BHEL: AN OVERVIEW

Bharat Heavy Electricals Limited (BHEL) is an Indian integrated power plant equipment manufacturer and operates as engineering and manufacturing company based in New Delhi, India. Established in 1964, BHEL ushered in the indigenous Heavy Electrical Equipment industry in India. The company has been earning profits continuously since 197172 and paying dividends since 1976-77. BHEL was established more than 50 years ago. It is the 7th largest power equipment manufacturer in the world. 74% of the total power generated in India is produced by equipment manufactured by BHEL. It is one of India's nine largest Public Sector Undertakings or PSUs, known as the Navratnas or 'the nine jewels'. It is also placed at 4th place in Forbes Asia's Fabulous 50 List of 2010. In the year 2011, it was ranked ninth most innovative company in the world by US business magazine Forbes. BHEL is the only Indian Engineering company on the list. BHEL manufactures over 180 products under 30 major product groups and caters to core sectors of the Indian Economy viz., Power, Transmission, Industry, Transportation, Renewable Energy, Oil & Gas, Defense, etc. The organization has a huge network of branches which is vital for any organization to succeed in a geographically huge country like India. It has 15 manufacturing divisions, two repair units, four regional offices, eight service centers, eight overseas offices and 15 regional centers and currently operates at more than 150 project sites across India and abroad. Most of its manufacturing units and other entities have been accredited to Quality Management Systems (ISO 9001:2008), Environmental Management Systems (ISO 14001:2004) and Occupational Health & Safety Management Systems (OHSAS 18001:2007).

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Project Report: Electrical Machines

Main Manufacturing Facilities

First Generation Units :
Heavy Electrical Plant (HEP), Bhopal Heavy Electrical Equipment Plant (HEEP), Haridwar Heavy Electrical Power Equipment Plant (HEPEP), Hyderabad High Pressure Boiler Plant , Trichy

Second Generation Units :

Transformer And Locomotive Plant, Jhansi Central Foundry and Forge Plant, Haridwar Seamless Steel Tube Plant (SSTP), Trichy

Unit Through Acquisition and Merger

Electronic Division (EDN), Bangalore Electro Porcelain Division (EPD), Bangalore

New Manufacturing Units

Boiler Auxiliaries Plant, Ranipet Insulator Plant, Jagdishpur Component Fabrication Plant, Rudrapur Industrial Valves Plant, Goindwal Bharat Heavy Plates and Vessels Limited, Vizag

Besides these manufacturing units there are four power sectors (PSNR-Noida, PSWR-Nagpur, PSER-Kolkata & PSSR-Chennai) which undertake EPC contract from various customers and are responsible for erection and commissioning of various BHEL and bought out equipment. Power sector HQ is located in Noida. The Research and Development arm of BHEL is situated in Hyderabad Two repair shops are at Varanasi i.e. HERP (Heavy Equipment Repair Plant) and at Mumbai i.e. EMRP (Electric machines repair plant).

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EVOLUTION OF THE ORGANISATION

February 1947 The advisory planning board felt the need for electrical machinery in India.

March 1948

Exploratory committee to set up heavy electrical generating body.

January 1955

S.A Gelkey committee reiterates need for an electrical equipment factory.

August 1956

Heavy Electrical (Pvt) Ltd incorporated later renamed H.E (1), Ltd at Bhopal.

November 1964

Bharat Heavy Electrical Ltd, established & plants at Hardwar, Hyderabad and Trichy setup.

July 1972

Action committee of public enterprise recommends integration.

July 1974

H.E (1) Ltd, and BHEL formally merged. Company prepares first corporate plan.

1980

Company prepared second corporate plan with emphasis on growth.

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1992

Government brings out liberalization policy. Allows private sector to manufacture power-generating equipments. Disinvestments policy of government on PSU shareholding, BHEL shares offered to employees also.

1995

BHEL shares listed on all principal stock exchanges of the country.

1997

Greater autonomy to PSUs BHEL. BHEL prepares document on Perspectives for 2002.

2009

BHEL wins Rs.1, 700 Million contract for setting up an Cogeneration power plant at Manali Refinery of CPCL*

June 2012

BHEL commissioned 250 MW power generating unit at Harduaganj in Uttar Pradesh. This would add six million units of electricity on a daily basis.

* Bharat Heavy Electricals Limited (BHEL) has secured a contract from Chennai Petroleum Corporation Limited (CPCL) for setting up an energy efficient and environment friendly co-generation power plant at its Manali. Reposing confidence in BHEL's capabilities, CPCL has placed an order worth Rs.1,700 Million, for setting up a 20 MW (Frame-5) Gas Turbine-based plant.
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MAJOR MANUFACTURING PLANTS AND THEIR PRODUCTS

Heavy Electrical Plant (HEP), Bhopal Hydro sets, Nuclear turbines, Thermal sets (110 MW), AC Motors & large Electric Motors, Power Transformers Traction Machine & Controls for traction & industrial applications, Diesel Generating sets, Switchgear, Capacitors, Industrial turbines. Power transformers (less than 220 KV) freight Loco transformers, Instrument transformers, AC Locos Diesel Electric Shunters, etc. Thermal sets, Gas turbine generator sets combined cycle/Co.gen plants Industrial TG sets, Compressors, Oil Rigs, mills, SF & MOCB switchgear, Heat exchanger. Casting and forging for thermal/Hydro sets, motors defense etc. Special facilities like 9000T press for forgings, electric arc furnaces for melting steel, etc.

