BHARAT HEAVY ELECTRICALS LIMITED

RANIPUR, HARIDWAR (UTTARAKHAND)

A Project Report On:-

“MANUFACTURING PROCESS OF 500 MW

TG STATOR WINDING BAR”

Submitted By:- Submitted To:-

Bhuwan Pratap Singh Sh. A.K. Dhiman
B.Tech- Final Year Sr.Engineer
SEC, Sikar(Raj.) BL-4, BHEL
Haridwar
 ACKNOWLEDGEMENT

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.)
 PREFACE

In the light of practical aspects of training for engineering. I

am a student of B.Tech. final year had been completed my
practical training at “BHARAT HEAVY ELECTRICALS
LIMITED (BHEL) HARIDWAR” for 30 days.

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.
I observe various electrical machineries that are used in
different large scale or a small scale industries and different
types of power plants.

BHEL is very large industry for making the

different types of equipments as well as mechanical
equipments.

I tried my best to get acquitted with over all plants.

I hope that I have excited enough in the report of my
training.
CONTENTS:-

CHAPTER I -> COMPANY PROFILE.

CHAPTER II -> BHEL - AN OVERVIEW

CHAPTER III -> ABOUT BHEL, HARIDWAR.

CHAPTER IV -> BLOCKS IN BHEL, HARIDWAR.

CHAPTER V -> BLOCK DIAGRAM OF BLOCK-4.

CHAPTER VI -> BRIEF SUMMARY OF CIM SHOP

(BLOCK-4)

CHAPTER VII -> MFG. PROCESS FLOW CHART OF

500 MW TG STATOR BAR.

CHAPTER VIII-> MANUFACTURING PROCESS OF

500 MW TG STATOR WINDING
BARS.
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CHAPTER - 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. 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. BHEL caters to core sectors of the Indian economy in power,
industry, transportation,defense etc.

The wide network of BHEL’s 14 manufacturing divisions, 9 service

centers & 4 power global players.

Power sector comprises thermal, nuclear, gas & hydro power plant
business today, BHEL supplied sets account for nearly 56, 318 MW or 65%
of the total installed capacity of 86, 636 MW in as against nit till 1969-70.

BHEL has proven turnkey capabilities for executing power projectors

from concept to commissioning. 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. Cogeneration and
combines cycle plants has been introduced to acheve higher plant efficencies.
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.
TRANSMISSION:-

BHEL also supplies a wide range of transmission products and system up to

400 KV class. These include high voltage power and distribution transformer,
instrument transformers, instrument, transformers, dry type transformers. SF6
switch gear, capacitor and insulator etc series and shunt compensation system
have been also developed and introduced to minimize transmission losses.

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. 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 BHEL have been leased to Indian railway, battery powered
road.

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. A few motable ones are 150 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 , Saudi Arabia, Oman ,
Greece and Egypt.
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CHAPTER - 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.

BHEL , wholly owned by the govt. of INDIA is and integrated engg.

Complex consisting of several plants in INDIA, where about 70000 workers
are busy in design and manufacturing of heavy electrical equipment.

At present 70% of the country electrical equipment is generated BHEL

HARIDWAR.

PRODUCT’s OF BHEL

Heaps product & capacity ratings

PRODUCT CAPACITY RATING

1. Thermal/nuclear set 210 MW – 1000 MW

2. Hydro set 115 MW
3. Generator Acc. To Requirement
4. Gas turbine 60 MW – 200 MW
5. Heat exchangers, condenser Up to 800 MW
6. AC/DC electrical machine 5 KW – 2000 KW
(a) - AC ( 250 KW – 1600 KW)
 (b) - DC ( 7KW – 1000 KW)

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CHAPTER - IV

BLOCKS IN BHEL

Block-1 -> Hydro & turbo generators, AC/DC machines

Block-2 -> Fabrication ( steam, hydro & gas turbine)

Block-3 -> Gas, hydro & steam turbine

Block-4 -> CIM

Block-5 -> Heat exchangers, forging & fabrication

Block-6 -> Electrical repair & maintenance of motor & transformer

Block-7 -> Wooden packing works

Block-8 -> Fabrication, seamless tuber and heat exchanges

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CHAPTER – II

BHEL- AN OVERVIEW

BHEL is the largest engineering and manufacturing enterprise in India in

the energy related / infrastructure sector. BHEL was established more than
40 years ago, ushering in the indigenous Heavy Electrical Equipment
industry in India, a dream which has been more than released with a well-
recognized track record of performance. It has been earning profits
continuously since 1971-72 and achieved a sales turnover of Rs. 18,739
crore with a profit before tax of Rs. 3,736 crore in 2006-07.

BHEL caters to core sectors of the India economy viz. Power Generation
and Transmission, Renewable Energy, Defence etc. The wide network of
BHEL’s 14 manufacturing divisions, 4 power sector regional centers, 8
service centers, 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, systems and services-
efficiently and at competitive prices.
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. 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. 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.
BHEL is the only PSU among the 12 Indian Companies to figure in
“Forbes Asia Fabulous 50” list. It has also won the “Business Standard
Star Public Sector Company Award 2006”. The company received MoU
Excellence Award for 2004-2005 and Merit Certificate for MoU
Excellence for 2005-2006.

Power Generation

Power generation Sector comprises Thermal, Gas, Hydrogen Nuclear

power plant business. As of 31.3.2007. BHEL supplied sets accounts for
80,781 MW or nearly 65% of the total install capacity of 1,25,414 MW in
the country. Significantly these sets contribute 73% of the total power
generated in the county.

