PROFILE OF HEEP ESTABLISHMENT AND DEVELOPMENT STAGES: DRP prepared in 1963 64 , construction started from Oct 1963.

Initial product of electric motors started from Jan 1967. Major contribution /election /commissioning completed by 1971 72 as per original DRP scope. Establishing in 1960s under the Indo- soviet agreement of 1959 and 1960 in the area of scientific, technical and industrial co-operation. Motor Facilities manufacturing technology up dated within siemens collaboration during 1984 87 . being modernized continually through Replacement, reconditing,

retrofitting, technological, operational balancing

HEEP PRODUCT PROFILE 1. THERMAL SETS: Steam turbines and generator up to 500MW capacity for utility and combined cycle applications; capability to manufacture up to 1000MW unit cycle. 2. GAS TURBINES: Gas turbines for industry and utility application; range-3 to 200 MW (ISO). Gas turbines based co-generation and combined cycle system. 3. HYDRO SETS : Custom built conventional hydro turbine of kaplan, Francis and Pelton with matching generators upto 250 MW unit size. Pump turbines with matching motor-generators Mini / micro hydro sets. Spherical butterfly and rotary valves and auxiliaries for hydro station .

4. EQUIPMENT FOR NUCLEAR POWER PLANTS: Turbines and generators upto 500MW unit size. Steam generator upto 500MW unit size. Reheaters / separators . Heat exchangers and pressure vessels.

5. CASTING AND FORGINGS: Sophisticated heavy casting and forging of creep resistant alloy steels, stainless steel and other grades of alloy meeting stringent international specifications. 6. DEFENCE PROCEDURE: Naval guns with collaboration of Italy.

BRIEF DESCRIPTION OF MANUFACTURING BLOCKS I, II, IV, V, VI, VII AND VIII Block- I Block-I, also known as Electrical Machines Block, is designed to manufacture Hydro generators, Turbo generators and Testing facilities for Turbo generators. There is also a special Test Bed for testing of turbo generators of capacity of 500 MW and above. Apart from facilities and equipment for manufacture of turbo generators, the Block also has a Bebitting Section.Bebitting of bearing liners for Turbo generators,

Turbines, Hydro generators, is carried out in this section. The Block has its own over speed balancing installation; where the dynamic balancing of Turbo generator-rotors of less than 500 MW rating is done. Rotors having higher rating are balanced in OSBT of Block-III. Fabricated components are received from fabrication blocks (Block-II, IV, VI, VIII), while other castings, forgings are received from CFFP and other sources for Turbo generators, Hydro generators and Electrical motors. Stampings are received from Stampings manufacture section; Block-VI and coils, bars, insulating details and sheet metal components are received from Block-IV. These are then machined, assembled, tested and dispatched.

Rotor Winding

Generator Testing

Block II Block-II, also known as Fabrication Block, is a feeder block for various productsSteam Turbines, Hydro Turbines, Turbo generators, Hydro generators, Electrical Machines, Apparatus and Control Gear, Aircraft and SRGM (Smooth Recoil Gun Mounting). The main processes in this Block are cutting, bending and welding of metal sheets etc. to form fabricated structures. The Block also has useful equipments like Hydraulic Bending Presses and Straightening Rollers. Other notable facilities include a CNC six-spindle drilling machine, a plasma-flame cutting machine, shot-blasting apparatus and various furnaces. The Block also has facilities for NDT (Non Destructive Testing) of various components. The following Non-Destructive tests can be conducted DP Test (Die Penetration Test), MPI (Magnetic Particle Inspection), UT (Ultrasonic Testing) and Radiography which includes X-ray and -ray testing. Block III

It Known as the TURBINE BLOCK, this is the major block for manufacturing turbines. All types of Hydro, Steam, Gas and Nuclear Turbines are manufactured and dispatched from this block. Blades of different stages are also manufactured here in this block.

Block- IV Block-IV, also called as CIM&ACM (Coil and Insulation Manufacturing & Apparatus and Control Gear Manufacturing), is a feeder block to Block-I. It is a feeder block for Class F windings for Turbo generators, Hydro generators and Class F and H insulation for AC and DC motors. It also supplies all insulation components for Turbo generators, Hydro generators, and motors. Control panels for Turbo generators, Hydro generators, Industrial drives for motors, and Turbo generators auxiliaries, contactor relays and master controllers are also manufactured in this Block.

Block -V Block-V, also called as Fabrication and Forge Block is again a feeder block. Fabrication work being done in this block is of Steam Turbine parts like Condenser, Water Box (Front and Rear), assemblies of LP cylinder, Storage Tanks etc.; Hydro Turbine parts, Hydro generator and motor assemblies and components. Forging of

carbon, alloy and stainless steels are manufactured in this block. It is equipped with pneumatic hammers, gas-fired furnaces and hydraulic manipulators.

