A

Seminar Report
On
Practical Training Undergone At
“BHARAT HEAVY ELECTRICALS LIMITED”
Submitted For

In partial fulfillment for the award of the degree for

Bachelor of Technology
In
Electrical Engineering

(2009)

SUBMITTED TO :
SUBMITTED BY:
Er. A.K.Dhiman
Deepika Mittal (Sr. ENGR.)
Roll No:12
Block - IV Electrical
Engineering
B.H.E.L. Haridwar

DEPARTMENT OF ELECTRICAL ENGINEERING

ARYA INSTITUTE OF ENGINEERING AND TECHNOLOGY
RAJASTHAN TECHNICAL UNIVERSITY

PREFACE
 Practical knowledge means the visualization of the
knowledge, which we read in our books. For this, we perform
experiments and get observations. Practical knowledge is very
important in every field. One must be familiar with the problems
related to that field so that he may solve them and become a
successful person.

After achieving the proper goal in life, an engineer has to

enter in professional life. According to this life, he has to serve an
industry, may be public or private sector or self-own. For the
efficient work in the field, he must be well aware of the
practical knowledge as well as theoretical knowledge.

To be a good engineer, one must be aware of the industrial

environment and must know about management, working in such a
industry, labor problems etc., so that he can tackle them
successfully.

Due to all the above reasons and to bridge the gap between
theory and practical, our engineering curriculum provides a practical
training of 30 days. During this period, a student works in the
industry and gets all type of experience and knowledge about
the working and maintenance of various types of machinery.
I have undergone my 30 days training (after VI Semester) at
BHARAT HEAVY ELECTRICALS LIMITED. This report is
based on the knowledge, which I acquired during my 30 days
training period at the plant.
 INDEX

S.No.

01. INTRODUCTION

02. BHEL-A Brief Profile

03. BHEL - AN OVERVIEW

04. HEEP: AN OVERVIEW

05. BRIEF SUMMARY OF THE BAR SHOP

06. TYPES OF TURBOGENERATORS

07. MATERIAL CHECKING

08. CONDUCTOR CUTTING AND END CLEANING

09. TRANSPOSITION OF CONDUCTORS

10. CROSSOVER INSULATION

11. PRESSING

12. ISS- TEST

13. FORMING OF BAR

14. ZERO PICKLING OF BAR END

15. COIL LUG MOUNTING

16. MAIN BRAZING

17. CONDUCTOR CUTTING, DEBBERING AND FACE MILLING

`18. FIRST PICKLING

19 BRAZING OF TOP PART

20. WATER FLOW TEST

21. NITROGEN LEAK TEST

22 THERMAL SHOCK TEST

23 HELIUM LEAKAGE TEST

24. INSULATION

25. IMPREGNATION AND BAKING

26. FINISHING

27. CONDUCTING VARNISH COATING

28. TESTING

28.1 TAN-DELTA TEST

28.2 HIGH VOLTAGE TEST

29. DISPATCHED FOR WINDING

30. MOTOR WINDING

31. CONCLUSION
 INTRODUCTION
In 1956, India took a major step towards the
establishment of its heavy engineering industry when Bharat
Heavy Electrical Ltd., the first heavy electrical manufacturing
unit of the country was setup at Bhopal. It progressed rapidly and
three more factories went into production in 1965. The main aim of
establishing BHEL was to meet the growing power requirement of the
country.

B.H.E.L appeared on the power map of India in 1969 when the

first unit supplied by it was commissioned at the Basin Bridge
Thermal Power Station in Tamil Nadu. Within a decade, BHEL
had commissioned the 100 unit at Santaldih. West Bengal.
BHEL had taken India from a near total dependence on imports to
complete self-reliance in this vital area of power plant equipment
BHEL has supplied 97% of the power generating equipment.
BHEL has already supplied generating equipment to various
utilities capable of generating over 18000 MW power. Today
BHEL can produce annually; equipment capable of generating
6000MW. This will grow further to enable BHEL to meet all of
India’s projected power equipment requirement. As well as sizeable
portion of export targets.

