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ACKNOWLEDGEMENT
“An engineer with only theoretical knowledge is not a complete engineer. Practical
knowledge is very important to develop and apply engineering skills”. It gives me a great
pleasure to have an opportunity to acknowledge and to express gratitude to those who
were associated with me during my training at BHEL.
Special thanks to Mr.suresh ballala for providing me with an opportunity to undergo
training under his able guidance.
I am very great full to our training and placement officer for his support.
I express my sincere thanks and gratitude to BHEL authorities for allowing me to
undergo the training in this prestigious organization. I will always remain indebted to
them for their constant interest and excellent guidance in my training work, moreover
for providing me with an opportunity to work and gain experience.
BHEL-AN OVERVIEW
The first plant of what is today known as BHEL was established nearly 40 years
ago at Bhopal & was the genesis of the Heavy Equipment industry in India.
BHEL is today the largest Engineering Enterprise of its kind in India with excellent
track record of performance, making profits continuously since 1971-1972
BHEL business operations cater to core sectors of the Indian Economy like
Power
Industry
Transportation
Transmission etc.
BHEL has 14 units spread all over India manufacturing boilers, turbines,
generators, transformers, motors etc. Besides 14 manufacturing divisions the
company has 4 power sector regional centres, 8 service centres and 18 regional
offices and a large number of project sites thus enable the Company to promptly
serve its customers and provide them with suitable products, systems and
services efficiently and at competitive prices. The high level of quality & reliability
of its products is due to the emphasis on design, engineering and manufacturing
to international standards by acquiring and adapting some of the best
technologies from leading companies in the world, together with technologies
developed in its own R&D centres.
BHEL’s vision is to become world-class engineering enterprise, committed to
enhancing stakeholder value. The company is striving to give shape to its
aspirations and fulfil the expectations of the country to become a global player.
BHEL, HYDERABAD
Heavy Electrical Equipment Plant is equipped to produce Steam and Hydro
Turbines with matching Generators, Industrial Manufacturing Thermal sets up to
1000 MW capacity.
Located immediately south of HEEP is the Central Foundry Forge Plant setup.
The Heavy Electrical Equipment Plant was set up in technical collaboration with
M/s Prommash
-
export of USSR. The construction of the plant commenced in
1962 and the production of equipment was initiated in early 1967. In 1976, BHEL
entered into a collaboration agreement with M/s Kraftwerk Union A.G. of West
Germany for design, manufacture, erection and commissioning of large size steam
turbines and turbo generators of unit rating up to 1000MW
.
The BHEL plants in Hyderabad have earned the ISO
-
9001 AND 9002 certificates for
its high quality and maintenance. These two units have also earned the ISO
-
14001
certificates.
2. INTRODUCTION
2.1 TURBOGENERATOR:
A turbo generator is a turbine directly connected to electric generator for the
generation of electricity. They are mostly used as large capacity generator driven
by steam/gas turbine.
2.2 PRINCIPLE OF OPERATION:
In case of turbo generator, Rotor winding is supplied with DC current (through
slip rings or brushless exciter) which produces constant magnetic field.
3 phase stator winding is laid in stator core.
When generator rotor is rotated (by a turbine) magnetic flux produced by
rotor winding also rotates.
Voltage is induced in stator winding according to Faraday’s law*.
3 phase stator winding also produces magnetic flux revolving at synchronous
speed (=120*f/2p). Rotor also rotates at synchronous speed. Both the
magnetic fields are locked and rotate together.
*Faraday’s Law:
E.M.F. (Voltage) is induced in a closed path due to change of flux linkages and is
proportional to rate of change of flux linkages. The change in flux linkages can be
caused by change in flux in a stationary coil or by motion of coil with constant flux
or both.
E = −N dϕ/dt
2.3 SIZING OF GENERATOR MODULE:
Basic equation for sizing of electrical machines
P=K.As.Bδ.D2 L .ns
It can also be written as
D
2
L=P/ (K.As. Bδ .ns)
Here
P = MW output
As = Electric Loading (Amp.cond/cm)
Bδ = Magnetic Loading (gauss)
D = Stator bore diameter (cm)
L = Stator core length (cm)
ns = Rated speed
D
2
L = Volume of Rotor or Size of the Machine
MW Rating:
Size of machine (D2
L) is directly proportional to its output (MW)
Speed:
Size of machine (D2
L) is inversely proportional to its speed
Synchronous Speed = 120*F/ P
2.4 SYNCHRONOUS GENERATOR CLASSIFICATION BASED ON THE
MEDIUM USED FOR GENERATION:
Turbo generators in Thermal, nuclear, Gas station
High speed – 3000 rpm
No. of poles – 2 poles
Horizontal construction
Cylindrical rotor
Hydro generators in hydel plants
Low speed – 500 to 1000 rpm
No. of poles – 6 or more
Vertical construction
Salient type of rotor