Transformer Plant (TP), Jhansi

Heavy Power Equipment Plant (HPEP), Hyderabad

Heavy Electricals Equipment Plant (HEEP), Haridwar

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Seamless Steel Tube Plant (SSTP), Trichy

Seamless steel tubes.

Boiler Auxiliaries Plant (BAP), Ranipet

Boiler auxiliary fans, Electrostatic Preheaters. Variable speed drives, programmable. Login and digital controllers, Power devices, meters, etc. Photovoltaic/solar Panels, simulators, etc. Insulators: solid core, bushings, pin. Post and ceramic lines. Disk Insulators, Ceramic liners. Industrial Valves Wind mills, solar water heaters and lanterns Telecom products & simulators.

Electronics Division (EDN), Bangalore

Electro Porcelains Division (EPD), Bangalore

Insulator Plant (IP), Jagadishpur

Industrial Valve Plant (IVP), Goindwal

Component Fabrication Plant (CFP), Rudrapur

ESD, Bangalore

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Their Vision, Mission and Values

Vision
To be a world class, innovative, competitive and profitable Engineering Enterprise providing total business solutions and committed to enhancing stakeholder value.

Mission
To be an Indian Multinational Engineering Enterprise providing Total Business Solutions through Quality Products, Systems and Services in the fields of Energy, Transportation, Infrastructure and other potential areas.

Values
Meeting commitments made to external and internal customers. Foster learning, creativity and team work. Respect for dignity and potential of individuals. Loyalty and pride in the company. Zeal for the change. Zeal to excel. Integrity and fairness in all matters. Strict adherence to commitments.

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Heavy Electrical Plant (HEP)

Heavy Electrical Plant, Bhopal is the mother plant of Bharat Heavy Electricals Limited, the largest engineering and manufacturing enterprise in India in the energy-related and infrastructure sector, today. With technical assistance from Associated Electricals (India) Ltd., a UK based company; it came into existence on 29th of August, 1956. Pt. Jawaharlal Nehru, first Prime minister of India dedicated this plant to the nation on 6th of November, 1960. It with state-of-the-art facilities, manufactures wide range of electrical equipments. Its product range includes Hydro, Steam, Marine & Nuclear Turbines, Heat Exchangers, Hydro & Turbo Generators, Transformers, and Switchgears, Control gears, Transportation Equipment, Capacitors, Bushings, Electrical Motors, Rectifiers, Oil Drilling Rig Equipments and Diesel Generating sets.
The first-ever indigenously built 2,000 HP industrial motor manufactured at the BHEL factory in Bhopal.

It has its own Laboratories for material testing and instrument calibration which are accredited with ISO 17025 by NABL. The Hydro Laboratory, Ultra High Voltage laboratory and Centre for Electric Transportation are the only laboratories of its own type. BHEL Bhopal's strength is its employees. The company continuously invests in Human Resources and pays utmost attention to their needs. The plant's Township, well known for its greenery is spread over an area of around 20 square kilometers and provides all facilities to the residents like, parks, community halls, library, shopping centers, banks, post offices etc. Besides, free health services are extended to all the employees through 350 bedded (inclusive of 50 floating beds) Kasturba Hospital and chain of dispensaries.

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Electrical Machines
An electrical machine is the apparatus that converts energy in three categories: 1. Generators which convert mechanical energy to electrical energy, 2. Motors which convert electrical energy to mechanical energy, and 3. Transformers which change the voltage level of an alternating current.

Generator
An electric generator is a device that converts mechanical energy to electrical energy. A generator forces electrons to flow through an external electrical circuit. The source of mechanical energy, may be a reciprocating or turbine steam engine, water falling through a turbine or waterwheel, an internal combustion engine, a wind turbine, a hand crank, air or any other source of mechanical energy. The two main parts of an electrical machine can be described in either mechanical or electrical terms: In mechanical terms, the rotor is the rotating part, and the stator is the stationary part of an electrical machine. In electrical terms, the armature is the power-producing component and the field is the magnetic field component of an electrical machine. The armature can be on either the rotor or the stator. The magnetic field can be provided by either electromagnets or magnets mounted on either the rotor or the stator. Generators are classified into two types; AC generators and DC generators.

AC generator
An AC generator converts mechanical energy into alternating current electricity. Because power transferred into the field circuit is much less than power
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transferred into the armature circuit, AC generators nearly always have the field winding on the rotor and the armature winding on the stator. AC generators are classified into several types. Induction (asynchronous) generator, its stator flux induces currents in the rotor. The prime mover then drives the rotor above the synchronous speed, causing the opposing rotor flux to cut the stator coils producing active current in the stator coils, thus sending power back to the electrical grid. Synchronous generator (alternator), the current for the magnetic field is provided by a separate DC current source.

DC generator
A DC generator produces direct current electrical power from mechanical energy. A DC generator can operate at any speed within mechanical limits and always output a direct current waveform. Direct current generators known as dynamos work on exactly the same principles as alternators, but have a commutator on the rotating shaft which converts the alternating current produced by the armature to direct current.

