RASHTRIYA ISPAT NIGAM LIMITED

(VISAKHAPATNAM STEEL PLANT)

VISAKHAPATNAM

A Project work submitted by

K. L. Sri Sai Havish 20010-EE-045

CH. Anusha 20010-EE-025

In partial fulfillment of the Industrial Training of

Semester – V

ELECTRICAL AND ELECTRONICS ENGINEERING

ANDHRA POLYTECHNIC , KAKINADA

Under the esteemed guidance of

Mr. A. Suresh Babu

DEPUTY MANAGER
ELECTRICAL REPAIR SHOP
VISAKHAPATNAM STEEL PLANT
 Certificate

This is to certify that K. L. Sri Sai Havish and CH. Anusha have attended
industrial training programme in ERS Dept. of VISAKHAPATNAM STEEL
PLANT and the project report entitled being submitted is a
record of bonafide work carried out by them under my guidance and
supervision.

Signature of the Guide

___________________
 ACKNOWLEDGEMENT

We express our heartfelt gratitude to the TTI Authorities and Management of

VISAKHAPATNAM STEEL PLANT for accepting to the training programme.

We wish to express our sincere thanks to Prof.Janardhan Rao , Principal ,APT-

Kakinada and Mr. A Suresh Babu, Deputy Manager, Steel Plant (Visakhapatnam)

for his sourceful knowledge and timely help regarding our project.

We extend our gratitude to Officers and Staff of the ERS department who directly

and indirectly who cooperated with our team in an amiable and pleasant manner in

order to complete this project successfully.

Finally, we extend our gratitude to our Professors & Head of the department and

the Staff Members of EEE department for obtaining the permission to do Industrial

Training in VISAKHAPATNAM STEEL PLANT.

 TABLE OF CONTENTS

S.NO TITLE Pg.no

1. Introduction To ERS

2. Various Sections In ERS

3. Bearings : Types And Significance

4. Classification of motors

5. Stroboscopic effect
 INTRODUCTION TO ELECTRICAL REPAIR SHOP (ERS)

The main objective of ERS is to repair of any faulty Electrical

Equipment in the plant. The process of repairing is also called as
Reverse Engineering Process. It is under services department, which
undertakes repair, rewinding and testing of all types of electrical
equipment. Throughout all the departments present in
Visakhapatnam Steel plant there are about 23000 3-Ø A.C and D.C
motors with 15000 more motors introduced overtime.
LAYOUT OF ELECTRICAL REPAIRSHOP (ERS)
JOB FLOW DIAGRAM FOLLOWED IN ELECTRICAL REPAIR
SHOP(ERS)
 VARIOUS SECTIONS IN ERS

 PLANNING SECTION

The Planning: Receipt and Dispatch section receives the electrical

machine for repair, overhauling and testing along with duly filed work
order and failure report from the customer department. Then a job
number is assigned to that machine . The work order copy consists of all
the name plate information of the machine, brief description of the fault,
required repair, visual defects observed and finalization by customer
department and ERS.

After assigning a job number, planning section allots the job to the
concerned section for the necessary work to be carried out.

Planning section also prepares the repair schedule of the received job
depending on the urgency of the customer department.

Planning section declares the job ready for dispatch in the job‟s work
order form after the repairs are done.

Motors are classified into two simple categories

Small motors and large motors. Small motors have a power rating of less
than 11KW.

Large motors are of two types. LT (low tension) and HT (high tension). LT
motors are the motors that have voltage rating less than 415V and HT
motors have voltage rating above 415V.

Planning section (ERS) also sends a letter to the customer department

stating the defects found in their machine and asks them to arrange for
spare parts.

The Planning section also maintains several reports regarding spares

along with Daily , weekly , monthly and annual reports including
performance reports with highlights from the particular year and all
these records are maintained safely for any kind of future reference
purpose.
IMAGE OF THE WORK ORDER RECEIVED AT ERS
 SMALL MOTORS DIVISION (SMD)

In this section all the motors which are having a power rating below
11KW are repaired by means of private contractors . The faulty bearings
for the motors are also replaced with new ones within the section.

The sections mainly maintains job allotment only for three private
contractors –

All the small jobs i.e. CT‟s (Control Transformers) , small coils are
assigned to one contractor
The motors which are having a rating below 1KW are assigned to one
contractor
The motors having a rating between 1.1-5KW are assigned to one
contractor and finally
The motors having a rating between 5.5-11KW are assigned to one
contractor

 ASSEMBLING AND DISMANTLING SECTION (A&D)

This section deals with the assembling and dismantling of the motors
received at the department . This is one of the key sections in the ERS as
almost every motor has to be either assembled or dismantled to carry out
the further production or repair respectively.

There are certain steps which are followed when it comes to either
assembling or dismantling a motor –

When a motor comes to the dismantling section, the drive and non-drive
ends are marked in the motor.

The drive end is that end of the motor to which the load is fixed. The
non- drive end is the other end of the motor. To the non-drive end a
cooling fan is fixed and sometimes breaking systems, if required.

The process of dismantling the motor always starts from the non-drive
end of the motor.

