SUBMITTED BY:-

SUBMITTED TO:- ANISH GUPTA

Mr. A.K. Dhiman PEC UNIVERSITY OF

TECHNOLOGY

B.E.(ELECTRICAL)
I take this opportunity with much pleasure to thank all the people who
have helped me through the course of journey through producing this
report.

Firstly, I would like to say that I am highly obliged to the BHEL

authorities which allowed me to do training at BHEL for the due course of
time.

I sincerely thank my thesis supervisor Mr. A.K. Dhiman for his guidance,
help and motivation.

I am also grateful to the workers and staff members of BHEL for

providing me their invaluable knowledge in guiding various works during
my training tenure.

ANISH GUPTA
B.E.(ELECTRICAL)
3RD YEAR
PEC UNIVERSITY OF TECHNOLOGY
 BHEL- Corporate Profile
In the late fifties Bharat Heavy Electrical Established Limited , better known
BHEL, is today the largest engineering and manufacturing enterprises of its kind in
India . the first plant of BHEL was established nearly 47 years ago in August 1956
at Bhopal and was the genesis of heavy electrical equipment industry in India.
The organization is engaged in engineering, development and manufacture of a
wide variety of electrical and mechanical equipments for generation, tansmission
and utilization of energy and electric power. The company provides product, system
and services for the energy sector as well as for industry and transportation. It has a
well recognized track record of performance, making profit continuously since
1971-72. It achieved a sales turnover of Rs. 5625 crores 1999-2000 and NAV per
share Rs. 135. A vast reservoir of manufacturing skills – the 80000- strong BHEL
family comprises a formidable team of engineers, scientists, managers, and trained
technicians. In the world power scene BHEL ranks among the top 12
manufacturers. It is the largest engineering and manufacturing enterprises of its
kind in India. It has a well recognized track record of performance making profit
continuously since 1971-72. It offers services from project feasibility studies trough
after – sales services, thus meeting all customer requirements. More than 456
countries ranging from USA and USSR in the west to Australia and New Zealand in
the east are BHEL‘s customers. Its operations are spread over 14 manufacturing
units, 4 power sectors regional centers, over 150 project sites and service centers,
and 15 regional offices, which enable the company to be closer to its customer and
provide them with suitable products, system and services at competitive prices.
Having attained ISO 14001 and TQM (total quality management) BHEL is now on
its journey towards ISO 18001 (OHSAS).

1. Heavy Electrical Equipment Plant & Central Foundry Forge Plant-

Haridwar.
2. Heavy Electrical Plant-Bhopal.

3. High Pressure Boiler Plant & Seamless & Steel tubes plant Tirichi.

4. Heavy Power Equipments Plant – Hyderabad.

5. Boiler Auxillaries Plant – Ranipet.

6. Electronics Division & Electro Porcelains Division - Bangalore.

7. Industrial Valves Plant – Goindwal.
8. Transformer Plant – Jhansi.
9. Component Fabrication Plant – Rudrapur.
Today, BHEL has a growing presence in the variety of areas besides the
power sector. They are:
 Industry
 Transportation
 Oil & gas
 Non Conventional Energy Sources
 Telecommunications

BHEL offers a variety of transportation systems to meet the growing needs of

the country. 65% of the railways are equipped with BHEL manufactured
traction equipment. India’s first underground rail Metro runs on drives and
controls supplied by BHEL. For pollution free transportation, BHEL offers
battery-operated passenger vans and electric trolley-bus systems. Equipment
for oil gas exploration and transportation is manufactured by BHEL. Range
covers super-deep drill rigs, mobile and desert rigs with matching draw-works
 and hoisting equipments, also Christmas-tree valves and well head assemblies.
BHEL has supplied several water heating systems, windmills, biogas
generators and photovoltaic systems. BHEL has entered the field of
telecommunications with electronic PABX systems based on indigenous
technology from C-DOT.