Motor
An electric motor converts electrical energy into mechanical energy. The reverse process of electrical generators, most electric motors operate through interacting magnetic fields and currentcarrying conductors to generate rotational force. Motors and generators have many similarities and many types of electric motors can be run as generators, and vice versa. Electric motors are found in applications as diverse as industrial fans, blowers and pumps, machine tools, household appliances, power tools, and disk drives. They may be powered by direct current or by alternating current which leads to the two main classifications: AC motors and DC motors.

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AC motor
An AC motor converts alternating current into mechanical energy. It commonly consists of two basic parts, an outside stationary stator having coils supplied with alternating current to produce a rotating magnetic field, and an inside rotor attached to the output shaft that is given a torque by the rotating field. The two main types of AC motors are distinguished by the type of rotor used. Induction (asynchronous) motor, the rotor magnetic field is created by an induced current. The rotor must turn slightly slower (or faster) than the stator magnetic field to provide the induced current. There are three types of induction motor rotors, which are squirrel-cage rotor, rotor and solid core rotor. Synchronous motor, it does not rely on induction and so can rotate exactly at the supply frequency or sub-multiple. The magnetic field of the rotor is either generated by direct current delivered through slip rings or by a permanent magnet.

DC motor
The brushed DC electric motor generates torque directly from DC power supplied to the motor by using internal commutation, stationary permanent magnets, and rotating electrical magnets. Brushes and springs carry the electric current from the commutator to the spinning wire windings of the rotor inside the motor. Brushless DC motors use a rotating permanent magnet in the rotor, and stationary electrical magnets on the motor housing. A motor controller converts DC to AC. This design is simpler than that of brushed motors because it eliminates the complication of transferring power from outside the motor to the spinning rotor. An example of a brushless, synchronous DC motor is a stepper motor which can divide a full rotation into a large number of steps. The motor's position can be controlled precisely without any feedback mechanism as long as the motor is carefully sized to the application.

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Transformer
A transformer is a static device that converts alternating current from one voltage level to another level (higher or lower), or to the same level, without changing the frequency. A transformer transfers electrical energy from one circuit to another through inductively conductorsthe transformer's coils. A varying electric current in the first or primary winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic field through the secondary winding. This varying magnetic field induces a varying electromotive force (EMF) or "voltage" in the secondary winding. This effect is called mutual induction.

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Hydro-electric Generator
Hydroelectric generators can turn the energy of moving water into usable electricity. This is most commonly accomplished by damming a river and then directing the water through one or more turbines. As the water causes the turbines to spin, they in turn operate electric generators. While damming rivers can have environmental repercussions, hydroelectric generators are typically considered to be a primary source of clean, renewable energy. About 20% of the electricity in the world comes from hydroelectric generators, which accounts for most of the electricity generated by renewable sources. Usually a hydroelectric generator manufactured is a salient-pole synchronous generator whose rotor is connected or coupled to the rotor of a hydraulic turbine. The design of a hydroelectric generator is basically determined by the position of its rotors axis, as well as by the frequency of rotation and power of the turbine. High-capacity, low-speed generators are usually manufactured with a vertical axis of rotation (with the exception of capsule-type hydroelectric units), whereas highspeed units with a bucket-type hydraulic turbine are made with a horizontal axis of rotation. Because of the topological and geological characteristics of rivers in the USSR, most high-speed generators are installed with a vertical axis of rotation. Hydro-electric Generators can be classified on various characteristics: 1. According to the design of rotor poles,

a. Salient Pole
More commonly used in smaller and medium power ranges is the salient-pole generator and are usually coupled with hydraulic
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turbines as most hydraulic turbines have to turn at low speeds as large number of poles is required on the rotor.

b. Non Salient Pole / Cylindrical/ Turbo

The largest generators used in major power stations are usually cylindrical generators. They operate at high speeds and are usually directly coupled to a steam or gas turbine. 2. According to the induced current phase

a. Single-Phase AC Generators
Also called Single-phase alternators. Single-phase AC generators produce a single, continuous source of alternating voltage. They are commonly used in smaller applications that require limited amounts of electricity, such as providing power for small-scale hydroelectric plants, remote villages, construction crews and standby power (emergency generators). Single-phase alternators produce 25 kilowatts of electrical energy or less.

b. Two-Phase AC Generators
Also called a Poly-phase AC generator. It is made of two or more single-phase windings that produce two different voltages. Each voltage can be considered as a separate single-phase voltage. The two voltages are generated independent of each other. Two phase alternators are used for self-starting hydroelectric motors.

c. Three-Phase AC Generators
Used for the distribution, transmission and generation of large-scale hydroelectric power. A three-phase alternator is made of three separate single-phase voltages (or coils) that are separated from each other by 120 degrees. When the generator is turned on, it produces three different AC waveforms that are 120 degrees apart.
NOTE: The advantage of a three-phase alternator is that the power never drops to zero i.e. provides a constant source of power and efficiently convert mechanical into electrical energy with minimum waste. Three-phase AC generators are preferred because they are cheaper than single-phase alternators, they use steel and copper more efficiently in their designs, they allow easier Page | 14 regulation of voltage, they are smaller and easier to operate also. Project Report: Electrical Machines It can also produce both three-phase power and single-phase power.