 Firstly the fan cover is removed

  Then , fan is removed from the shaft after removing the key from the
keyway on the shaft.
 After the fan is removed, the motor is left with outer grease cup and
inner grease cup on the drive and non-drive ends. Outer grease cup is
removed from both the ends of the motor.
 The end shield is removed. The bearings rest on the end shield/rotor
depending on the type of bearings used.
 Bearings are removed from the shaft and the bearing number is noted
 Inner grease cups are removed from both the ends.
 The rotor is separated from the stator and the job number is marked on
the rotor and the parts of the dismantled motor so as to avoid confusion
while assembling the motor.

VISUAL STAGES WHILE DISMANTLING A MOTOR

The various parts observed while dismantling a motor are as follows

 Terminal box
 Terminal block
 Terminal box cover
 Inspection covers
 Shaft
 Shaft key and keyway
 Fan
 Fan cover
 End cover/shield
 Inner grease cups
 Outer grease cups
 Slip rings
 Bearings

Facilities Available -

 Hydraulic jack
 Two and three leg puller
 Stud and plate puller
 Jib crane
 Induction bearing heater
 Torch for gas heating and cutting

 PRE-REWINDING ACTIVITIES (PRA) SECTION

PRE-REWINDING SECTION has two main functions. One is to remove the old
windings from the rotor and stator of burnt motor. And the other is to note the
winding data of the burnt motor in a winding data sheet.

To remove the old burnt windings from the motor , the following procedure is
followed:

 Rotor/stator is kept in the heating oven (generally overnight). This is

done for the windings to expand and loosen and to remove moisture.
 After heating, the rotor windings are removed with the help of rotor
winding pulling machine.
 Stator windings are removed with the help of stator winding removing
machine.
 Large rotors and stators are held with the help of cranes to remove their
windings since they do not fit into the winding removing machines.
 ROTOR COIL PULLER

STATOR COIL PULLER

After windings are removed, the empty stator/rotor is cleaned.

 Gas cleaning: cleaning with a mixture of oxygen and LPG flame to burn
off the remains of insulation papers or any kind of dust.
 After cleaning, the rotor/stator is cleaned by blowing high pressure air
on on the stator/rotor body. This is done to completely remove the
leftover burnt paper and dust particles.
 The rotor/stator is given a coating of bectol red to prevent it from
attracting dust and moisture.

The following is a format of a winding datasheet filled in the pre-

rewinding section.
 STAGES OF WINDING REMOVAL IN PRA

STATOR BEFORE STRIPPING OVERHANG

STATOR AFTER STRIPPING

Facilities available –

 Charring oven
 Jib crane
 Stator coil puller
 Rotor coil puller

 RE-WINDING SECTION

In AC machines, four types of windings are done -

Single layered

Double layered

Mixed windings

Concentric windings

Single layered windings are used in low rated motors since they have more
leakage reactance.

Concentric windings are used in motors to reduce harmonics. These windings

have variable coil span.
 CONCENTRIC WINDING

MIXED LAYER WINDING

Mixed windings consist of both single layered and double layered windings.

The re-winding of a stator/rotor can be explained with the help of an example

(as seen in ERS)

There is a stator of an induction motor that is supposed to give a speed of 600

rpm.
 N=120f/P

For 600 rpm this machine will be a 10 pole machine

This stator has 90 slots. Whether this stator will have single or double layered
or any other type of winding will be decided by the customer department.

If we have to put double layer windings, then for 90 slots we need to have 90
active coils. The coil span of this stator would be 9 so if one side of the coil
rests on the first slot then other side will rest on the 10th slot.

Windings are either connected in star or delta.

One end of the coil is given to the supply and other end is either connected in
star or delta with other 2 phases.

STAR DELTA

Delta connected coils are high voltage coils since line voltage and phase voltage
are equal.

Windings are connected in parallel or normal manner. Suppose we have 10

pole 10 parallel windings

Suppose we have 90 slots. 30 per phase. And coiling is done in groups of 3.

(Grouping can be changed also. We can take coils in groups of 1, 2, or 5 also.
But here we have taken 3 for clear explanation)
There will be 10 such coil groups per phase.

The above is a 10 pole 10 parallel connection. Here R phase is shown.

There is a 10 pole 2 parallel connection

Similarly we can make 10 pole 5 parallel also. All this is done depending upon
the requirement of the customer department.

In the above circuit we see how the north and south poles are induced when
supply is given. And the connection between two separate sets of coils is called
a jumper.

Two leads are joined by brazing. Brazing is a metal-joining process where a

filler metal (in this case, a lead bar)is heated above melting point and
distributed between two or more close-fitting parts by capillary action. The filler
metal is brought slightly above its melting (liquid) temperature while protected
by a suitable atmosphere, usually a flux. It then flows over the base metal
(known as wetting) and is then cooled to join the work pieces together. It is
similar to soldering, except the temperatures used to melt the filler metal are
higher for brazing.

Windings have to be insulated from each other. They have a copper enamel
coating to provide individual insulation. But when one phase of windings has
to be insulated from another phase, then copper enamel coating is not enough.
Insulation paper is used to insulate 2 groups of windings. Insulation paper is
used to insulate the core from windings and the coil sets of each phase . The
insulation paper used is a H class insulation paper of the trade name NOMEX.