BHEL has collaboration with following

companies:
 Combustion Engineering Inc. U.S.A.
 Sludge Brothers, Switzerland.
 International general electrical co. Inc., U.S.A.
 Creset loire, France.
 Nuoveo pignore S.P.A., Italy.
 Svenska Flaktabrites, Sweden.
 Siemens Ag., W.Germany.
 Enlish Electro Co., U.k.
 Pronum Ashenport, U.S.S.R.
 Weir Pumps Ltd., U.K.

BHARAT HEAVY ELECTICALS LIMITED

The product profile of BHEL is very vast and includes following equipments and
services:

Thermal Sets:

 Turbine generator sets along with all Auxillaries of thermal power plant of
the utilities are supplied for rating of 30, 60, 110, 120, 200, 210 & 500 MW
capacities.
Hydro Sets:

 Custom built conventional hydro-turbines of Kaplan, Francis and Peloton

type with matching generators.
 Pump turbines with matching motor generators.
 Mini/ micro hydro sets such as horizontal tubular turbines.
 Spherical, butterfly & rotary valves and Auxillaries for hydro stations.
 Governors (Mechanical and Electro-hydraulic type), drainage and dewatering
systems, compressed air systems, centralized grease lubrication system and
other control and protection systems.

Equipments for Nuclear Power Plant:

 Turbines and Generators.

 Steam generators.
 Re-heaters/ separators.
 Heat exchangers & condensers.

Heat Exchangers:

 Surface condensers.
 Low pressure heaters for re-generative feed heating systems.
 High pressure heaters.
 Chimney and gland steam-condensers for all operating conditions.
 Coolers, condensers, separators and seal oil regulators, tanks, for upto 300
atm on channel sides of any material.
 Try type de-areators for TG sets.
 Steam operated air ejectors.
Boiler Auxiliaries:

 Fans-Axial reaction fans of single stage and double stage for clean air
application with capacity ranging from 25m^3/sec to 800m^3/sec with
pressure ranging from 120 to 1480 meters of gas column. Axial impulse fans
single and double suction radial fans etc are also.
 Air heaters-Ljungstrong regenerative air-heaters for boiler and process
furnaces in a broad range of size and capacities.
 Gravimetric feeders.
 Pulverizes- slow and medium speed coal pulverizes upto a capacity of 100
tones/ hour.
 Electro static precipitators- of any capacity with efficiency upto 99.5% for fly
ash removal in power plants.
 Mechanical separators.

Boiler & Pressure Vessels:

 Steam generators for utilities; range- 30MW to 500MW using coal, oil,
natural gas or a combination of these fuels.
 Steam generators for industrial applications; range- 6tonnes/hour to
300tonnes/hour using coal, oil, natural gas, industrial gases, wood, bio gases
or a combination of these fuels.
 Waste heat recovery boilers.
 Recovery boilers for paper industry; range- 100tonnes/day to 1000 tons/day
of dry solids.
 Pressure vessels.
  Fluidized bed boilers.
Pumps:

 Boiler feed pumps (motor or steam turbine driven).

 Condensate booster pumps.
 Boiler feed booster pumps.
 Condensate pumps.
 Circulating water pumps.
 Emergency oil pumps.
 Lubricating oil pumps.
 Standby oil pumps.
Power station Electronic equipments:

 Static excitation equipment.

 Data acquisition systems.
 Micro-processors based distributed digital control.
 Automatic voltage regulators.
 Electro-hydraulic governor control.
 Controls for HP / LP bypass valves.
 Turbine supervisory system and controls.
 Static shunt compensator.
 Station and industrial turbo-sets.
 Equipments for thermal, hydro, nuclear power.
 Controls for electrostatic precipitators.
Oil field equipments:

 Diesel electric oil rigs for onshore drilling for depths upto 9000m complete
with matching draw-works and hoisting equipments.
 Christmas tree valve and well head assembly.
Compressors:
  Centrifugal compressors of varying size for industrial applications range
covers MCL series (pressure upto 40kg/cm^2 and capacity upto
350,000NM^3/hr) amd BCL series (pressure upto 800kg/cm^2 and capacity
upto 50,000 NM^3 /hr) and package SRL series (pressure ratio upto 40 and
capacity upto 240,000 NM^3/hr).