Block -VI Block-VI, also called as Fabrication Block, is also a feeder block. Manufacturing of all types of dies, including stamping dies and press forms is carried out in one bay, while stamping for Turbo generators, Hydro generators and motors are manufactured in other bay. The Block is equipped with Welding, Drilling, Shot Blasting and CNC Flame cutting facilities. The tems manufactured in this block are Condensers, Steam Turbine components (Oil Tanks and Hollow Guide Blades), Hydro Turbine components (Stay Rings), Hydro generator and motors (Stator Frames) etc.

Block -VII Block-VII, also called as Woodworking section, is also a feeder block. Bay-I, known as Packaging section manufactures packages for packaging and dispatch of various products.

Block- VIII Block-VIII, also called as Heat Exchanger Block, is designed to manufacture Heat Exchanger Units for Steam Turbines, Hydro Turbines, Turbo generators, Hydro generators etc. Blanks cut to size and shape are received from Block-II and Block-VI. These are assembled, welded and machined. The items manufactured here are LP Heater, Ejectors, Gland Steam Coolers, Oil Coolers, Oil Tanks, Bearing Covers, Turbine shaft Covers, Oil Bath and Thrust Bearings. Block 1:Block-I, also known as Electrical Machines Block, is designed to manufacture Hydro generators, Turbo generators and Testing facilities for Turbo generators. There is also a special Test Bed for testing of turbo generators of capacity of 500 MW and above. Apart from facilities and equipment for manufacture of turbo generators, the Block also has a Bebitting Section. Bebitting of bearing liners for Turbo generators, Turbines, Hydro generators, is carried out in this section. The Block has its own over

speed balancing installation; where the dynamic balancing of Turbo generator-rotors of less than 500 MW rating is done. Rotors having higher rating are balanced in OSBT of Block-III. Fabricated components are received from fabrication blocks (Block-II, IV, VI, VIII), while other castings, forgings are receivedfrom CFFP and other sources for Turbo generators, Hydro generators and Electrical motors. Stampings are received from Stampings manufacture section; Block-VI and coils, bars, insulating details and sheet metal components are received from Block-IV. These are then machined, assembled, tested and dispatched.

Manufacturing process of turbo generator:1.Stator Frame Fabrication:Firstly the cutting, bending, welding and N.D.T testing of stator frame and End Shield is done in block 2.Material used for stator frame and End Shield is Carbon Steel.

CUTTING:CNC Gas and CNC Plasma is used for cutting at 6000 *C.Gas used for Gas cutting is Oxygen and Acetylene and for Plasma cutting it is Argon, Hydrogen and Nitrogen.

DRILLING:After cutting drilling of material is done. BENDING:Three Roll Bending is used for Bending the sheets. WELDING:Arc welding is used to weld the parts and bend material and For some parts gas welding is also used.

N.D.T :-After the welding NON DESTRUCTIVE TESTING (N.D.T) Of the material is done. 2.Stator Frame Machined:-

HOLES:Holes are formed of dia 36 where End Shield Is to be Bolted. INTERNAL DIA.:Internal dia is formed according to The drawing.

COOLING WINDOW:Cooling windows are also Formed during machining.

3.Hydraulic Testing:After the drilling hydraulic testing of frame is done at high 8,10kg/cm2. Pressure of 2, 5,

4.Core Building:Than frame send to the core department in block-1 Process of Core Department:1. Elastic Property of Body is Checked. 2. Baskets are formed: Total 7 Baskets in one stator body and in one Basket 3 Spring 2 vertical and 1 horizontal. Vertical springs are to bear the load Horizontal spring is to control the vibration. 3. Stator body placed in Core pit vertically.

5. Stator Winding: - During this process Electrical winding of the stator like bars are Inserted with insulation and total 24 core bars are inserted which are formed of stainless steel at the Turbine end and core bar of Mild Steel at the Exciter end and one core bar is of 6 mt.Headers are also inserted during winding which are used for the entry of cold water and exit of the hot water. Stamping are inserted in the stator which are Formed of Silicon Steel. It is of .5mm in width and 70mm Stamping used in one package and after each package Ventilation is used for the flow of Hydrogen as a coolant and total 87 Packages are used. Dove Tails Bars are inserted and then pressing of packages is done. At the ends of packages End Stampings are used for the external Support.

 A Core building of stamping is formed and coil are inserted during winding and than this core building is transfer to impregnation plant. Impregnation Process: Pre-heating in curing oven for about one hour. Drying under vacuum (<= 0.1 mbar) for 15 hrs. Impregnation with resin mix and pressure increase gradually to ensure filling of voids. Curing in oven at 145c for minimum 8 hours Epoxy resin fills all gaps/ voids by capillary action without blocking vent canals due to its low viscosity

6.End Shield Fabrication:-End shield fabrication is done in block 2 as per Requirements.

7.End Shield Machined:-After fabrication End shield machined is done in Block 1.