Classes of Insulation based on the temperature which they can withstand.

Class of Insulation Temperature Materials used
Y 90 Wood , Paper
A 105 Leatheroid paper, Preston paper
E 120 Polyester material
B 130 Minilex
F 155 Flexitron, Jute, Fibre
H 180 Nomex, Mica , Glass
C >180 Mica, Asbestos, Ceramic

When the stator/rotor is re-winded, it is sent for intermediate testing.

LT WINDINGS

MAKING OF COILS
 COIL FORMER

 ELECTRICAL MAINTENANCE
To carry out the work smoothly, ERS which is having coil winding
machines, EOT (Electrical Over head Travelling cranes), testing equipment,
over head lighting, ovens, winding coil puller, welding machines, jib cranes
and other allied equipment. This section caters for maintenance and trouble
free performance of all such equipment within the department.

 MACHINE AND MAGNETS SECTION

This section will carry out all the mechanical works like welding,fitting,
shaft repairs, turning of mechanical parts, over hang insulation banding,
Magnets preparation etc. All the electromagnets facing any kind of
problem are brought to this section.
 CIRCULAR MAGNET

 HT/DC SECTION
HT motor has the same principle of operation as LT motors. HT motors
operate at a higher rated voltage. Voltage greater than or equal to 415V.
Windings consist of bundled conductors instead of single conductors. In
HT motors high current flows and this causes skin effect. To avoid skin
effect , bundled conductors are used.

In case of LT motors, if a part of the winding is burnt, the entire winding

is replaced. But in HT motors if a part of winding is burnt, only that part
is repaired as the coils are of high cost.

Testing in HT motors is done in the same manner as it is done for LT

motors.

In HT motors the value of insulation resistance should not be less than

100 mega ohms.

HT motors are too large to be dipped in varnish, so air dry varnishing is

done on HT motors.

In this section DC motors are also repaired ,DC motors usually don‟t
require much repair except for the main poles and interpoles.

DC motors are used even in this modern (AC) era as it has a better speed
control than AC and the finishing of the production is usually better
looking when a DC motor is being used.
BUNDLED
CONDUCTORS

STATOR OF A HT MOTOR

IMAGES OF A DISMANTLED DC MOTOR

 TESTING SECTION
There are three stages of testing done on any motor during its repair
within the ERS

PRELIMINARY TESTING
INTERMEDIATE TESTING
FINAL TESTING

Testing involves the use of the following instruments –

- Mega ohmmeter (Megger)

Megger is an instrument which is used to measure insulation (in

ohms). Insulation resistance is measured between two phases and
between a single phase and the body of the motor. Ideally the
insulation resistance should be infinite. Practically the minimum
value of insulation resistance that should be there in LT motors is
1megaohm. Megger supplies high value of voltage (1000KV-5000KV)
to the windings in order to measure the insulation resistance.

LT MEGGER

- Milli ohmmeter

Milli ohmmeter is used to measure the winding resistance. Ideally

the winding resistance should be zero. Practically it is less than one
milliohm.
 MILLI OHM-METER

- Raytek (temperature gun)

This is a laser gun which shows the temperature of the portion on

which laser is pointed. Temperature is measured without bringing
the instrument in contact with the motor body.

- Surge test equipment

The surge test equipment consists of an oscilloscope which shows

the current waveforms. Surge testing kit has 4 terminals. Three are
connected to three phases of the windings and one is for neutral.
 What surge kit does is, it supplies a number of high voltage impulse
signals to the windings. When this supply is given, the current
waveforms are seen on the oscilloscope. The oscilloscope shows two
waveforms of two phases keeping one phase as reference. If the two
waveforms perfectly overlap each other then there are balanced
currents flowing in the two windings. Similarly other two phases are
also taken as reference one after the other. If the waveforms do not
overlap, it means that there is some fault in the winding. For
example in a motor there is a fault in R phase. We first take R as
reference. We get two perfectly overlapping waveforms. When Y
phase is taken as reference then two waveforms not perfectly
overlapping each other are seen. Same is seen in the case when B
phase is taken as reference.

- Magnetic compass

Magnetic compass is used to check whether stator provides a

rotating flux or not. And it is also used to calculate and verify the
number of induced poles in the motor.

- High voltage DC supply

High DC voltage is given to the stator to check if the windings can

withstand voltage surges. Whenever a motor is switched on or off ,
the flux linkages in a coil donot change immediately. So there is a
rise in current for a small period of time. To see whether the
windings can withstand this rise, high voltage DC supply is given.
The voltage given is shown below:

2*(1KV+ 2 times rated voltage)

 If the windings are not able to withstand high voltage, then MCB on
the DC supply machine trips.

- Tachometer

This instrument measures speed of the motor.

PRELIMINARY TEST

Preliminary testing is done after dismantling the motor. Preliminary tests

are performed on both stator and rotor separately. Though the tests
performed on them are the same.

The tests performed are –

- Measurement of Insulation Resistance (IR) between windings and

body, between two phases.

