PROJECT REPORT ON

SUMMER TRAINING UNDERTAKEN AT

BHARAT HEAVY ELECTRICALS LIMITED

ON MANUFACTURING PROCESS OF 500 MW TG STATOR WINDING BAR

SUBMITTED BY ANUJ KUMAR ID NO. 40587 III YEAR B.TECH (ELECTRICAL) COLLEGE OF TECHNOLOGY, G.B.P.U.A.T., PANTNAGAR

ACKNOWLEDGEMENT
My sincere thanks goes to Er. A. K. Dhiman for his prodigious guidance, precaution, painstaking, attitude reformative and suggestion throughout my summer training schedule. Special thanks goes to Mrs niraj Kumar 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

Anuj Kumar Id. No - 40587 Electrical Engg. College of technology Pantnagar

CONTENTS:-> ABOUT BHEL, HARIDWAR. . -> BLOCKS IN BHEL, HARIDWAR. -> BLOCK DIAGRAM OF BLOCK-4. -> BRIEF SUMMARY OF CIM SHOP (BLOCK-4) -> MFG. PROCESS FLOW CHART OF 500 MW TG STATOR BAR. -> MANUFACTURING PROCESS OF 500 MW TG STATOR WINDING BAR

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. PRODUCTs OF BHEL Heaps product & capacity ratings PRODUCT 1. Thermal/nuclear set 2. Hydro set 3. Generator 4. Gas turbine 5. Heat exchangers, condenser 6. AC/DC electrical machine CAPACITY RATING 210 MW 1000 MW 115 MW Acc. To Requirement 60 MW 200 MW Up to 800 MW 5 KW 2000 KW (a) - AC ( 250 KW 1600 KW) (b) - DC 7KW 1000 KW)

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 and ACM 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

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 cooled generator.

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.

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 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

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 pre-insulated 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 Conductor No.In 1 Bar c- 500 mm Hollow - 20 Solid - 20

Upper Bar :
U 10050 mm Conductor size c- 5 mm 8*4.6*1.5 mm (Hollow) 8*1.3 mm (Solid) Hollow - 20 Solid 40

Conductor No. in 1 Bar

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. Equalize the voltage generator 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 insulating spacers 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 bar 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 etectrical connection 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 (30C) 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.

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.