Transformers:

 Power transformers for voltage upto 400KV.

 HVDC transformer and reactors.
 Series and shunt reactors upto 400KV.
 Instrument transformers: current transformers upto 400KV, electromagnetic
voltage transformer upto 220KV and capacitor voltage transformer upto
400KV.

Electrical Machines:

 DC general purpose and rolling mill machines.

 DC auxiliaries mill motors.
 AC induction motors- squirrel cage and slip ring motor from 150KW to
15000KW.
 AC synchronous motors- from 400KW to 15000KW.
 AC alternators- from 500KW to 25000KW.
 Synchronous condensers- from 2200KVAr to 100,000KVAr.
Insulators:

 Disc/ suspension insulator for ac/dc applications; range- 45KN to 160KN

electro mechanical strength for clean and polluted atmospheres.
  Pin and post insulator upto 33KV.
 Bushings upto 220KV.
 Solid core insulator of 25KV rating for railways.
 Special ceramics including ceramic liners for process industry.
Seamless steel tubes:

 Hot finished and cold drawn seamless steel tubes with a range varying from
outer diameter of 14mm to 159mm and wall thickness 12.5mm in carbon
steel and low alloy steels to suit ASTM/AP and other international
specifications.
 Capacitors:
 Power capacitors for industrial use from 2to 20KVAr at 400V.
 Capacitors for high voltage installation.
 Coupling/ CVT capacitors for high voltage upto 400KV.
 Electrolytic and paper capacitor for motor start and motor run duties.

Transportation Equipments:

 Traction motors.
 Traction generators/ alternators.
 Auxiliary machines.
 Field diverting inductive shunts.
 Eddy current clutches.
 Transformers/ rectifiers.
 Electronic control equipments.
 Diesel electric shunting locomotives (350 HP to 700 HP).
 Battery operated passenger vans.
 Electric trolley buses.
Castings & Forgings:
  Sophisticated heavy castings and forgings of creep resistant alloy steel and
other grades of alloy steels and meeting stringent international specification.

Thyristor Equipment:

 Thyristor convertor equipment.

 Thyristor inverter equipment.
 Static ac variable speed drives systems.
 Thyristor valves for HVDC transmission upto 500KV.
Telecommunications:

 Electronic PABX systems.

 Data transmission.

Non-Conventional Energy Systems:

 Biogas operated engines.

 Windmills.
 Solar thermal pumps.
 Solar water heating systems.
Systems and Services:

 Turnkey power stations.

 Combined- cycle power plants.
 Cogeneration systems.
 Modernization & rehabilitation of power stations.
 Sub- stations & switchyards.
 HVDC transmission systems.
 Shunt & series compensator systems.
  Traction systems.
 Industrial devices and control systems.
 Cathode protection systems.
 Consultancy services.
 Erection, commissioning, operation and maintenance services.

BHEL- Haridwar

B.H.E.L. (Ranipur), Haridwar is located against the picturesque shivalik foothills of

the Himalayas. It has two manufacturing plants:

> HEEP (Heavy Electrical Equipment Plant) and

> CFFP (Central Foundry & Forge Plant)

HEEP was set up in technical collaboration with M/S Prommash-export of USSR, for
the manufacture of power plant equipments. AC/DC motors of various sizes were
available with associated control equipment and started production in Jan 1976. In
1976 BHEL entered in to collaboration with M/S Kraftwerk Union A.G. of Germany
for design, manufacture, erection and commissioning of large size steam turbines
and turbo generators of unit rating upto 1000MW.

CFFP established in technical collaboration with M/S Creusot Loire of France and
became operational in 1976. It was established for production of highly
sophisticated alloy steel castings and forgings. CFFP has produced international
creep resistant steel , heat resistant steel , armour steel etc. it supplies casting for
steam turbines , turbo generators press ring , hydro turbines coupling blades.

