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A Mini Project Report on

VACCUM PRESSURE IMPREGNATION IN A TURBO GENERATOR

BACHELOR OF TECHNOLOGY IN ELECTRICAL AND ELECTRONICS ENGINEERING

BY

C.PAVAN SAMEER KUMAR (08311A0226)

Department of Electrical & Electronics Engineering SREENIDHI INSTITUTE OF SCIENCE & TECHNOLOGY Yamnampet, Ghatkesar, Hyderabad - 501301. Affiliated to Jawaharlal Nehru Technological University (2011-2012)

A Mini Project Report on

VACCUM PRESSURE IMPREGNATION IN A TURBO GENERATOR

Submitted in partial fulfillment of the requirements for the award of degree of

BACHELOR OF TECHNOLOGY IN ELECTRICAL AND ELECTRONICS ENGINEERING BY C.PAVAN SAMEER KUMAR (08311A0226)

Department of Electrical & Electronics Engineering SREENIDHI INSTITUTE OF SCIENCE & TECHNOLOGY Yamnampet, Ghatkesar, Hyderabad - 501301. Affiliated to Jawaharlal Nehru Technological University (2011-2012)1

Department of Electrical Electronics Engineering SREENIDHI INSTITUTE OF SCIENCE & TECHNOLOGY (Affiliated to JNTU)

CERTIFICATE
This to certify that the mini project entitled VACCUM

PRESSURE IMPREGNATION IN A TURBO GENERATOR has been carried out by the following student:

C.PAVAN SAMEER KUMAR (08311A0226)

Of III year, II semester B.Tech (Electrical & Electronics Engineering) under our supervision during the year 2010-2011 in the partial fulfillment of the requirement for the award of Bachelor of Technology degree in Electrical & Electronics University, Hyderabad. Engineering, Jawaharlal Nehru Technological

Prof. SHESHAGIRI RAO

(Internal guide) Dept. of EEE, SNIST
3

Dr. S.Venkateswarulu
( Professor & Head) Dept. of EEE, SNIST

ACKNOWLEDGMENT

I express our profound sense of gratitude to our external guide

Mr. G. Suresh Kumar, Engineer, BHEL(Bharat Heavy Electricals Limited), Ramachandrapuram , Hyderabad for permitting us to do the mini project, his valuable guidance, constructive criticism and consistent enthusiastic interest during the course of investigation and writing of manuscript that led this work to its successful completion. We regard our sincere thanks to the technical staff that helped us during the project and made our project successful. I have great pleasure to convey our gratitude to Prof.Sheshagiri Rao , our internal guide and Associate professor of EEE department for his guidance during the course of project work. I express our heartiest gratitude and respectful regards to Dr. S. Venkateshwarulu, Sreenidhi Institute of doing the project. Last but not the least our special thanks to my parents and friends for their support and constant encouragement during the project work C.PAVAN SAMEER KUMAR (08311A0226) Professor & Head of the Department of EEE,

Science and Technology for his encouragement for

ABOUT BHEL (Bharat Heavy Electricals Limited):

ESTABLISHED: First plant was set up at Bhopal in 1956, followed by three more major plants at Haridwar, Hyderabad and Tiruchirapalli. FUNCTIONING: BHEL caters to the core sectors of the Indian Economy, viz. Power, Transmission, Industry, Transportation, Renewable Energy, Oil & Gas and Defense. ACHEIVEMENTS: BHEL has Installed equipment for over 1,00,000 MW of power generation- for Utilities, Captive and Industrial users. Supplied over 2,25,000 MVA transformer capacity and other equipment operating in Transmission & Distribution network up to 400 kV (AC & DC). Supplied over 25,000 Motors with Drive Control System to Power projects, Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants, etc. Supplied Traction electrics and AC/DC locos to power over 12,000 kms Railway network. Supplied over one million Valves to Power Plants and other Industries. NO OF EMPLOYEES: The greatest strength of BHEL is its highly skilled and committed team of 46,748 employees. QUALITY POLICY: BHEL has acquired certifications to Quality Management Systems (ISO 9001), Environmental Management Systems (ISO 14001) and Occupational Health & Safety Management Systems (OHSAS 18001) and is also well on its journey towards Total Quality Management. VISION: BHEL's vision is to become a world-class engineering enterprise, 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 industry, energy, transportation , infrastructure and other potential areas. VALUES: Zeal to Excel and Zest to Change. Integrity and Fairness in all matters.

