A Report on industrial training at

“BHARAT HEAVY ELECTRICALS LIMITED”

Haridwar, India.

Manufacture and assembly of Turbo Generators and

Exciter motors

Under the able guidance of

Sh. P.S. Jangpangi (Sr. DGM) – Block 1

Submitted by

Utsav Goyal
B. Tech 4th year
Department of Electrical & Electronics Engineering
Naraina College of Engineering & Technology, Kanpur
Uttar Pradesh, India
 ACKNOWLEDGEMENT

Practical knowledge means the visualization of the knowledge,

which we read in our books. For this, we perform experiments and get
observations. Practical knowledge is very important in every field. One
must be familiar with the problems related to that field so that he may
solve them and become a successful person.

After achieving the proper goal in life, an engineer has to

enter in professional life. According to this life, he has to serve an
industry, may be public or private sector or self-own. For the efficient
work in the field, he must be well aware of the practical knowledge
as well as theoretical knowledge.

To be a good engineer, one must be aware of the industrial

environment and must know about management, working in such a
industry, labor problems etc., so that he can tackle them successfully.

Due to all the above reasons and to bridge the gap between theory
and practical, our engineering curriculum provides a practical training of
30 days. During this period, a student works in the industry and gets
all type of experience and knowledge about the working and
maintenance of various types of machinery.

I have undergone my 30 days training (after VI Semester) at

BHARAT HEAVY ELECTRICALS LIMITED. This report is
based on the knowledge, which I acquired during my 30 days training
period at the plant.

UTSAV GOYAL
 INDEX

S.No.

01. INTRODUCTION

02. BHEL-A Brief Profile

03. BHEL - AN OVERVIEW

04. HEEP: AN OVERVIEW

05. BRIEF SUMMARY OF THE BAR SHOP

06. TYPES OF TURBOGENERATORS

07. MATERIAL CHECKING

08. CONDUCTOR CUTTING AND END CLEANING

09. TRANSPOSITION OF CONDUCTORS

10. CROSSOVER INSULATION

11. PRESSING

12. ISS- TEST

13. FORMING OF BAR

14. ZERO PICKLING OF BAR END

15. COIL LUG MOUNTING

16. MAIN BRAZING

17. CONDUCTOR CUTTING, DEBBERING AND FACE MILLING

`18. FIRST PICKLING

19 BRAZING OF TOP PART

20. WATER FLOW TEST

21. NITROGEN LEAK TEST

22 THERMAL SHOCK TEST

23 HELIUM LEAKAGE TEST

24. INSULATION

25. IMPREGNATION AND BAKING

26. FINISHING

27. CONDUCTING VARNISH COATING

28. TESTING

28.1 TAN-DELTA TEST

28.2 HIGH VOLTAGE TEST

29. DISPATCHED FOR WINDING

30. MOTOR WINDING

31. CONCLUSION
 INTRODUCTION
In 1956, India took a major step towards the
establishment of its heavy engineering industry when Bharat
Heavy Electrical Ltd., the first heavy electrical manufacturing unit
of the country was setup at Bhopal. It progressed rapidly and three more
factories went into production in 1965. The main aim of establishing
BHEL was to meet the growing power requirement of the country.

B.H.E.L appeared on the power map of India in 1969 when the first
unit supplied by it was commissioned at the Basin Bridge Thermal
Power Station in Tamil Nadu. Within a decade, BHEL had
commissioned the 100 unit at Santaldih. West Bengal.
BHEL had taken India from a near total dependence on imports to
complete self-reliance in this vital area of power plant equipment
BHEL has supplied 97% of the power generating equipment. BHEL
has already supplied generating equipment to various utilities capable
of generating over 18000 MW power. Today BHEL can produce
annually; equipment capable of generating 6000MW. This will grow
further to enable BHEL to meet all of India’s projected power equipment
requirement. As well as sizeable portion of export targets.

Probably the most significant aspect of BHEL’s growth

has been it’s
diversification. The constant reorientation of the organization to meet the
varied needs in
time with time a philosophy that has led to the development of a
total capability from concepts to commissioning not only in the field
of energy but also in industry and transportation.

In the world power scene, BHEL ranks among the top ten
manufactures of power plant equipment and in terms of the spectrum of
products and services offered, it is right on top. BHEL’s technological
excellence and turnkey capabilities have won it worldwide recognition.
Over 40 countries in the world over have placed orders with BHEL
covering individual equipment to complete power stations on a turnkey
basis.