Together, the two plants contribute significantly to the BHEL energy is generated
from the power equipment supplied by BHEL Haridwar. The Pollution Control
Research Institute has also been set up at BHEL Haridwar with the help of United
Nations Development Program (UNDP). The main objective of the institute is to
evolve industrial pollution control technologies with respect to air, water, noise,
and solid waste in order to avoid unintended side effects of economic growth of
country. BHEL Haridwar possesses very strong engineering base, R&D
infrastructure, very précised CNC and conventional machine tools.

BHEL has the latest Hardware and computer

software for design development:
 Latest computational techniques for design analysis and integrated
manufacturing like CAD, FEM, and CAM etc, are used.
 Use of solid modeling, finite element modeling and further
downstream applications for solution of design structure, heat
transfer electromagnetic applications etc, for optimization.
 The computer software is also used for thermal network, solutions
and ventilation system, which are vital parameters for large capacity
machines.
Various unique facilities which are provided at
BHEL, Haridwar are highlighted below:
 Over speed vacuum balancing turbine (for rotors 1300MW ST/TG)
16m length, 320T.
 Turbine blade shop with modern facilities.
 Over speed balancing Installation (non-magnetic) for large TG rotors
upto 80MT, 4M, and 12M length.
 Central plant laboratory.
 Hydro turbine model testing laboratory.
 Machine tool maintenance, capital repair shops and CNC laboratory.

Tool Room:
 Die and stamping shop.
 ICIM-39-270-270-20 mainframe computer along with satellite micros
& PC’s CAD/CAE stations.
 Micalastic insulation systems.
 Large size turbo generators test bed (upto 500MW IG).
 Radio remote control for EOT cranes in certain areas.
 Service plants (oxygen, nitrogen, PGP Acetylene, compressed air,
central refrigeration).
 Pollution control research institute.
 Generator research institute.
 Metal research and testing: Various types of modern inspection and
quality control equipment/ devices and testing/ calibration facilities
(NDT, outline inspection, scanning, electron microscope,
 spectroscope, electrical insulation spectrograph/ spectrometer,
industrial X ray/ gamma ray apparatus etc.

HEEP
Heavy Electrical Equipment Plant of BHEL, Haridwar involves in the
manufacturing of the power equipments such as turbines and AC/DC machines. It
comprises of following main blocks:
Electrical Machines Block (Block-I):
It is designed to manufacture hydro-generator, turbo-generators and large &
medium sized AC/DC electrical machines. There are number of self-propelled
electrically driven transfer trolleys for the inner bay movement of component/
assemblies.
Fabrication Block (Block-II):
It is the feeder block for various products- steam turbine, turbo generators,
hydro generators, electrical machines, apparatus and control gears, aircraft and
medical lines. This block has facilities for compressed air, oxygen, acetylene
and carbon-dioxide gas pipelines.
Turbine & Auxiliary Block (Block-III):
It manufactures turbines, hydro turbine, and gas turbines and turbine blades.
Special toolings for all products are also manufactured in the Tool Room
located in the same block. The block is equipped with the facilities of EOT
cranes, compressed air, steam, OSBT, indicating stands for steam turbine
rotors, one test stand for testing 210MW steam turbine and two separate test
stands for testing of governing assembly of steam and hydro turbine.

Feeder Block (Block –IV):

There are two feeder block other than the fabrication blocks to feed electric
machines manufacturing by block-I via CIM (coil & insulation
manufacturing) and ACM (apparatus & control-gear manufacturing). It is a
feeder block for class F-windings for turbo generators, hydro generators and
class F&H insulation components for TG, HG and motors.
Fabrication & Forge Block (Block-V):
Fabrication work been done in this section is of steam turbine parts like
condenser , water box, assemblies for LPC , storage tanks etc and hydro
turbine parts. Fabrication of hydro generators and motor assemblies and
components are also carried out. Forging of carbon, alloy and stainless steel
are manufactured in the forging sections. It is equipped with pneumatic
hammer from 500Kg to 3tonnes capacity, gas fired furnace for heating of
billets, blooms and for subsequent heat treatment for forging, hydraulic
manipulators of various capacities are also used to handle the forgings on the
hammer.

