A Project Report On:-


Submitted By:Bhuwan Pratap Singh B.Tech- Final Year SEC, Sikar(Raj.)

Submitted To:Sh. A.K. Dhiman Sr.Engineer BL-4, BHEL Haridwar

My sincere thanks goes to Sh. A.K. Dhiman (Sr. Engineer) for his prodigious guidance, precaution, painstaking, attitude reformative and suggestion throughout my summer training schedule. Special thanks goes to Smt. G.D. Mehta who helped me a lot in giving minute details of the “Manufacturing Process Of 500 MW TG Stator Winding Bars” and enlightened me with the knowledge of essential equipments and their working. Last but not the least, my sincere thanks to all the staff members of “BLOCK-4, BHEL, RANIPUR, HARIDWAR”

Bhuwan Pratap Singh B. Tech- Final Year SEC , Sikar (Raj.)

I am a student of B. I observe various electrical machineries that are used in different large scale or a small scale industries and different types of power plants. I tried my best to get acquitted with over all plants.PREFACE In the light of practical aspects of training for engineering.Tech. . The objects of training in engineering couse is to correlate the theory with practical aspects and to make students familiar with the difficulties arises during practical application so that they can face challenges boldly while working in the field. As I am a student of electrical engineering so training at “BHEL” had been particularly beneficial for me. final year had been completed my practical training at “BHARAT HEAVY ELECTRICALS LIMITED (BHEL) HARIDWAR” for 30 days. BHEL is very large industry for making the different types of equipments as well as mechanical equipments. I hope that I have excited enough in the report of my training.


BHEL caters to core sectors of the Indian economy in power. BHEL supplied sets account for nearly 56. To make efficient use of the higher ash content coil manufacturers 235 MW nuclear turbine generator sets and has commenced production of 500 MW nuclear turbine generator head discharge combinations are also engineered and manufactured is also competitive. BHEL has proven turnkey capabilities for executing power projectors from concept to commissioning. BHEL is today the largest engineering enterprise of its kind in India with well recognized track records of performance making profits continuously since 1971-72 it achieved a sales turnover of 1023 crore in 1977-78. industry. It possess the technology and capability to produce thermal power plant equipments up to 1000 MW rating and gas turbine generator sets up to a unit rating of 240 MW. 636 MW in as against nit till 1969-70. nuclear.defense etc.---------------------****---------------------- CHAPTER . transportation. Power sector comprises thermal. 318 MW or 65% of the total installed capacity of 86. Cogeneration and combines cycle plants has been introduced to acheve higher plant efficencies. The wide network of BHEL’s 14 manufacturing divisions. 9 service centers & 4 power global players. gas & hydro power plant business today.I COMPANY PROFILE The first plant of what is today known as BHEL was established nearly 40 years ago at BHOPAL and was genius of heavy electrical equipment industry in India. .

International operations:BHEL’s product series and projects have been exported to over so countries ranging from UNITED STATES in the west to NEW ZEALAND in for east INDIA is over 3000 MW. instrument. . instrument transformers. In Cyprus. Saudi Arabia. SF6 switch gear. The company supplies broad gauge. hydro generator to New Zealand and hydro power plant to Thailand . power station in Libya and Turkey. TRANSPORTATION:A high percentage of trains operated by Indian Railway are equipped with BHEL’s traction and traction control equipments including the metro at Calcutta and delhi. Greece and Egypt. Tripoli west. Electrical locomotive to Indian railway and diesel shunting locomotives to various industries 5000/6000 hp ac/dc locomotive developed and manufactured by BHEL have been leased to Indian railway. transformers. Oman .TRANSMISSION:BHEL also supplies a wide range of transmission products and system up to 400 KV class. dry type transformers. battery powered road. capacitor and insulator etc series and shunt compensation system have been also developed and introduced to minimize transmission losses. utility boiler and open cycle gas turbine plant to MALAYSIA. A few motable ones are 150 MW gas turbine to GERMANY. These include high voltage power and distribution transformer.

