Documente Academic
Documente Profesional
Documente Cultură
ON
Submitted
To: -
By: -
Amit Kumar
B.Tech
Electrical & Electronic Engineering
SRM University Haryana
ACKNOWLEDGEMENT
Amit Kumar
B.Tech (EEE)
SRM University Haryana
CONTENTS
CHAPTER 1 BHEL
1.1 Introduction
1.2 Heavy Electrical Equipment Plant
04
05
07
08
11
11
13
13
14
14
14
15
15
16
16
18
18
19
19
19
20
21
21
22
22
23
23
4.1 Introduction
HAPTER 5 - Summary
25
HAPTER 6
6.1 Conclusion
6.2 References
26
26
CHAPTER-1
1.1 Introduction
BHEL is an integrated power plant equipment manufacturer and one of
the largest engineering and manufacturing company of its kind in India engaged
in the design, engineering, manufacture, construction, testing, commissioning
and servicing of a wide range of products and services for core sectors of the
economy, viz. Power, Transmission, Industry, Transportation (Railways),
Renewable Energy, Oil & Gas, Water and Defence with over 180 products
offerings to meet the needs of these sectors. BHEL has been the bedrock of
India's Heavy Electrical Equipment industry since its incorporation in 1964.
BHEL's growth has been synchronous with achieving self-sufficiency in the
indigenous manufacturing of heavy electrical equipment. Out of the available
35,000 MW per annum capacity for power plant equipment manufacturing in
the country, BHEL alone constitutes a mammoth 20,000 MW per annum
capacity. A widespread network of 17 Manufacturing Divisions, 2 Repair Units,
4 Regional Offices, 8 Service Centres, 6 Overseas Offices, 6 Joint Ventures, 15
Regional Marketing Centres and current project execution at more than 150
project sites across India and abroad corroborates the humungous scale and size
of its operations.
BHEL also has a widespread overseas footprint in 80 countries with cumulative
overseas installed capacity of BHEL manufactured power plants nearing 10,000
MW including Belarus, Bhutan, Egypt, Indonesia, Iraq, Kazakhstan, Malaysia,
New Zealand, Oman, Rwanda, Sudan, Tajikistan and UAE.
BHEL places strong emphasis on innovation and creative development. The
R&D efforts of the company are aimed not only at improving the performance
and efficiency of existing products, but also developing new products using
state-of-the-art technologies and processes. With its innovation-led growth
strategy, BHEL continues to rank among the highest R&D spenders in the
country in the engineering and manufacturing segment. 477 patents and
copyrights were filed during the year 2015-16, enhancing the company's
intellectual capital to 3,441.
4
(1.d)- Block-1
**FACTS**
The generator may be classified based upon the cooling system used in
them such as: THRI, TARI, THDI, THDD, THDF, THFF and THW.
T (First alphabet) >>> Type of generator i.e. Turbo-generator or Hydro-generator.
H/A (Second alphabet) >>> Cooling media used for the cooling of rotor i.e.
Hydrogen gas or Air.
R/D/F/I (Third alphabet) >>> Type of cooling of rotor e.g. Radial, Indirect, Forced
and Direct.
I/D/F (Fourth alphabet) >>> Type of cooling of stator e.g. Indirect, Direct and
Forced.
W >>> Cooling media used for cooling of stator coil e.g. water.
CHAPTER-2
Coil & Insulation Manufacturing (CIM)
(Block-IV)
2.1 Introduction
Coil & Insulation manufacturing Block 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.
(2.a)
(2.b)
Fig. (2.a) - Layout of CIM Block IV; (2.b) - Main Products of CIM block
There are four BAYS in this block each bay manufactures stator bars and coils
for different machines i.e. BAY-0, BAY-I, BAY-II, BAY-III.