Probably the most significant aspect of BHEL’s

growth has been it’s
diversification. The constant reorientation of the organization to meet
the varied needs in
time with time a philosophy that has led to the development of
a total capability from concepts to commissioning not only in
the field of energy but also in industry and
transportation.
 In the world power scene, BHEL ranks among the top ten
manufactures of power
plant equipment and in terms of the spectrum of products and services
offered, it is right
on top. BHEL’s technological excellence and turnkey capabilities
have won it worldwide
recognition. Over 40 countries in the world over have placed orders
with BHEL covering
individual equipment to complete power stations on a turnkey basis.

In 1978-79 export earnings reached Rs. 122 crores, the highest

for any one-year.
BHEL has its headquarters at New Delhi. Its operations
are spread over 11
manufacturing plants and number of engineering and service divisions
located across the
country/ the service divisions includes a network of regional
branch offices throughout
India.
 BHEL-A Brief Profile

BHEL is the largest engineering and manufacturing enterprise

in India in the energy-related / infrastructure sector, today. BHEL is
ushering in the indigenous Heavy Electrical Equipment industry in
India-a dream that has been more than realized with a well-
recognized track record of Performa

A widespread network comprising of 14 manufacturing

companies, which have international recognition for its commitment
towards quality. With an export presence in more than 60 countries,
BHEL is truly India’s ambassador to the world. BHEL’s vision is
to become world class engineering enterprise, committed to
enhancing stakeholder value.

BHEL has:-
 Installed equipment for over 90,000MW of power
generation for Utilities, captive and Industrial users.
 Supplied over 25000 Motors with Drive Control System to
power projects, Petrochemicals Refineries, Steel, Aluminum,
Fertilizer, Cement plant, etc.
 Supplied Traction electrics and AC/DC locos over
12000 kms Railway network.
 Supplied over one million Values to Power Plants and other
Industries

BHEL - AN OVERVIEW
 The first plant of what is today known as BHEL was established
nearly 40 years ago at Bhopal & was the genesis of the Heavy
Electrical Equipment industry in India.

BHEL is today the largest Engineering Enterprise of its

kind in India with excellent track record of performance, making
profits continuously since 1971-72.

BHEL business operations cater to core sectors of the Indian

Economy like.

 Power

 Industry

 Transportation

 Transmission

 Defenses etc.

Today BHEL has

 14 Manufacturing Divisions

 9 Service Centers

 4 Power Sector Regional Centers

 150 Project sites

BHEL’s vision is to become world -class engineering

enterprise, committed to enhancing stakeholder value. The
greatest strength of BHEL is its highly skilled and committed
44,000 employees.

Spread all over India & abroad to provide prompt and effective
service to customers.

BUSINESS SECTOR

BHEL operations are organized around business sectors to

provide a strong market orientation. These business sectors are
Power Indus and International operations.

POWER SECTOR

Power sector comprises of thermal, nuclear, gas and hydro

business. Today BHEL supplied sets account for nearly 65% of
the total installed capacity in the country as against nil till 1969-
70.

 BHEL has proven turnkey capabilities for executing power

projects from concept to commissioning and manufactures
boilers, thermal turbine generator set and auxiliaries up to
500MW.

 It possesses the technology and capability to procure

thermal power generation equipment up to 1000MW.
 Co-generation and combined cycle plants have also been
introduced.

 For efficient use of the high ash content coal-BHEL supplies

circulating fluidized boiler.
  BHEL manufactures 235MW nuclear sets and has also
commenced production of 500MW nuclear set.

Custom-made huge hydro sets of Francis, Elton and Kaplan types

for different head- discharge combinations are also engineered and
manufactured by BHEL.