Insulation can fail due to accumulation of dust inside, or moisture

and water, or due to high temperature. The cause of insulation
failure has to be known. The megger has 2 terminals. One is
attached to the phase and other to the body. One value of IR is
obtained. Now if these terminals are interchanged another value of
IR is obtained. If these two values are equal, then the reason for
insulation failure is either dust or failure of insulation due to high
temperature. If those IR values are not equal, then the reason is
accumulation of moisture or water. This IR changes because of
hydrolysis.

- Resistance of the windings is measured.

The resistance of windings of all three phases should be equal.

Winding resistance is taken by connecting the ohmmeter at starting
and end of one winding. If the winding is star or delta connected at
the other end, then the winding resistance should be measured
between two phases.

measure between RY,YB,BY.

In this case the megger value is taken only between body and
phase. Between phases it will show zero.

*Surge test is performed to check whether currents are balanced or

not.
*Field rotation of the stator is checked with the help of a magnetic
compass. It is checked whether the stator is providing rotating
magnetic flux or not.
*Temperature of end connections of windings is measured with a
non- contact thermometer (raytek).

The following is a sample of a testing data sheet -

INTERMEDIATE TEST

Intermediate test is performed after rewinding and before

varnishing. It involves the following tests.

IR value is checked
Resistance of the wire is checked.
Surge test is performed.

It is obvious that if winding resistances are equal then currents will

also be balanced. But windings may be connected in a wrong
manner inside. In this case we get same winding resistances. But
we will get different currents.

Field rotation is checked with the help of a magnetic compass.

Temperature of end connections is checked

High voltage test is performed by supplying the windings with high

DC voltage. This is done to check the endurance of windings
towards voltage surges.

Pole formation - Pole formation is checked by giving 2 phase

supply to the rotor. The voltage supply given should be very low.
Pole formation is checked by putting the magnetic compass in the
stator body and moving it from slot to slot.

If three phase supply is given then rotating magnetic field is

obtained. Voltage should be less. At 2-5% of rated voltage full load
current flows in the windings.

The following is a sample of a testing data sheet –

FINAL TEST

Final test is performed after final assembly of the motor.

Supply being given to a repaired motor before no load test

 The following tests are performed in final test:

IR value is taken
Winding resistance is checked
Physical check-up is done

Physical check-up involves the check of various physical conditions

of the motor. It involves temperature check; temperature should be
uniform throughout the body of the motor. Temperature may
increase but it has to be uniform. Foot balance, cracked bars which
may cause vibrations are checked. It is seen if the rotor distribution
of mass is uniform and not concentrated to one particular part of the
rotor.

- NO-LOAD test is performed.

The induction motor is made to run at no load, rated voltage and

frequency. Per phase values of applied stator voltage and current
are noted. Our requirement here is that all the three phase currents
should be equal and not exceed rated current. Voltage is slowly
increased with the help of control panels present in the testing
section of ERS.

If the motor being tested is a daily use motor which is run

continuously for long hours , the testing is done for half an hour
generally.
The Following is a sample data sheet of final testing -
 BEARINGS
A Bearing is a machine element that constrains relative motion and
reduces friction between moving parts in order to get the desired motion. In an
electrical machine, the design of the bearings is such that it provides the
desired free rotation around the fixed axis. The bearings also facilitate the
desired motion by minimizing the friction.

The term “bearing” is derived from the verb „to bear‟, a bearing being a machine
element that allows one part to support another. In a rotating electrical
machine that is a motor or a generator, the bearings provide mechanical
support to the rotor and also help in the free rotation of the rotor. Bearings are
broadly classified broadly according to the type of operation, the motions
allowed, or to the directions of the forces applied to the parts. In electrical
motors or generators, generally two types of bearings are used, ball bearings
and roller bearings -:

 Ball Bearings
This type of bearing contains inner and outer races between which the balls
roll. The ball contacts with each race across a very narrow area. Thus, there
are opposing forces and sliding motions at each ball-race contact .The purpose
of ball bearings in motors and generators is to reduce rotational friction and
support radial and axial loads. Although they can tolerate some misalignment,
but they tend to lower load capacity for their size compared to other kinds of
rolling bearings. So, they are generally used on the non-drive end of the
motors.

 Roller Bearings
Roller bearings are the earliest known type of rolling-element bearing, dating
back to at least 40 BC. Common roller bearings use cylinders of slightly greater
length than diameter. Roller bearings typically have higher load capacity than
ball bearings, but a lower capacity and higher friction under loads
perpendicular to the primary supported direction. If the inner and outer races
are misaligned, the bearing capacity drops quickly compared to ball bearings.
Due to their greater load capacity, they are generally used on the Drive end of
the motors.
 The life of a rolling bearing depends on the number of stress cycles and
the loads incurred by rolling elements and raceways. An increasing local
stress may result in the fracture of the ring. Other than overloading and
mechanical stress, there are various other reasons for bearing damage and
failure. Following are some of the reasons behinds the failure of rolling
bearings-:

- Faulty Mounting

This type of damage occurs if the inner ring of a roller bearing is

inserted out of square into the outer ring.

