ACKNOWLEDGEMENT

Training is the act of increasing the knowledge and skill of an

employee for doing a particular job.

This project report has been made as a part of the

industrial training underwent at the B.H.E.L Haridwar
plant, Uttarakhand.
I would like to extend sincere thanks to Mr.A.K.Dhiman,
deputy manager for his prodigious guidance throughout
my training and I would specially like to thank Mr.Vinod
Bharadwaj and Mrs.M.Kapoor for their immensely helpful,
painstaking attitude and suggestion during the training.
Efforts have been made to make the report as succinct as
possible. Quantitative data has been presented through
tables, charts and suitable illustrations.
The project would not have been possible without the
help and cooperation of the aforementioned officials. Last
but not the least; I would like to thank all the staff
members of B.H.E.L. Block-4, Ranipur, Haridwar.

Animesh kumar
B.Tech. 3 rd year
Electrical and Electronics
Engineering
DIT School of engineering

TABLE OF CONTENTS

CHAPTER 1- INTRODUCTION ON B.H.E.L.

CHAPTER 2- BLOCK 4 CIM SHOP

CHAPTER 3-MANUFACTURING PROCESS OF 600MW TG STATOR

BARS

CONCLUSION

CHAPTER 1

INTRODUCTION ON BHEL
Bharat Heavy Electricals Limited (BHEL) is an Indian
integrated power plant equipment manufacturer and operates as
engineering and manufacturing company based in New Delhi, India.
Established in 1964, BHEL ushered in the indigenous Heavy Electrical
Equipment industry in India. The company has been earning profits
continuously since 1971-72 and paying dividends since 1976-78.
It is engaged in the design, engineering, manufacture, construction, testing,
commissioning and servicing of a wide range of products and services for the
core sectors of the economy, viz. Power, Transmission, Industry,
Transportation, Renewable Energy, Oil & Gas and Defence. It has 15
manufacturing divisions, two repair units, four regional offices, eight service
centres, eight overseas offices and 15 regional centres and currently
operates at more than 150 project sites across India and abroad. Most of its
manufacturing units and other entities have been accredited to Quality
Management Systems (ISO 9001:2008), Environmental Management
Systems (ISO 14001:2004) and Occupational Health & Safety Management
Systems (OHSAS 18001:2007).
It is the 7th largest power equipment manufacturer in the world. In the year
2011, it was ranked ninth most innovative company in the world by US
business magazine Forbes. BHEL is the only Indian Engineering company on
the list, which contains online retail firm Amazon at the second position with
Apple and Google at fifth and seventh positions, respectively. It is also placed
at 4th place in Forbes Asia's Fabulous 50 List of 2010. BHEL was established
more than 50 years ago, ushering in the indigenous Heavy Electrical
Equipment industry in India. The company has been earning profits
continuously since 1971-72 and paying since 1976-77. 74% of the total
power generated in India is produced by equipment manufactured by BHEL.
It is one of India's nine largest Public Sector Undertakings or PSUs, known as
the Navratnas or 'the nine jewels'.In June 2012, BHEL commissioned 250 MW
power generating unit at Harduaganj in Uttar Pradesh. This would add six
million units of electricity on a daily basis.

BHEL HARIDWAR
At the foothills of the majestic Himalayas, on the bank of the Holy Ganges in
Ranipur, Uttarakhand is located Heavy electrical equipment plant (HEEP) of
B.H.E.L.
BHEL, completely owned by the Government of India is an integrated
engineering complex consisting of several plants of India, where about
70,000 workers are employed in the design and manufacturing of heavy
electrical equipment.
At present, 70 % of countrys electrical equipment is generated at BHEL
Haridwar.

PRODUCTS OF BHEL HARIDWAR AND THEIR

CAPACITY RATINGS

1
.
2
.
3
.
4
.
5
.
6
.

Thermal/nuclear set

210MW-1000MW

Hydro set

115MW

Generator
gas turbine

according to
requirement
60MW-200MW

heat exchangers, condensers

Upto 800MW

AC/DC electrical machine

5kW-2000kW
(a)AC (250 kW1600kW )
(b)DC (7kW-1000kW)

BHEL has turnkey capabalities for executing power projectors from concept
to commissioning. it possesses the technology and capability to produce

thermal power plant equipment upto 1000MW rating and gas turbine generator
sets upto a unit rating of 240MW.Cogeration and combine cycle plants have
been introduced to achieve higher plant efficiencies. To make efficient use of
the higher ash content crash coil manufacturers 235MW nuclear turbine
generator sets and has commenced the generation of 500 MW nuclear
turbine generator head discharge combinations are also engineered and
manufactured is equally competitive.

