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Last but not the least, my sincere thanks to all the staff
members of “BLOCK-4, BHEL, RANIPUR,
HARIDWAR”
Bhuwan Pratap
Singh
B.
Tech- Final Year
SEC
, Sikar (Raj.)
PREFACE
CHAPTER - I
COMPANY PROFILE
The first plant of what is today known as BHEL was established nearly 40
years ago at BHOPAL and was genius of heavy electrical equipment industry
in India. BHEL is today the largest engineering enterprise of its kind in India
with well recognized track records of performance making profits
continuously since 1971-72 it achieved a sales turnover of 1023 crore in
1977-78. BHEL caters to core sectors of the Indian economy in power,
industry, transportation,defense etc.
Power sector comprises thermal, nuclear, gas & hydro power plant
business today, BHEL supplied sets account for nearly 56, 318 MW or 65%
of the total installed capacity of 86, 636 MW in as against nit till 1969-70.
TRANSPORTATION:-
International operations:-
BHEL’s product series and projects have been exported to over so countries
ranging from UNITED STATES in the west to NEW ZEALAND in for east
INDIA is over 3000 MW. A few motable ones are 150 MW gas turbine to
GERMANY, utility boiler and open cycle gas turbine plant to MALAYSIA,
Tripoli west, power station in Libya and Turkey. In Cyprus, hydro generator
to New Zealand and hydro power plant to Thailand , Saudi Arabia, Oman ,
Greece and Egypt.
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CHAPTER - III
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.
PRODUCT’s OF BHEL
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CHAPTER - IV
BLOCKS IN BHEL
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CHAPTER – II
BHEL- AN OVERVIEW
BHEL caters to core sectors of the India economy viz. Power Generation
and Transmission, Renewable Energy, Defence etc. The wide network of
BHEL’s 14 manufacturing divisions, 4 power sector regional centers, 8
service centers, 15 regional offices and a large number of Projects sites
spread all over India and abroad enables the company to promptly serve its
customer and provide them with suaitable products, systems and services-
efficiently and at competitive prices.
BHEL has attained ISO 9001 certification for quality management and all
the manufacturing units/divisions of BHEL have been upgraded to the
latest ISO 9001:2000 version. All the major units/divisions of BHEL have
been awarded ISO 14001 certification for Environmental Management
System and OHSAS-18001 certification for Occupational Health and
Safety management System. BHEL become the first Public Sector
Company in the country to win the coveted “PRIZE” for its Haridwar unit
under the CII Exim Award for business excellence as per the globally
recognized model of European Foundation for Quality Management.
BHEL is the only PSU among the 12 Indian Companies to figure in
“Forbes Asia Fabulous 50” list. It has also won the “Business Standard
Star Public Sector Company Award 2006”. The company received MoU
Excellence Award for 2004-2005 and Merit Certificate for MoU
Excellence for 2005-2006.
Power Generation
BHEL has proven turnkey capabilities for executing power projects from
Concept to Commissioning. It possesses the technology and capability to
produce Thermal sets with super critical parameters upto 1000MW unit
rating and gas turbine generator sets of upto 300MW units rating. Co-
generating and Combined cycle plants have been introduce to achieve
higher plant efficiencies. To make efficient use of the high-ash-content
coal available in India. BHEL also supplies circulating Fluidized Bed
Combustion (CFBC) boilers for Thermal plants.
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CHAPTER - VI
2- Also manufactured heavy duty generator stator bars with New CNC M/c
No, 3-464 i.e. Robol bar centre.
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.
(Note:- The manufacturing of Hydro Gen Stator Bars has been shifted from
BHEL Haridwar to BHEL Bhopal to since 2008.
The plant has capacity and technology to manufacture 800MW and 1000MW
generators.
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CHAPTER - VII
3. Transposition of conductor.
14. Repickling.
INSULATION CLASSIFICATION:
Class – Y upto 90 C
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.
generator or Hydro-generator.
H/A-> Second alphabet stands for the coding media used for
W-> Cooling media used for cooling of stator coil e.g. water.
Resin system:
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CHAPTER - VIII
1.Conductor Cutting :
Lower Bar :
8*2.8 mm (Solid)
L - 10200 mm c- 500 mm
U – 10050 mm c- 5 mm
Conductor size 8*4.6*1.5 mm (Hollow)
8*1.3 mm (Solid)
2. Transposition:
3. Crossover Insulation :
The pre insulation of the copper conductor may get damaged due to
mechanical bending in die during transposition, hence the insulatingspacers
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.
The consolidated oar 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.
The bar is tested for water flow test, nitrogen leak test and pressure test for
given duration.
The cycles of hot (80C) and cold (30°C) water are flew through the bar to
ensure the thermal expansion and contraction of the joints.
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.
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.
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.
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.
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CONCLUSION
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MANUFACTURING OF BAR IN BLOCK
-IV
STATOR WINDING SECTION IN BLOCK-I