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ACKNOWLEDGEMENT

“Training is the act of increasing the knowledge and skill of an employee for doing a particular job.”

This project report has been made as a part of the industrial training underwent at the B.H.E.L Haridwar plant, Uttarakhand. I would like to extend sincere thanks to Mr.A.K.Dhiman, deputy manager for his prodigious guidance throughout my training and I would specially like to thank Mr.Vinod Bharadwaj and Mrs.M.Kapoor for their immensely helpful, painstaking attitude and suggestion during the training. Efforts have been made to make the report as succinct as possible. Quantitative data has been presented through tables, charts and suitable illustrations. The project would not have been possible without the help and cooperation of the aforementioned officials. Last but not the least; I would like to thank all the staff members of B.H.E.L. Block-4, Ranipur, Haridwar.

Tech. 3rd year Electrical and Electronics Engineering AKGEC. GHAZIABAD. .JUHI NAGPAL B.

CHAPTER 2.E.BLOCK 4 CIM SHOP CHAPTER 3-MANUFACTURING PROCESS OF 600MW TG STATOR BARS CONCLUSION .L.TABLE OF CONTENTS CHAPTER 1.INTRODUCTION ON B.H.

four regional offices. It is engaged in the design. Power. BHEL is the only Indian Engineering company on the list. ushering in the indigenous Heavy Electrical Equipment industry in India. which contains online retail firm Amazon at the second position with Apple and Google at fifth and seventh positions. it was ranked ninth most innovative company in the world by US business magazine Forbes. It has 15 manufacturing divisions. The company has been earning profits continuously since 1971-72 and paying dividends since 1976-78. construction. Established in 1964. testing. India. The company has been earning profits continuously since 1971-72 and paying since 1976-77. BHEL ushered in the indigenous Heavy Electrical Equipment industry in India. Environmental Management Systems (ISO 14001:2004) and Occupational Health & Safety Management Systems (OHSAS 18001:2007). BHEL was established more than 50 years ago. It is also placed at 4th place in Forbes Asia's Fabulous 50 List of 2010. manufacture. respectively. eight service centres. . Oil & Gas and Defence. eight overseas offices and 15 regional centres and currently operates at more than 150 project sites across India and abroad. Transportation. Industry. Renewable Energy. Most of its manufacturing units and other entities have been accredited to Quality Management Systems (ISO 9001:2008). In the year 2011. commissioning and servicing of a wide range of products and services for the core sectors of the economy. engineering. Transmission. two repair units. 74% of the total power generated in India is produced by equipment manufactured by BHEL. It is the 7th largest power equipment manufacturer in the world.CHAPTER 1 INTRODUCTION ON BHEL Bharat Heavy Electricals Limited (BHEL) is an Indian integrated power plant equipment manufacturer and operates as engineering and manufacturing company based in New Delhi. viz.

This would add six million units of electricity on a daily basis. BHEL commissioned 250 MW power generating unit at Harduaganj in Uttar Pradesh.It is one of India's nine largest Public Sector Undertakings or PSUs.In June 2012. known as the Navratnas or 'the nine jewels'. - .

Uttarakhand is located Heavy electrical equipment plant (HEEP) of B. on the bank of the Holy Ganges in Ranipur.H. condensers 6. completely owned by the Government of India is an integrated engineering complex consisting of several plants of India.E. BHEL. Thermal/nuclear set 2. where about 70.000 workers are employed in the design and manufacturing of heavy electrical equipment. gas turbine 5. AC/DC electrical machine 210MW-1000MW 115MW according to requirement 60MW-200MW Upto 800MW 5kW-2000kW (a)AC (250 kW-1600kW ) (b)DC (7kW-1000kW) . heat exchangers.L. Hydro set 3.BHEL HARIDWAR At the foothills of the majestic Himalayas. PRODUCTS OF BHEL HARIDWAR AND THEIR CAPACITY RATINGS 1. Generator 4. 70 % of country’s electrical equipment is generated at BHEL Haridwar. At present.

