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ACKNOWLEDGEMENT
It is always a pleasure to remind the fine people in the engineering program for
their sincere guidance to uphold my practical as well as theoretical skills in
engineering.
Firstly, I would like to thanks my collage Chancellor (SRM University) &
Vinod K. Joneja (TPO, SRM University) for meticulously planning academic
curriculum in such a way that students are not academically sound but also
practically by including such industrial training patterns.
I express my sincere thanks and gratitude to BHEL authorities for allowing me
to undergo the training in this prestigious organization. Special thanks Mr.
Sarvagya Singh Sr. Engineer (CIM, Block-4 BHEL, Haridwar) allowing my
training under his able guidance and for his supportive nature.
I will always remain indebted to them for their constant interest and excellent
guidance in my training work, moreover for providing me with an opportunity
to work and gain experience.
At last but not least I would thank to all the well experienced workers in the
block, who constantly provided me required knowledge at different stages.
Shubham Goel
B.Tech (EEE)
SRM University Haryana
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CONTENTS
CHAPTER 1 - BHEL
1.1 Introduction 04
1.2 Heavy Electrical Equipment Plant 05
HAPTER 5 - Summary 24
HAPTER 6
6.1 Conclusion 25
6.2 References 25
CHAPTER-1
3
1.1 Introduction
4
Fig 1.a – Rotor of Turbo Generator
5
. (1.b) -TG Stator (1.c) - Internal of stator (Front view)
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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.
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2.2 Flow Chart
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CHAPTER 3
Manufacturing Process of 800 MW Bars
(Bay I & II)
**NOTE**
Upper Bar:-
9
Type of Conductor Length Number of
conductor Size (mm) (mm) conductor
Solid 14*1.8 11282 50
Copper
Hollow 14*4 11282 10
hollow
Lower Bar:-
Type of Conductor Length Number of
conductor Size (mm) (mm) conductor
Solid Copper 14*1.8 11077 50
Hollow 14*4 11077 10
hollow
. (3.2.a) (3.2.b)
10
. (3.2.c) (3.2.d)
11
3.3 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 of
moulding micanite) is provided along the height of the bar to maintain the
rectangular shape and to cover the difference of level of conductors.
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3.6 Inter Strand Test (IST)
The pressed bar 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 which damage the side
conductor and its insulation thus damage whole bar when it place in stator. For
this test all the bare conductors at both the ends are separated from each other
by putting them in comb so that they do not short circuit.
Then testing knob is connect to an adjacent conductor and check for whether it
is short or not by glow of bulb (which is series connected).Same is done for up-
down conductors. If the lamp lights up it shows short circuit between the two
conductors due to improper insulation between them. It shows insulation failure
between the conductors, these conductors are then replaced and bar is followed
through all the previous processes.
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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.
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The end of the bar is dipped in thinner to remove the dust or oil particles then
dried with the help of N2 gas. After that the bar end is dipped in pickling
solution for 5 to 10 minutes followed by dipping in water. Then the bar is
dipped in rectified spirit to make the water contents evaporate as soon as
possible also dried with N2 gas.
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16
The two types of brazing processes are:-
Thermal brazing (using LPG)
Induction brazing
As induction brazing is more beneficial than thermal brazing as it does not
requires any inflammable gas for heating. So in BHEL, induction brazing
process is used. Carbon has very high resistance and when the current is
allowed to pass through it due to induction the material to be brazed i.e. Contact
Sleeve gets super-heated. Induction heating is hence faster and even more
efficient than thermal heating.
When the contact sleeve becomes red hot at 750°C, the brazing material (alloy
of Ag+Cu+Au+Brass) is then pushed to fill the air gaps and to consolidate the
contact sleeve on the bar. It is then allowed to cool.
The hollow Steel conductors are welded with water box bottom part through
process of TIG welding. This is done by CNC Machine. Before welding, the
opening hole of conductors are adjust with help of chisel. Heat generated by
Tungsten melt down the hollow steel conductor (2mm) and water box bottom
part, due to this both join to each other, thus no filler material use here.
