary DC for turbo generator system. Principal behind this is that PMG is mounted on the common shaft which generates electricity and that is fed to yoke of main exciter . This exciter generates electricity and this is of AC in nature . This AC is that converted into DC and is that fed to turbo generator via C/C bolt.

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COMPONENTS :- The brushless exciter mainly consists of:- rectifier wheels t hree phase main exciter three phase pilot exciter Metering and supervisory equipment.

Operation of Brushless Exciter:

Operation of Brushless Exciter

A BUSHLESS EXCITER OF A T.G:

A BUSHLESS EXCITER OF A T.G

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Three Phase Pilot Exciter :- It is a sixteen-pole revolving field unit . The three phase winding is placed on the stator and magnetic poles are placed on the rotor Each pole consists of separate permanent magnets that are housed in a non-magnetic metallic enclosure .

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Three phase main exciter :- The three phase main exciter is a six-pole armature-revolving unit . The stator frame accommodates the field winding. The armature consists of stacked lamination and the three phase winding is inserted into the slots of the laminated armature. At the pole shoe , bars are provided which are connected to form a damper winding .

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Rectifier Wheel :- The silicon diode is the main component of the rectifier wheels, which are arranged in a three phase bridge circuit . With each diode, a fuse is provided which serves to cut off the diode from the circuit if it fails . For suppression of the momentary voltage peaks arising from commutation, R-C blocks are provided in each bridge in parallel with each set of diode DC leads fuse

Advantages Of Brushless Excitation System:

Advantages Of Brushless Excitation System Eliminates slip rings and brushes Eliminates the problem of transfer of current via sliding contacts Eliminates the problems of changing brushes Eliminates Brush losses Minimum operating and maintenance cost Earth Fault Measurement through provision of Instrument Slip Rings

TESTING OF TURBO GENERATOR:

TESTING OF TURBO GENERATOR

Testing Of Turbo Generator:

Testing Of Turbo Generator SHORT CIRCUIT TEST OPEN CIRCUIT TEST INTER STRAND TEST HIGH VOLTAGE TEST ON ROTOR AND STATOR WINDING HELIUM TEST

CONCLUSION:

CONCLUSION Industrial training at BHEL provided a deep insight into Manufacturing Process Of Turbo Generator Turbo Generator is the main product manufactured at BHEL Haridwar Turbo Generator is manufactured in various steps Assembly of stator frame and core are done at BLOCK 1 Rotor Shaft is imported from Germany and is coupled to Brushless Exciter Various tests are performed to check the reliability of turbo generator

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