3. According to the mechanical i.e. bearing arrangement,

a. Umbrella Type
Due to low speed (80 200 rpm), it does not require a top guide bearing, and combines bottom thrust and guide bearing.

b. Semi-Umbrella Type
It is applicable to medium speed (130- 250rmp) with the combination of bottom thrust, guide bearing and top guide bearing, where the latter one is supported by a light bracket. Cost wise more expensive than umbrella type.

Semi-Umbrella Type

c. Standard Type
This is the most expensive generator design for high speed applications (170 - 1000rmp) with small rotor diameter. Here Top mounted thrust & guide bearing supported on a heavy bracket

Standard Type

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4. According to the shaft alignment,

a. Horizontal Type
They are usually of low speeds of 3001200 revolutions per minute (rpm). The normal power-factor rating of small synchronous generators is between 0.8 and 1.0 with 0.9 being common.

b. Vertical Type
They are usually larger and more easily adapted to small hydraulic heads. For large generators, a rating of 0.90.95 is common with the machines able to operate up to 1.0 when the load requires.

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Working Principle Of Hydro-electric Generator

Hydro-electric generator works on the principles discovered by Faraday. He found that when a magnet is moved past a conductor, it causes electricity to flow. In a large generator, electromagnets are made by circulating direct current through loops of wire wound around stacks of magnetic steel laminations. These are called field poles, and are mounted on the perimeter of the rotor. The rotor is attached to the turbine shaft, and rotates at a fixed speed. When the rotor turns, it causes the field poles (the electromagnets) to move past the conductors mounted in the stator. This, in turn, causes electricity to flow and a voltage to develop at the generator output terminals. According to Faraday's law, the induced electromotive force in any closed circuit is equal to the negative of the time rate of change of the magnetic flux through the circuit. The electric current generated in electric circuit is due to faradays law is also termed as electro-motive force (emf). An electromotive force is induced in a coil whenever a coil cuts through a magnetic field or a magnetic field cuts through a coil. Electromotive force induction is due to relative motion between two parts i.e. coil and magnetic field. This relative motion is caused due to rotation of two mechanical parts known as rotor and stator.

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Generators Subassemblies and Auxiliaries

Subassemblies 1. Stator 2. Rotor with fans 3. Lower bracket with brakes and jacks 4. Upper bracket Thrust bearing

Auxiliaries 1. Unit control board 2. Hydrostatic Lubrication System 3. Cooling System 4. Brake/Jack System 5. Dust collector

5. Guide bearings 6. Air, oil coolers and pipe lines 7. SSG speed sensing gear 8. Excitation system 6. Stator heater (Anti condensation heater) 7. Air, oil and water pipe lines. 8. Fire extinguishing system / CO2 system.

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Stator Of Hydro Generator

Stator consists of steel frame enclosing a cylindrical core (made up of laminations of silicon steel), which carries the three-phase windings in slots on the inside. It is mounted between two end brackets i.e. upper and lower bracket Stator Core consists of thin silicon steel sheet lamination. These laminations are punched as arcs of a circle and then assembled into the finished circular stator frame. This is supported by a steel frame known as Stator Frame. The inner diameters of laminations have slots running the entire axial length of the core for stator coils. These slots extend into each punching deeply enough to contain the stator winding. This stator core is built using thin laminations to minimize eddy losses or hysteresis losses.

Stator winding is made of copper, and shall be of sufficiently transposed one turn coil placed in double layer in each slot having uniform shape and dimensions, and is replaceable and exchangeable. The windings are insulated from each other and also from the iron core. They form a large number of conductor loops which are each subjected to the rotating magnetic field i.e. interacting with the rotating air gap flux provided by the rotor to convert mechanical energy into electrical energy.

Rotor Of Hydro Generator

Rotor (or pole wheel) is attached to the rotating shaft. It consists of a frame (rotor spider), an iron ring made from stacked steel sheets, and rotor poles. The rotor is separated from the stationary stator by an air-gap.
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The rotor of a hydro generator consists of following sub-assemblies: a) b) c) d) Generator Shaft Rotor Spider Rotor Rim Poles and their interconnections e) Current carrying leads f) Rotor Fan g) Slip-Ring The primary function of generator rotor is to carry the field poles necessary for excitation of the stator winding. The generator rotor must effectively make all the mechanical connections for the various attached components and carry all loads without creating unacceptable vibration due to unbalancing of rotor. The structural part of the rotor assembly is typically a cast structure, sometimes called a Spider, machined to allow bolting/keying to the generator shaft at the center and the rotor rim to be installed on the arms with keys. Rotor Rim assembly is a laminated cylindrical structure that stacks on a horizontal machined surface at the end of the spider arm. Fixing and clamping of this lamination helps to achieve a rim that floats during runaway speed but retains its original position while returning to its rated speed. Rotor Poles are also constructed from laminated steel sheets; hold the field winding, which provides the fundamental magnetic field excitation. Excitation current is provided to the field poles by the field leads mounted on the rotor arm which are mechanically and electrically connected to the slip rings. The field poles are electrically connected in series.