TRANSMISSIONBHEL also supplies a wide range of transmission products and systems upto
400kV class. These include high voltage power, distribution transformers,
instrument transformers, dry type transformer,SF6 switch gear, capacitor and
insulator,etc.Series and shunt compensation systems have been also
developed and introduced to minimize transmission losses.
TRANSPORTATIONA high percentage of trains operated by the Indian Railways are equipped
with BHELs traction and control equipment 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 B.H.E.L. have been leased to Indian Railway, battery
powered road.
INTERNATIONAL OPERATIONSB.H.E.L.s product series and projects have been exported to countries
ranging from United states in the west and New Zealand in the east and for
India over 3000MW.a few notable ones are a 15o 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, Oman, Greece and Egypt.

CHAPTER 2
CIM SHOP (BLOCK IV)

BAY-1: Bar winding shop: Manufacturing of stator winding bars of generator,

Micalastic Tank & Oven
BAY-2: Heavy duty generator stator bars with New CNC M/c No, 3-464 i.e.
Roebel bar centre, TIG Welding
BAY-3: Insulation detail shop: Manufacturing of hard insulation & machining
of hares insulation part (Glass textolite) such as packing, washer, insulation
box, wedges etc. & CNC Taping Machine
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.

TURBO-GENERATORS: The manufacturing of bars of standard capacity

such as: 100MW, 130MW, 150Mw, 210/235MW, 500MW, 600MW.
The plant has capacity and technology to manufacture 660MW, 800MW and
1000MW generators.

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 e.g. 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.

TYPES OF INSULATION
Thermal classification depends upon the temperature withstand capability of
the insulation.
class Y-upto 90 degree celsius
class A-upto 105 degree celsius
class E-upto 120 degree celsius
class B-upto 130 degree celsius
class F-upto 155 degree celsius
class H-upto 180 degree celsius
class C- > 180 degree celsius

ISSUE
OF
CONDUCTOR
CUTTING
AND
END
CLEANING

TRANSPOSITION

ASSEMBL
Y
OF
CONDUCTORS
CROSS
OVER
INSULA
TION

I.S.

TEST

FORMING

PICKLING

MOUNTING

BRAZING

REPICKLING
W
A
TER
FLOW
AND
NITROGEN
TEST
THERMAL
SHOCK
TEST
HELIUM
LEAK
TEST
REFORMING
OF
OVERHANG
POR
TION
INSULA
TION
ON
CNC
MACHINE

IMPREGNA
TION

SURF
ACE
FINISHING
OUTER
CORONA
PROTECTION
(OCP)
H.V
.

AND
T
AN
TEST

CHAPTER 3
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

Length

Number
conductors

8*4.6*1.5mm(Hollow)
8*2.8 mm (Solid)

10200 mm

Hollow- 20
Solid - 20

Conductor size

Length

Number
conductors

8*4.6*1.5mm(Hollow)
8*1.3 mm (Solid)

10050 mm

Hollow- 20
Solid - 40

of

Upper Bar
of

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 the comb 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 carried out. 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. 2.Equalize the voltage generator
3. To minimize skin effect of ac current, small cross section of conductor is used and
also
hollow conductors are used to effect cooling 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 insulating spacers
are provided at the crossover portion of the conductors. A filler material
(insulating putty or molding 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 1600 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. (300V 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 electrical connection contact and water
box for inlet and outlet of water are brazed.
8. Thermal shock test
26 cycles of hot (800C) and cold (30C) water are flown through the bar to
ensure the thermal expansion and contraction of the joints.
9. Helium leakage test
After thermal shock test bar is tested for any leakage with the help of helium
gas.
10. 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.

11. 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 vacuum
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 Micalastic system:
The individual (separate) bar is heated in vacuum and impregnated in resin.
Then bar is taken out and pressed in closed box fixture and then baked at
given temperature for given duration.
12. Finishing
The baked and dimensionally correct bars are sanded-off to smooth the
edges and the surface is calibrated, if required, for the dimension.
13. 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.

RESIN SYSTEM:

a) Rich Resin or Thermo-reactive 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 shelf 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 is prepared 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.

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. The capacitance of the bar
is found and the angle of deviation due to the impurity in the insulation is
obtained from the formula
C4*R4*10-4 =tan
b)

H.V. Test:

(High Voltage Test) each bar is tested momentary at high voltage increased
gradually to three times higher than rated voltage.

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.

CONCLUSION
This training has proved to be quite faithful. This gave me, a chance to have
an encounter with such heavy machines like turbo generator (TG)
500MW.The architecture of B.H.E.L. ,the way the various units are linked and
the way the working of the whole plant is controlled, makes the student
realize that engineering is not just the structural description but more of
planning and management. It has provided an opportunity to learn that
optimization of technology used at proper place and time can save a lot of
labour.
The training has proved to be immensely helpful as it has helped me to have
an exposure of the practical implementation of the theoretical knowledge
that I have gained till date.