7
I.S.T Repair
NOT OK
Final Pressing
Radius Milling
I.S.T
NOT OK
Water Flow
NOT OK
Forming
Main Brazing
Water Box- Top Part
Welding (TIG)
NOT OK
Nitrogen Test
NOT OK
Thermal Shock
Mat Filling
Helium Leak Test
NOT OK
Inner Corona
Protection (ICP)
Main Body Insulation
Impregnation
NEXT PAGE
Impregnation
Wagon Setting &
Pressing Of Bar
Curing
Surface Finishing &
Calibration
Outer Corona Protection
Inter Corona
Protection (ICP)
High Voltage & Tan
Delta Preparation
H.V. & Tan Delta Test
Borescope
Marking & End Corona
Protection Coating
(ECP)
Protection Warping Of
ECP
Conductive Wrapping of
Slot
Packing Of Bar
Send the Bar to
1
Block
10
CHAPTER 3
Manufacturing Process of 800 MW Bars
(Bay I & II)
3.1 Conductor Drawn From Store & Insulation Check
For the manufacturing of stator bars, insulated solid
Copper conductors are brought from Bangalore and hollow Steel conductors are
brought from Germany\England.
Hollow Steel conductors use for both conduction as well as to facilitate
the flow of coolant (e.g. Water).
Insulating materials and the conductors are ensured to be certified.
The insulation is checked by the respective agencies.
**FACT**
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.
11
Upper Bar:Type of
conductor
Solid Copper
Conductor Size
(mm)
14*1.8
Length (mm)
11282
Number of
conductor
50
Hollow
hollow
14*4
11282
10
Type of
conductor
Solid Copper
Conductor
Size (mm)
14*1.8
Length (mm)
11077
Number of
conductor
50
Hollow hollow
14*4
11077
10
Lower Bar:-
(3.2.a)
(3.2.b)
12
(3.2.c)
(3.2.d)
horizontally in the Pressing Machine. The pressing machines are also provided
with the heaters
Each bar is loaded on each tier of heating plate and it is then provided with an
initial pressure of 355 kg/cm2 and an initial temperature of 100-110 C. Then
the temperature is allowed to raise to the maximum of 160C, this temperature
is kept for at least one hour with a final pressure of 8010 kg/cm2 vertically and
7010 kg/cm2 horizontally.
Then the bars are cooled and both ends of bars are cleaned with rectified spirit
and sand paper for the inter strand test.
14
and water profile is checked at other end. Profile must be same for every hollow
conductor.
If there is any kind of blockage inside the hollow conductors of the bar then it is
indicated by flow of water i.e. flow of water will be not uniform or profile is
disturbed so the bar is assumed to be chocked. Then chocked conductors are
repaired and water test is again performed to check the flow of water.
3.8 Forming
In this process the bars are bending from both the ends of
the bar i.e. at exciter side and turbine side at specific angles and shape as per
design.
This process is done manually. First the former is set according to the design
making different angles at different positions. Each bar of a variant is bent or
formed at same angle. Once the former is set, the bar is mounted on it and
formed manually by tools (e.g. mallet, clamper etc.) from both the ends.
While forming, the bars are assumed to get loosen. Thus the formed portion of
the bar are clamped at different places and provided with heaters to
reconsolidate the formed portion. After few hours the bar is then allowed to cool
at room temperature.
15
3.10
Brazing is a metal-joining process in which two or more metal items are joined
together by melting and flowing a filler metal into the joint, the filler metal
having a lower melting point than the adjoining metal.
The two types of brazing processes are: Thermal brazing (using LPG)
Induction brazing
16
Current (Amp)
55-70
Feed (mm/min)
102
Time (sec)
20-30
Table 3.9.a TIG welding of tubes with water box bottom part.
The top water box is also welded on water box bottom part through the method
of TIG welding. For this it should be kept in mind that water box bottom part
should have same material as that of water box top part. Shielding gas use here
is Argon gas and filler material use here is stainless steel.
Tungsten Inert Gas (TIG) welding, is an arc welding process that uses a nonconsumable tungsten electrode to produce the weld. The weld area is protected
from atmospheric contamination by an inert shielding gas (Ar & He), and a
filler metal is normally used.
(3. 9.a)
Fig. (3.9.a) - TIG Welding
17
18
3.15 Reforming
After all the previous processes which had undergone on
the bar it is assumed that the shape of the bar is deformed from its original
shape due to handling of the bar from one place to another for different
processes. So to keep the shape of the bar as per design, the bar is checked if it
is found distorted then it is reformed in the previous former machine by placing
the bar on the former and do the forming process again.
Impregnation:
20
Drying: The stator windings are to be dried under vacuum 0.1 m bar at
(605) C for 15 hours, minimum. The drying temperature is to be
increased to (652) C if the initial viscosity of the impregnating resin
mixture is high. The temperature distribution should be as uniform as
possible.
