BHEL, Block 4, Haridwar

PRACTICAL TRAINING SEMINAR ON

An Industrial Training on

Manufacturing of 600MW Stator Barsat

Presented ByNeeraj Varshney1216521034Electrical & Electronics Engg.

Introduction to BHELKey Features of BHELBHEL mission, vision & valuesBlocks in BHEL, HaridwarLayout & study of Block 4Manufacturing of 600MW stator barsConclusionContents

Introduction toBharat Heavy Electricals Limited, Haridwar

Key Features of BHEL:-

FEATURES DESCRIPTIONINDUSTRY1. Heavy Electrical Equipment Plant2. Central Foundry Forge Plant

ESTABLISHED IN 1964HEADQUARTER New Delhi,IndiaAWARDS & RANK1. Largest PSU with MAHARATNA STATUS2. 4th rank in FORBES 50 list3. Quality, Safety, Environmental Management CompanyTOTAL TURNOVER 9.07 billion $PRODUCTS Turbines, Boilers, Generators, Sensors, Drives, Circuit Breakers, Switch Gears, Motor etc.

FEATURES DESCRIPTION

CERTIFICATIONSISO 9001:2000 for Quality ManagementISO 14001 for Environmental Management SystemOHSAS-18001 for Occupational Health & Safety Management System CAPACITY59% in Indias total Installed Generating Capacity.EMPLOYMENT49,280EXPORTSTo about 21 countries.

BHEL MISSION,VISION & VALUES :

LOCATION SHOWING THE PLANTS OF B.H.E.L OVER INDIA : HEADQUARTER MANUFACTURING UNITS CHECK & REPAIRING UNIT

NEW DELHI

KOLKATAVARANASI

GOINDWAL

HARIDWARRUDRAPURJAGDISHPURJHANSIBHOPALHYDERABADBANGALORERANIPETTIRUCHIRAPALLYCHENNAI

BLOCKS IN BHEL,HARIDWAR

BLOCKS DESCRIPTIONBlock -1Machine block(Turbo generators & Exciter manufactured )

Block-2Power equipment manufactured & AssembledBlock-3Turbine sectionBlock-4Coil & insulation manufacturing blockBlock-5Water box & turbine partsBlock-6Stator frames & rotor blades manufacturedBlock-7Stampings & Dies for motor & generatorBlock-8Coolers & oil tanks

BLOCK-4

BAY-2

BAY-1BAY-3

Bar Winding Shop

Bars with CNC machines

Insulation Detail Shop

LAYOUT OF BLOCK-4

MANUFACTURING OF 600 MW STATOR BAR : Why we call it bar????It is difficult to wind a large capacity generator with a specific gauge of Cu conductor or a wire. In large capacity generators we use bunch of Cu conductors is used after pass through a process. Those Cu strips called as bar. Bar may be 210MW, 500MW, 600MW etc.

PROCEESES INVOLVED:-

INSULATION CHECK

CONDUCTOR CUTTING

TRANSPOSITIONSTACK PRESSINGINTER STRAND SHORT TESTFORMING

PICKLING PROCESS

BRAZING

WATERTEST

NITROGENTEST

INTERNAL PICKELING

BAROSCOPIC TEST

THERMAL TEST

HELIUM LEAKAGE TEST

INSULATION

IMPREGNATION & BAKING

FINISHING

VARNISH & COATING

Insulation check : Insulated Copper conductors are used: (1) Solid Cu conductor (2) Hollow Cu conductor

Conductor cutting : It is done by C.N.C MACHINE. LOWER BAR : UPPER BARCONDUCTOR SIZELENGTH NO. OF CONDUCTORS9.5*4.4*1.3mm hollow11053mmHollow-149.5*1.2mm solid11053 mmSolid-28

CONDUCTOR SIZELengthNO. OF CONDUCTORS9.5*4.4*1.3mm (Hollow)10887mmHollow 149.5*1.2mm (Solid)10887mmSolid- 28

Transposition : 1). To reduce eddy current in bar. 2). Done manually

Stack pressing : This is done for hollow & solid conductors to make a one unit. Bar is pressed both vertically & horizontally.

Inter strand short test : (1) To check the short circuit between conductors. (2) No current flow between the conductors.

Pickling process : BASIC SOLUTION FOR PICKELING PROCESS 1). For cleaning job (oily, dirty and dusty job) and for remove acidic properties.2). Solution is heat upto 50 C.3). Then our job is dipped in pickling solution for 15 minutes.

Forming : 1). Done on Universal forming Machine. 2). A bend is given to the bar, both side . 3). Bend use for terminal connections.

SOLUTION NAMEPERCENTAGE(%)SULPHURIC ACID10%PHOSPHORIC ACID5%HYDROGEN PEROXIDE5%

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.

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.

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.4. Determines the strength of the bar.

Internal pickling: 1. Done for cleaning of hollow conductors. 2. Used for removing the impurities from inside.

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/cmsq.Insulation : 1. To prevent short circuit, insulation is done. 2. MICALASTIC is used as insulating tape

Conductor varnish and Coating (1) ECP(End corona protection) coatingGrey semiconducting varnish is applied at the end of the bars.

OCP(Outer corona protection)coatingBlack semiconducting varnish coating is applied at the core length.

Finishing1. Bars are sanded off.2.The edges are smoothened.

Manufactured BarsBars used in generator

Conclusion

The training has proved to be useful as well as faithful.Got a chance to encounter with the generators, its manufacturing units, etc.Gives an opportunity to learn about the optimization of technology.It also helped me to have an exposure of the practical implementation of the theoretical knowledge.