In 1978-79 export earnings reached Rs. 122 crores, the highest for
any one-year.
BHEL has its headquarters at New Delhi. Its operations are
spread over 11
manufacturing plants and number of engineering and service divisions
located across the
country/ the service divisions includes a network of regional branch
offices throughout
India.

BHEL-A Brief Profile

 BHEL is the largest engineering and manufacturing enterprise in
India in the energy-related / infrastructure sector, today. BHEL is
ushering in the indigenous Heavy Electrical Equipment industry in India-a
dream that has been more than realized with a well-recognized track
record of Performa

A widespread network comprising of 14 manufacturing

companies, which have international recognition for its commitment
towards quality. With an export presence in more than 60 countries,
BHEL is truly India’s ambassador to the world. BHEL’s vision is to
become world class engineering enterprise, committed to enhancing
stakeholder value.

BHEL has:-
 Installed equipment for over 90,000MW of power
generation for Utilities, captive and Industrial users.
 Supplied over 25000 Motors with Drive Control System to power
projects, Petrochemicals Refineries, Steel, Aluminum, Fertilizer,
Cement plant, etc.
 Supplied Traction electrics and AC/DC locos over
12000 kms Railway network.
 Supplied over one million Values to Power Plants and other
Industries

BHEL - AN OVERVIEW
 The first plant of what is today known as BHEL was established
nearly 40 years ago at Bhopal & was the genesis of the Heavy Electrical
Equipment industry in India.

BHEL is today the largest Engineering Enterprise of its kind in

India with excellent track record of performance, making profits
continuously since 1971-72.

BHEL business operations cater to core sectors of the Indian Economy

like.

 Power

 Industry

 Transportation

 Transmission

 Defenses etc.

Today BHEL has

 14 Manufacturing Divisions

 9 Service Centers

 4 Power Sector Regional Centers

 150 Project sites

BHEL’s vision is to become world -class engineering enterprise,

committed to enhancing stakeholder value. The greatest strength of
BHEL is its highly skilled and committed 44,000 employees.
 Spread all over India & abroad to provide prompt and effective
service to customers.

BUSINESS SECTOR

BHEL operations are organized around business sectors to

provide a strong market orientation. These business sectors are Power
Indus and International operations.

POWER SECTOR

Power sector comprises of thermal, nuclear, gas and hydro

business. Today BHEL supplied sets account for nearly 65% of the
total installed capacity in the country as against nil till 1969-70.

 BHEL has proven turnkey capabilities for executing power projects

from concept to commissioning and manufactures boilers,
thermal turbine generator set and auxiliaries up to 500MW.

 It possesses the technology and capability to procure thermal

power generation equipment up to 1000MW.
 Co-generation and combined cycle plants have also been introduced.

 For efficient use of the high ash content coal-BHEL supplies

circulating fluidized boiler.

 BHEL manufactures 235MW nuclear sets and has also commenced

production of 500MW nuclear set.

Custom-made huge hydro sets of Francis, Elton and Kaplan types for
different head- discharge combinations are also engineered and
manufactured by BHEL.

INDUSTRY SECTOR

BHEL is a major contributor of equipment and system to important

industries like
  Cement

 Petrochemicals

 Fertilizers

 Steel paper

 Refineries

 Mining and Telecommunication

The range of system and equipment supplied including captive power

stations

 High speed industrial drive turbines

 Industrial boilers and auxiliaries

 Waste heat recovery boilers

 Gas turbines pump, valves, seamless steel tubes

 Heat exchangers

 Process control etc.

TRANSPORATION :-

BHEL supplies a wide equipment and system to Indian Railways.

 Electric locomotive

 Traction electric and traction control equipment

TELECOMMUNICATION:-

BHEL also caters to Telecommunication sector by way of

small, medium and large switching system.

BHEL has been divided into many blocks:-

1). Block-1:-
In block one turbo generator, generator, exciter motors
(A.C&D.C) are manufactured & assembled

2). Block-2:-
In block two large size fabricated assemblies\component for power
equipment are manufactured & assembled.

3) Block-3:-
In block -3 steam turbine, hydro turbines, and gas turbines,
turbines blade are manufactured & assembled

4) Block-4:-
In block -4winding for turbo generator, hydro generator, insulation
of A.C&D.C motors insulating component for turbo generator,
hydro generator motors are manufactured & assembled

5) Block-5:-
In block -5 fabricated parts of steam turbine water box, hydro
turbine turbines parts are manufactured & assembled

6) Block-6:-
In block -6 fabricated oil tanks hollow guide blades, rings,
stator frames rotor spiders are manufactured & assembled

7) Block-7:-
 In block -7all types of dies including stamping dies, stamping
for generators &motors are manufactured & assembled

8) Block-8:-
In block -8 LP heaters, ejectors, steam coolers, oil coolers, ACG
coolers, oil tanks are manufactured & assembled

MANUFACTURING DIVISIONS
 Heavy Electrical Plant, Piplani, Bhopal
 Electrical Machines Repair Plant (EMRP), Mumbai

 Transformer Plant P.O. BHEL, Jhansi.

