Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.

6 MONTHS INDUSTRIAL TRAINING PPT EE BY KHUSHI RAM BHARDWAJ(DAVIET JALANDHAR)

7,881 views

Published on

Published in: Education
  • Be the first to comment

6 MONTHS INDUSTRIAL TRAINING PPT EE BY KHUSHI RAM BHARDWAJ(DAVIET JALANDHAR)

  1. 1. KHUSHI RAM BHARDWAJ<br />D.A.V.I.E.T(JALANDHAR)<br />JUNE 2011<br />KAPSONS INDUSTRIES LTD.<br />
  2. 2. Established in 1981<br />ESTABLISHED AS KRISHNA LAMINATIONS PRIVATE LTD. JALANDHAR<br />
  3. 3. KAPSONS TODAY<br />KAPSONS INDUSTRIES TODAY SPREADING IN 4 MAJOR PLANTS IN JALANDHAR AND PUNE.<br />
  4. 4. Quality<br />ISO 16949:2000, ISO 14001:1996, is/ISO 9001:2000, ISO 9001-2000 certified.<br />
  5. 5. Infrastructure<br />Covered Area-::<br /> Unit I 62,568 Sq. Ft.<br /> Unit-II & III 72732 Sq. Ft.<br /> Unit IV 85000 Sq Ft(pune)<br />
  6. 6. Safety and Attendance<br />ATT/TO Data<br />2010<br /><ul><li>Absenteeism Rate 0.04%</li></ul>2011- YTD 5thjune<br /><ul><li>Absenteeism Rate 0.016%</li></ul>Safety Data<br />2010<br />Total Hours Worked<br /> 4018 hours<br />Minor First-Aid Cases 27<br />Cases Days Away 3<br />2011 YTD 5thjune<br />Total Hours Worked 1668<br />Minor First-Aid Cases 13<br />Cases Days Away 0<br />
  7. 7. Annual turnover<br />2007 rs. 350 crore<br />2008 rs. 395 crore<br />2009 rs. 432 crore<br />2010 rs. 500 crore<br />
  8. 8. Equipment List<br />Presses<br />(1) Gauging Machine<br /> (2) Sorting Machine<br /> (3) Lapping Machine<br /> (4) Roll Forming Machine<br /> (5) Steel Ball Plant<br /> (5) Wire Forming Machine<br /> (6) Double Disk Grinding Machine<br /> (7) Blade Grinding Machine<br /> (8) Rough Grinding Machine<br /> (9) Surface Grinding Machine<br />
  9. 9. Gauging & Sorting Machine <br />
  10. 10. Lapping Machine<br />
  11. 11. Rolling machine<br />
  12. 12. Products and services<br />
  13. 13. Clientele<br />M/S. Asea Brown Boveri Ltd. Faridabad.<br /> M/S. Bharat Bijlee Ltd. , Thane.<br /> M/S. Alstom Ltd. (AEI Works), Calcutta.<br />M/S. Crompton Greaves Ltd M/S. Alstom Ltd. (Paharpur Works), Calcutta.<br />
  14. 14. GENERATORS MAINTENANCE <br />
  15. 15. Typical Generator Maintenance <br />
  16. 16.
  17. 17. Generators <br />
  18. 18.
  19. 19. System controls <br />
  20. 20.
  21. 21.
  22. 22.
  23. 23.
  24. 24.
  25. 25.
  26. 26.
  27. 27.
  28. 28.
  29. 29.
  30. 30.
  31. 31.
  32. 32.
  33. 33. REASONS WHY GENERATORS FAIL<br />FOREIGN OBJECT DAMAGE<br />Problem: Objects can come from external sources or<br />failure of internal components, they can pick up energy<br />from the spinning rotor and do extensive damage<br />Prevention: Inspect on a regular basis all internal parts<br />that are prone to failure or can be dislodged.<br />Inspection tests can be a combination of visual<br />inspection along with ultrasonic or magnetic particle<br />tests on rotating components<br />
  34. 34. STATOR WINDING VIBRATION<br />Problem: Primarily a design related problem that<br />affects large (>300Mw) generators which have<br />insufficient end winding bracing to limit the<br />movement of end turns.<br />Prevention: Proper bracing of the end winding is<br />required to limit motion caused by steady state and<br />transient electromagnetic forces.<br />
  35. 35. ROTOR WINDING DISTORTION<br />Problem: Rotor winding distortion caused by poor end<br />turn blocking support design or by foreshortening of<br />the rotor coils. Foreshortening is caused by thermal<br />forces which compress rotor coils.<br />Prevention: Proper design of rotor coils and bracing to<br />support the coils under axial load is essential.<br />Rotors should be tested for turn to turn shorts at<br />operating speed.<br />