Electrical locomotive to Indian Railway and diesel shunting locomotives to various industries 5000/6000 hp AC/DC locomotive developed and . To make efficient use of the higher ash content crash coil manufacturers 235MW nuclear turbine generator sets and has commenced the generation of 500 MW nuclear turbine generator head discharge combinations are also engineered and manufactured is equally competitive. These include high voltage power.SF6 switch gear.Cogeration and combine cycle plants have been introduced to achieve higher plant efficiencies. dry type transformer. instrument transformers.BHEL has turnkey capabalities for executing power projectors from concept to commissioning. TRANSPORTATIONA high percentage of trains operated by the Indian Railways are equipped with BHEL’s traction and control equipment including the metro at Calcutta and Delhi.Series and shunt compensation systems have been also developed and introduced to minimize transmission losses. it possesses the technology and capability to produce thermal power plant equipment upto 1000MW rating and gas turbine generator sets upto a unit rating of 240MW. distribution transformers.the company supplies broad gauge. TRANSMISSIONBHEL also supplies a wide range of transmission products and systems upto 400kV class.etc. capacitor and insulator.

INTERNATIONAL OPERATIONSB.H.H.E. have been leased to Indian Railway. Greece and Egypt.E. power station in Libya and Turkey .utility boiler and open cycle gas turbine plant to Malaysia. hydro generator to New Zealand and hydro power plant to Thailand.L.’s product series and projects have been exported to countries ranging from United states in the west and New Zealand in the east and for India over 3000MW.L.in Cyprus. Oman.a few notable ones are a 15o MW gas turbine to Germany .manufactured by B. Tripoli west. . battery powered road.

Why do we call it bar: It is quite difficult (rather impossible) to manufacture. The plant has capacity and technology to manufacture 660MW. 500MW. 210/235MW. 130MW. 150Mw. & CNC Taping Machine Bar Shop: This shop is meant for manufacturing of stator winding coils of generator that may be turbo-generator or hydro-generator. TYPES OF GENERATORS: . wedges etc. That is why we make coil in two parts. 3-464 i. Micalastic Tank & Oven BAY-2: Heavy duty generator stator bars with New CNC M/c No.e. 800MW and 1000MW generators.CHAPTER 2 CIM SHOP (BLOCK – IV) BAY-1: Bar winding shop: Manufacturing of stator winding bars of generator. 600MW. TIG Welding BAY-3: Insulation detail shop: Manufacturing of hard insulation & machining of hares insulation part (Glass textolite) such as packing. insulation box. TURBO-GENERATORS: The manufacturing of bars of standard capacity such as: 100MW. handle and wind the coil in stator slot of generator of higher generation capacity because of its bigger size and heavy weight. washer. One part is Bottom part of coil called bottom or tower bar and other part of coil is called top bar or upper bar. Roebel bar centre.

water.g. indirect.g. I/D/F-> Last alphabet stands for the type of cooling of stator e. THDD. forced cooling.e. forced. indirect cooling. direct cooling. hydrogen gas or air. direct etc. W-> Cooling media used for cooling of stator coil e.The generator may be classified based upon the cooling system used in the generators such as-THRI. turbo-generator or Hydro-generator. TYPES OF INSULATION Thermal classification depends upon the temperature withstand capability of the insulation. THDF. T-> First alphabet signifies the type of generator i.e. THFF. R/D/F/I-> Third alphabet signifies the type of cooling or rotor e. .g. TARI. radial. THDI. H/A-> Second alphabet stands for the coding media used for the cooling of rotor i. THW.

class Y-upto 90 degree celsius class A-upto 105 degree celsius class E-upto 120 degree celsius class B-upto 130 degree celsius class F-upto 155 degree celsius class H-upto 180 degree celsius class C.> 180 degree celsius .

V.ISSUE OF CONDUCTOR CUTTING AND END CLEANING TRANSPOSITION ASSEMBLY OF CONDUCTORS CROSS OVER INSULATION I. TEST FORMING PICKLING MOUNTING BRAZING REPICKLING WATER FLOW AND NITROGEN TEST THERMAL SHOCK TEST HELIUM LEAK TEST REFORMING OF OVERHANG PORTION INSULATION ON CNC MACHINE IMPREGNATION SURFACE FINISHING OUTER CORONA PROTECTION (OCP) H. AND TAN ∆ TEST .S.