INDUSTRY SECTOR

BHEL is a major contributor of equipment and system to

important industries like

 Cement

 Petrochemicals

 Fertilizers

 Steel paper

 Refineries

 Mining and Telecommunication

The range of system and equipment supplied including captive power

stations
  High speed industrial drive turbines

 Industrial boilers and auxiliaries

 Waste heat recovery boilers

 Gas turbines pump, valves, seamless steel tubes

 Heat exchangers

 Process control etc.

TRANSPORATION :-

BHEL supplies a wide equipment and system to Indian

Railways.

 Electric locomotive

 Traction electric and traction control equipment

TELECOMMUNICATION:-

BHEL also caters to Telecommunication sector by way of

small, medium and large switching system.

BHEL has divided into many blocks:-

1). Block-1:-
In block one turbo generator, generator, exciter motors
(A.C&D.C) are manufactured & assembled

2). Block-2:-
In block two large size fabricated assemblies\component for
power equipment are manufactured & assembled.

3) Block-3:-
In block -3 steam turbine, hydro turbines, and gas turbines,
turbines blade are manufactured & assembled

4) Block-4:-
In block -4winding for turbo generator, hydro generator,
insulation of A.C&D.C motors insulating component for turbo
generator, hydro generator motors are manufactured &
assembled

5) Block-5:-
In block -5 fabricated parts of steam turbine water box,
hydro turbine turbines parts are manufactured & assembled

6) Block-6:-
In block -6 fabricated oil tanks hollow guide blades, rings,
stator frames rotor spiders are manufactured & assembled

7) Block-7:-
In block -7all types of dies including stamping dies,
stamping for generators &motors are manufactured & assembled

8) Block-8:-
In block -8 LP heaters, ejectors, steam coolers, oil coolers, ACG
coolers, oil tanks are manufactured & assembled

MANUFACTURING DIVISIONS
 Heavy Electrical Plant, Piplani, Bhopal
 Electrical Machines Repair Plant (EMRP), Mumbai

 Transformer Plant P.O. BHEL, Jhansi.

 Bharat Heavy Electrical Limited :

 Central Foundry Forge Plant., Ranipur, Hardwar

 Heavy Equipment Repair Plant, Varanasi.

 Insulator Plant, Jagdishpur, Distt. Sultanpur.

 Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad

 High Pressure Boiler Plant & Seamless Steel Tube Plant,

Tiruchirappalli.

 Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex,

Ranipet.

 Industrial Valves Plant, Goindwal.

 Electronics Division :

 Electronics Systems Division.

 Amorphous Silicon Solar Cell Plant (ASSCP).

 Electro porcelains Division.

BANGALORE
 Component Fabrication Plant, Rudrapur.
 Piping Centre, Chennai.
 Heavy Electrical Equipment Plant,
 Regional Operations Division, New Delhi

HEEP: AN OVERVIEW
Over the years, Bharat Heavy Electrical Limited has
emerged as world class engineering and Industrial giant, the best of
its kind in entire South East Asia. Its business profile cuts across
various sectors of engineering/power utilities and industry. The
company today enjoys national and international presence
featuring in the " fortune international-500” and is ranked among
the top 12 companies of the world, manufacturing power generation
equipment. BHEL has now 14 manufacturing division, 8 service
centers and 4power power sectors regional centers besides a
large number of project sites spread over India and abroad.

The company is embarking upon an ambitious growth path

through clear vision, mission and committed values to sustain and
augment its image as a world-class enterprise.

VISION

A world-class innovating, competitive and profitable

engineering enterprise providing total business solution.
 MISSION

To be the leading Indian engineering enterprise providing

quality products system and services in the field of energy,
transportation, infrastructure and other potential areas.

VALUES

 Meeting commitments made to external & internal

customers
 Foster learning creative and speed of response
 Respect for dignity and potential of individual
 Loyalty and pride in the company
 Team playing
 MANUFACTURING PROCESS OF
TURBO GENERATOR & STATOR BAR

BRIEF SUMMARY: ABOUT THE BAR SHOP

 This shop is meant for manufacturing of stator winding coils of
generator that may be turbo generator or hydro generator.