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Generator shaft is a non-performance but a reliability related component of the generator. Shafts may be a single piece manufactured from forged steel but some of large shafts can be fabricated. The primary function of the shaft is to transmit the torque delivered by the turbine to rotate the generator rotor so that this power may convert to electrical energy.

The connection of the turbine shaft to the generator shaft is made with a bolted connection. Alignment of the generator and turbine shafts, attachments and assemblies is necessary to create and maintain air gap, turbine clearances and bearing loading. It may have a rotating exciter mounted on top of the generator rotor which provides excitation current and voltage to the field poles.

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Excitation System
A generator produces output voltage proportional to the magnetic field, which is proportional to the excitation current; if there is no excitation current there is zero voltage. A generator can thus be considered as an amplifier: a small amount of power may control a large amount of power. This principle is very useful for voltage control: if the system voltage is low, excitation can be increased; if the system voltage is high, excitation can be decreased. Types of excitation system used in generators are; 1. Separate excitation: For large or older generators, it is usual to be operate separate exciter dynamo in conjunction with the main power generator. This is a small permanent-magnet or battery-excited dynamo that produces the field current for the larger generator. 2. Self-excitation: Modern generators with field coils are self-excited, where some of the power output from the rotor is used to power the field coils. The rotor iron retains a residual magnetism when the generator is turned off. The generator is started with no load connected; the initial weak field creates a weak voltage in the stator coils, which in turn increases the field current, until the machine "builds up" to full voltage.

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Project Report: Electrical Machines

Generators Cooling System

The generator cooling system consists of fan blades mounted on the rotor, raw cooling water (RCW) system, and generator air coolers. The primary purposes of a generator cooling system is to provide adequate cooling for the stator/field winding insulation material and limit thermal stresses to acceptable levels. A typical generator cooling system for enclosed housings will be composed of two fluid flow paths to cool the generator. The air flow path is a closed system established by the air housing which allows the air to be discharged from the fan blades and circulate through the generator. The normal flow path is from the blades, by the field poles, through slots in the generator iron core, into a large area in the frame, through the generator air coolers into the air housing, then back to the fan blades by passing over (under)

the stator frame.

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Project Report: Electrical Machines

As a subsystem of the cooling system, the Raw Cooling Water (RCW) system functions as a heat sink for generator losses. The raw cooling water system is an open system in which water flows are discharged back to the headwater or tailwater. A RCW strainer removes suspended solid material (wood, rocks, sand, biological matter, etc.) from the RCW to minimize fouling of the generator air cooler heat exchanger.

Thrust Bearing
Units are classified mechanically by the location of the thrust bearing relative to the rotor as follows. For a suspended unit, the thrust bearing is above the rotor and there may be one or two guide bearings one of which is always above the rotor. In an umbrella arrangement, the thrust bearing is on the bottom side of the rotor usually with an integral guide bearing. The modified umbrella type generator locates the thrust bearing on the bottom side of the rotor with a guide bearing both top and bottom. The thrust bearing is basically a non-performance but reliability related component. The purpose of the thrust bearing is to provide axial static and dynamic support for the unit. A generator thrust bearing consist of the thrust pot configuration, oil baffles, oil with specification, bearing adjustment hardware, and coolers.

Guide Bearing
The guide bearing provides support for radial load. Both pivoted and sleeve type bearings are similar to the thrust bearing. These are manufactured from forged steel with a babbitted contact surface. The sleeve designs have structural castings typically in halves with babbitted sleeve surfaces. Babbitt, also called Babbitt metal or bearing metal, is any of several alloys used for the bearing surface in a plain bearing. Babbitt metal is most commonly used as a thin surface layer in a complex, multi-metal structure. Babbitt metal is soft and easily damaged, which suggests that it might be unsuitable for a bearing surface. However, its structure is made up of small
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hard crystals dispersed in a softer metal, which makes it a metal matrix composite.

Upper and Lower Bracket

The upper and lower bearing brackets support the generator guide and thrust bearings. These brackets are composed of a central hub and steel plate arms assembled to the hub by bolting and welding. These components are located in the upper and lower parts of the stator frame, and their movement from the original position must be monitored.

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Blocks in BHEL, Bhopal

Block-1 Block-2 Block-3 Block-4 Block-5 Block-6 Block-7 Block-8 Hydro Turbines & Heat Exchangers Electrical Machines Transformers Switch Gears Coil & Insulation Manufacturing Steam Turbine Traction Motor & Alternators Gears & Tools Manufacturing

Brief Summary: Block-2 (i.e. Electrical Machines)

Block-2 consists of various bays where fabrication and assembly of electrical machines takes place. It contains various divisions i.e. PLM, IMM and LEM divisions. Each bay has been divided into two parts by pathway i.e. left and right side. Generally, there are machine shop and material storage in left side, while assembly area, winding area, and testing area in right side of each bay. BAY-I & II In left side, Fabrication of traction motors or alternators shaft takes place using various machines such as popping m/c, center lathe m/c, centering m/c, drilling m/c ,CNC grinding m/c and CNC slotting m/c. In right side, Fabrication of stator frame and its other components takes place using draw cut shaper m/c, vertical slotting m/c and deburring. BAY-III Tooling on lathe m/cs and winding & insulating coils takes place.