Curing: To prevent heating in the overhang portion, the curing of the
impregnated stator winding is to be done with a maximum 160C hot air.
The curing period is extended for such a long time till the measurement
positions in the core indicate (1405) C for minimum 8 hours.
Tan test
Test is performed to find the capacitance of the bar
because bar will act as capacitor when it is laid in the stator of the generator. In
21
this test Schering Bridge which works on the principle of wheat-stone bridge is
used to find the unknown capacitance of the bar.
When the bar wrapped with aluminium there are two conducting material i.e.
the aluminium sheet and the conductors of the bar, which act as two plates of
the capacitor and the insulation on the bar act as dielectric medium for the
capacitor. The capacitance of the bar is found and of angle of deviation due to
impurity in the insulation is obtained from the formula:
C4 * R4 * 104 = tan
22
CHAPTER 4
Manufacturing of Insulation
(Bay III)
4.1 Introduction
Bay 3 is the manufacturer of insulating material of
different shapes and sizes as required according to the design. This bay is also
called as I.D. Section (Insulation Design Section). For the manufacturing of
insulations, different raw materials having insulating properties are brought by
this section. The raw materials having different insulating properties are then
processed in this section and moulded to different shapes as per design.
The raw materials used in this bay are:
Nylon Sheet
Ebonite
Perspex Glass Sheet
Nomex Paper
Asbestos Sheet
Asbestos Paper
All the insulating raw materials mentioned above are in the decreasing order of
their insulating property. The insulating materials used in the manufacturing of
insulation moulds are categorized according to their laying requirement in the
machine i.e. if an insulation mould is to be fixed in the place where the risk of
fire is high, then at those places moulds of Glass based Textolite sheet are
preferred because cotton based or paper based textolite sheet could catch fire at
those places.
Teflon Sheet has an important property and i.e. Teflon is non heat transferring
material. So an insulating mould of Teflon is placed above the bearings of the
rotor so that is any fault in the bearings of the rotor produces any heat then it is
prevented by this material to get transferred to the rotor, and hence prevents the
rotor of the machine.
For the manufacturing of insulation moulds, the glass insulation raw material in
fibres is first pressed into blocks in a pressing machine with the help of heaters
and hydraulic pressure. Fibres are made into blocks because if fibre is used as it
is then volume of the material will be very large. So blocks are placed on
weighing machine and then weighed equal to the product required according to
design. So then these blocks are placed in the mould and heated and moulded in
the shape as that of the mould by applying sufficient pressure and temperature.
24
CHAPTER 5
Summary
Construction
Each bar consists of solid as well as hollow conductor with cooling water passing through
the latter. Alternate arrangement hollow and solid conductors ensure an optimum solution
for increasing current and to reduce losses. The conductors of small rectangular cross
section are provided with glass lapped strand insulation.
A separator insulates the individual layers from each other. The transposition provides for
mutual neutralization of voltage induced in the individual strands due to the slots cross
field and end winding field. The current flowing through the conductor is uniformly
distributed over the entire bar cross section reduced.
To ensure that strands are firmly bonded together and give dimensionally stability in slot
portion, a layer of glass tape is wrapped over the complete stack. Bar insulation is done
with epoxy mica thermosetting insulation. This insulation is void free and posses better
mechanical properties. This type of insulation is more reliable for high voltage. This
insulation shows only small increases in dielectric dissipation factor with increasing test
voltage. The bar insulation is cured in an electrically heated process and thus epoxy resin
fill all voids and eliminate air inclusions.
25
Insulation
Bar is tapped with several layers of thermosetting epoxy tape. This is applied
continuously and half overlapped to the slot portion. The voltage of machine determines
the thickness of insulation. The tapped bar is then pressed and cured in electrical heated
press mould for certain fixed temperature and time.
CHAPTER 6
6.1 Conclusion
I would like to say that this training program is an excellent opportunity for us
to get to the ground level and experience the things that we would have never
gained through going straight into a written material.
The main objective of the industrial training is to provide an opportunity to
undergraduates to identify, observe and practice how engineering is applicable
in the real industry.
The architecture of B.H.E.L., the way various units are linked and the way
working of whole plant is controlled make the students realize that Engineering
is not just structural description but greater part is planning and management.
It proved an opportunity for encounter with such huge machines with their
working. Overall this training is totally satisfactory for me.
6.2 References
26
27