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Bharat Heavy Electrical limited Internship Rport
Bharat Heavy Electrical limited Internship Rport
AT
SUBMITTED BY SUBMITTED TO
BHEL caters to core sectors of the Indian economy viz., Power generation and
transmission, Industry, Transportation, Renewable Energy, Defense etc. The wide
network of BHEL’s 14 manufacturing divisions, 4 power sectors regional centers,
18 regional offices and a large number of Project Sites spread all over India and
abroad enables the company to promptly serve its customers and provide them
with suitable products, system and services- efficiently and at a competitive
prices.
The company has, and manufacturing plants that are situated in Bangalore,
Ranipet, Goindwal , Jagdishpur, Tiruchy, Rudrapur, Hyderabad.
The Gross Block and Net Block of the company as on 31.3.07 are Rs 3822 crores
and 982 crores respectively. The turnover of the company for 2006-07 was Rs
18739 crores. Total provisional turnover for year 2007-08 is Rs 21608 crores.
BHEL, RUDRAPUR
INTRODUCTION
In order to divert components/Products of less sophisticated nature from the
existing manufacturing plants to new locations and also for achieving higher
indigenization, it was decided in March 1983 to establish a Component
Fabrication Plant (CFP) at Rudrapur in Udham Singh Nagar District of Uttar
Pradesh (now Uttarakhand) at a total cost of Rs.95 lakh for an annual turnover of
Rs.160 lakhs in the first phase with an internal rate of return of 14.50 per cent.
The project cost was revised in January 1987 at Rs.175 lakh (including housing) at
an internal rate of return 18.80 per cent.
However, before taking a decision to set up CFP Plant, neither any feasibility study
was conducted nor a project report prepared. The civil work at the plant site
started in December 1983 and were completed in October 1984. The commercial
production started in November 1984. The project cost on completion worked out
to Rs.177.52 lakhs.
The following seven items were envisaged to be taken up for the production in
the original and revised project report: -
However, the general facilities which were created for the above items were
utilized for the manufacture of only two items viz: Solar Water Heating
Systems (SWHS) and Wind Mills. The production of wind mills was stopped
from the year 1988-89 and subsequently the plant taken up the manufacturing
of Solar Lanterns from 1992-93 and fabrication of Bus Ducts for BHEL, Jhansi
from the year 1994-95.The net turnover of BHEL, Rudrapur for financial year
2009-10 80 crores & the net profit was 25 crores. The targetted turnover of
BHEL Rudrapur for financial year 2010-11 is about 150 crores.
INTRODUCTION
Bus Ducts are designed considering the current and voltage requirement, short
circuit requirement, the availability of space and aesthetic aspects.
Bus ducts are used to carry very high current between the generator and
associated transformer in the power stations. In the power stations the generator
voltages vary from 12 KV to 24 KV whereas auxiliary supply voltage are 3.3 KV, 6.6
KV or 12 KV.
Bus Ducts are thick metal connectors, usually of aluminium, which carry large
current up to 10 KA for 200/250 MW sets and around 35 KA for 500 MW set. The
conductors are metal enclosed, usually aluminium to provide safety and reliable
operation.
The conductor and enclosure are provided welded joints as far as possible to give
reduced maintenance. Bolted joints are provided where opening is necessary
during operation.
TYPES OF BUS DUCTS
Broadly bus ducts are classified into Isolated Phase Bus duct, Segregated Phase
Bus duct, non-segregated Phase Bus duct. Various types of Bus ducts are depicted
in the following table;
Depending upon the type of cooling; i.e. Natural cooled & Forced cooled
Forced Cooling: Higher rating of Bus ducts beyond 800 MW unit capacity
requires higher enclosure size and sometimes this posses layout and other
constraints and hence are considered with forced cooling arrangement.
Depending upon the layout point of view ; i.e. Main run, Delta run,Tap off
run
Main run: Isolated three phase bus ducts run from generator phase
terminals/phase terminal segregated terminal adaptor box to the generator
transformer terminals, is designated as Main run.
Delta run: Isolated phase bus duct which forms delta connection of
generator transformer is designated as delta run bus duct.
Tap- off Run: Isolated three phase bus duct tapped from main run of the
isolated phase bus duct and connects to the Unit/Auxiliary transformer
terminals and other equipments such as LAVT/NG cubicle and excitation
transformer is generally known as Tap-off Run of Isolated phase bus ducts.
CONSTRUCTIONAL ASPECTS:
The bus ducts enclosure is made of aluminum alloy sheet and supplied in length
up to 6-7 meters. It is further reinforced with aluminum channel rings at intervals
which are also used for enclosure and insulator mounting. Sealed openings are
provided in the busduct run near insulator for inspection and maintenance.
Different sections of each phase are generally connected together effectively at
the ends by aluminum make up pieces at site.
Segregated phase busduct are generally employed in medium voltage system and
serves as interconnection between the switchgear and transformer. Bus duct
forms the electrical link between generator, transformers and associated
equipments such as LAVT cubicle, UAT cubicle, NG cubicle etc.
Segregated phase busducts are generally available for current and voltage rating
up to 5000 amp and 33Kv respectively & with short circuit ratings up to 63KAfor 2
seconds.
CONSTRUCTIONAL ASPECTS:
The bus duct enclosure is made of aluminum alloy sheet and supplied in length up
to 3.72 meters. Insulating barrier of 2 mm thick aluminum sheet provide complete
phase segregation inside the enclosure. The aluminum sheet is welded on a frame
work made up of aluminum Angles.