Process of End Shield machining:1. Stator joining Holes are drilled. 2. End to End shield Holes. 3. Surface Machining. 4. Cooler windows. 5. Blue Matching. 8.Pneumatic Testing:-After the End Shield is machined Pneumatic testing (air leakage testing) is done at 6 kg/cm2 for max 4 hrs.

9. Rotor Forging:-Forging of the Rotor shaft is done in Foundry plant .

10.Rotor Machined:-After the forging Rotor shaft is machined.

Process of Rotor Machining:1. Final dia of shaft is checked. 2. Slot milling is done for the insertion of Coils. 3. Coupling Holes for coupling at Turbine and Exciter end are formed.

11.Rotor Winding:-In this process Electrical winding of 250 MW,500MW AND 600 MW of the Rotor is done.

Process of Rotor Winding:1.Insertion of coil is done in two parts i.e two poles are there and in each pole 7 coil in each pole and total 14 coils in two pole and one coil is formed by the 11 long strips and they are joined by the insulating material called as Texolite. 2.Than four pins are formed at the exciter side end for the current supply. 3.Now heating is done at 130 C for insulation and again heating is done at 160 C. 4.Than Ritter ring is used to cover the winding. 5.At last Rotor balancing is done at 3600 rpm in Balancing Tunnel.

12.Final Assembly:-Now final assembly of generator is done. Process of Final assembly:-

1. Wound Stator and Wound Rotor are assembled at testing bed. 2. Wound Rotor is inserted in the wound Stator with the help of high capacity cranes. 3. After the insertion of Rotor following products are inserted for the smooth and safe
running of Generator. Primary water tank at the top of the Generators. Bearings in the End Shield. Inner oil catchers. Outer oil catchers. Air gap seal rings. Seal body +Seal rings. Baffels rings for circulation of Hydrogen. Terminal box. Terminal bushings. Hydrogen coolers in End shield. Support ring used at the Exciter End. Magnetic shunt used at Exciter and Turbine End to reduce the leakage of flux.

Support Ring for the over hang winding of wound Stator. At last End Shields are fitted. Now the Generators Testing is done.

ENGINEERING CAPABILITIES -EXTENDING LIMITS WITH LATEST TECHNIQUES BHEL possesses very strong engineering base, R&D

infrastructure, very precise CNC & conventional machine tools, sophisticated technologies and capabilities to produce hydro-generators of capacity up to 300 MW based on customers requirements as per national /international standards. BHEL has the latest hardware and computer software for design development of large capacity (> 250 MW) and large size hydro-generators.

Latest
integrated used.

computational manufacturing

techniques like

for CAD,

design FEM,

analysis CAM etc.

and are

Use of solid modelling, finite element modelling and further down stream applications for solution of design structure, heat transfer, electro-magnetic applications etc. for optimisation. The computer and software is also used for which thermal are network vital

solutions

ventilation

system,

parameters for large capacity machines

HYDROGEN AND WATER COOLED TURBO GENERATORS OF 500 MW RANGE (TYPE: THDF)

SALIENT DESIGN FEATURES 1 Stator winding directly water- cooled 2 Rotor winding directly hydrogen cooled (axial) 3 Leaf spring suspension of stator core

4 Micalastic insulation system 5 End shield mounted bearings 6 Support ring for stator over hang 7 Magnetic shunt to trap end leakage flux 8 Ring type shaft seals with double flow 9 Multistage compressor and vertical coolers on turbine end 10 Brushless/static excitation 11 Integral coupling of rotor

HYDROGEN COOLED TURBOGENERATORS OF 140-260 MW RANGE (TYPE: THRI)

SALIENT DESIGN FEATURES 1. Stator core and rotor winding directly hydrogen cooled 2. Indirect cooling of stator winding 3. Micalastic insulation system 4. End shield mounted bearings 5. Ring type shaft seals 6. Symmetrical ventilation. 7. Brushless/static excitation 8. Integral coupling of rotor

HYDROGEN AND WATER COOLED TURBOGENERATORS OF 500 MW RANGE (TYPE: THDF-115/59) SALIENT DESIGN FEATURES

Stator winding directly water-cooled Rotor winding directly hydrogen cooled (axial) Leaf spring suspension of stator core Micalastic insulation system End shield mounted bearings Support ring for stator over hang Magnetic shunt to trap end leakage flux Ring type shaft seals with double flow Multistage compressor and vertical coolers on turbine end Brushless/static excitation Integral coupling of rotor

HYDROGEN AND WATER COOLED TURBOGENERATORS OF 200-235 MW RANGE (TYPE: THW) SALIENT DESIGN FEATURES Stator winding directly water- cooled Rotor winding directly hydrogen cooled by gap pickup method Resiliently mounted stator core on flexible core bars Thermo reactive resin rich insulation for stator winding Top ripple springs in stator slots Enclosed type slip rings with forced ventilation Ring/thrust type shaft seals Two axial fans for systematic ventilation and four Hydrogen Coolers Static excitation

TURBO GENERATOR