ppt on coil and insulation manufacturing block, BHEL, haridwar manufacturing process of stator bar by bhel for practical training or industrial training.about bhel

1. A
seminar on
Practical Training
At
“BHEL(Haridwar)”
PRESENTED BY:
Shashi Kesh Kant
4th year, EE
DEPARTMENT OF ELECTRICAL ENGINEERING
POORNIMA COLLEGE OF ENGINEERING
ISI-6 RIICO INSTITUTIONALAREA,
JAIPUR -302022
SUBMITTED TO:
Mr. Shivaraj Sharma
Asst. Professor
Dept. Of Electrical Engg.
2015-16

2. CONTENT
1. Overview-BHEL
2. Main BHEL manufacturing plants
3. About BHEL, Haridwar
4. Various block at BHEL
5. Product profile
6. Turbo-generator
7. Salient Technical Data of TG
8. Coil & insulation manufacturing
Shop block-4
9. Different Section in block-4

3. OVERVIEW – BHEL
• BHEL – Bharat Heavy Electricals Limited.
• BHEL is one of the most leading company of India in the power
sector and its headquarter is in New Delhi, India.
• BHEL owned by Government of India, is a power plant
equipment manufacturer and operates as
an engineering and manufacturing company.
• It was established in1964 at that time It’s name was heavy
electricals limited.
• Heavy Electricals (India) Limited was merged with BHEL in
1974.

4. • It is one of India's first largest Public Sector Undertakings (PSUs), known
as the Maharatna.
List of Maharatna companies
• Bharat Heavy Electricals Limited
• Coal India Limited
• GAIL (India) Limited
• Indian Oil Corporation Limited
• NTPC Limited
• Oil & Natural Gas Corporation Limited
• Steel Authority of India Limited

5. Main BHEL manufacturing plants
SI NO Name of plant Place State
1 HEAVY ELECTRICALS PLANT Bhopal Madhya Pradesh
2 HEAVY ELECTRIACAL EQUIPMENT PLANT Haridwar Uttarakhand
3 HEAVY POWER EQUIPMENT PLANT Hyderabad Andhra Pradesh
4 TRANSFORMER PLANT Jhansi Uttar Pradesh
5 HIGH PRESSURE BOILER PLANT Tiruchirapalli Tamil Nadu
6 BOILER AUXILIARIES PLANT Ranipet Tamil Nadu
7 ELECTRO PORCELAIN DIVISION Bangalore Karnataka
8 INSULATOR PLANT Jagdishpur Uttar Pradesh

6. About BHEL, Haridwar
 The Heavy Electricals Equipment Plant is one of the major
manufacturing units of BHEL.
 It was established in 1967 with the help of Russia.
 BHEL Haridwar has a campus of 7,000 acres (28 km2).
 Bharat heavy Electricals Limited is the 12th largest
power equipment producer in the world.
 74% of the total power generated in India is produced
by equipment manufactured by BHEL.

7. .

8.  The core business of HEEP includes design and manufacture of large size steam and
gas turbines, turbo generators, heat exchangers, condensers and auxiliaries.
 The Central Foundry Forge Plant (CFFP) is engaged in manufacture of large size
Castings and Forgings of various types of steels like alloy steels, creep resistant steel
and supercritical grade steel.
 HEEP & CFFP both have been awarded certificates for Quality Systems (ISO-9001:2008)
Environment(ISO-14001) and Occupational Health & Safety (ISO-18001).
 HEEP is the only Public Sector unit in India to have won the CII-EXIM Bank Prize for
Business Excellence (2006).

