Manufacturing Process of TG 800 MW ,

Stator Winding Bar

BHEL, Production Block-4, HEEP
 BHEL is a
• Type - State-owned
enterprise
• Industry - Electrical
equipment
• Areas served – Worldwide

• Products - Includes (Gas

and Steam Turbines),
Boilers, generators, Heat
Exchangers, Pumps, circuit
  INTRODUCTION TO HEEP

• Block-1:- (Electrical Machine Final Assembly)

• Block-2:- (Gas & Steam Turbine Fabrication Block)
• Block-3:- (Gas & Steam Turbine Manufacturing Block)
• Block-4:- [CIM (Coil & Insulation Manufacturing)Block]
• Block-5:- (Heat Exchangers Fabrication Block)
• Block-6:- (Stampings Block)
• Block-7:- (Wooden Packing works Block)
• Block-8:- (Heat Exchanger Tubes Block)
MAIN PRODUCTS OF CIM/ACM BL-4
 BAY’S IN CIM BL-4
BAY-I: Bar winding shop:
Manufacturing of stator winding bars of generator
BAY-II:
Manufacturing of heavy duty generator stator bars with
New CNC M/c
BAY-III: Insulation detail shop:
Manufacturing of hard insulation & machining of hares
insulation part (Glass Textolite) such as packing, washer,
insulation box.
Manufacturing Process of TG 800MW,
Stator Winding Bar
1.Condutor drawn from store.
2.Conductor cutting and transposition.
3. Cross over insulation

4. Pressing

5. I.S.T.

6. Final Pressing

7. Radius Milling
8. Water Flow

9. Forming

10. End cutting

11. Contact Sleeve And Bottom Mounting

12. Tig Welding & Brazing

13. Nitrogen test
slot portion

14. D.P. test overhang portion

 15. Thermal Shock test

Thermal shock test is performed to check whether the

bar can withstand extreme conditions i.e. when the
generator is working or running at about 3000 rpm.
16. Helium Leak Test
17. Reforming

18. CNC tapping

19. I.C.P

20. O.C.P

21. E.C.P
22.(A) Impregnation Plant

Wagon Setting & Pressing of bar

(B) Curing

Patent by Cemens Company

23. Surface Finishing

24. H.V. & TAN Delta Preparation

26. Boro scope

27. Final Finishing

28. Packing of Bar

Send the Bar Block -1

1) Block-1 (Electrical Machine Final Assembly)

• Mainly Block-I is designed to manufacture Turbo

Generators.

Products

Stator frame Rotor & Rotor

Stator core Windings Exciter
 STATOR CORE & STATOR FRAME
» Finishing of Rotor & Finished Rotor
 ROTOR AFTER FINAL ASSEMBLY
.Coils are placed
in the gaps which
allows the flow
of current when
the rotor rotates.

.The hydrogen
gas is circulated
within the rotor
enclosure, and
cooled by a gas-
to-water heat
exchanger.
Final assembly of Turbo Generator 800 MW.
TG 800 MW , View from the Exciter end.
Fuses and the
capacitors
mounted on
the exciter
part to
generate
starting toque
and fuse to
prevent from
the over
current.

Exciter enables the synchronous generator to

generate its own reactive energy. The exciter also
regulates its own power.
 TURBINES MANUFACTURED IN BHEL

Steam Turbine
Gas Turbine
LP Turbine