  36. 36. STATOR WINDING VIBRATION<br />Problem: Primarily a design related problem that<br />affects large (>300Mw) generators which have<br />insufficient end winding bracing to limit the<br />movement of end turns.<br />Prevention: Proper bracing of the end winding is<br />required to limit motion caused by steady state and<br />transient electromagnetic forces.<br />
  37. 37. OVERHEATING<br />Problem: Overheating of the rotor or stator can lead to<br />insulation failure, shorting of turns and ground<br />faults. Overheating can result from blocked<br />ventilation passages caused by shifting insulation<br />components or slot wedges.<br />Prevention: Inspect on a regular basis to ensure all rotor<br />wedges are "locked" in place preventing migration<br />and thus blocking of cooling passages.<br />
  38. 38. CONTAMINATION<br />Problem: For air cooled machines, dirt and dust cause<br />tracking which can lead to electrical ground faults.<br />Prevention: Inspect air filterson a regular basis , the<br />filters must be checked and cleaned regularly.<br />Polarization index (PI) tests give a good indication of<br />overall cleanliness of the rotor winding.<br />
  39. 39. ROTOR VIBRATION<br />Problem: There are many causes, turn-to-turn shorts,<br />rotor coil foreshortening, electrical grounds,<br />mechanical imbalances, overheating, etc.<br />Prevention: Comprehensive vibration measuring is effective<br />combined with a regular maintenance program.<br />
  40. 40. STATOR WEDGE LOOSENESS<br />Problem: When stator wedges become loose, coils can<br />vibrate causing insulation wear leading to ground<br />faults or turn-to-turn shorts.<br />Prevention: Inspect on a regular basis tightness of<br />wedge blocks.<br />
  41. 41. STATOR CORE DAMAGE<br />Problem: Stator core looseness can occur over time as<br />pre-tensioned through bolts relax. A loose core<br />results in insulation wear to coils and laminations<br />resulting in hot spots and core-to-coil failures.<br />Prevention: Inspect bolt tightness on a regular basis.<br />
  42. 42. GENERATOR MAINTENANCE<br />The following tests which should be carried out annually in addition to vendor recommended maintenance.<br />
  43. 43. A) INITIAL GENERATOR TEST<br />• “Megger” rotor winding<br />• “Megger” exciter armature winding<br />• “Megger” exciter field winding<br />• Complete polarization index (pi) on main stator<br />• Check bearing insulation<br />
  44. 44. B) INSPECTION ON STATIC EXCITER<br />• Remove exciter end cover<br />• Examine condition of diode carrier<br />• Examine exciter armature/stator for contamination<br />• Examine exciter armature/stator for winding wear<br />• Check pmg magnets for contamination<br />
  45. 45. C) ELECTRICAL CONTROL/PROTECTION PANEL<br />• Visually inspect external surfaces of panel<br />• Complete insulation resistance checks of panel wiring<br />• Check function of all relays<br />• Check all fuses<br />• Check all lamps<br />• Check operation of all switches<br />• Check operation of panel heaters<br />• Run generator; recalibrate avr<br />• Secondary inject all protective relays<br />
  46. 46. E) ROTOR EARTH FAULT PROTECTOR<br />• Carry out static checks to confirm operation of<br />detector<br />• Carry out functional check to confirm operation of<br />detector<br />
  47. 47. F) SLIP-RINGS AND BRUSH-GEAR (IF FITTED)<br />• Check all brushes for grade and length<br />• Check condition of brush holders/mountings<br />• Check that spring tensions are correct<br />• Check conditions of slip-rings<br />• Check mechanical run-out of slip-rings<br />• Check cooler and leakage alarms<br />

×