9. VARIOUS BLOCKS AT BHEL
Block-1:- Electrical Machine Final Assembly
Block-2:- Gas & Steam Turbine Fabrication Block
Block-3:- Gas & Steam Turbine Manufacturing Block
Block-4:- Coil & Insulation Manufacturing(CIM)Block
Block-5:- Heat Exchangers Fabrication Block
Block-6:- Stampings Block
Block-7:- Wooden Packing works Block
Block-8:- Heat Exchanger Tubes Block

10. Product profile
Turbo generator
DC Exciter

11. Steam turbine
Gas turbine

12. TURBO GENERATOR
 A turbo generator is the combination of a turbine directly connected
to an electric generator for the generation of electric power.
 TG is a device which converts the mechanical energy into electrical
energy by the utilization of heat energy of steam.
 Turbo generator is operated at high speed (3000 rpm).
GENERATOR EXCITERTURBINE
3-PHASE
AC

13. Salient Technical Data
 Rated output : 588 MVA, 500 MW
 Terminal voltage : 21 KV
 Rated stator current : 16 KA
 Rated frequency : 50 Hz
 Rated power factor : 0.85 Lag
 Efficiency : 98.55%
Important dimensions & Weights
 Heaviest lift of generator stator : 255 Tons
 Rotor weight : 68 Tons
 Overall stator dimensions (L*B*H) : 8.83 * 4.1 * 4.02 (in meter)
 Rotor dimensions (Dia and length) : 1.15 m and 12.11 m
 Total weight of turbo generator : 428 Tons

14. 500 MW turbo generators
Two-pole machine with the following features :
 Direct cooling of stator winding with water.
 Direct hydrogen cooling for rotor.
 Michalastic insulation system.
 Spring mounted core housing for effective transmission vibrations.
 Brushless excitation system.
 Vertical hydrogen coolers.

15. COIL & INSULATION MANUFACTURING
SHOP BLOCK – 4
 Block – 4 is a feeder block for insulating items, winding with class-B
bituminous insulation and sheet metal components for all the products of
block-1 i.e. Turbo-generators, Hydro-generators, A.C. and D.C.
machines.
 There are three Bays in this block each bay manufactures stator bars
and coils for different machines.
 After the manufacturing of coils and winding, it send into assembly
section of block-1.

16. BAY-1: Bar winding shop : manufacturing of stator winding
bars of generator
BAY-2: Manufacturing of heavy duty generator stator bars with
new CNC machines
BAY -3: Insulation details shop: Manufacturing of hares insulation
parts.
Such as packing, washer, insulation box, wedges etc.
Bar shop: This is meant for manufacturing of stator winding coils
of turbo-generator and hydro-generator.

17. BLOCK-4 BAY-2
BAY-1
BAY-3
MANUFACTURE OF
STATOR BAR OF
TURBO
GENERATORS
MANUFACTURE OF
STATOR BAR OF
HYDRO GEN,AC
MANUFACTURE OF
Insulation MATERIAL
ACC DESIGN

18. 1) Assembly Section
It is equipped with small size
• Drilling machines
• Welding sets
• Hydraulic testing equipment
for manufacturing turbo-generator
Mechanical assemblies.
2) Stator Bar Winding Section
It ¡s equipped with
• Conductor cutting, insulation
• transposition section.
• Stack consolidation section,
forming and lug brazing sections.
• Insulation taping sections with
automatic taping facilities in air-
conditioned
3) Impregnation Section
It is equipped with
• Impregnation tank.
• Ovens for impregnation of DC pole coils.
DIFFERENT SECTIONS IN BIOCK-4

19. 4) Armature winding, Rotor coil and stator bar section
It is equipped with
• Conductors cutting.
• U-bending and terminal conductor cutting machines.
• Semi-automatic winding machine.
• Planking, boat pulling and diamond pulling machine.
• Insulation and pressing of AC coils.
5) Insulation Section
It is equipped with
• Small size lathes.
• Milling and radial drilling machines.
• Jet cutting saw.
• Electrical ovens & Hydraulic presses.
• Plastic molding section.

20. MANUFACTURING OF 500 MW STATOR BAR
Why do we call it bar?
It is quite difficult (rather impossible) to manufacture, handle and wind in
the 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 its bottom part of coil called bottom or lower bar and other part of coil
is called top bar or upper bar.
Bar may be for 210MW,500MW,600MW etc.