20 Solid . Insulation is removed from both ends of the conductor cut.5mm(Hollow) 8*2.5mm(Hollow) 8*1. Then the conductors are taken out from the comb and die and placed with their ends in a line and transposition is carried out.6*1.CHAPTER 3 MANUFACTURING PROCESS OF BARS Some Points of Manufacturing Process are in brief as below:1.40 of 10200 mm Hollow.6*1. Lower Bar: Conductor size Length Number conductors 8*4. This process is repeated for making 10050 mm Hollow.8 mm (Solid) Upper Bar Conductor size Length Number conductors 8*4. Transposition Transposition means changing/shifting of position of each conductor in active core (slot) part. In this process the preinsulated copper conductor is cut into number of required length.20 Solid . the conductors are arranged on the comb in staggered manner and then bends are given to the conductors with the help of bending die at required distance. After cutting the required number of conductors.20 of .3 mm (Solid) 2.Conductor Cutting This process is done by automatic CNC machine.

M. 5. 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 1600 C for a given period. water. hence the insulating spacers are provided at the crossover portion of the conductors. Crossover Insulation The pre insulation of the copper conductor may get damaged due to mechanical bending in die during transposition. To eliminate inter turn short at bends during edges wise bending and leveling of bars in slots portion for proper stack pressing. 4. 2. Inter Strand Short Test The consolidated oar stack is tested for the short between any two conductors in the bar. This is done to ensure that no local current is flowing due to short circuit between conductors. To minimize skin effect of ac current. (300V A/C supply) . small cross section of conductor is used and also hollow conductors are used to effect cooling by D. The two halves of the bar are overlapped over each other and a spacer is placed between the two -halves.Equalize the voltage generator 3. To reduce eddy current losses. 3. 1. The consolidated stack is withdrawn from the press and the dimensions are checked.another half of the bar which would be mirror image of the first half. A filler material (insulating putty or molding micanite) is provided along the height of the bar to maintain the rectangular shape and to cover the difference of level of conductors. 2. if found then it has to be rectified.

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. with resin. Helium leakage test After thermal shock test bar is tested for any leakage with the help of helium gas. Then extra resin is drained out and bars are heated and baked under pressed condition in closed box fixture. 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. the electrical connection contact and water box for inlet and outlet of water are brazed. Forming The straight bar stack is formed as per overhang profile (as per design). the overhang portion is consolidated after forming. . 10.6. 9. 7. layer by layer. Thermal shock test 26 cycles of hot (800C) and cold (30°C) water are flown through the bar to ensure the thermal expansion and contraction of the joints. b) Micalastic system In case of poor resin system the insulated bars are heated under vacuum and the impregnated (dipped) in heated resin so that all the air gaps are filled. Brazing of coil lugs For water cooled generator bars. 8. 11.

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. 13. 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. . RESIN SYSTEM: a) Rich Resin or Thermo-reactive insulation system: In this type of insulation system the bond content in resin 36-37%. if required. The raw materials are ready to use and require preservation and working on temperature 20-25':C. Finishing The baked and dimensionally correct bars are sanded-off to smooth the edges and the surface is calibrated. 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. 12. Then bar is taken out and pressed in closed box fixture and then baked at given temperature for given duration. for the dimension. Its shelf life is one year when kept at temperature 20 C which could be increased when kept at temperature of 5 C. VIP Micalastic system: The individual (separate) bar is heated in vacuum and impregnated in resin.

V. The insulating material is applied on job and then the same is impregnated (fully dipped) in the resin. dirt. The temperature control need not required. rain etc are send to Block-I (Electric Machines Production Block – I. dense or rare and measured the capacitance loss. The capacitance of the bar is found and the angle of deviation due to the impurity in the insulation is obtained from the formula C4*R4*10-4 =tan∆ b) H.e.b) Poor resin or Micalastic insulation system: In this type of insulation the bond content in the resin is 5-7% and insulating material is prepared with accelerator treatment. Turbo Generators and Hydro Generators) for winding. Test: (High Voltage Test) each bar is tested momentary at high voltage increased gradually to three times higher than rated voltage. TESTING a) Tan∆ test: This test is carried out to ensure the healthiness of dielectric (Insulation) i. . oil. Dispatched for Winding The bars preserved with polythene sleeves to protect from dust.

CONCLUSION This training has proved to be quite faithful.H.The architecture of B. The training has proved to be immensely helpful as it has helped me to have an exposure of the practical implementation of the theoretical knowledge that I have gained till date. a chance to have an encounter with such heavy machines like turbo generator (TG) 500MW. makes the student realize that engineering is not just the structural description but more of planning and management. . . This gave me.the way the various units are linked and the way the working of the whole plant is controlled. It has provided an opportunity to learn that optimization of technology used at proper place and time can save a lot of labour.L.E.