BHEL has proven turnkey capabilities for executing power projects from
Concept to Commissioning. 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. Co-
generating and Combined cycle plants have been introduce to achieve
higher plant efficiencies. To make efficient use of the high-ash-content
coal available in India. BHEL also supplies circulating Fluidized Bed
Combustion (CFBC) boilers for Thermal plants.

The company has proven expertise in Plant Performance Improvement

through Renovation, Modernization and Uprating of a variety of Power
plant equipment, besides specialized know-how of residual life assessment
health diagnostics and life extension of plants. Overall, BHEL built
Thermal sets achieved the highest ever PLF of 78.3% in 2006-2007 which
is 1.5% higher than the National average. The combined operating
availability of these sets was 84.7%.

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CHAPTER - 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, main pole

coil, inter-pole coil, equalizer coil etc.

2- Also manufactured heavy duty generator stator bars with New CNC M/c
No, 3-464 i.e. Robol bar centre.

BAY-III: Insulation detail shop; Manufacturing of hard insulation &

machining of hares insulation part (Glass textolite) such as packing, washer,
insulation box. wedges etc.

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.

HG Bars: The manufacturing of bars of different capacity as required by the

customer depends upon the water head available at site. The Hydro generator
is air cooie^ generator of te

comparison to its tagger diameter.

(Note:- The manufacturing of Hydro Gen Stator Bars has been shifted from
BHEL Haridwar to BHEL Bhopal to since 2008.

TURBO-GENERATORS: The manufacturing of bars of standared capacity

such as:

100MW, 130MW, 150Mw, 210/235MW.

The plant has capacity and technology to manufacture 800MW and 1000MW
generators.

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CHAPTER - VII

MFG. PROCESS FLOW CHART OF 500MW

TG STATOR BAR

1. Conductor Draw From Store.

2. Conductor cutting and end cleaning.

3. Transposition of conductor.

4. Assembly of all conductors to be used in stator Bars.

5. Cross over insulation.

6. Consolidation if slot portion of Bar.

7. IS Test(i.e. inter strand test).

8. Forming or Bar (to shape overhang portion).

9. Pickling of bar ends (1)

10 Mounting of Contact sleeve & bottom part of water box.

11. Brazing of Contact sleeve & bottom part of water box.

12. Pickling of bar ends (2)

13. Mounting of water box leak test.

14. Repickling.

15. Water flow and N2 test.

16. Thermal Shock Application.

17. Helium Leak Test.

18. Reforming of Bar.(i.e. overhang portion).

19. Insulation of bar on CNC macnine.

20. Impregnation an curing of bar insulation.

21. Surface finishing of stator bar.

22. OCP on stator Bar.

23. Preparation of bar for HV and TanQ Test.

24. If O.K. Dispatch to Bicck-1 for laying in the generator.

INSULATION CLASSIFICATION:

Thermal classification of insulation depends upon the temperature

Withstand capability of the insulation.

Class – Y upto 90 C

Class – A upto 105 C

Class – E upto 120 C

 Class – B upto 130 C

Class – F upto 150 C

Class – H upto 180 C

Class – C >180 C upto 220 C.

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

eg. 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.

Resin system:

a) Rich Resin or Thermoreactive 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 sheif 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 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.

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CHAPTER - VIII

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

preinsulated copper conductor is cut into number of required length.
Insulation is removed from both ends of the conductor cut.

Lower Bar :

Conductor size 8*4.6*1.5 mm (Hollow)

8*2.8 mm (Solid)

L - 10200 mm c- 500 mm

Conductor No.In 1 Bar Hollow - 20

Solid - 20
Upper Bar :

U – 10050 mm c- 5 mm
Conductor size 8*4.6*1.5 mm (Hollow)

8*1.3 mm (Solid)

Conductor No. in 1 Bar Hollow - 20

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 thecomb 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 carriedout. 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. Equalize the voltage generator
3. 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.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 insulatingspacers
are provided at the crossover portion of the conductors. A filler material
(insulating putty or moulding 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 160 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.(300 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 etectricalconnection contact and water
box for inlet and outlet of water are brazed.

8. Nitrogen Leak Test :

The bar is tested for water flow test, nitrogen leak test and pressure test for
given duration.

9. 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.

10. Helium leakage test:

After thermal shock test bar is tested for any leakage with the help of helium
gas.

11. 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.

12. 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 vaccum 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 Micalstic system: The individual (separate) bar is heated in vaccum and
impregnated in resin. Then bar is taken out and pressed in closed box fixture
and then baked at given temperature for given duration.

13. Finishing:

The baked and dimensionally correct bars are sanded-off to smoothen the
edges and the surface is calibrated, if required, for the dimension.

14. 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.

15. 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.

b) H.V. Test: Each bar is tested momentary at high voltage increased

gradually to three times higher than rated voltage.

16. 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.

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 CONCLUSION

Engineering students will have to serve in the public and

private sector industries, laboratories and workshops based
training & teaching in classroom has its own limitations. The
lack of exposure to real life, materials processes and
functioning of industrial organization is the measure
hindrances in the student employment.

In the open economy era of fast modernization and tough

competition, technical institutes should procedure pass outs as
near to job function as possible.

Practical training is one major step in this direction. This

training helped me in gaining in depth knowledge of the
working of a telephone exchange.
At last I would only say that this training was helpful for my
future prospects.

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MANUFACTURING OF BAR IN BLOCK
-IV
STATOR WINDING SECTION IN BLOCK-I