 Bharat Heavy Electrical Limited :

 Central Foundry Forge Plant., Ranipur, Hardwar

 Heavy Equipment Repair Plant, Varanasi.

 Insulator Plant, Jagdishpur, Distt. Sultanpur.

 Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad

 High Pressure Boiler Plant & Seamless Steel Tube Plant,

Tiruchirappalli.

 Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex, Ranipet.

 Industrial Valves Plant, Goindwal.

 Electronics Division :

 Electronics Systems Division.

 Amorphous Silicon Solar Cell Plant (ASSCP).

 Electro porcelains Division.

 HEEP: AN OVERVIEW
Over the years, Bharat Heavy Electrical Limited has emerged
as world class engineering and Industrial giant, the best of its kind in
entire South East Asia. Its business profile cuts across various sectors
of engineering/power utilities and industry. The company today
enjoys national and international presence featuring in the " fortune
international-500” and is ranked among the top 12 companies of the
world, manufacturing power generation equipment. BHEL has now 14
manufacturing division, 8 service centers and 4power power sectors
regional centers besides a large number of project sites spread over
India and abroad.

The company is embarking upon an ambitious growth path through

clear vision, mission and committed values to sustain and augment its
image as a world-class enterprise.

VISION

A world-class innovating, competitive and profitable

engineering enterprise providing total business solution.

MISSION

To be the leading Indian engineering enterprise providing quality

products system and services in the field of energy, transportation,
infrastructure and other potential areas.

VALUES

 Meeting commitments made to external & internal customers

 Foster learning creative and speed of response
 Respect for dignity and potential of individual
 Loyalty and pride in the company
 Team playing

MANUFACTURING PROCESS OF TURBO

GENERATOR & STATOR BAR

BRIEF SUMMARY: ABOUT THE BAR SHOP

 This shop is meant for manufacturing of stator winding coils of
generator that may be turbo generator or hydro generator.

HR BARS
 Manufacturing of bars of different capacity depends upon the
water head available at site. The hydro generator is air called
generator of lesser length.

TURBO GENERATOR BAR

 For the turbo generator the manufacturing of bars of standard
capacity such as 100 MW, 130MW, 150MW, 210/235MW,
210/250MW. This plant has capacity and technology to
manufacturing 800 MW 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 =i.e. Turbo Generator or Hydro Generator.
H/A =i.e. Hydrogen Gas or Air.
R/D/F/I =i.e. Radial, indirect, forced, direct etc.
I/D/F =i.e. Indirect cooling, direct cooling, forced cooling.
W =i.e. cooling media used for cooling of stator coil e.g.
water.

MATERIAL CHECKING

 First we check the material of the conductor. And the total

insulation upon the conductor. The width of the copper conductor
should be:
a. For Lower bar = 8 x 2.8mm (Solid)
b. For Upper bar = 8 x 1.3mm (Solid)
c. For Hollow conductor = 8 x 4.6 x 1.5mm (Solid)
CONDUCTOR CUTTING AND END CLEANING
 This process is done by the automatic CNC machine, in this
process the length of lower bar & upper bar is decided as
following as per drawing-

 Lower Bar
a. Solid conductor length = 10,200mm (10 Plates)
b. Hollow conductor length = 10,200mm (10 Plates)
 Upper Bar
a. Solid conductor length = 10,050mm (10 Plates)
b. Hollow conductor length = 10,050mm (10 Plates)
This insulation is removed from both ends after the cutting of conductor
i.e. 500mm for both lower & upper bar.

TRANSPOSITION OF CONDUCTOR
 Transposition means changing or shifting of position of each
conductor in active care (slot) part. After cutting the required
number of conductors are arranged on the comb in staggered
manner and than bands are given to the conductor with the help of
bending die at required distance.
  Setting of die

a. Comb of setting for lower bar’s

Die 1st Die 2nd Die 3rd
2200.2mm 3735.3mm 6586.2mm
b. Comb of setting for Upper bar’s
Die 1st Die 2nd Die 3rd
2109mm 3620.2mm 6496.2mm
This process is repeated to making another half of the bar.

