BHILAI INSTITUTE OF TECHNOLOGY, DURG

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

BRANCH:- EEE 7TH SEMESTER

A PRESENTATION ON INDUSTRIAL SUMMER TRAINING at

ELECTRICAL REPAIR SHOP (ERS), BHILAI STEEL PLANT

-: SUBMITTED TO :- -: SUBMITTED BY :-
DR. ANUPAM AGRAWAL KUNAL KUMAR SAHU
(Asst. Professor) EEE 7TH SEMESTER
URN- 300102520020
 CONTENT

 BHILAI STEEL PLANT – AN OVERVIEW

 INTRODUCTION TO ERS
 SECTIONS OF ERS
 DC MOTOR
 FAULTS OCCURRENCE IN DC MOTORS
 TESTING OF DC MACHINES
 ADVANTAGES OF DC MOTOR OVER AC MOTORS
 ADVANTAGES OF DC MOTOR
 DISADVANTAGES OF DC MOTOR
 APPLICATION OF DC MOTOR
 CONCLUSION
 BHILAI STEEL PLANT – AN OVERVIEW

 Bhilai Steel Plant, a unit of Steel Authority of India Ltd. is a public sector undertaking.
 The plant is located at the central position of India, which is one of the major iron belt of India.
 It is about 40 kilometres from Raipur, capital of Chhattisgarh.
 The captive mines of the plant located at Dalli-Rajahara supplies iron ore and lime stone used to be
available from Nandini captive mines. At present lime stone is procured from outside.
 The other major raw material, coal is purchased from outside either through import or from indigenous
market.
 Bhilai Steel Plant, an integrated steel works, was commissioned in 1959 with production capacity of 1.0
million tonne of steel.
 The production indices of Bhilai Steel Plant for the year 2007-08 is 5.2 million tonne of hot metal, 5
million tonne of crude steel and 4.4 million tonne of saleable steel.
 The annual turnover of the company for the year 2013-2014 is Rs. 17640 crores.
 Bhilai Steel Plant has been honoured 11 times with coveted “Prime Minister’s Trophy” as best Integrated
Steel Plant of the country.
 INTRODUCTION TO ERS
 Looking towards any integrated steel plant scenario, the important contribution of an Electrical Repair
Shop can very well be visualized.
 It is one of the major service shops which carries out repair of all electrical machines used inside the plant.
 There are around 42000 electrical machines installed and running continuously year's together, in different
processes of production in Bhilai Steel Plant.
 General maintenance like cleaning, greasing and physical inspection / check-up is done by concerned shops
where the machines are used.
 All major repairs like winding repairs, mechanical repairs, modification in existing winding, periodic
overhauling and innovative repairs etc. are being carried out by Electrical Repair Shop either at site or at ERS.
 SECTIONS OF ERS
1. RECIEPT AND ISSUE- Defective motors from various departments of b.s.p. are received here in
this department for repairing and maintenance

2. ASSEMBLY SECTION- For different motors different assembly sections are their. Basically differentiated
according to the rating of the motor-
1. Small assembly 2. Medium assembly 3.Big assembly
In this section first of all the machine is being dismantled and every part of the motor is observed carefully
to find the faults. The faults both mechanical and electrical.
3. COIL SECTION- In this section the defected coil is removed measured and replaced by new coil.

4. WINDING SECTION- this section is of two types ac & dc winding section. In this the burned winding is
removed & the motor is rewinded again.

5. TESTING & QUALITY ASSURANCE- In this section different tests are done such as:-
1. Megger test 2. High voltage test 3.Polarity test
4.Drop test 5.Surge test 6.No load test 7.Regenerative test (load test)

6. READY MACHINES- In this section machines to be dispatched are placed.

 DC MOTORS
Introduction:
 D.C. machine is highly versatile energy conversion device.
 It can meet the demand of loads requiring high starting torque, high accelerating and decelerating torques. In view of
this outstanding feature, D.C. Machine possesses a high degree of flexibility.
 At present annual production of D.C. machines is about 40% of the rupee volume in electrical machines production
and sales.
 Therefore D.C. motors are almost universally employed in steel and aluminium rolling mills, power shovels, electric
elevators, railroad locomotives and large earth-moving equipment.

Components of D.C. Motors:

In D.C. machine, the field winding is on the stator and the armature winding is on the rotor.

1. Stator Components:
 Yoke
 Field Coil
 Field (or Exciting ) Winding
 Interpoles
 Compensating winding
 Brushes
2. Rotor Components:
 Armature core
 Armature winding
 Commutator
 Shaft

Interpole Armature Commutator

Field Coil Yoke Shaft
 FAULTS OCCURRENCE IN D.C. MOTORS

1. Electrical Faults
1. Neutral Axis Fault :
 Occurrence: The incorrect position of setting the brushes on the commutator of D.C. machines with interpoles
 Testing: a) Kick Neutral Method b) Improved Kick Zero c)Improved Kick Voltage

2. Temperature Rise Fault:

 Occurrence: Overloading of motors, sparking in windings of motors.
 Testing: Back to Back load test

