TRAINING SEMINAR ON BHEL ANKIT TYAGI FINAL YEAR, EE-07006

ABOUT BHEL

HISTORY  ESTABLISHED IN 1965  FIRST HEAVY ENGINEERING INDUSTRY IN INDIA, SETUP AT BHOPAL (MP)  SUPPLIES EQUIPMENTS CAPABLE FOR GENERATING 6000MW/YEAR  EXPORTS REACHED Rs.122 CRORES, HIGHEST FOR ANY YEAR IN  HEAD OFFICE IN NEW DELHI

BHEL IN PRESENT SCENARIO….  A widespread network comprising of 14 manufacturing companies  With an export presence in more than 60 countries  Supplied over Motors with Drive Control System to power projects, Petrochemicals Refineries, Steel, Aluminum, Fertilizer, Cement plant, etc.  150 Project sites

CONTD…  Supplied Traction electrics and AC/DC locos over 12000kms Railway network.  Supplied over one million Values to Power Plants and other Industries  Installed equipment for over 90,000MW of power generation for Utilities, captive and Industrial users.  14 Manufacturing Divisions  9 Service Centers  4 Power Sector Regional Centers

CLIENTS INCLUDE..  POWER  INDUSTRY  TRANSPORTATION  TRANSMISSION  TELECOMMUNICATION  DEFENCES ETC.

BHEL HARIDWAR  HAS 8 DIFFERENT BLOCKS  Block-1:- In block one turbo generator, generator, exciter motors (A.C&D.C) are manufactured & assembled  Block-2:- In block two large size fabricated assemblies\component for power equipment are manufactured & assembled.  Block-3:- In block -3 steam turbine, hydro turbines, and gas turbines, turbines blade are manufactured & assembled  Block-4:- In block -4winding for turbo generator, hydro generator, insulation of A.C&D.C motors insulating component for turbo generator, hydro generator motors are manufactured & assembled

 Block-5:- In block -5 fabricated parts of steam turbine water box, hydro turbine turbines parts are manufactured & assembled  Block-6:- In block -6 fabricated oil tanks hollow guide blades, rings, stator frames rotor spiders are manufactured & assembled  Block-7:- In block -7all types of dies including stamping dies, stamping for generators &motors are manufactured & assembled  Block-8:- In block -8 LP heaters, ejectors, steam coolers, oil coolers, ACG coolers, oil tanks are manufactured & assembled

BLOCK-4 MANUFACTURING OF BAR BY STEP:  Conductor cutting lower bar upper bar  Transposition  Crossover insulation  Forming  Brazing of coil lugs  Nitrogen leak test

 Thermal shock test  Helium leak test  Insulation  Impregnation and baking thermo reactive system micalastic system VIP micalstic system  Finishing

 Conducting varnish coating OCP(outer corona) ECP(end corona protection)  Testing h.v. test

BLOCK – 01 Conventional Bay-wise broad distribution  LSTG Area large size turbo generators  BAY-1 hydro generators, their exciters, PMG and Large size Turbo- Generators  BAY-2 Turbo-generators, their exciters and Heavy Electrical Motors  BAY-3 Medium size Electrical Motors

 Block-1 is designed to manufacture hydro- generators and large and medium size AC and DC Electrical machines.  The Block consists of 3 Bays: Bay-1(36*482 meters),Bay- 2, (36*360 meters) and Bay-3 of size 24*360 meters each. For handling and transporting the various components over-head crane facilities are available, depending upon the products manufactured in each bay. There are also a number of self propelled electrically driven transfer trolleys for the inter-bay movements of components/assemblies

MANUFACTURING PROFILE  Generator 1) Kraft Work Union- i) THDF ii) THRI iii) TARI TARI: Capacity 500 MW, Cooling is done by air. THRI: Capacity MW. Water is the cooling medium. Stator is indirectly cooled while Rotor is radially cooled.

 Hydrogen Cooled Turbo generators Of Mw Range (Type: THRI ) Salient Design Features  Stator core and rotor winding directly  hydrogen cooled  Indirect cooling of stator winding  Rigid core bar mounting  Micalastic insulation system  End shield mounted bearings  Top ripple springs in stator slots  Ring type shaft seals  Symmetrical ventilation.

Salient Technical Data  Rated output : 588 MVA, 500 MV  Terminal voltage : 21 KV  Rated stator current : 16 KA  Rated frequency : 50 Hz  Rated power factor : 0.85 Lag  Efficiency : 98.55%

Important Weights  Heaviest Lift of Generator Stator : 255 Tons  Rotor Weight :68 Tons  Total Weight of Turbo Generator : 428 Tons

Large DC Machines Salient features of large custom-built m/c  Compact design with smaller size.  MICALASTIC insulation using VPI technology for high electrical and mechanical strength  Sturdy mechanical construction to meet frequent reversals  Low moment of inertia  Skewed armature slots for reduced noise level  Fully compensated for high overloads & wide speed range.

Technical Data  Ratings:-from 1400 kW at 1000 rpm to kW at 70 rpm  Voltage: - up to 1200 V. Higher voltages on request  Mountings: - both horizontal and vertical

MEDIUM SIZE AC MOTORS  Very high efficiency.  Torsionally rigid, rugged housing and end shields made of cast iron.  External and internal ribbing on slip ring enclosure and servicing cover.  MICALASTIC insulation using VPI technology.  Proven anti-friction bearing concept.  Compact dimensions.  Ratings: -200 to 2500 kW  Voltage range: to 11 kV, 50 Hz.  Number of poles: -4 to 12  Shaft heights (in mm.):- 355, 400, 450, 500 and 560 salient featuresTechnical Data

STATOR  the main part of every motor and generator  very hard, size depends upon its characteristics  Stator frame  suitably ribbed with annular rings

CONCLUSION  WE GOT KNOWLEDGE ABOUT TGs & MOTORS.  BASICALLY THE WHOLE PROCESS OF MAKING A TURBO GENERATOR RIGHT FROM THE ENRICHMENT OF THE ROTOR TO THE TESTING BED.  APART FROM THAT WE LEARNED HOW DOES THE INDUSTRIES WORK.