At present 70% of the country electrical equipment is generated BHEL HARIDWAR. Generator 4. Complex consisting of several plants in INDIA.AC ( 250 KW – 1600 KW) . PRODUCT’s OF BHEL Heaps product & capacity ratings PRODUCT 1. of INDIA is and integrated engg. Heat exchangers. where about 70000 workers are busy in design and manufacturing of heavy electrical equipment.---------------------****--------------------- CHAPTER . BHEL . AC/DC electrical machine CAPACITY RATING 210 MW – 1000 MW 115 MW Acc. Hydro set 3. Gas turbine 5.III ABOUT BHEL HARIDWAR At the foothills of the majestic Himalayas on the bank of the holy ganges in Ranipur near “HARIDWAR” is located Heavy Electrical Equipment Plant (HEEP) of BHEL. wholly owned by the govt. Thermal/nuclear set 2. To Requirement 60 MW – 200 MW Up to 800 MW 5 KW – 2000 KW (a) . condenser 6.

(b) .IV BLOCKS IN BHEL Block-1 -> Hydro & turbo generators. seamless tuber and heat exchanges ---------------------****---------------------- .DC ( 7KW – 1000 KW) ---------------------****---------------------- CHAPTER . forging & fabrication Block-6 -> Electrical repair & maintenance of motor & transformer Block-7 -> Wooden packing works Block-8 -> Fabrication. hydro & gas turbine) Block-3 -> Gas. hydro & steam turbine Block-4 -> CIM Block-5 -> Heat exchangers. AC/DC machines Block-2 -> Fabrication ( steam.

The wide network of BHEL’s 14 manufacturing divisions. Power Generation and Transmission. ushering in the indigenous Heavy Electrical Equipment industry in India.739 crore with a profit before tax of Rs. . a dream which has been more than released with a wellrecognized track record of performance. Defence etc. BHEL caters to core sectors of the India economy viz. systems and servicesefficiently and at competitive prices. 15 regional offices and a large number of Projects sites spread all over India and abroad enables the company to promptly serve its customer and provide them with suaitable products.CHAPTER – II BHEL. Renewable Energy.AN OVERVIEW BHEL is the largest engineering and manufacturing enterprise in India in the energy related / infrastructure sector. 18. 3.736 crore in 2006-07. It has been earning profits continuously since 1971-72 and achieved a sales turnover of Rs. BHEL was established more than 40 years ago. 8 service centers. 4 power sector regional centers.

2007. Hydrogen Nuclear power plant business. BHEL has proven turnkey capabilities for executing power projects from Concept to Commissioning. Gas. Power Generation Power generation Sector comprises Thermal. BHEL is the only PSU among the 12 Indian Companies to figure in “Forbes Asia Fabulous 50” list. Significantly these sets contribute 73% of the total power generated in the county. BHEL become the first Public Sector Company in the country to win the coveted “PRIZE” for its Haridwar unit under the CII Exim Award for business excellence as per the globally recognized model of European Foundation for Quality Management. Cogenerating and Combined cycle plants have been introduce to achieve .BHEL has attained ISO 9001 certification for quality management and all the manufacturing units/divisions of BHEL have been upgraded to the latest ISO 9001:2000 version.3. BHEL supplied sets accounts for 80.25. All the major units/divisions of BHEL have been awarded ISO 14001 certification for Environmental Management System and OHSAS-18001 certification for Occupational Health and Safety management System. It possesses the technology and capability to produce Thermal sets with super critical parameters upto 1000MW unit rating and gas turbine generator sets of upto 300MW units rating.414 MW in the country. The company received MoU Excellence Award for 2004-2005 and Merit Certificate for MoU Excellence for 2005-2006. It has also won the “Business Standard Star Public Sector Company Award 2006”.781 MW or nearly 65% of the total install capacity of 1. As of 31.

7%. Modernization and Uprating of a variety of Power plant equipment. The combined operating availability of these sets was 84.5% higher than the National average. BHEL also supplies circulating Fluidized Bed Combustion (CFBC) boilers for Thermal plants. Overall.higher plant efficiencies. The company has proven expertise in Plant Performance Improvement through Renovation. BHEL built Thermal sets achieved the highest ever PLF of 78. besides specialized know-how of residual life assessment health diagnostics and life extension of plants. ---------------------****---------------------- . To make efficient use of the high-ash-content coal available in India.3% in 2006-2007 which is 1.

insulation box.CHAPTER .e. . Robol bar centre. 3-464 i. inter-pole coil. equalizer coil etc. washer. Bar Shop: This shop is meant for manufacturing of stator winding coils of generator that may be turbo-generator or hydro-generator. main pole coil. Manufacturing of hard insulation & machining of hares insulation part (Glass textolite) such as packing. 2.Also manufactured heavy duty generator stator bars with New CNC M/c No. wedges etc. BAY-III: Insulation detail shop.VI BRIEF SUMMARY OF CIM SHOP (BLOCK – IV) BAY-1: Bar winding shop: Manufacturing of stator winding bars of generator BAY-II: 1-Manufacturing of motor stator coil: DC armature coil.