- Contamination

This type of damage occurs because of the abrasive effects of the

foreign particles on the bearing. This accelerates the bearing
failure. Contamination maybe due to inadequate seals
contaminated lubricants or metallic abrasion.

- Corrosion

Corrosion in rolling bearings may occur in various forms and have

different causes. The damage shows in an uneven and loud
running noise. Possible causes of corrosion are inadequate sealing
against moisture, acid fumes, lubricants containing acids, or
condensation.
- Passage of Electric Current

Continuous passage of electric current is also one of the major

reasons of bearing failure.

- Imperfect Lubrication

Due to the starved lubrication or use of irrelevant lubricants, the

mechanical stresses and frictional forces increases which increase
the wear and tear of the bearings and accelerate the process of
bearing failure.

AN IMAGE OF A DAMAGED BEARING

Bearing Number –
A bearing number is composed of a basic number and a
supplementary code, denoting bearing specifications including
bearing type, boundary dimensions, running accuracy, and
internal clearance.
 Dimension series code
Bearing type Bearing series code Type code
Width series1） Diameter series

67 6 （1） 7

68 6 （1） 8

69 6 （1） 9

1602） 6 （0） 0

60 6 （1） 0

62 6 （0） 2

Single-row deep groove ball bearing 63 6 （0） 3

64 6 （0） 4

NU 10 NU4） 1 0

NU 2 NU4） （0） 2

NU 22 NU4） 2 2

NU 32 NU4） 3 2

NU 3 NU4） （0） 3
 Dimension series code
Bearing type Bearing series code Type code
Width series1） Diameter series

NU 23 NU4） 2 3

NU 4 NU4） （0） 4

- The cylindrical roller bearings which are designed to carry heavy

radial loads and are suitable for high speed applications. Their
rolling elements are ground to provide maximum contact with the
raceway and are precisely crowned to avoid edge loading due to
shaft misalignment.

- NU style bearings have two machined flanges on the outer ring

and no flanges on the inner ring. The rollers and cages are
assembled in the outer ring. Because there are no flanges in the
inner ring, this bearing cannot carry a thrust load.

- N style bearings have two machined flanges on the inner ring and
no flanges on the outer ring, with rollers and cage on the inner
ring. Like the NU style, the N has no thrust load carrying
capability.

- NJ style bearings have two machined flanges on the outer ring and
a machined flange on one side of the inner ring. The roller and
cage assembly is in the outer ring. The integral flange on the inner
ring allows this bearing to carry an axial load.
 CLASSIFICATION OF MOTORS
The primary classification of motor or types of motor can be tabulated as
shown below –
History of A Motor

In the year 1821 British scientist Michael Faraday explained the conversion of
electrical energy into mechanical energy by placing a current carrying
conductor in a magnetic field which resulted in the rotation of the conductor
due to torque produced by the mutual action of electrical current and field.
Based on his principle the most primitive of machines a D.C.(direct current)
machine was designed by another British scientist William Sturgeon in the year
1832. But his model was overly expensive and wasn‟t used for any practical
purpose. Later in the year 1886 the first electrical motor was invented by
scientist Frank Julian Sprague. That was capable of rotating at a constant
speed under a varied range of load, and thus derived motoring action.

CONSTRUCTIONAL DETAILS OF AN AC MACHINE

It can be discussed in two parts -

Stator -
 It is the stationary part of the machine.
 The outer part of the body is called as the stator frame. It is made of
cast iron which is brittle and porous. This property enables the
machine to withstand high load and vibration.
 The base of the outer body is called the motor feet .
 The circular hook on top of frame is called the eye bolt or eye hook.
 A terminal unit is fixed to the stator body which consists of the
terminal box, terminal block and a terminal cover.
 The projections on the surface of the body are called as cooling fins.
They increase the surface area and hence improve rate of cooling of
the machine.

Stator Frame Core

 Core -
 A cylindrical laminated core made up of silicon sheet steel is
placed inside the stator frame.
 The laminations decrease the eddy current losses while the
silicon added to steel will increase the permeability of the core
thereby decreasing the hysteresis losses.
 Inner periphery of the core is cut into no. of slots.
Three phase windings -
 The three phase windings are made of copper.
 They are placed in the slots provided.
 6 leads come out of the three windings and fixed to the terminal
block studs.
 Core plate varnish is applied between laminations of core
during manufacture.

Rotor –
 The moving part of the machine is known as the rotor.
 There are mainly two types of rotors

Slip Ring Induction Rotor -

 Rotor consists of shaft made up of mild steel (<1% C + Fe) for

better rotation of the shaft.
 Core is manufactured as in the stator and placed on the shaft.
 On the outer periphery, slots are made making provision for the
conductors of the 3 phase winding.
 It is connected in Star fashion in the rotor itself and 3 leads are
brought out to the terminal box situated on the stator frame.
 As the rotor is rotating part of the machine, the leads cannot be
directly brought out to the terminal box. Hence brush gear
arrangement is used.
 The 3 leads are connected to 3 slip rings provided on the rotor
shaft, from which the leads are taken out through the brushes.
 They are provided with some spring arrangement for providing
tension to the brush opposing the centrifugal force that will be
acting on the brushes while rotating.
 With the help of a pig tail, the terminals are brought out onto
the rocker arms which are used to suspend this brush gear unit
from the end covers.
 From the end covers they are brought onto the terminal box
provided on the stator.
 The terminals of the rotor are represented by D, E, F; or K, L,
M.
 Dynamic Balancing is done to the rotor to distribute the mass of
the machine uniformly by adding some weights for a smooth
acceleration and deceleration of the machine.
 In some cases, Rotor conductors come in parallel with the
Stator conductors (in which the fluxes produced will be
magnetically locked which is not desired.)
 To overcome this, Skewing is done i.e., rotor slots are made
making an angle with the vertical.