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Project Report: Electrical Machines

BAY-IV & V These bays come under the IMM (Industrial Machines Manufacturing) Division. In left side, stacking of laminations and shaft machining takes place. In right side, stator frame machining, coil insulation, winding and assembly of IMM components takes place completely that is then packed and transported to its site. BAY-VI & VII These bays come under the PLM Division where manufacturing of hydrogenerators and machining of some of the components of turbines takes place. In left side, there is a machine shop where machining of casted structure know as spider, stator frame, rotor, upper & lower bracket and various other components takes place. Also, blanking of thin silicon steel sheet takes place for stacking laminations. In right side, stacking of laminations for stator frame is packed in small packages. Also, stacking of thin steel sheets for making field pole having windings and electric leads. Since, the size of hydro-generator is quite huge, it is not so easy to transport the hydro-generator to its site which may be either a hilly area or bank of any river. So, the small packets are being formed of stator core laminations for the ease in transportation. Rotor, spider, field pole, etc. are taken individual to the site. Since, the stator frame diameter is quite large, it is being manufactured in two or more parts which can be bolted together. All these components are being assembled at site. The process of assembly is called as Erection
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Project Report: Electrical Machines

BAY-VI & VII These bays come under the LEM Division. In left side, machining rotor, rotor frame, and stator frame takes place. In right side, stator frame stacking of laminations, coil insulation and winding takes place. All components are being assembled and then testing takes place.

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Machining Shop

Control Methods
There are three basics ways in which an operator can interact with a fabrication machines. Either manual manipulation of the machine, Numerical Control with a punched card system or using Computer Numerical Control using a preexisting interface designed for that machine. The first two options are rarely if ever used today. CNC operated machines are the most technologically advanced, efficient, reliable systems in the manufacturing industry.

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Project Report: Electrical Machines

Numerical Control
Numerical control is a method of automatically operating a manufacturing machine based on a code of letters, numbers, and special characters as opposed to controlled manually via handwheel or levers, or mechanically automated via cams alone. The first NC machines were built in the 1940s and 1950s by John Parsons, based on existing tools that were modified with motors that moved the controls to follow points fed into the system on punched tape. The numerical data required to produce a part is provided to a machine in the form of a program, called part program or CNC program. The program is translated into the appropriate electrical signals for input to motors that run the machine.

Computer Numerical Control (CNC)

CNC may be considered to be a means of operating a machine through the use of discrete numerical values fed into the machine, where the required input technical information is stored on a kind of input media such as floppy disk, hard disk, CD-ROM, USB flash drive, etc. The machine follows a predetermined sequence of machining operations at the predetermined speeds necessary to produce a workpiece of the right shape and size and thus according to completely predictable results. A different product can be produced through reprogramming. The two control systems are; Open Loop Systems have no access to the real time data about the performance of the system and therefore no immediate corrective action can be taken in case of system disturbance. This system is normally applied only to the case where the output is almost constant and predictable.

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 Close Loop Systems have feedback devices to closely monitor the output and nay disturbance will be corrected in the first instance. Therefore, high system accuracy is achievable. This system is more powerful than the open loop system and can be applied to the case where the output is subject to frequent change. A CNC system consists of the following six major elements: 1. 2. 3. 4. Input Device Machine Control Unit Machine Tool Driving System (DC Servo Motor, AC Servo Motor, Stepping Motor, or Linear Motor) 5. Feedback Devices 6. Display Unit Axis of Motion: In generally, all motions have 6 degree of freedom. In other words, motion can be resolved into 6 axes, namely, 3 linear axes (X, Y, and Z axis) and 3 rotational axes (A, B, and C axis).

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Lathe Machine
The purpose of a lathe is to rotate a part against a tool whose position it controls. It is useful for fabricating parts and/or features that have a circular cross section. The spindle is the part of the lathe that rotates. Various work holding attachments such as three jaw chucks, collets, and centers can be held in the spindle. The spindle is driven by an electric motor through a system of belt drives and/or gear trains. Spindle speed is controlled by varying the geometry of the drive train.

The tailstock can be used to support the end of the workpiece with a center, or to hold tools for drilling, reaming, threading, or cutting tapers.it can be adjusted in position along the ways to accommodate different length workpieces. The ram can be fed along the axis of rotation with the tailstock handwheel.

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Project Report: Electrical Machines

Choosing a Cutting Tool

Generally, Carbide (or tungsten/titanium carbide) is a very common material on any sort of cutting tool. For example, lathe bits, drill bits, router bits, etc. are generally made of carbide. Carbide is so popular in these sorts of tools because it stays sharper longer than most other materials. A good carbide tip might hold an edge ten to twenty times longer than a tool steel tip. Carbide tips do get dull eventually. It may be sharpened using the same techniques used with tool steel, but because they are so hard, we use a different abrasive. The figure above shows a typical cutting tool and the terminology used to describe it. The actual geometry varies with the type of work to be done. The standard cutting tool shapes are shown below:

Facing tools are ground to provide clearance with a center. Roughing tools have a small side relief angle to leave more material to support the cutting edge during deep cuts. Finishing tools have a more rounded nose to provide a finer finish. Round nose tools are for lighter turning. They have no back or side rake to permit cutting in either direction. Left hand cutting tools are designed to cut best when traveling from left to right.
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Feed, Speed, and Depth of Cut

Cutting Speed is defined as the speed at which the work moves with respect to the tool (usually measured in feet per minute). Feed Rate is defined as the distance the tool travels during one revolution of the part. Cutting speed and feed determines the surface finish, power requirements, and material removal rate. The primary factor in choosing feed and speed is the material to be cut. However, one should also consider material of the tool, rigidity of the workpiece, size and condition of the lathe, and depth of cut. To calculate the proper spindle speed, divide the desired cutting speed by the circumference of the work. Experiment with feed rates to achieve the desired finish.