The plant has capacity and technology to manufacture 800MW and 1000MW generators. 150Mw. TURBO-GENERATORS: The manufacturing of bars of standared capacity such as: 100MW.The manufacturing of Hydro Gen Stator Bars has been shifted from BHEL Haridwar to BHEL Bhopal to since 2008. ---------------------****---------------------- . That is why we make coil in two parts. The Hydro generator is air cooie^ generator of te comparison to its tagger diameter. (Note:. handle and wind the coil in stator slot of generator of higher generation capacity because of its bigger size and heavy weight. HG Bars: The manufacturing of bars of different capacity as required by the customer depends upon the water head available at site.Why do we call it bar: It is quite difficult (rather impossible) to manufacture. 130MW. One part is Bottom part of coil called bottom or tower bar and other part of coil is called top bar or upper bar. 210/235MW.

Forming or Bar (to shape overhang portion). Conductor Draw From Store. Assembly of all conductors to be used in stator Bars. Conductor cutting and end cleaning. Transposition of conductor. 5. 6. 2.CHAPTER . Pickling of bar ends (1) 10 Mounting of Contact sleeve & bottom part of water box. PROCESS FLOW CHART OF 500MW TG STATOR BAR 1.e. IS Test(i. 11. Cross over insulation. Consolidation if slot portion of Bar.VII MFG. 3. Brazing of Contact sleeve & bottom part of water box. 7. inter strand test). 8. 9. . 4.

Helium Leak Test. OCP on stator Bar. Mounting of water box leak test.(i.e. 16. Dispatch to Bicck-1 for laying in the generator. Thermal Shock Application. 18. Preparation of bar for HV and TanQ Test. overhang portion). Repickling. 17. 24. 20.K. 15. Reforming of Bar. 23. Insulation of bar on CNC macnine. If O. 14.12. Impregnation an curing of bar insulation. Class – Y Class – A Class – E upto 90 C upto 105 C upto 120 C . Water flow and N2 test. 21. 22. Surface finishing of stator bar. Pickling of bar ends (2) 13. 19. INSULATION CLASSIFICATION: Thermal classification of insulation depends upon the temperature Withstand capability of the insulation.

I/D/F-> Last alphabet stands for the type of cooling of stator e. THW. H/A-> Second alphabet stands for the coding media used for the cooling of rotor i. W-> Cooling media used for cooling of stator coil e.THDI. turbogenerator or Hydro-generator. water.indirect. The raw materials are ready to use and require preservation and working on temperature 20-25' :C.e. TARI. .g. T-> First alphabet signifies the type of generator i. TYPES OF GENERATORS: The generator may be classified based upon the cooling system used in the generators such as-THRI. THDD. direct cooling. hydrogen gas or air. indirect cooling. R/D/F/I-> Third alphabet signifies the type of cooling or rotor eg. Radial.e. forced cooling. Resin system: a) Rich Resin or Thermoreactive insulation system: In this type of insulation system the bond content in resin 36-37%.g.Class – B Class – F Class – H Class – C upto 130 C upto 150 C upto 180 C >180 C upto 220 C. THFF. THDF. direct etc. forced.

b) Poor resin or Micalastic insulation system: In this type of insulation the bond content in the resin is 5-7% and insulating material isprepared with accelerator treatment. ---------------------****---------------------- . The temperature control need not required. The insulating material is applied on job and then the same is impregnated (fully dipped) in the resin.Its sheif life is one year when Kept at temperature 20 C which could be increased when kept at temperature of 5 C.

500 mm Hollow .20 Solid .5 mm c. In this process the preinsulated copper conductor is cut into number of required length.20 . Insulation is removed from both ends of the conductor cut.VIII MANUFACTURING PROCESS OF BARS: Some Points of Manufacturing Process are in brief as below:--1. Lower Bar : Conductor size 8*4.6*1.10200 mm Conductor No.In 1 Bar Upper Bar : U – 10050 mm c.CHAPTER .5 mm (Hollow) 8*2.8 mm (Solid) L .Conductor Cutting : This process is done by automatic CNC machine.

