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KHUSHI RAM BHARDWAJD.A.V.I.E.T(JALANDHAR)
JUNE 2011
KAPSONS INDUSTRIES LTD.
Established in 1981
ESTABLISHED AS KRISHNA LAMINATIONS PRIVATE LTD. JALANDHAR
KAPSONS TODAY
KAPSONS INDUSTRIES TODAY SPREADING IN 4 MAJOR PLANTS IN JALANDHAR AND PUNE.
Quality
ISO 16949:2000, ISO 14001:1996, is/ISO 9001:2000, ISO 9001-2000 certified.
Infrastructure
Covered Area-:: Unit I 62,568 Sq. Ft. Unit-II & III 72732 Sq. Ft. Unit IV 85000 Sq Ft(pune)
Safety and Attendance
Safety Data2010
– Total Hours Worked 4018 hours– Minor First-Aid Cases
27– Cases Days Away
3
2011 YTD 5th june – Total Hours Worked 1668– Minor First-Aid Cases
13– Cases Days Away
0
ATT/TO Data2010
– Absenteeism Rate 0.04%
2011- YTD 5th june– Absenteeism Rate
0.016%
Annual turnover
2007 rs. 350 crore 2008 rs. 395 crore 2009 rs. 432 crore 2010 rs. 500 crore
Equipment List
Presses (1) Gauging Machine
(2) Sorting Machine
(3) Lapping Machine
(4) Roll Forming Machine
(5) Steel Ball Plant
(5) Wire Forming Machine
(6) Double Disk Grinding Machine
(7) Blade Grinding Machine
(8) Rough Grinding Machine
(9) Surface Grinding Machine
Gauging & Sorting Machine
Lapping Machine
Rolling machine
Products and services
Clientele
M/S. Asea Brown Boveri Ltd. Faridabad.
M/S. Bharat Bijlee Ltd. , Thane. M/S. Alstom Ltd. (AEI Works),
Calcutta. M/S. Crompton Greaves Ltd M/S.
Alstom Ltd. (Paharpur Works), Calcutta.
GENERATORS MAINTENANCE
Typical Generator Maintenance
Generators
System controls
REASONS WHY GENERATORS FAIL
FOREIGN OBJECT DAMAGE Problem: Objects can come from
external sources or failure of internal components,
they can pick up energy from the spinning rotor and do
extensive damage Prevention: Inspect on a regular
basis all internal parts that are prone to failure or can be
dislodged. Inspection tests can be a
combination of visual inspection along with ultrasonic
or magnetic particle tests on rotating components
STATOR WINDING VIBRATION
Problem: Primarily a design related problem that
affects large (>300Mw) generators which have
insufficient end winding bracing to limit the
movement of end turns. Prevention: Proper bracing of
the end winding is required to limit motion caused
by steady state and transient electromagnetic forces.
ROTOR WINDING DISTORTION
Problem: Rotor winding distortion caused by poor end
turn blocking support design or by foreshortening of
the rotor coils. Foreshortening is caused by thermal
forces which compress rotor coils. Prevention: Proper design of
rotor coils and bracing to support the coils under axial load
is essential. Rotors should be tested for turn
to turn shorts at operating speed.
STATOR WINDING VIBRATION
Problem: Primarily a design related problem that
affects large (>300Mw) generators which have
insufficient end winding bracing to limit the
movement of end turns. Prevention: Proper bracing of
the end winding is required to limit motion caused
by steady state and transient electromagnetic forces.
OVERHEATING
Problem: Overheating of the rotor or stator can lead to
insulation failure, shorting of turns and ground
faults. Overheating can result from blocked
ventilation passages caused by shifting insulation
components or slot wedges. Prevention: Inspect on a regular
basis to ensure all rotor wedges are "locked" in place
preventing migration and thus blocking of cooling
passages.
CONTAMINATION
Problem: For air cooled machines, dirt and dust cause
tracking which can lead to electrical ground faults.
Prevention: Inspect air filterson a regular basis , the
filters must be checked and cleaned regularly.
Polarization index (PI) tests give a good indication of
overall cleanliness of the rotor winding.
ROTOR VIBRATION
Problem: There are many causes, turn-to-turn shorts,
rotor coil foreshortening, electrical grounds,
mechanical imbalances, overheating, etc.
Prevention: Comprehensive vibration measuring is effective
combined with a regular maintenance program.
STATOR WEDGE LOOSENESS
Problem: When stator wedges become loose, coils can
vibrate causing insulation wear leading to ground
faults or turn-to-turn shorts. Prevention: Inspect on a regular
basis tightness of wedge blocks.
STATOR CORE DAMAGE
Problem: Stator core looseness can occur over time as
pre-tensioned through bolts relax. A loose core
results in insulation wear to coils and laminations
resulting in hot spots and core-to-coil failures.
Prevention: Inspect bolt tightness on a regular basis.
GENERATOR MAINTENANCE
The following tests which should be carried out annually in addition to vendor recommended maintenance.
A) INITIAL GENERATOR TEST
• “Megger” rotor winding • “Megger” exciter armature
winding • “Megger” exciter field winding • Complete polarization index (pi)
on main stator • Check bearing insulation
B) INSPECTION ON STATIC EXCITER
• Remove exciter end cover • Examine condition of diode
carrier • Examine exciter
armature/stator for contamination
• Examine exciter armature/stator for winding wear
• Check pmg magnets for contamination
C) ELECTRICAL CONTROL/PROTECTION PANEL • Visually inspect external
surfaces of panel • Complete insulation
resistance checks of panel wiring
• Check function of all relays • Check all fuses • Check all lamps • Check operation of all
switches • Check operation of panel
heaters • Run generator; recalibrate
avr • Secondary inject all
protective relays
E) ROTOR EARTH FAULT PROTECTOR
• Carry out static checks to confirm operation of
detector • Carry out functional check
to confirm operation of detector
F) SLIP-RINGS AND BRUSH-GEAR (IF FITTED) • Check all brushes for grade
and length • Check condition of brush
holders/mountings • Check that spring tensions
are correct • Check conditions of slip-
rings • Check mechanical run-out of
slip-rings • Check cooler and leakage
alarms