Squirrel Cage Induction Rotor –

 Rotor consists of shaft made up of mild steel (<1% C + Fe) for

better rotation of the shaft.
 Core is manufactured as in the stator and placed on the shaft.
 On the outer periphery, slots are made making provision for the
conductors of the 3 phase winding.
 Here the conductors are placed inside the slots.
 They are made up of either Copper or Aluminium in circular or
rectangular shape.
 At both the ends, they are shorted by end rings which are again
made by the same material as that of the rotor conductors.
 Fans are provided in some rotors.
 Squirrel Cage Induction Rotor

CONSTRUCTIONAL DETAILS OF DC MACHINE

It can be discussed as:

Field -

 The object of the field system is to create a uniform magnetic

field, within which the armature rotates.
 Electro magnets are preferred in comparison with permanent
magnets on account of their greater magnetic effect and their
field strength regulation, which can be achieved by controlling
its magnetizing current.
 The outer body of the field is called Yoke, made of cast iron to
provide mechanical strength to the body for withstanding the
vibrations.
 Generally, these are not provided with any cooling fills as the
surface area is sufficiently high to dissipate the heat generated
due to the core losses.
 Electromagnetic poles are fitted from inside to the yoke which
are responsible for producing the main operating field flux.
 The main poles are divided into two parts namely, pole core
and pole shoe.
 Yoke Slots for compensating winding

 The winding is done on the pole core which is made up of thin

silicon sheet steel laminations. The function of pole shoe is to
hold the coil from slipping and also to distribute the flux.
 Slots are made on the pole shoe for housing the compensation
winding whose terminals are denoted by C1, C2.
 The terminals of the main field winding are denoted by F1, F2
and are brought into the terminal box. It is a high resistance
winding (has more number of turns with less cross-sectional
area.)
 The poles are formed according to the current directions
through the field windings.
 Interpoles is a low resistance winding (has more cross-sectional
area ). The terminals are denoted by I1, I2.
 In case of DC Compound Machine, a series winding is present
in series with the armature (which is of low resistance). The
terminals are denoted by S1 and S2.

Armature –

 It consists of a cylindrical core made up of silicon sheet steel to

reduce hysteresis losses and is laminated to reduce eddy
current losses .
 It is placed on the rotor shaft made up of mild steel.
 Outer periphery of the core is made into slots for housing the
armature windings.
 A small air gap exists between the pole pieces and the armature
so that there will be no rubbing in the machine.
 Each lamination is about 1mm thick. The slots are skewed at
small angle to axis to avoid vibration of teeth.
 DC Rotor

Commutator –

 The commutator is a form of rotating switch placed between the

armature and the external circuit.
 It is essentially of cylindrical structure and is built up of wedge
shape segments of high conductivity hard drawn copper( or
dropped frog copper.)
 These segments are insulated from each other by thin layer of
mica.
 The segments are held together by means of two V-shaped rings
that fit into V-grooves cut into the segments.
 If the armature and commutator diameters are not differing
much, the winding ends are directly soldered to the commutator
bars. Otherwise they are soldered with copper lugs or risers.
 Commutator

 As the commutator does not provide any leads through which

supply can be given or taken, a brush-gear arrangement is
used.
 Brushes are to be placed on the riser of the commutator in the
Magnetic Neutral Axis (MNA) i.e., at a position where voltage is
zero (no effect of flux).
 The brush position is tested after they are kept. Number of
brushes placed decides the number of parallel paths.
 In case of lap winding, number of brushes to be placed is equal
to number of poles of the machine but whereas in wave winding
they are always equal to 2.
 The armature windings are of two types namely –

Lap Winding - One coil is connected to commutator segment

and to start end of the adjacent coil situated under same
pole and similarly all coils are connected. These are further
classified as simplex or multiplex windings.

Wave Winding - The coil side is not connected back but

progresses forward to another coil side. Passing successively
every n-pole and s-pole till it returns to coil the side from
where it was started. Thus the connections always progress
in the same direction around armature instead of moving in
alternate directions like that of lap winding.

Brushes –

 The function of brushes is to collect current from the

commutator and supply it to the external load circuit.
 The brushes are rectangular in shape and rest on the
commutator.
 Brushes are manufactured in a variety of composition and
degree of hardness to suit the commutation requirements.

