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.

JUHI NAGPAL
B.Tech. 3rd year
Electrical and Electronics Engineering
AKGEC, GHAZIABAD.
 TABLE OF CONTENTS

CHAPTER 1- INTRODUCTION ON B.H.E.L.

CHAPTER 2- BLOCK 4 CIM SHOP

CHAPTER 3-MANUFACTURING PROCESS OF 600MW TG STATOR BARS

CONCLUSION
 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, India. Established in 1964, BHEL ushered in the
indigenous Heavy Electrical Equipment industry in India. The company has been
earning profits continuously since 1971-72 and paying dividends since 1976-78.
It is engaged in the design, engineering, manufacture, construction, testing,
commissioning and servicing of a wide range of products and services for the core
sectors of the economy, viz. Power, Transmission, Industry, Transportation, Renewable
Energy, Oil & Gas and Defence. It has 15 manufacturing divisions, two repair units, four
regional offices, eight service centres, eight overseas offices and 15 regional centres and
currently operates at more than 150 project sites across India and abroad. Most of its
manufacturing units and other entities have been accredited to Quality Management
Systems (ISO 9001:2008), Environmental Management Systems (ISO 14001:2004) and
Occupational Health & Safety Management Systems (OHSAS 18001:2007).
It is the 7th largest power equipment manufacturer in the world. In the year 2011, it
was ranked ninth most innovative company in the world by US business magazine
Forbes. BHEL is the only Indian Engineering company on the list, which contains online
retail firm Amazon at the second position with Apple and Google at fifth and seventh
positions, respectively. It is also placed at 4th place in Forbes Asia's Fabulous 50 List of
2010. BHEL was established more than 50 years ago, ushering in the indigenous Heavy
Electrical Equipment industry in India. The company has been earning profits
continuously since 1971-72 and paying since 1976-77. 74% of the total power
generated in India is produced by equipment manufactured by BHEL.
It is one of India's nine largest Public Sector Undertakings or PSUs, known as the
Navratnas or 'the nine jewels'.In June 2012, BHEL commissioned 250 MW power
generating unit at Harduaganj in Uttar Pradesh. This would add six million units of
electricity on a daily basis.

-
BHEL HARIDWAR

At the foothills of the majestic Himalayas, on the bank of the Holy Ganges in Ranipur,
Uttarakhand is located Heavy electrical equipment plant (HEEP) of B.H.E.L.

BHEL, completely owned by the Government of India is an integrated engineering

complex consisting of several plants of India, where about 70,000 workers are
employed in the design and manufacturing of heavy electrical equipment.

At present, 70 % of country’s electrical equipment is generated at BHEL Haridwar.

PRODUCTS OF BHEL HARIDWAR AND THEIR CAPACITY RATINGS

1. Thermal/nuclear set 210MW-1000MW

2. Hydro set 115MW
3. Generator according to requirement
4. gas turbine 60MW-200MW
5. heat exchangers, condensers Upto 800MW
6. AC/DC electrical machine 5kW-2000kW
(a)AC (250 kW-1600kW )
(b)DC (7kW-1000kW)

BHEL has turnkey capabalities for executing power projectors from concept to
commissioning. 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.Cogeration and combine cycle plants have been introduced to achieve higher
plant efficiencies. 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.
TRANSMISSION-

BHEL also supplies a wide range of transmission products and systems upto 400kV class.
These include high voltage power, distribution transformers, instrument transformers,
dry type transformer,SF6 switch gear, capacitor and insulator,etc.Series and shunt
compensation systems have been also developed and introduced to minimize
transmission losses.

TRANSPORTATION-

A 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.the company
supplies broad gauge.

Electrical locomotive to Indian Railway and diesel shunting locomotives to various

industries 5000/6000 hp AC/DC locomotive developed and manufactured by B.H.E.L.
have been leased to Indian Railway, battery powered road.

INTERNATIONAL OPERATIONS-

B.H.E.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.a
few notable ones are a 15o MW gas turbine to Germany ,utility boiler and open cycle
gas turbine plant to Malaysia, Tripoli west, power station in Libya and Turkey .in Cyprus,
hydro generator to New Zealand and hydro power plant to Thailand, Oman, Greece
and Egypt.
 CHAPTER 2
CIM SHOP (BLOCK – IV)

BAY-1: Bar winding shop: Manufacturing of stator winding bars of generator, Micalastic
Tank & Oven
BAY-2: Heavy duty generator stator bars with New CNC M/c No, 3-464 i.e. Roebel bar
centre, TIG Welding
BAY-3: Insulation detail shop: Manufacturing of hard insulation & machining of hares
insulation part (Glass textolite) such as packing, washer, insulation box, wedges etc. &
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.
Why do we call it bar: It is quite difficult (rather impossible) to manufacture, handle and
wind the coil in stator slot of generator of higher generation capacity because of its
bigger size and heavy weight. That is why we make coil in two parts. One part is Bottom
part of coil called bottom or tower bar and other part of coil is called top bar or upper
bar.

