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A Presentation on

Presented by: Akshay Dhaka B-Tech, Final Year(ECE)

So, what is special about the holy city Haridwar:-The City Of Gateway To GOD

Places of interests in Haridwar:

Chandi devi Daksh mahadev Mansa devi temple Maya devi Bharat mata mandir Har-ki-pauri Sati kund Sapt rishi ashram

BHEL An Overview
In 1950s: At Bhopal with British collaboration 30MW &120MW hydrogen cooled. In 1960s: At Haridwar with Russian collaboration 100MW & 200MW hydrogen cooled. In1970s: At Hyderabad with Germany collaboration 60MW air cooled.

Complex is situated at the foot hills of Shivalik range Haridwar district of Uttaranchal state.

Principle of operation:
The a.c generators works on the principle of

Stator is the stationary, outer part of generator which is used for housing the rotor.

Rotor is the rotating part of the generator which rotates in b/w the magnetic field provided by stator.

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.

Stator frame
It is made up of steel iron with welding process.

Stator core
Silicon steel laminations are used. Ventilation is used in b/w the packets. In a typical 350 MW generator-116 packets are used (55,47,36 Si sheets in each packets)

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 into 3 categories: a) Normal bar b) Mid-phase bar c) Phase bar

With 3 types of bars we get total 6 terminals, which are connected in star to get 3 phases and a neutral point. These bars are connected according to SLOT-PITCH. Finally upper and lower bars are connected through BRAZING.

These rotor shaft are brought from the Germany. 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 the shaft.

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.

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 portion for keeping the wdg. intact at one position.

After the manufacturing of both the stator and rotor, these are assembled together at the assembly bed.

It is the process by which the electrical conductivity of any material increases at around 100 times.

Uses VPI technology. ( Vapour pressure impregnation)

Uses resins in the tank.

Explosion proof software controlled oven with rotator facility.

Rotor withdrawal during initial inspection not required. Possibility of loosening and fastening of core eliminated. Big savings in spares' cost.
Additional revenue of approx 3750 lakhs.

Improved Heat transfer during operation.

Manufacturing cycle time reduces by 4-5 months.

Mechanically firm binding b/w core and winding components, better suited against thermal stress.

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

Mechanical tests.
Vibration test. Temperature test. tan test ( Software operated ).

Atlast, after all the manufacturing processes and testings, the journey of the Generator starting from Germany to the BHEL has come to an end. Now its time for the generator to say ByeBye to BHEL(HARIDWAR)