Diagram of a brushed DC motor

STROBOSCOPIC EFFECT
The stroboscopic effect is the phenomena which causes running or
moving objects to appear stationary or to appear to be operating
slower than their actual speed
This effect is the reason why most industries do not use fluorescent
lamps and tube lights in the workshops
Explanation –
In the fluorescent lamps/tube lights , the tube consists of mercury
vapour. When the supply is provided to the tube light via the starter
, a positive charge is built up at the end of the tube and the charge
is converted into Ultra-violet (UV) light and flows through the tube
thereby closing the circuit
The UV light further hits the Phosphor lining of the tube which
causes it to glow .
This effect is due to the AC supply provided to the tube light i.e. the
output of the lamp has fluctuations due to the cyclic variations in
the current in the AC circuit.
Due to the phenomena of Persistance of vision , the naked eye
cannot see these fluctuations but however when this light hits a
moving object , due to Illusion our human eye identifies the object
to be moving slower or stationary or maybe moving in reverse
direction .
Hence due to this effect which may lead to several kind of accidents
is why industries prohibit the use of fluorescent lamps/tube lights
in the workshops.
The stroboscopic effect can be minimized by –
- Using a Twin-lamp circuit i.e. two lamps connected in
parallel with one-phase supply and in connection of the
one lamp a capacitor is connected in series with the
choke.
 - Using three different lamps on each phase of the 3- Ø
supply.

- Using Light Emitting Diodes (LED‟s) and Halide lamps.

DSL BUSBARS
DSL Bus-bars are made up of highly electrically conductive metals and they
distribute & carry power from a source to a destination or multiple
destinations. They are used in EOT Cranes to supply power from the grid to the
crane control panel. Full Form of DSL bus-bar is Down Shop Lead.

DSL Bus-bar profiles reduce the overall weight of the system as compared to
flat bus-bars and provide the cost benefit to the user. Prefabricated Bus-bars
are advantageous to flat bus-bars because they optimize the space of
installation, help make the installation easy. Long installation bus-bars should
be using profiles to reduce the Skin effect. Depending upon the electrical
frequency of the AC voltage, due to skin effect the AC current tends to flow
near the surface of the conductor. Hence areas of the bus-bar with low current
density can be removed, thereby saving weight and cost. The Skin depth of
copper bus-bar is 7.83mm at 50 hertz frequency.

As the frequency of the AC voltage increases, the skin depth reduces. Using
DSL bus-bar profiles helps reduce the effect of skin depth by optimizing the
areas of higher and lower current density and achieving better performance
even when utilizing less weight than flat bus-bars. Current density can be
uniformly spread across the cross section of the profile.

DSL Bus-bars are made up of highly electrically conductive sheet metal and
they distribute and carry power from source to a destination or multiple
destinations. They can be used in all kinds of Factories, Buildings, Malls,
Airports etc.

DSL Bus-bars come in a variety of configurations, shapes, sizes, materials and

current carrying capacity.

- When you need to conduct a significant amount of current, DSL

bus-bars are your best bet. For example, if you want to power
many of your heavy duty cranes in one bay, you use a system of
DSL bus-bars.

- The efficiency of a bus-bar will depend upon the Ratio of the Input
Power to the Power Output.

- DSL Bus-bars are a very efficient system to carry significant

amounts of current between different electrical subsystems.

- Current carrying capacity of a busbar can range from 1 Ampere to

1200 Amperes.

Materials Used in DSL Busbars

 SS
 Galvanized iron

Melting point of Iron: 1538 °C

Boiling Point of Iron: 2862 °C
Density of Iron: 7.874 g/cm 3
Electrical Resistivity of Iron: 96.1 nΩ-m
  Aluminium/copper

Different types of Joints for DSL Busbars

Bolt Type Joint Pin Type Joint

Weld Type Joint Rivet Type Joint

Busbar Protection
- Protection from Short Circuits
In a 3- Ø power delivery system, a minimum of three parallel DSL
Bus-bars will be used to deliver power to the crane machinery. The
gap between the DSL Bus-bars is an important parameter to avoid
short circuits.

If there is a short circuit, the current will rise until the protection
device kicks in. This very high current will heat the DSL Bus-bars
and will cause mechanical stress to the bus-bar as well as its
support units.

- Protection from Human Touch

Insulated DSL Bus-bars are only recommended, because like every
other electrical circuit, DSL Bus-bars need to be protection from
human touch. No live or HOT sections are exposed to the external
environment.

Safe distance should also be maintained between two parallel DSL

Bus-bars. Insulation will also help in prevention of short circuit in
the presence of foreign material touching two DSL Bus-bars.

Voltage Drop
Voltage drop of a bus-bar is very important parameter to consider. In lay-mans
terms –

The amount of voltage not reaching the desired equipment from the power supply
= Voltage Drop.

- It is highly dependent on the resistance of the bus-bar being used

and the amount of current being consumed.
- Temperature also affects the voltage drop to some degree.
CRGO CORE
As we know that the ferromagnetic materials i.e. their crystal
substances have a particular direction which offers high
Permeability for easy magnetization. Other than this particular easy
direction, the crystal offers low permeability and hence difficult to
magnetize.

Thus, to obtain the easy directions out of an electrical sheet steel iit
is oriented in such a way that their axes are parallel to the direction
of the magnetic field applied.

