Lokesh Training report from BHEL

A PRACTICAL TRAINING

SEMINAR ONMANUFACTURING PROCESS

OF500 MW STATOR BAR

ATBHARAT HEAVY

ELECTRICALS LIMITED,HARIDWAR

SUBMITTED TO SUBMITTED BY SHRI S C MITTAL LOKESH KHATRISHRI M K LALVANI ELECTRICAL ENGG. UNIVERSITY COLLEGE OF ENGINEERING ,KOTA(RAJASTHAN)

Table of contents About the organization B.H.E.L Haridwar: A Glance Over view of 500 MW stator bar Manufacturing process of 500 MW Stator Bar

About the organization : BHARAT HEAVY ELECTRICALS LIMITED ,HARIDWAR

KEY FEATURES OF BHEL :FEATURES DESCRIPTIONINDUSTRY 1. HEAVY ELECTRICAL EQUIPMENT PLANT

2. POWER GENERATION

ESTABLISHED IN 1964

HEADQUARTER NEW DELHI,INDIA

AWARDS & RANK 1. LARGEST PSU WITH ‘MAHARATNA STATUS’2. 4TH RANK IN FORBES 50 LIST3. QUALITY ,SAFETY, ENVIORMENTAL MANAGEMENT COMPANY

TOTAL TURNOVER 9.07 billion $

PRODUCTS TURBINES, BOILERS, GENERATORS, SENSORS, DRIVES, CIRCUITBREAKERS, SWITCHGEARS, MOTOR etc.

BHEL MISSION,VISION & VALUES :

TYPE DESCRIPTION

DIVISIONS 15 MANUFACTURING, 2 REPAIR, 8 REGIONAL, 8 SERVICE CENTERS

CAPACITY 59% IN INDIA’S TOTAL INSTALLED GENERATING CAPACITY

EMPLOYMENT 49,280

EXPORTS TO ABOUT 21 COUNTRIES

LOCATION SHOWING THE PLANTS OF B.H.E.L OVER INDIA :

HEADQUARTER

MANUFACTURING UNITS

CHECK & REPAIRING UNIT

NEW DELHI

KOLKATA

VARANASI

GOINDWAL

HARIDWARRUDRAPUR

JAGDISHPURJHANSI

BHOPAL

HYDERABAD

BANGALORERANIPET

TIRUCHIRAPALLY

CHENNAI

B.H.E.L HARIDWAR : A GLANCE : BHEL Hardwar divided into 8 blocks. these blocks are.

Blocks Description of block

Block -1 Machine block(Turbo generators & Exciter manufactured )

Block-2 Power equipment manufactured & Assembled

Block-3 Turbine section

Block-4 Coil & insulation manufacturing block

Block-5 Water box & turbine parts

Block-6 Stator frames & rotor blades manufactured

Block-7 Stampings & Dies for motor & generator

Block-8 Coolers & oil tanks

BLOCK-4 BAY-2

BAY-1

BAY-3

MANUFACTURE OF STATOR BAR OF

TURBO GENERATORS

MANUFACTURE OF STATOR BAR OF

HYDRO GEN,AC

MANUFACTURE OF Insulation MATERIAL

ACC DESIGN

MANUFACTURING OF 500 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.

STATOR BARS

Overview of manufacturing process :

INSULATION CHECK

CONDUCTOR CUTTING TRANSPOSITION STACK

PRESSING

INTER STRAND

SHORT TEST

FORMINGPICKLING PROCESS

BRAZING

WATERTEST

NITROGENTEST

INTERNAL PICKELING

BARSCOPIC TEST

THERMAL TEST

HELIUM LEKAGE TESTINSULATIONIMPREGNATI

ON & BAKING

FINISHING WARNISH & COATING

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

Conductor cutting : It is done by C.N.C MACHINE. LOWER BAR :

UPPER BAR

CONDUCTOR SIZE LENGTH NO. OF CONDUCTORS

8*4.6*1.5mm hollow 10200 mm Hollow-20

8*2.8mm solid 10200 mm Solid-20

CONDUCTOR SIZE Length NO. OF CONDUCTORS

8*4.6*1.5mm(Hollow) 10500mm Hollow – 20

8*1.3mm(Solid) 10500mm Solid- 40

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.

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

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

FORMING FIG.

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.

SOLUTION NAME PERCENTAGE(%)

SULPHURIC ACID 10%

PHOSPHORIC ACID 5%

HYDROGEN PEROXIDE

5%

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.

Internal pickling : 1). Done for cleaning of hollow conductors.

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.

Thermal shock fig.

Helium leakage test : (1)Test is done in front of customer (2) By passing the helium inside the bar. (3). It pass at presssure of 11kg/cmsq.

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

Impregnation: (1) Thermo reactive system(Rich Resin System) (2) Micalastic system(Poor Resin System)

Finishing : Smooth the edges of impregnated bars

Conductor varnish and Coating (1) ECP(End corona protection) coating (2)OCP(Outer corona protection)coating

THANK YOU

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