CROSS OVER INSULATION

 Cross over insulation is give to the conductor for the protection in

which the insulating spacer are provided at the cross over portion. In
this insulation the No-max paper is used.
Here the filter material (insulating putty of moulding micanite)
spacer is provided along the high of bar to maintain the rectangular
shape. The size of spacer should be –
1st Band = 146mm
2nd Band = 219mm
3rd Band = 292mm
STACK CONSOLIDATION OR PRESSING

 The core part of the bar stack is pressed in press under the pressure
between 70kg to 80kg (various from product to product) and the
temperature between 90 Deg.C to 160 Deg.C for a given period.
Here four bars is pressed in one time and six to eight plates are used
for pressing. After that the consolidated stack is withdrawn from the
press.

INTER STAND SHORT TEST (I.S.S.Test)

 In this test first we make the distance to the non insulating portion of
the bar. Here we check the short between any two conductor. After
this test the bars are again go for the second pressing. In which
attached full slot separator between two half bar no-max paper and
tapped with transparent film. In this test if any error is found then it
has to be rectified.

FORMING OF BAR

 In this operation the straight bar stack is formed as per overhang

profile. In this process bars should be formed on universal former
and marked for the thermal space. After it they are moved for cutting
of extra conductor.
ZERO PICKLING OF BAR END

 Pickling is the process of the cleaning of components by the

chemicals. The pickling solutions are:
a. Water = 100 parts by weight
b. Sulphuric Acid = 10 parts by weight
c. Phosphoric Acid = 5 parts by weight
d. Hydrogen per Oxide = 5 parts by weight

The temperature should be maintain 50 Deg.C to 60 Deg.C. The end

portion of bar is dipping in this solution upto 10 to 15 min.

During this pickling process some aciditic properties are effected to

the end portion of bar. So to neutralization of it dipped the bars again in
the ammonia solution. For the shining of end part the bars are dipped in
ethyal alcohol (C2H5OH) solution and dry with nitrogen Pressure.

COIL LUG MOUNTING

 In this process contact sleeve and the bottom part of the water box
are adjust at the give dimensions. The operation of mounting of
contact sleeve and bottom part of water box is complete in following
steps-
a. Check the dimension of contact sleeve and water box bottom part.
b. Stand by bar for setting of lug.
 c. Setup to the solid conductor in each row as per drawing.
d. Then insert the contact sleeve upon the solid and hollow conductor
and temporally installed to it. And also installed the bottom part of
water box.
e. Maintain the gap between contact sleeve and bottom part of water
box approx 20mm.
After the lug mounting cutting of extra solid conductor.

MAIN BRAZING

 There are the following steps to brazed the lug.

a. Stand by bar of setting for brazing.
b. Then heated the lug point through the two indictor at the temperature
of 700 Deg.C .
c. For brazing use brazing alloy L-Ag-15P by four person. This is the
silver platinum alloy wire of melting point 700 Deg.C to 750 Deg.C.
d. This Temperature is give through the laser rays.

CONDUCTOR CUTTING, FACE MILLING AND DEBBERING

 After the main brazing bars is moved for cutting of extra part of
conductors as per drawing. Here cut the end part of the bottom part
of water box and taken for face milling.
  In this process the conductor is given the accurate shaped as per the
measurement and it is taken in account that any part of the surface is
not left uneven and dull.
 Then in Debbering, the bars edges are many a time left with twigs
and sharp needle type mettle cutting known as bar and this process
of removing is known as Debbering.

FIRST PICKLING

 This is the same process of pickling which is done before the lug
mounting or zero pickling. After this pickling process the bar is
moved the brazing of top part of water box in both side.

BRAZING OF TOP PART

 Thought the induction process the top part of water box is brazed in
both side.

As per the previous main brazing first we stand by bars of setting for
brazing then we attached the top part from the bottom part of water
box. Then healed the top part by top inductors at the temperature of
400Deg.c.
 For this type of brazing use L-Ag-40Cd. This is the alloy silver
academy which have 40% cadmium and the melting point is 400 Deg.C
to 500 Deg.C. This brazing is done for both end.

After the brazing the bars is go for second pickling which is the same
process as previously explain.

WATER FLOW TEST

 Thought this test check the flow water equivalently in the hollow
conductor of the bar. There is the following steps of checking-
a. Water should be exit all the total hollow conductor.
b. If some burrs are jammed it should be removed to give very high
pressure of water and clean with the help of solid wire.
c. The main point of testing is that the water flow into the bar and exit
from the water box fall down approximately to cover 1 Mtr. From
each conductor.