Various Operations Performed

Turning The lathe can be used to reduce the diameter of a part to a desired dimension. First, clamp the part securely in a lathe chuck. The part should not extend more than three times its diameter. Then install a roughing or finishing tool (whichever is appropriate). If feeding the saddle toward the headstock use a right-hand turning tool. Move the tool off the part by backing the carriage up with the carriage handwheel, and then use the cross feed to set the desired depth of cut. Facing A lathe can be used to create a smooth, flat, face very accurately perpendicular to the axis of a cylindrical part. First, clamp the part securely in a lathe chuck. Then, install a facing tool. Bring the tool approximately into position, but slightly off of the part. Always turn the spindle by hand before turning it on. This ensures that no parts interfere with the rotation of the spindle. Move the tool outside the part and adjust the saddle to take the desired depth of cut. Then, feed the tool across the face with the cross slide. If a finer finish is required, take just a few thousandths on the final cut and use the power feed.

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Project Report: Electrical Machines

Parting A parting tool is deeper and narrower than a turning tool. It is designed for making narrow grooves and for cutting off parts. When a parting tool is installed, ensure that it hangs over the tool holder enough that the holder will clear the workpiece. Ensure that the parting tool is perpendicular to the axis of rotation and that the tip is the same height as the center of the part. Drilling A lathe can also be used to drill holes accurately concentric with the centerline of a cylindrical part. First, install a drill chuck into the tail stock. Make certain that the drill chuck seats properly in the tail stock. Move the saddle forward to make room for the tailstock. Move the tailstock into position, and lock it in place (otherwise it will slide backward as we try to drill). Always use a center drill to start the hole. Boring Boring is an operation in which a hole is enlarged with a single point cutting tool. A boring bar is used to support the cutting tool as it extends into the hole. Because of the extension of the boring bar, the tool is supported less rigidly and is more likely to chatter. This can be corrected by using slower spindle speeds or by grinding a smaller radius on the nose of the tool. Single Point Thread Turning External threads can be cut with a die and internal threads can be cut with a tap. But for some diameters, no die or tap is available. In these cases, threads can be cut on a lathe. A special cutting tool should be used, typically with a 60 degree nose angle. To form threads with a specified number of threads per inch, the spindle is mechanically coupled to the carriage lead screw.

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Project Report: Electrical Machines

Grinding Machine

The cylindrical grinder is a type of grinding machine used to shape the outside of an object. The cylindrical grinder can work on a variety of shapes; however the object must have a central axis of rotation. This includes but is not limited to such shapes as a cylinder, an ellipse, a cam, or a crankshaft. Cylindrical grinding is defined as having four essential actions: 1. 2. 3. 4. The work (object) must be constantly rotating The grinding wheel must be constantly rotating The grinding wheel is fed towards and away from the work Either the work or the grinding wheel is traversed with the respect to the other.

While the majority of cylindrical grinders employ all four movements, there are grinders that only employ three of the four actions. Outside Diameter Grinding is grinding occurring on external surface of an object between the centers. The centers are end units with a point that allow the object to be rotated. The grinding wheel is also being rotated in the same direction when it comes in contact with the object.
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Project Report: Electrical Machines

Inside Diameter Grinding is grinding occurring on the inside of an object. The grinding wheel is always smaller than the width of the object. The object is held in place by a collet, which also rotates the object in place. Plunge Grinding is a form of outside diameter grinding, however the major difference is that the grinding wheel makes continuous contact with a single point of the object instead of traversing the object. Creep Feed Grinding is a form of grinding where a full depth of cut is removed in a single pass of the wheel. Successful operation of this technique can reduce manufacturing time by 50%, but often the grinding machine being used must be designed specifically for this purpose. This form occurs in both cylindrical and surface grinding. Center-less Grinding is a form of grinding where there is no collet or pair of centers holding the object in place. Instead, there is a regulating wheel positioned on the opposite side of the object to the grinding wheel. A work rest keeps the object at the appropriate height but has no bearing on its rotary speed.

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Project Report: Electrical Machines

Boring machine
A boring machine is a machine tool which bores holes or used to enlarge already drilled hole in horizontal as well as in vertical direction depending upon machines type. There are three main types; table, planer, and floor. The table type is the most common and, as it is the most versatile, it is also known as the universal type. Boring machines are often heavy-duty industrial machines used for roughing out large components but there are high-precision models too. Modern machines use advanced CNC control systems and techniques. Charles DeVlieg entered the Machine Tool Hall of Fame for his work upon a highly precise model which he called a JIGMIL.