Abstract
Ever since man began contriving, the requirement of energy has been heightening space. The demand for energy attained its pinnacle in the 21 st century which advocated him to explore efficient and economical sources of power. Electrical energy is one flexible form of energy which demonstrates mans ability to cogitate. Most of the electrical power is obtained from the thermal power plants where turbo generators convert mechanical energy to electrical energy. My project report gives a brief insight into the manufacturing of a turbo generator, and then proceeds with the process of vacuum pressure impregnation(VPI).VPI is a novel technique adopted to prevent the occurrence of short circuits in an turbo generator due to formations of voids. VPI completely removes air, moisture and gases if any from the system. It also ensures legion advantages like better heat dissipation, longer insulation life, lesser susceptibility to cracking and corona, improved resistance to moisture and chemicals, reduction of coil movement and ultimately improved quality.

CONTENTS DESCRIPTION CERTIFICATE CERTIFICATE ACKNOWLEDGEMENT ABOUT BHEL ABSTRACT LIST OF FIGURES PAGE NO. iii iv v vi vii x

CHAPTER

1. INTRODUCTION
1.1 TURBO GENERATOR-PRINCIPLE OF OPERATION 1.2 FARADAYS LAWS OF ELECTROMAGNETIC INDUCTION 1.3 VACUUM PRESSURE IMPREGNATION

2. COMPONENTS OF TURBO GENERATOR

2.1 STATOR 2.1.1 Stator Frame 2.2.2 Stator Core 2.2.3 Stator Windings 2.2.4 End Covers

2.2 ROTOR 2.2.1 Rotor Shaft

2.2.2 Rotor Winding and Retaining rings 2.2.3 Field Connection and Multiple Contacts 2.3 BEARINGS 2.4 COOLING SYSTEMS 2.5 EXCITER SYSTEM 2.5.1 Types of Exciters 2.5.2 Three Phase Pilot Exciter 2.5.3 Three Phase Main Exciter 2.6 ROTOR BALANCING 2.6.1 Static Balancing 2.6.2 Dynamic Balancing 2.7 AUTOMATIC VOLTAGE REGULATOR (AVR)

3. INSULATIONS USED IN TURBO GENERATOR 3.1 ROLE OF INSULATION SYSTEM 3.2 PROPERTIES OF INSULATING MATERIALS 3.2.1 Electrical Properties 3.2.2 Thermal Properties 3.2.3 Chemical Properties 3.2.4 Mechanical Properties 3.3 CLASSIFICATION OF INSULATING MATERIALS 3.3.1 According to substance and materials 3.3.2 According to temperature 3.4 EFFECT OF MOISTURE ON INSULATION

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3.5 INSULATIONS USED IN MACHINES 4. VPI TECHNICAL SPECIFICATIONS 4.1 VPI-A BRIEF INSIGHT 4.2 COMPARISON OF RESIN RICH AND RESIN POOR 4.3 VPI OF RESIN POOR INSULATED JOBS 4.4 VPI PLANT RATING AT BHEL HARIDWAR

5. VPI PROCEDURE 5.1 GETTING THE JOB READY5.2 PREHEATING 5.3 JOB INSERTION INTO THE PREHEATED TUB 5.4 INSERTION INTO THE IMPREGNATION TANK 5.5 DRYING THE JOB IN VACCUM 5.6 HEATING THE RESIN IN THE STORAGE TANK 5.7 ADMISSION OF RESIN INTO THE IMPREGNATION TANK 5.8 PRESSURISING 5.9 WITHDRAWL OF RESIN TO STORAGE TANK 5.10 TAKING OUT THE TUB FROM IMPREGNATION TANK 5.11 POST CURING THE JOB 5.12 ELECTRICAL TESTING

6. ADVANTAGES AND APPLICATIONS OF VPI 7. EFFICIENCY OF TURBO GENERATOR 8. CONCLUSION 9. REFERRENCES 10