Bolted type inspection covers provide access to the conductor joints and
insulators. Neoprene bonded cork gaskets are provided between the inspection
covers and the enclosure in order to achieve fully weather proof duct and air tight
construction. The adjacent enclosure is connected together by means of bolted
type flange to flange joints. Space heaters are provided to maintain IR value inside
the duct.
The non segregated phase bus ducts serves as an interconnection between 1.1 KV
switchgear/indoor Power Control Center/ Motor Control Centre and its auxiliary
transformer. It is also used for trunking connection between two separate
switchgear/PCC/MCC panels, wherever applicable.
Non segregated phase bus duct is used for reliable distribution of small to
medium amounts of electric power, with maintenance and ease of installation
thereby contributing to reduced time for final assembly at jobsite.
CLASSIFICATION:
Non segregated phase busduct are basically of two types;
The preferred standard ratings of different bus ducts are given in table below;
SELECTION CRITERIA:
The shape and size of bus duct is selected considering the following aspects:
INSULATOR ARRANGEMENT:
The dielectric strength of system is ensured by providing adequately sized
insulators/seal of bushings, which are designed to withstand the expected high
voltage and transient lightning impulse.
The insulator arrangement also serves the purpose of withstanding the dynamic
forces caused by a sever short circuit fault on the system. In case of Generator
Busduct, which is generally isolated phase type, the connection between
Generator and Generator Transformer is designed to withstand the fault level,
which is higher among fault level fed by the system sources or the generator
source.
The insulator arrangement and span for tap off bus ducts to auxiliary transformers
and delta connection provided for phase Generator Transformer bank has to be
designed to cater the fault level equivalent to sum of the fault current by system
source and the generator source.
The three insulators can be placed either at 120 degree or 90 degree apart from
each other. The positioning of insulators in first case shall be 2,6 and 10 O’clock.
The same for later case shall be 3,6 and 9 O’clock.
Diagram
ACCESSORIES:
The bus duct is provided with many accessories required for successful operation
during its life span. These accessories are described as follows;
CURRENT TRANSFORMER
The generator bus duct houses current transformers required to comply the
protection scheme requirements of the plant. The current transformers shall be
epoxy cast- resin, single core/multi core ring type /wound primary/bar primary
type. Mounted with in the bus duct enclosure and suitable for operation at an
ambient temperature existing within the bus duct enclosure which may be in
range of 90 deg c to 100 deg c. The CT secondary leads the brought out through
conduits to marshalling boxes (MBs). The facility for shorting and grounding is to
be provided at the terminal blocks (in the marshalling boxes) using links.
VOLTAGE TRANSFORMER
A voltage transformer shall be epoxy cast- resin type, suitable for nominal voltage
operations, connected from line to ground. These VT’s are of single or multi core
and provided with built-in fuses, or externally mounted primary fuses. The
secondary of VT are wired through LV FUSE or MCB to a common marshalling box
mounted on the SP VT cubicle.
LIGHTENING ARRESTER
The lightening arresters are provided to protect the generator and other
connected equipment from the lightening/switching surges. They shall be of
Gapless-metal oxide, station class and hermetically sealed type, connected
between line and ground designed suitably for the BIL of the generator. A
discharge counter shall preferably be provided for each lightning arrester.
SURGE CAPACITOR
A surge capacitor is a device designed to absorb switching surges and/or reduce
the steepness of their wave front. The surge capacitor basically protects the main
generator from switching surges. It is generally housed in a cubicle connected
across the lightning Arrestors in the VT& SP cubicle.
The voltage transformer along with secondary fuses shall be mounted on draw
out type carriage. Suitable guide slots and stops shall be provided to ensure easy
withdrawal and positioning. The draw out frame shall be grounded at all times. A
reliable automatically operated shutter mechanism shall be provided for isolating
the bus bar live parts when the VT is drawn out position to ensure safety. The
secondary leads from the voltage transformer shall be extended to terminal
cabinet flush mounted in the compartment. The LA discharge counter register
shall be visible without having to open the compartment door.
SHORTING PLATE
Shorting plate of aluminum alloy are provided to make the three phase isolated
phase busduct enclosures continuous. The following ends of the enclosures are
shorted to ensure continuous flow of induced currents:
CONDUCTOR HARDWARE
The bus conductor shall be designed for welded continuous except at equipment
terminations, bolted disconnect links, and bolted flexible. All connection
hardware shall be non-magnetic and shall have high correction resistance.
WIRING
All wiring shall be done with insulated stranded copper conductor of not less than
2.5sq.mm cross-section with suitable lugs on both sides.
The wiring inside the bus duct enclosure (i.e., for CT etc.) shall be suitable for
operating in the ambient temperature existing inside the bus duct.
NAME PLATE
Name plate shall be furnished for each equipment, disconnect link, voltage
transformer compartment, lightening arrester compartment and fuse block,
current transformer TB, air pressurization cubicles etc.
FINISH
Except for supporting steel structures which shall be galvanized, all equipment
including bus duct enclosure shall be finished with an under coats of high quality
primer followed by two coats of synthetic enamel paint which shall have a
thickness not less than 50 microns.
PAINT
The interior surface finish of bus duct enclosure shall be as per manufacturer
standard. The shade of exterior surface shall be as per the project requirement.
The shade of interior surface of cubicles shall be glossy white.
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