TURBO-GENERATORS: The manufacturing of bars of standard capacity such as: 100MW,

130MW, 150Mw, 210/235MW, 500MW, 600MW.
The plant has capacity and technology to manufacture 660MW, 800MW and 1000MW
generators.

TYPES OF GENERATORS:

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

TYPES OF INSULATION
Thermal classification depends upon the temperature withstand capability of the
insulation.

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

 ISSUE OF
CONDUCTOR

CUTTING AND END

CLEANING

TRANSPOSITION

ASSEMBLY OF
CONDUCTORS

CROSS OVER
INSULATION

I.S. 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.V. AND TAN ∆ TEST

 CHAPTER 3
MANUFACTURING PROCESS OF BARS

Some Points of Manufacturing Process are in brief as below:-

1.Conductor Cutting
This process is done by automatic CNC machine. In this process the pre-insulated copper
conductor is cut into number of required length. Insulation is removed from both ends
of the conductor cut.
Lower Bar:
Conductor size Length Number of
conductors
8*4.6*1.5mm(Hollow) 10200 mm Hollow- 20
8*2.8 mm (Solid) Solid - 20

Upper Bar

Conductor size Length Number of

conductors
8*4.6*1.5mm(Hollow) 10050 mm Hollow- 20
8*1.3 mm (Solid) Solid - 40

2. Transposition
Transposition means changing/shifting of position of each conductor in active core
(slot) part. After cutting the required number of conductors, 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. Then the conductors are
taken out from the comb and die and placed with their ends in a line and transposition
is carried out. This process is repeated for making another half of the bar which would
be mirror image of the first half. The two halves of the bar are overlapped over each
other and a spacer is placed between the two -halves.
1. To reduce eddy current losses.
2. 2.Equalize the voltage generator
3. To minimize skin effect of ac current, small cross section of conductor is used and also
hollow conductors are used to effect cooling by D.M. water.
3. Crossover Insulation
The pre insulation of the copper conductor may get damaged due to mechanical
bending in die during transposition, hence the insulating spacers are provided at the
crossover portion of the conductors. 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. To eliminate inter turn short at bends
during edges wise bending and leveling of bars in slots portion for proper stack
pressing.
4. 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. The consolidated
stack is withdrawn from the press and the dimensions are checked.
5. Inter Strand Short Test
The consolidated oar stack is tested for the short between any two conductors in the
bar, if found then it has to be rectified. This is done to ensure that no local current is
flowing due to short circuit between conductors. (300V A/C supply)
6. Forming
The straight bar stack is formed as per overhang profile (as per design), the overhang
portion is consolidated after forming.
7. Brazing of coil lugs
For water cooled generator bars, the electrical connection contact and water box for
inlet and outlet of water are brazed.
8. 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.
9. Helium leakage test
After thermal shock test bar is tested for any leakage with the help of helium gas.
10. 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.

11. 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.
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, layer by layer,
with resin. Then extra resin is drained out and bars are heated and baked under pressed
condition in closed box fixture.
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.
VIP Micalastic system:
The individual (separate) bar is heated in vacuum and impregnated in resin. Then bar is
taken out and pressed in closed box fixture and then baked at given temperature for
given duration.
12. Finishing
The baked and dimensionally correct bars are sanded-off to smooth the edges and the
surface is calibrated, if required, for the dimension.
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.
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.

RESIN SYSTEM:
a) Rich Resin or Thermo-reactive insulation system: In this type of insulation system the
bond content in resin 36-37%. The raw materials are ready to use and require
preservation and working on temperature 20-25':C. Its shelf life is one year when kept at
temperature 20 C which could be increased when kept at temperature of 5 C.
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. The
temperature control need not required. The insulating material is applied on job and
then the same is impregnated (fully dipped) in the resin.

TESTING
a) Tan∆ test:
This test is carried out to ensure the healthiness of dielectric (Insulation) i.e. 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.V. Test:
(High Voltage Test) each bar is tested momentary at high voltage increased gradually to
three times higher than rated voltage.

Dispatched for Winding

The bars preserved with polythene sleeves to protect from dust, dirt, oil, rain etc are
send to Block-I (Electric Machines Production Block – I, Turbo Generators and Hydro
Generators) for winding.
 CONCLUSION

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

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.