3. Over speed Fault:

 Occurrence: Increase in distance between main pole and armature.
 Testing : No Load Test
4. Short Circuit in Coil Fault:
 Occurrence: Short circuit of coil may occur due to Local heating of coil due to insulation breakdown. It may also
occur due to soldering of coil.
 Testing: a) Drop Test b) Surge Comparator Test c) Impedance Test
5. Open Circuit In Coil Fault-
 Occurrence: The fault may burn out the coil due to intense local heating and cause open circuited of the coil.
 Testing: a)Drop Test b)Surge Arrester test c)Impedance Test

6. An Earth On One Or More Arm Coil Fault-

 Occurrence: Due to faulty coil segment.
 Testing: a) Megger test b) High Voltage Test

2. Mechanical Faults
1. Foundation Fault-
 Occurrence: Due to continuous load variation or overloading of motor.
 Testing: Physical Observation

2. Shaft Bend Fault-

 Occurrence: Due to continuous load variation.
 Testing: Physical Observation

3. Key Way Fault-

 Occurrence: Vibration in motor due to overload and load variation.
 Testing: Physical Observation (shows cutting of key way and coupling, breaking of key way due to friction).
4. End Cover Fault-
 Occurrence: Due to physical damage, wrong bolting and friction.
 Testing: Observation ( Inner Diameter of end cover increase).

5. Grease Cover Fault-

 Occurrence: Due to vibration in shaft and friction.
 Testing: Physical observation and absurd sound.

6. Bearing Fault-
 Occurrence: Vibration in shaft, friction between shaft and bearing, bending of shaft.
 Testing: Play between shaft and bearing.

7. Balancing Fault-
 Occurrence : Due to shaft bend, continuous running of motor, body shifting of armature due heating and melting.
 Testing: Vibration, Sound and Jumping of motor.

8. Commutator Fault-
 Occurrence: Wrong brushes firm contact with commutator surface and fast rotation
of commutator.
 Testing: By observing the sparking between brush and commutator and absurd sound in motor.
 TESTING OF DC MACHINES

1. MEGGER TEST-
 Megger test is the most important test for any electrical machine. Insulation resistance quality of an electrical system
degrades with time, environment condition i.e. temperature, humidity, moisture & dust particles.
 It also get impacted negatively due to the presence of electrical & mechanical stress.
 This test is use to measure the insulation resistance.

2. HIGH VOLTAGE TEST-

 This test is done in order to check whether the insulation of the winding can withstand high voltage under abnormal
conditions.
 For medium voltage input coils like 2.4 kV, 4.16 kV, 13.8 kV, etc., testing during and after winding or repair with
high voltage is one of many recommended.
 Tests to verify the integrity of the coils.

3. DROP TEST-
 This test is done to check the insulation between the armature conductors.
 While the rotor voltage drop test is useful in identifying inter turn faults in the rotors.
 Since the rotor is a rotating object, there are shorts which may form only during running due to
action of centrifugal
force on the rotor.
4. POLARITY TEST-
 In this test the polarity of the main pole and inter-pole is tested.
 The polarity of the adjacent poles must be in proper order.
 Strength of all the poles should be equal.

5. SURGE TEST-
 High voltage Surge Comparison Testing can detect faults before they shut down the motor.
 A majority of insulation faults start as weakness in the turn insulation.
 The internal capacitor is charged to a known voltage by the power supply.

6. NO LOAD TEST-
 In this test machine weather it is a motor or a generator is run as no load shunt motor at rated speed with rated terminal
voltage.
 By this method we check the rated speed of motor at no load and temperature of bearings.
 In this we see whether axial play is there or not and also check the commutator beating.

7. REGENERATIVE TEST (LOAD TEST)-

 This test is the final test of a DC machine in ERS.
 The repaired machine is couple both mechanically and electrically with another identical DC machine.
 One of them acting as a generator and the other as a motor.
 The machine acting as a motor consumes the power generated by the machine acting as the generator.
 ADVANTAGES OF DC MOTORS OVER AC MOTORS

DC motors have higher starting torque compared to AC motors, they are preferred for applications like
electrical traction.
They are considered ideal for dealing with heavy loads for starting conditions in machines such as locomotives and
cranes.
They can Easily Control Speed Unlike most AC motors in the market, DC motors are capable to control
speed above/below the rated levels.
DC Motors are better for Low-Cost Operations Many people opt for DC motors as opposed to others because they are
cheaper.
 Because DC motors have been around for more than 130 years, the installed base is also large and familiarity for
maintenance impressive.
ADVANTAGES OF DC MOTOR
 DC motors are smaller in size.
 These motors operate on DC supply then they can be used in electronics devices.
 DC motors are suitable for traction systems for driving heavy loads.
 DC series motors have will high starting torque.

DISADVANTAGES OF DC MOTOR
 DC motors have a high initial cost.
 Maintenance cost is high and increased operation due to the presence of brushes and commutator.
 Due to sparking at brush DC motors cannot operate in explosive and hazardous conditions.

APPLICATIONS OF DC MOTOR
 Wiper
 Automatic windscreen
 Drills
 Fans
 Cranes
 Lifts
 Conveyors
 CONCLUSION

Various tests are done to analyse the faults in D.C. motors and ensure the health of the motor. Mainly two
types of faults are occurs in D.C. motors: Electrical and Mechanical Faults.

By the help of the respective tests, we diagnose the faulty component and then these are repaired.
Suitable remedial measures are adopted to rectify these faults out of the faulty components.

“ANALYSIS OF FAULTS & FAILURES IN D.C. MACHINES” is studied and been experienced
processes involve in repairing are also studied.