This can be achieved by controlling the rolling and annealing of the

silicon- iron / silicon-steel sheets at room temperature i.e. ‘Cold
Rolled Grain Orientation’.

The figures above show the difference between a randomly oriented

grains(steel) and a grain oriented steel.

The non-oriented sheets need a higher magnetizing field to

magnetize them due to the difference in the permeability values
between them.
Hysteresis loss is also reduced as a result of grain orientation. The
sheet steel obtained by the result of Cold Rolling is Cold Rolled
Grain Oriented Silicon Steel.

The non-oriented steel tends to draw more amount of magnetizing

force to establish the flux in the core (i.e. to magnetize the core).
But, this magnetizing force will only be sufficient to force the
domains whose axes are divergent from the applied field axis to
align in the direction of applied field.

Whereas, in a grain oriented steel the domains are not divergent

from the alignment and hence the magnetizing force required is
comparatively small.

This is the reason why the Transformer cores are manufactured

with the help of CRGO steel.

- It is very important to note that while using the CRGO

steel to build a transformer core, the core must be
assembled properly so that the crystal/domain direction
is parallel to that of the flux path. Otherwise, the core
will offer high reluctance and low permeability.
 Building a Transformer Core to keep the Orientation of The grains

In the same direction as the flux path throughout the core length

Mercury Arc Rectifier

A mercury arc valve or arc rectifier is an electrical rectifier used to
convert high voltage or high current , alternating current(AC) into direct
current(DC)

The cathode of a mercury arc rectifier is a pool of liquid mercury which is

self-restoring (cold cathode).

It was invented by Peter Cooper Hewitt in 1902 which were used to provide
power industrial motors, railways, locomotives, radio transmitters as well
as for HVDC transmission.

Operation of the mercury arc rectifier mainly depends on the discharge of

arc between electrodes in a sealed unit containing low pressure mercury.
Since, the properties of mercury does not deteriorate with time hence the
cathode is self-restoring.
The mercury emits electrons which pass through the tube in one
direction as the carbon which is used as the anode emits very few
electrons even when heated. So, the electrons flow from cathode to
anode.

When an arc is formed, electrons are emitted from the surface of the
pool of mercury which in-turn causes the ionization of mercury
vapour along the path to anode. The mercury ions are attracted
towards the cathode. Due to this attraction, the bombardment of
ions is caused within the pool of mercury which maintains the
working temperature of the emission spot as long as a few amperes
of current flows.

While the current is carried out by the electrons within the vacuum
tube, an effect called the Space Charge effect which limits the
performance of vacuum tubes is eliminated as the positive ions
returning to the cathode are unaffected by this effect and hence the
conduction path.

The mercury arc rectifier is a highly efficient rectifier because it can

carry high amount of current even at low voltages (i.e. 20-30V)

The temperature of the valve must also be controlled carefully as

the arc formed is majorly dependent on the vapour pressure of the
mercury.
The considerable temperature is maintained by the coldest spot on
the enclosure wall i.e. 40°C and a mercury vapour pressure of 7
milli-pascals .

The mercury ions also emit light at certain wavelengths, which is

again dependent on the pressure of the mercury vapour.

At low pressure, the light appears pale blue-violet which is mostly

ultra-violet (UV) light which can be seen in the picture below.
 UV Light

Reasons why the use of mercury arc rectifier was discontinued –

- The arrival of solid state rectifiers was one of the reasons

why the mercury arc valve was discontinued as they were
less cost efficient and required very less maintenance
comparatively.
- Mercury compounds were highly toxic and persisted in
the environment and hence they were a threat to the
human beings and the environment.
- The potential release of mercury into the environment
was high as it was enclosed in a fragile glass bulb.
- The cleaning up of the mercury residues was also quite a
tricky process and ultimately the mercury vapour was a
hazardous activity to cope up with.
 Latest modified version of HT motor

Two Terminal Boxes

This modified HT motor has two terminal boxes on each side of the
motor which can be seen from the above picture

This is so because, one of the terminal box is connected in STAR

and the other terminal box is given a 3-Ø supply based on which
side the production line is situated on.
 CONCLUSION

In the modern world of competition, optimum usage of equipment is

a necessity. To know the usage and performance of the electrical
machines, just studying the theory of operation and procedures of
electrical machines is not enough. In addition to the theoretical
knowledge, practical knowledge is also required to know the
operating procedure, characteristics of the different machines to
deal and use the equipment in optimum level in any industry or
organization.

This report deals about the “ ”.

In this regard, we physically observed the different parts of the
machine (in dismantled condition of the various AC/DC
motors), repair procedures, trouble shooting, maintenance
and testing of various electrical equipments in ERS
department of VSP.

By putting utmost observation to the Reverse Engineering

process of electrical machines, we came to know the different
types of repairs performed in every stage of the motor‟s
journey throughout the workshop. We also observed the
several working conditions required for a job to be completed
in a certain due of time.
Finally we conclude that we have gained more knowledge
about electrical equipment regarding usage, troubleshooting
and testing of the same by attending this industrial training
programme which would not be possible by mere class room
study.