HR BARS
 Manufacturing of bars of different capacity depends upon the
water head available at site. The hydro generator is air called
generator of lesser length.

TURBO GENERATOR BAR

 For the turbo generator the manufacturing of bars of standard
capacity such as 100 MW, 130MW, 150MW, 210/235MW,
210/250MW. This plant has capacity and technology to
manufacturing 800 MW generators.
TYPE 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
T =i.e. Turbo Generator or Hydro Generator.
H/A =i.e. Hydrogen Gas or Air.
R/D/F/I =i.e. Radial, indirect, forced, direct etc.
I/D/F =i.e. Indirect cooling, direct cooling, forced cooling.
W =i.e. cooling media used for cooling of stator coil
e.g. water.

MATERIAL CHECKING

 First we check the material of the conductor. And the total

insulation upon the conductor. The width of the copper
conductor should be:
a. For Lower bar = 8 x 2.8mm (Solid)
b. For Upper bar = 8 x 1.3mm (Solid)
c. For Hollow conductor = 8 x 4.6 x 1.5mm (Solid)
CONDUCTOR CUTTING AND END CLEANING
 This process is done by the automatic CNC machine, in this
process the length of lower bar & upper bar is decided as
following as per drawing-

 Lower Bar
a. Solid conductor length = 10,200mm (10
Plates)
b. Hollow conductor length = 10,200mm (10 Plates)
 Upper Bar
a. Solid conductor length = 10,050mm (10
Plates)
b. Hollow conductor length = 10,050mm (10 Plates)
This insulation is removed from both ends after the cutting of
conductor i.e. 500mm for both lower & upper bar.

TRANSPOSITION OF CONDUCTOR
 Transposition means changing or shifting of position of each
conductor in active care (slot) part. After cutting the required
number of conductors are arranged on the comb in staggered
manner and than bands are given to the conductor with the
help of bending die at required distance.
  Setting of die
a. Comb of setting for lower bar’s
Die 1st Die 2nd Die 3rd
2200.2mm 3735.3mm 6586.2mm
b. Comb of setting for Upper bar’s
Die 1st Die 2nd Die 3rd
2109mm 3620.2mm 6496.2mm
This process is repeated to making another half of the bar.

CROSS OVER INSULATION

 Cross over insulation is give to the conductor for the protection

in which the insulating spacer are provided at the cross over
portion. In this insulation the No-max paper is used.
Here the filter material (insulating putty of moulding
micanite) spacer is provided along the high of bar to maintain
the rectangular shape. The size of spacer should be –
1st Band = 146mm
2nd Band = 219mm
3rd Band = 292mm
STACK CONSOLIDATION OR PRESSING

 The core part of the bar stack is pressed in press under the
pressure between 70kg to 80kg (various from product to
product) and the temperature between 90 Deg.C to 160 Deg.C
for a given period. Here four bars is pressed in one time and six
to eight plates are used for pressing. After that the consolidated
stack is withdrawn from the press.

INTER STAND SHORT TEST (I.S.S.Test)

 In this test first we make the distance to the non insulating

portion of the bar. Here we check the short between any two
conductor. After this test the bars are again go for the second
pressing. In which attached full slot separator between two half
bar no-max paper and tapped with transparent film. In this test if
any error is found then it has to be rectified.

FORMING OF BAR

 In this operation the straight bar stack is formed as per overhang

profile. In this process bars should be formed on universal
former and marked for the thermal space. After it they are
moved for cutting of extra conductor.
ZERO PICKLING OF BAR END

 Pickling is the process of the cleaning of components by the

chemicals. The pickling solutions are:
a. Water = 100 parts by weight
b. Sulphuric Acid = 10 parts by weight
c. Phosphoric Acid = 5 parts by weight
d. Hydrogen per Oxide = 5 parts by weight

The temperature should be maintain 50 Deg.C to 60 Deg.C. The

end portion of bar is dipping in this solution upto 10 to 15 min.