A Horizontal Boring Machine has its work spindle parallel to the ground and worktable. Typically there are 3 linear axes in which the tool head and part move. Convention dictates that the main axis that drives the part towards the work spindle is the Z axis, with a cross-traversing X axis and a vertically-traversing Y axis. The work spindle is referred to as the C axis and, if a rotary table is incorporated, its center line is the B axis.

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Project Report: Electrical Machines

A Vertical Boring Machine has its work spindle perpendicular to the ground and worktable but except this everything is similar to horizontal boring machine. It is generally used in case of length of the workpiece is less than the diameter of workpiece.

Here, the cutting tool is stationery and mounted in the tool head. This tool head can be moved linearly or upward and downward motion to reach near to the workpiece. The workpiece is mounted on the table which is rotating. Two columns are used to have rigid support to the tool head.

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Project Report: Electrical Machines

Milling machine
A milling machine is a machine tool used to machine solid materials. Milling machines exist in two basic forms: horizontal and vertical, which refers to the orientation of the cutting tool spindle. Both types range in size from small, bench mounted devices to room-sized machines. Unlike a drill press, this holds the workpiece stationary as the drill moves vertically to penetrate the material, milling machines also move the workpiece against the rotating cutter, which cuts on its flanks as well as its tip. Workpiece and cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by means of precision ground slides and lead screws or analogous technology. Milling machines may be manually operated, mechanically automated, or digitally automated via computer numerical control (CNC).

Plano Milling Machine is generally used in BHEL, Bhopal.

Milling machines can perform a vast number of operations, some very complex, such as slot and keyway cutting, planning, drilling, rebating, routing, etc. Cutting fluid is often pumped to the cutting site to cool and lubricate the cut and to wash away the resulting swarf (also known as turnings, chips, or filings, are shavings and chippings of metal the debris or waste resulting from metalworking operations).
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Project Report: Electrical Machines

Vertical Mill In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle and rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bed mill and the turret mill. A turret mill has a stationary spindle and the table is moved both perpendicular and parallel to the spindle axis to accomplish cutting. Turret mills often have a quill which allows the milling cutter to be raised and lowered in a manner similar to a drill press. This type of machine provides two methods of cutting in the vertical (Z) direction: by raising or lowering the quill, and by moving the knee. In the bed mill, however, the table moves only perpendicular to the spindle's axis, while the spindle itself moves parallel to its own axis. Turret mills are generally considered by some to be more versatile of the two designs. However, turret mills are only practical as long as the machine remains relatively small. As machine size increases, moving the knee up and down require considerable effort and it also becomes difficult to reach the quill feed handle (if equipped). Therefore, larger milling machines are usually of the bed type.

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Project Report: Electrical Machines

Planer Machine
A planer is a type of metalworking machine tool that uses linear relative motion between the workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe, except that it is linear instead of helical (Adding axes of motion can yield helical toolpaths). A planer is analogous to a shaper, but larger, and with the entire workpiece moving on a table beneath the cutter, instead of the cutter riding a ram that moves above a stationary workpiece. The table is moved back and forth on the bed beneath the cutting head either by mechanical means, such as a rack and pinion drive or a leadscrew, or by a hydraulic cylinder. Linear Planning The most common applications of planers and shapers are linear-toolpath ones, such as: Generating accurate flat surfaces (While not as precise as grinding, a planer can remove a tremendous amount of material in one pass with high accuracy). Cutting slots (such as keyways). Helical Planning Although the toolpath of a planer is linear, helical toolpaths can be accomplished via features that correlate the tool's linear advancement to simultaneous workpiece rotation. To use today's terminology, one can give the machine other axes in addition to the main axis.

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Project Report: Electrical Machines

Radial Arm Drill Machine

Radial arm drill press is a large geared head drill press in which the head can be moved along an arm that radiates from the machine's column. As it is possible to swing the arm relative to the machine's base, a radial arm drill press is able to operate over a large area without having to reposition the workpiece. This saves considerable time because it is much faster to reposition the drill head than it is to unclamp, move, and then re-clamp the workpiece to the table. The size of work that can be handled may be considerable, as the arm can swing out of the way of the table, allowing an overhead crane or derrick to place a bulky workpiece on the table or base. A vise may be used with a radial arm drill press, but more often the workpiece is secured directly to the table or base, or is held in a fixture. Power spindle feed is nearly universal with these machines and coolant systems are common. Larger size machines often have power feed motors for elevating or moving the arm. Radial arm drills are specified by the diameter of the column and the length of the arm.

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Project Report: Electrical Machines

CONCLUSION
The Vocational training at BHEL, Bhopal helped me in improving my practical knowledge and awareness regarding Hydro-Generators to a large extent. Here I came to know about the technology and material used in manufacturing of hydro generators. Besides this, I also visualized the parts involved or equipments used in the power generation. Here I learnt about how the electrical equipments are being manufactured and how they tackle the various problems under different circumstances. At least I could say that the training at BHEL Bhopal is great experience for me and it really helped me in making or developing my knowledge about hydro generator and other equipment used in power generation. It has allowed us an opportunity to get an exposure of the practical implementation of theoretical fundamentals.

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Project Report: Electrical Machines