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