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Bhel Haridwar Training Report 800 MW Bar CIM Block 4 EEE
Bhel Haridwar Training Report 800 MW Bar CIM Block 4 EEE
ON
Submitted
To: - By: -
Mr. A.K Dhiman Amit Kumar
(Manager) B.Tech
(CIM, Block-4) Electrical & Electronic Engineering
BHEL, Haridwar SRM University Haryana
1
ACKNOWLEDGEMENT
Amit Kumar
B.Tech (EEE)
SRM University Haryan
2
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
3
CHAPTER-1
1.1 Introduction
4
Fig 1.a – Rotor of Turbo Generator
5
. (1.b) -TG Stator (1.c) - Internal of stator (Front view)
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.
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CHAPTER-2
Coil & Insulation Manufacturing (CIM)
(Block-IV)
2.1 Introduction
. (2.a) (2.b)
Fig. (2.a) - Layout of CIM Block –IV; (2.b) - Main Products of CIM block
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.
7
2.2 Flow Chart
Conductor Drawn
From Store
Crossover Insulation
Final Pressing
Radius Milling
I.S.T
NOT OK
Water Flow
NOT OK
Forming
NEXT PAGE
8
Contact Sleeve &
Bottom Mounting
Main Brazing
Nitrogen NOT OK
Test
Thermal Shock
Mat Filling
Inner Corona
Protection (ICP)
Main Body
Insulation
Impregnation
NEXT PAGE
9
Impregnation
Curing
Borescope
Protection Warping Of
ECP
Conductive Wrapping
of Slot
Packing Of Bar
10
CHAPTER 3
Manufacturing Process of 800 MW Bars
(Bay I & II)
**FACT**
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Upper Bar:-
Type of Conductor Size Length (mm) Number of
conductor (mm) conductor
Solid Copper 14*1.8 11282 50
Hollow 14*4 11282 10
hollow
Lower Bar:-
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)
12
. (3.2.c) (3.2.d)
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horizontally in the Pressing Machine. The pressing machines are also provided
with the heaters
Each bar is loaded on each tier of heating plate and it is then provided with an
initial pressure of 35±5 kg/cm2 and an initial temperature of 100°-110° C. Then
the temperature is allowed to raise to the maximum of 160°C, this temperature is
kept for at least one hour with a final pressure of 80±10 kg/cm2 vertically and
70±10 kg/cm2 horizontally.
Then the bars are cooled and both ends of bars are cleaned with rectified spirit
and sand paper for the inter strand test.
14
If there is any kind of blockage inside the hollow conductors of the bar then it is
indicated by flow of water i.e. flow of water will be not uniform or profile is
disturbed so the bar is assumed to be chocked. Then chocked conductors are
repaired and water test is again performed to check the flow of water.
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.
15
3.10 Contact Sleeve & Bottom Mounting
After the pickling process and end cutting is done, contact
sleeve and water box bottom parts are mounted on both the ends of the bar.
Contact sleeve - it is a rectangular sleeve which is used to make contact between
upper and lower bars when laid out in the generator to form a complete coil.
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.
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super-heated. Induction heating is hence faster and even more efficient than
thermal heating.
When the contact sleeve becomes red hot at 750°C, the brazing material (alloy of
Ag+Cu+Au+Brass) is then pushed to fill the air gaps and to consolidate the
contact sleeve on the bar. It is then allowed to cool.
The hollow Steel conductors are welded with water box
bottom part through process of TIG welding. This is done by CNC Machine.
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.
(3. 9.a)
Fig. (3.9.a) - TIG Welding
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3.12 Nitrogen Test & Dye Penetration Test
This test is performed to check any leakage in bar i.e. to
check the TIG welding. This test is similar to puncture test that is inflated tube is
dipped in water for any leakage, the air bubbles gives us the exact position of the
puncture. Similarly, this test is performed with the help of Nitrogen gas.
In this test, nitrogen at a pressure of 10Kg/cm2 is forced from one end of the bar
and other end of the bar is blocked then the pressure of 10Kg/cm2 is maintained
and both the ends of the bar are dipped in water. If bubbles appear then welding
is done again and same test is performed to ensure TIG welding of water box top
and bottom part is done properly.
Dye Penetration Test used to locate surface-breaking defects in all non-porous
materials. Liquid with certain dye is applied on water box and check for breaks
on surface.
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.Fig (3.13.a) – Layout for thermal shock of bar.
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.
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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.
• 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
20
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.
• 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.
21
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
22
When the bars under goes all the previous step successfully
then they are packed and ready for shipment i.e. sending of the bars to BLOCK -
1. There they are going to place in stator core of Turbo Generator.
CHAPTER 4
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
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❖ 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.
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.
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CHAPTER 5
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 —
25
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.
CHAPTER 6
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
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• Bharat Heavy Electricals Limited (2016). About BHEL
http://www.bhel.com/about.php
• Bharat Heavy Electricals Limited (2016). About Research & Development
http://www.bhel.com/about_rd.php
• Wikipedia, the free encyclopaedia (2016). About TIG welding, Brazing etc.
https://en.wikipedia.org
• Google Images (2016). Various Pictures https://www.google.co.in
• Machine operators (Dec-2016). Provide visiting diary notes.
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