NITROGEN LEAK TEST

 In this test the bar is tested for leakage into the components of bar. In
this test flow of nitrogen gas with pressure of 10kg/Cm2 to check the
leakage in to the hollow conductor. If leakage found the bar is
rejected.
THERMAL SHOCK TEST

 The cycles of hot (80 Deg.C) and cold (30 Deg.C) water are flew
thought the bar to ensure the thermal expansion and contraction of
the joints. The time of low of hot & cold water should be approx 32
to 40min and give the time between to flow of hot & cold water is 5
min. this process is applied atleast 8 hours.

HELIUM LEAKAGE TEST

 In this test the bar’s end is tested to flow of helium gas with the
given pressure if the end part of the bar is leakage then the helium
gas is covered the surface of water box and indicator indicate the
point of leakage.

INSULATION

 For the insulation sunmika therm tape or sunmika pleese tape is used
which is the combination of mica + glass + varnish. It is used for
corona protection. In this insulation to layer of pleese tape + to layer
of therm tape and after them again to mica pleese tape is used.
  Process of Insulation
a. Clean the bar.
b. Clean with chemical or thinner.
c. Taping
d. Realizing film from the mica plastic section.
In insulation the wall thickness of insulation is subjected to the generating
voltage of the machine.

IMPREGNATION AND BAKING

1. 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.
2. Micalastic system: In case of poor resin system the insulated bars
are heated under vaccum and 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
in resin and then fixture with box is baked under given temperature
for the given duration.

VIP Micalastic System

 The individual 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.

FINISHING

 The baked and dimensionally correct bars are sanded-off to

smoothen the edges and surface calibrated if required for the
dimension.

CONDUCTING VARNISH COATING

 OCP (Outer Corona Protection) Coating: The black semi-

conducting varnish coating is applied on the bar surface on the core
length.
 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.
TESTING

1. Tan Test: This test is carried out to ensure the healthiness of

dielectric (insulation) i.e. dense or rare and measured the capacitance
loss.
2. H.V. Test: The each bar is tested momentarily at high voltage
increased gradually to three times higher than rated voltage.

DISPATCHED FOR WINDING

 If the bar is passed in all the operation and testing after completing
then the bar is send for stator winding.

TURBO GENERATORS

(a) Air Cooled Generators Upto 200 Mw Range (Type:

TARI ) Salient Design Features

 Stator core and rotor winding direct

air-cooled

 Indirect cooling of stator winding

 Horizontally split casing design of

stator
  Vertically side mounted coolers in a

separate housing

 Micalastic bar type insulation system

 Separately assembled stator core and

winding for reducing the manufacturing cycle

 Brushless/static excitation system

(b) Hydrogen Cooled Turbogenerators Of 140-260 Mw Range

(Type: THRI ) Salient Design Features

 Stator core and rotor winding directly

 hydrogen cooled

 Indirect cooling of stator winding

 Rigid core bar mounting

 Micalastic insulation system

 End shield mounted bearings

 Top ripple springs in stator slots

 Ring type shaft seals

 Symmetrical ventilation.
MOTOR WINDING

9.1 Technical Requirements

(1) Count the coil groups in the anti clock wise direction locking from the

connection end.

(2) Leads of the coils groups lying on the outer periphery of the overhang

position shall be the finish and those lying on the inner periphery shall be

the start to coil groups.

(3) Leads shall be taken form the coil side lying at inner periphery of slot

No.1.

(4) The coil group No.1 shall Lie at top with its axes coinciding with the

vertical axis of the frame.

(5) Take out terminal leads 02 U2, V2, W2 for left hand side terminal box

and 02 U1, V1, W1 for right hand side terminal box. When looking

form the connection end.

Circuit diagram:-

WINDING DIAGRAM OF MOTOR WINDING

9.2 Winding data

NO. OF PHASE 3
NO. OF POLES 6
PHASE CONNECTION Y
NO. OF PARELLEL PATH 2
NO. OF COIL GROUP 18
9.3 Connection of motor winding
 CONCLUSION

The second phase of training has proved to be quite faithful.

It proved an opportunity for encounter with such huge machines like
turbo-generator hydro generator etc.

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 provides an opportunity to learn tech.
Used at proper place and time can save a lot of labour.

But there are few factors that require special mention. Training
is not carried in true spirit. It is recommended that there should be
projectors especially for trainees where presence of authorities is ensured.

However, training has proved to be satisfactory. It has allowed us an

opportunity to get an exposure of the practical implementation of
theoretical fundamentals.