Training from BHEL, Haridwar Training expoasure in Manufacturing of 500MW stator busbar

1. A
PRACTICAL TRAINING
SEMINAR ON
MANUFACTURING PROCESS
OF
500 MW STATOR BAR
AT
BHARAT HEAVY
ELECTRICALS LIMITED,
HARIDWAR
SUBMITTED TO
SHRI S C MITTAL
SHRI M K LALVANI
SUBMITTED BY
LOKESH KHATRI
ELECTRICAL ENGG.
UNIVERSITY COLLEGE OF ENGINEERING ,KOTA(RAJASTHAN)

2. 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

3. About the organization :
BHARAT HEAVY ELECTRICALS LIMITED ,HARIDWAR

4. KEY FEATURES OF BHEL :
FEATURES
DESCRIPTION
INDUSTRY
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 LIST
3. QUALITY ,SAFETY, ENVIORMENTAL
MANAGEMENT COMPANY
TOTAL TURNOVER
9.07 billion $
PRODUCTS
TURBINES, BOILERS, GENERATORS, SENSORS,
DRIVES, CIRCUITBREAKERS, SWITCHGEARS,
MOTOR etc.

5. 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
BHEL MISSION,VISION & VALUES :

6. LOCATION SHOWING THE PLANTS OF B.H.E.L OVER INDIA :
GOINDWAL
NEW DELHI
HARIDWAR
RUDRAPUR
JAGDISHPUR
JHANSI
VARANASI
BHOPAL
KOLKATA
HYDERABAD
BANGALORE
CHENNAI
RANIPET
TIRUCHIRAPALLY
HEADQUARTER
MANUFACTURING UNITS
CHECK & REPAIRING UNIT

7. B.H.E.L HARIDWAR : A GLANCE :
BHEL Hardwar divided into 8
blocks. these blocks are.
Blocks
Block -1
Description of block
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

8. BAY-1
BLOCK-4
MANUFACTURE OF
STATOR BAR OF
TURBO
GENERATORS
BAY-2
MANUFACTURE OF
STATOR BAR OF
HYDRO GEN,AC
BAY-3
MANUFACTURE OF
Insulation MATERIAL
ACC DESIGN

9. 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

10. Overview of manufacturing process :
INSULATION
CHECK
CONDUCTOR
CUTTING
TRANSPOSITION
STACK
PRESSING
BRAZING
PICKLING
PROCESS
FORMING
INTER
STRAND
SHORT TEST
WATER
TEST
NITROGEN
TEST
INTERNAL
PICKELING
BARSCOPIC
TEST
IMPREGNATI
ON & BAKING
INSULATION
HELIUM LEKAGE
TEST
THERMAL
TEST
FINISHING
WARNISH &
COATING

11. 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 :
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
UPPER BAR

12. 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.

13. 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 :
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.
BASIC SOLUTION FOR PICKELING PROCESS
SOLUTION NAME
PERCENTAGE
(%)
SULPHURIC ACID
10%
PHOSPHORIC ACID
5%
HYDROGEN
PEROXIDE
5%

14. 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.

15. 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.

16. 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

17. Impregnation:
(1) Thermo reactive system(Rich Resin System)
(2) Micalastic system(Poor Resin System)
Finishing :
Smooth the edges of impregnated bars

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

19. THANK YOU

20. ANY QUERIES
?