During this pickling process some aciditic properties are

effected to the end portion of bar. So to neutralization of it dipped the
bars again in the ammonia solution. For the shining of end part the
bars are dipped in ethyal alcohol (C2H5OH) solution and dry with
nitrogen Pressure.
COIL LUG MOUNTING

 In this process contact sleeve and the bottom part of the water
box are adjust at the give dimensions. The operation of
mounting of contact sleeve and bottom part of water box is
complete in following steps-
a. Check the dimension of contact sleeve and water box bottom
part.
b. Stand by bar for setting of lug.
c. Setup to the solid conductor in each row as per drawing.
d. Then insert the contact sleeve upon the solid and hollow
conductor and temporally installed to it. And also installed the
bottom part of water box.
e. Maintain the gap between contact sleeve and bottom part of
water box approx 20mm.
After the lug mounting cutting of extra solid conductor.
MAIN BRAZING

 There are the following steps to brazed the lug.

a. Stand by bar of setting for brazing.
b. Then heated the lug point through the two indictor at the
temperature of 700 Deg.C .
c. For brazing use brazing alloy L-Ag-15P by four person. This is
the silver platinum alloy wire of melting point 700 Deg.C to 750
Deg.C.
d. This Temperature is give through the laser rays.

CONDUCTOR CUTTING, FACE MILLING AND DEBBERING

 After the main brazing bars is moved for cutting of extra part of
conductors as per drawing. Here cut the end part of the bottom
part of water box and taken for face milling.
 In this process the conductor is given the accurate shaped as per
the measurement and it is taken in account that any part of the
surface is not left uneven and dull.
 Then in Debbering, the bars edges are many a time left with
twigs and sharp needle type mettle cutting known as bar and this
process of removing is known as Debbering.
FIRST PICKLING

 This is the same process of pickling which is done before the lug
mounting or zero pickling. After this pickling process the bar is
moved the brazing of top part of water box in both side.

BRAZING OF TOP PART

 Thought the induction process the top part of water box is

brazed in both side.

As per the previous main brazing first we stand by bars of

setting for brazing then we attached the top part from the bottom
part of water box. Then healed the top part by top inductors at the
temperature of 400Deg.c.

For this type of brazing use L-Ag-40Cd. This is the alloy

silver academy which have 40% cadmium and the melting point is
400 Deg.C to 500 Deg.C. This brazing is done for both end.

After the brazing the bars is go for second pickling which is the
same process as previously explain.
WATER FLOW TEST

 Thought this test check the flow water equivalently in the

hollow conductor of the bar. There is the following steps of
checking-
a. Water should be exit all the total hollow conductor.
b. If some burrs are jammed it should be removed to give very
high pressure of water and clean with the help of solid wire.
c. The main point of testing is that the water flow into the bar and
exit from the water box fall down approximately to cover 1 Mtr.
From each conductor.

NITROGEN LEAK TEST

 In this test the bar is tested for leakage into the components of
bar. In this test flow of nitrogen gas with pressure of 10kg/Cm2
to check the leakage in to the hollow conductor. If leakage
found the bar is rejected.
THERMAL SHOCK TEST

 The cycles of hot (80 Deg.C) and cold (30 Deg.C) water are
flew thought the bar to ensure the thermal expansion and
contraction of the joints. The time of low of hot & cold water
should be approx 32 to 40min and give the time between to flow
of hot & cold water is 5 min. this process is applied atleast 8
hours.

HELIUM LEAKAGE TEST

 In this test the bar’s end is tested to flow of helium gas with the
given pressure if the end part of the bar is leakage then the
helium gas is covered the surface of water box and indicator
indicate the point of leakage.

INSULATION

 For the insulation sunmika therm tape or sunmika pleese tape is

used which is the combination of mica + glass + varnish. It is
used for corona protection. In this insulation to layer of pleese
tape + to layer of therm tape and after them again to mica pleese
tape is used.
  Process of Insulation
a. Clean the bar.
b. Clean with chemical or thinner.
c. Taping
d. Realizing film from the mica plastic section.
In insulation the wall thickness of insulation is subjected to the
generating voltage of the machine.

