Académique Documents
Professionnel Documents
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ON
COIL AND INSULATION
MANUFACTURING
(CIM)
800MW BARS
(BLOCK IV)
1
CONTENTS
CHAPTER 1 –BHEL
1.1 Introduction 04
1.2 Heavy Electrical Equipment Plant 05
CHAPTER 5 -Summary 25
CHAPTER 6
6.1 Conclusion 26
6.2 References 26
2
CHAPTER-1
1.1 Introduction
3
1.2 Heavy Electrical Equipment Plant
BHEL's Heavy Electrical Equipment Plant (HEEP) was set up in technical
collaboration with USSR, for the manufacturing of power plant equipment, AC/DC
motors of various rating with associated control equipment and started production
in January 1967. In 1976, BHEL entered into a collaboration agreement with M/s
Kraftwerk Union, AG of Germany for design, manufacturing, erection and
commissioning of large size steam turbines. More than 40 percent of the country's
electrical energy is generated from the power equipment supplied by BHEL,
Haridwar. Products manufactured include power transformers, instrument
transformers, dry type transformers, series — and stunt reactor, capacitor tanks,
vacuum — and SF circuit breakers gas insulated switch gears and insulators. The
products, which are manufactured in HEEP, are: - Steam Turbines, Turbo
Generators, hydro turbines, Gas turbines, etc.
**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.
4
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.
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.
5
2.2 Flow Chart
Conductor Drawn
From Store
Crossover Insulation
Final Pressing
Radius Milling
I.S.T
NOT OK
Water Flow
NOT OK
Forming
6
Contact Sleeve &
Bottom Mounting
Main Brazing
NitrogenTest NOT OK
Thermal Shock
Mat Filling
Inner Corona
Protection (ICP)
Main Body
Insulation
Impregnation
NEXT PAGE
7
Impregnation
Curing
H.V.& Tan
Delta Test
Borescope
Protection Warping Of
ECP
Conductive Wrapping
of Slot
Packing Of Bar
8
CHAPTER3
Manufacturing Process of800 MW Bars
(Bay I & II)
**FACT**
9
UpperBar:-
Type of Conductor Size Length (mm) Number of
conductor (mm) conductor
Solid Copper 14*1.8 11282 50
Hollow 14*4 11282 10
hollow
LowerBar:-
Type of Conductor Length (mm) Number of
conductor Size (mm) conductor
Solid Copper 14*1.8 11077 50
Hollow hollow 14*4 11077 10
.
(3.2.a) (3.2.b)
10
Transposition is done in two ways:
Half Pitch Transposition: - In this transposition, the first conductor at one
end of the bar becomes the last conductor at the other end of the bar.
Full Pitch Transposition: - In this method of transposition, the first
conductor at one end of the bar becomes the last conductor in the mid of the
bar and then again becomes the first conductor at the other end of the bar.
11
3.5 Radius Milling
After hydraulic pressing of bar, the bar is brought for radius
milling. Due to hydraulic pressing, the bar’s edges become sharp. In this process
the sharp end of bar is grinded to give a smooth finish of uniform radius.
12
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.
13
All the remaining hollow Steel conductors are cut after the contact sleeve is fitted
leaving 2 mm for TIG welding (automatic).
Both the ends of the bar are then again pickled along with contact sleeve and water
box bottom part following the same procedure of pickling.
14
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.
15
3.13 Thermal Shock Test
Thermal shock test is performed to check whether the bar can
withstand extreme conditions i.e. when the generator is working or running at
about 3000 rpm.
Thermal shock test consist of series of hot water & cold water cycles alternatively.
So firstly hot water at temperature of about 80-90°C is passed through the bar and
then cold water at about room temperature 25-30°C approx. is flowed inside the
bar alternatively. This process is repeated again and again. This process is repeated
for about 6 times i.e. it has 6 cycles of hot and cold water. So this test tells us the
strength of the bar so that it can withstand the working conditions of the generator.
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.
16
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.
17
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.
18
Tan δ 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 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 δ
19
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.
20
CHAPTER4
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.
21
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.
22
CHAPTER5
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.
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.
23
CHAPTER6
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
24