Voltage (V) Current (Amp) Feed (mm/min) Time (sec)
8-9 55-70 102 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 non-
consumable 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.
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3.12 Nitrogen Test & Dye Penetration Test
This test is performed to check any leakage in bar i.e. to check the TIG welding.
This test is similar to puncture test that is inflated tube is dipped in water for any
leakage, the air bubbles gives us the exact position of the puncture. Similarly,
this test is performed with the help of Nitrogen gas.
In this test, nitrogen at a pressure of 10Kg/cm 2 is forced from one end of the bar
and other end of the bar is blocked then the pressure of 10Kg/cm 2 is maintained
and both the ends of the bar are dipped in water. If bubbles appear then welding
is done again and same test is performed to ensure TIG welding of water box
top and bottom part is done properly.
Dye Penetration Test used to locate surface-breaking defects in all non-porous
materials. Liquid with certain dye is applied on water box and check for breaks
on surface.
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.
Fig (3.13.a) – Layout for thermal shock of bar.
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.
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3.16 Main Body Insulation & Impregnation
The bar is insulated with the specific number of layers to build the wall
thickness of insulation subjected to the generating voltage of the machine.
Insulation is basically done to prevent any kind of short circuit between the bar
and the stator core when the bar is assembled in the stator of the machine. The
stator bars are insulated with Micalastic (trade name) insulation. The bar is
provided with many layers of insulation which is done by machine called CNC
TAPPING MACHINE.
For insulation with micalastic, the conductor strands are arranged together to
form a compact assembly and set to the required shape. This assembly is then
baked with epoxy resin to give it mechanical strength required for further
processing. The bars are then dried under vacuum and impregnated with
synthetic resin, which by reason of its low viscosity penetrates the insulation
thoroughly and eliminates all voids.
Impregnation:
The impregnation resin mixture is to be heated in the working tank, to (60±3)
°C. At a temperature of 50°C, the impregnating resin mixture is to be degassed
with 1-5 m bar vacuum. Subsequently the stator windings are to be dipped
continuously in resin hardener mix such that the highest locations of the
windings are at least 100 mm below the resin level. After 10 minutes of resin
stabilization, pressure is increased by application of nitrogen. Pressure is to be
gradually increased in uniform stages within 80 minutes to 4 bars and to be
maintained for 120 minutes in the impregnation tank.
The impregnation of the stator winding is to be monitored continuously. Further
it is to be decided whether to increase the pressure or to stop the impregnation
process, however the total period of nitrogen pressure cycle shall in any case not
exceed 4 hours.
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3.17 Pressing Of Bar & Curing
After impregnation under vacuum, the impregnated bars then brought to the
required dimensions in moulds and cured in an oven at a high temperature.
Pressing: The bars are pressed to bring them back to the original
dimensions.
Drying: The stator windings are to be dried under vacuum 0.1 m bar at
(60±5) °C for 15 hours, minimum. The drying temperature is to be
increased to (65±2) °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 160°C hot air.
The curing period is extended for such a long time till the measurement
positions in the core indicate (140±5) °C for minimum 8 hours.
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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 δ
H.V. (High Voltages Testing):
This test is also known as insulation test because this test is performed to check
the insulation of the bar. In this test the bar which is already wrapped with
aluminium is used. High voltage is applied to the bar using auto-transformer
and it is increased three times the working voltage of the bar. If the insulation is
weak the bar will puncture at the place of weaker insulation.
The bar is tested to three times the rated voltage. If any of the bar fails this test
i.e. bar is punctured at any point then the bar is sent back for ICP and along with
re-insulation all the processes are repeated again.
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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:
Glass based Textolite Sheet
Cotton based Textolite Sheet
Paper based Textolite Sheet
Mica Glass sheet
Teflon Sheet
Mica Sheet
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.
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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.
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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 possess 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.
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.
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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
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