IMPREGNATION AND BAKING

1. Thermoreactive system: In case of rich resin insulation the bar

is pressed in closed box in heated condition and baked under
pressure and temperature as per requirement for a given period.
2. Micalastic system: In case of poor resin system the insulated
bars are heated under vaccum and impregnated (dipped) in
heated resin so that all the air gaps are filled, layer by layer with
resin then extra resin is drained out and bars are heated and
baked under pressed condition in closed box fixture.

VPI Micalastic System

 The bars already laid in closed fixture and full fixture is

impregnated in resin and then fixture with box is baked under
given temperature for the given duration.
VIP Micalastic System

 The individual 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.

FINISHING

 The baked and dimensionally correct bars are sanded-off to

smoothen the edges and surface calibrated if required for the
dimension.

CONDUCTING VARNISH COATING

 OCP (Outer Corona Protection) Coating: The black semi-

conducting varnish coating is applied on the bar surface on the
core length.
 ECP (End Corona Protection) Coating: The grey semi-
conducting varnish is applied at the bend outside core end of
bars in gradient to prevent from discharge and minimize the end
corona.
TESTING

1. Tan Test: This test is carried out to ensure the healthiness of

dielectric (insulation) i.e. dense or rare and measured the
capacitance loss.
2. H.V. Test: The each bar is tested momentarily at high voltage
increased gradually to three times higher than rated voltage.

DISPATCHED FOR WINDING

 If the bar is passed in all the operation and testing after

completing then the bar is send for stator winding.
 TURBO GENERATORS

(a) Air Cooled Generators Upto 200 Mw Range (Type:

TARI ) Salient Design Features

 Stator core and rotor winding direct

air-cooled

 Indirect cooling of stator winding

 Horizontally split casing design of

stator

 Vertically side mounted coolers in a

separate housing

 Micalastic bar type insulation system

 Separately assembled stator core and

winding for reducing the manufacturing cycle

 Brushless/static excitation system
 (b) Hydrogen Cooled Turbogenerators Of 140-260 Mw Range
(Type: THRI ) Salient Design Features

 Stator core and rotor winding directly

 hydrogen cooled

 Indirect cooling of stator winding

 Rigid core bar mounting

 Micalastic insulation system

 End shield mounted bearings

 Top ripple springs in stator slots

 Ring type shaft seals

 Symmetrical ventilation.
 MOTOR WINDING

9.1 Technical Requirements

(1) Count the coil groups in the anti clock wise direction locking

from the connection end.

(2) Leads of the coils groups lying on the outer periphery of the

overhang position shall be the finish and those lying on the inner

periphery shall be the start to coil groups.

(3) Leads shall be taken form the coil side lying at inner periphery of

slot No.1.

(4) The coil group No.1 shall Lie at top with its axes coinciding with

the vertical axis of the frame.

(5) Take out terminal leads 02 U2, V2, W2 for left hand side terminal

box and 02 U1, V1, W1 for right hand side terminal box. When

looking form the connection end.

Circuit diagram:-

WINDING DIAGRAM OF MOTOR WINDING

9.2 Winding data

NO. OF PHASE 3
NO. OF POLES 6
PHASE CONNECTION Y
NO. OF PARELLEL PATH 2
NO. OF COIL GROUP 18

9.3 Connection of motor winding

 CONCLUSION

The second phase of training has proved to be quite

faithful. It proved an opportunity for encounter with such huge
machines like turbo-generator hydro generator etc.

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 provides an
opportunity to learn tech. Used at proper place and time can save a lot
of labour.

But there are few factors that require special mention.

Training is not carried in true spirit. It is recommended that there
should be projectors especially for trainees where presence of
authorities is ensured.

However, training has proved to be satisfactory. It has allowed

us an opportunity to get an exposure of the practical implementation
of theoretical fundamentals.