After cutting the required number of conductors.6*1. This process is repeated for making another half of the bar which would be mirror image of the first half. water 3. Equalize the voltage generator 3.20 Solid . A filler material (insulating putty or moulding micanite)is provided along the height of the bar .Conductor size 8*4. 1. Transposition: Transposition means changing/shifting of position of each conductor in active core (slot) part. in 1 Bar Hollow .3 mm (Solid) Conductor No. Crossover Insulation : The pre insulation of the copper conductor may get damaged due to mechanical bending in die during transposition. The two halves of the bar are overlapped over each other and a spacer is placed between the two -halves. the conductors are arranged on thecomb in staggered manner and then bends are given to the conductors with the help of bending die at required distance. To minimize skin effect of ac current so small cross section of conductor is used and also hollow conductor are used to effect colling by D.40 2. Then the conductors are taken out from the comb and die and placed with their ends in a line and transposition is carriedout.M.5 mm (Hollow) 8*1. To reduce eddy current losses. 2. hence the insulatingspacers are provided at the crossover portion of the conductors.

Brazing of coil lugs : . if found then it has to be rectified. Stack Consolidation : The core part of the bar stack is pressed in press (closed box) under pressure (varies from product to product) and temperature of 160 C for a given period. Inter Strand Short Test : The consolidated oar stack is tested for the short between any two conductors in the bar.(300 A/C supply) 6. 5. Forming : The straight bar stack is formed as per overhang profile (as per design).to maintain the rectangular shape and to cover the difference of level of conductors. To eliminate inter turn short at bends during edges wise bending and leveling of bars in slots portion for proper stack pressing. The consolidated stack is withdrawn from the press and the dimensions are checked. 4. The overhang portion is consolidated after forming. 7. This is done to ensure that no local current is flowing due to short circuit between conductors.

Thermal shock test: The cycles of hot (80C) and cold (30°C) water are flew through the bar to ensure the thermal expansion and contraction of the joints. . Impregnation and baking: a) Thermoreactive system: In case of rich resin insulation the bar is pressed in closed box in heated condition and baked under pressure and temperature as per requirement for a given period. 11. 12. Insulation: The bar is insulated with the given number of layers to build the wall thickness of insulation subjected to the generating voltage of the machine. 8.For water cooled generator bars. 9. Helium leakage test: After thermal shock test bar is tested for any leakage with the help of helium gas. nitrogen leak test and pressure test for given duration. the etectricalconnection contact and water box for inlet and outlet of water are brazed. Nitrogen Leak Test : The bar is tested for water flow test. 10.

with resin. Testing: . 13. 14. layer by layer. for the dimension. if required. Then bar is taken out and pressed in closed box fixture and then baked at given temperature for given duration.b) Micalastic system: In case of poor resin system the insulated bars are heated under vaccum and the impregnated (dipped) in heated resin so that all the air gaps are filled. Then extra resin is drained out and bars are heated and baked under pressed condition in closed box fixture. ii) ECP (End Corona Protection) coating: The grey semi-conducting varnish is applied at the bend outside core end of bars in gradient to prevent from discharge and minimize the end corona. 15. Finishing: The baked and dimensionally correct bars are sanded-off to smoothen the edges and the surface is calibrated. VIP Micalstic system: The individual (separate) bar is heated in vaccum and impregnated in resin. VPI Micalastic system: The bars already laid in closed fixture and full fixture is impregnated (dipped) in resin and then fixture with box is baked under given temperature for given duration. Conducting varnish coating: i) OCP (Outer Corona Protection) coating: The black semi-conducting varnish coating is applied on the bar surface on the core length.

Test: Each bar is tested momentary at high voltage increased gradually to three times higher than rated voltage. dirt. Dispatched for Winding : The bars preserved with polythene sleeves to protect from dust.a) Tan@ test: This test is carried out to ensure the healthiness of dielectric (Insulation) i. ---------------------****---------------------- . Turbo Generators and Hydro Generators) for winding. oil. b) H. rain etc are send to Block-I (Electric Machines Production Block – I. dense or rare and measured the capacitance loss. 16.e.V.

The lack of exposure to real life. Practical training is one major step in this direction. . laboratories and workshops based training & teaching in classroom has its own limitations. In the open economy era of fast modernization and tough competition. This training helped me in gaining in depth knowledge of the working of a telephone exchange. technical institutes should procedure pass outs as near to job function as possible. materials processes and functioning of industrial organization is the measure hindrances in the student employment.CONCLUSION Engineering students will have to serve in the public and private sector industries.

At last I would only say that this training was helpful for my future prospects. ---------------------****---------------------- .