21. OVERVIEW OF MANUFACTURING PROCESS
INSULATION
CHECK
CONDUCTO
R CUTTING
TRANSPOSITIO
N
STACK
PRESSING
INTER
STRAND
SHORT
TEST
FORMING
PICKLING
PROCESS
BRAZING
WATER
TEST
NITROGEN
TEST
INTERNAL
PICKELING
BARSCOPIC
TEST
THERMAL
TEST
HELIUM
LEKAGETEST
INSULATION
IMPREGNATI
ON &
BAKING
FINISHING
WARNISH &
COATING

22. Insulation check : Insulated Cu conductors are used:
(1) Solid Cu conductor
(2) Hollow Cu conductor
Conductor cutting : It is done by C.N.C MACHINE.
LOWER BAR
UPPER BAR
CONDUCTOR SIZE LENGTH NO. OF CONDUCTORS
8*4.6*1.5mm hollow 10200 mm Hollow-20
8*2.8mm solid 10200 mm Solid-20
CONDUCTOR SIZE Length NO. OF CONDUCTORS
8*4.6*1.5mm(Hollow) 10500mm Hollow – 20
8*1.3mm(Solid) 10500mm Solid- 40

23. Inter strand short test
(1) To check the short circuit between conductors.
(2) No current flow between the conductors.
Transposition
It means changing/shifting of position of each conductor in active core (slot) part.
1). To reduce eddy current in bar.
2). Equalize the voltage generator
Stack pressing
This is done for hollow & solid conductors to make a one unit.

24. Forming
1). Done on Universal forming Machine.
2). A bend is given to the bar both side .
3). Bend use for terminal connections.
Pickling process
1). For cleaning job (oily, dirty and dusty job)
and for remove acidic properties.
2).Solution is heat up to 50˚ C.
3). Then our job is dipped in pickling solution
for 15 minutes.
SOLUTION NAME PERCENTAGE
(%)
SULPHURICACID 10%
PHOSPHORICACID 5%
HYDROGEN
PEROXIDE
5%
Brazing
1). Brazing is basically the process of fixation of both
the contact sleeve and water box bottom part to bar.
2).It is done by Induction machine.
Basic solution for pickling process

25. Water test
1). To check any blockage and vent in the bar.
2). Also check the flow of water in the bar.
Nitrogen test
1). To check any puncture in the bar.
2). If there is any puncture air bubble give us exact
location of puncture.
Internal pickling
1). Done for cleaning of hollow conductors.
Thermal shock test
(1) To check the bar at extreme condition.
(2) Process repeated at 26 times.
(3) 26 hot water & 26 cold water
cycle.

26. Helium leakage test
(1)Test is done in front of customer
(2) By passing the helium inside the bar.
(3). It pass at pressure of 11kg/cm sq.
Insulation
(1)To prevent short circuit, insulation is done.
(2) Micalastic is used as insulating tape.
Finishing
Smooth the edges of impregnated bars.

27. Conductor varnish and Coating
(1) ECP(End corona protection) coating
(2) OCP(Outer corona protection)coating

28. CONCLUSION
The Vocational training at BHEL Haridwar helped us in improving our practical
knowledge and awareness regarding Turbo Generator to a large extent. Here we
came to know about the technology and material used in manufacturing of turbo-
generators. Besides this, we also visualized the parts involved or equipment used in
the power generation.
Here we learnt about how the electrical equipment are being manufactured and how
they tackle the various problems under different circumstances. At least we could say
that the training at BHEL Haridwar is great experience for us and it really helped us in
making or developing our knowledge about turbo generator and other equipment used
in power generation.

29. • http://www.bhel.com/about_publication.php
• http://en.wikipedia.org/wiki/Turbo_generator
• http://en.wikipedia.org/wiki/Hydrogencooled_turbogenerator
• A text book of electrical machines by P.S.BIMBRA, khanna Publication
• A text book of electrical technology by B.L.THERAJA, S.Chand publication
• BHEL Internal material
REFERENCE