 CIM (Coil & Insulation Manufacturing)

 ACM(Advanced Control Manufacturing)
BAY-I: Bar winding shop:- manufacturing of stator winding bars of generators.
BAY-II:

 Manufacturing of motor stator coil, DC armature coil , main pole coil , inter
pole coil , equalizer coil etc.
 Also manufacture heavy duty generator stator bar with new CNC machines
i.e. Robot bar center.
BAY-III: Insulation detail shop:- Manufacturing of hard insulation and machining
of hard insulation part (glass textile) such as packing, washer, insulation box,
wedges etc.
Bar: It is quite difficult 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- bottom (lower) and top (upper) part.

Insulation classification:
Thermal classification of insulation depends upon the temperature withstand
capability of the insulation.
Class Temperature
Y Upto 90 C
A Upto 105 C
E Upto 120 C
B Upto 130 C
F Upto 150 C
H Upto 180 C
C >180 C & upto 220 C
Types of generators:
The generators may be classified based on the cooling system used in the generators
such as: THRI, TARI, THDD, THFF, and THW.
T= Ist alphabet signifies the type of generator i.e. turbo or hydro generator.
H/A=IInd alphabet stands for the cooling media used for the cooling of rotor i.e.
hydrogen gas or air.
R/D/F/I=IIIrd alphabet signifies the type of cooling of rotor e.g. radial, indirect,
forced, direct, etc.
I/D/F=last alphabet stands for the type of cooling of stator e.g. indirect, forced,
direct, etc.
W=cooling media used for cooling the stator coil e.g. water.

Resin Systems:

 Rich resin is thermo reactive insulation system: in this type of insulation

system the bond content in resin is 35 to 37 %. The raw materials are ready to
use and requires reservation and working on temperature 20 to 25 C. Its shelf
life is one year when kept at temp. 20 C which could be increased when kept
at temperature of 5 C.
 Poor resin or micalastic insulation system: In this type of insulation the bond
content in the resin is 5 to 7 % and insulating material is prepared with
accelerator treatment. The temperature control is not required. The insulating
material is applied on job and then the same is impregnated (fully dipped).
Manufacturing Process of 500MW TG Stator Bar

Material check
 Copper conductor 8*28mm[solid, for lower bar]
 Hallow Copper conductor 8*4.6*1.5mm
 Copper Conductor 8*1.3mm[solid, for upper bar]

1. Conductor Cutting
This process is done by automatic CNC machine. In this process
the pre insulated copper conductor is cut in to number of pieces
of required length. Insulation is removed from both ends of the
copper conductor cut.
LOWER BARS:
 Solid conductors – length 10,200mm(10 no.s)- 1 bar
 Hollow conductors – length 10,200mm(10 no.s)
UPPER BARS:
 Solid conductors – length 10050mm( 20 no.s)- 1 bar
 Hollow conductors – length 10050mm( 10 no.s)
We have to clean both sides of ends – 500mm.
CNC (Computerized Numeric Control)
Conductor Cutting Machine:
1. Copper storage
2. Bobbin ready to use
3. Tool rack
4. Bobbin revolving machine
5. Tension device
6. Conductor cutting
7. Drum for plastic waste
8. Control panel
9. Operator control desk
10. Waste glass dust collection
11. Conductor shifting table

2. Transposition
Transposition means changing/shifting of position of each conductor in
active core (slot) part. After cutting the required number of conductors,
the conductors are arranged on the comb and in staggered manner and
the bends are given to the conductors with the help of bending die at
required distance. Then the conductors are taken cut from, the comb and
die and placed with their ends in a line and transposition is carried out.
This process is repeated for making another half of the bar which would
be mirror image of the first half. The two halves of the bar are overlapped
over each other and a spacer is placed between the two halves.
Requirement: The main reason of doing transposition is to
generate equal emf in each bar. Also, it is done so that average distance of
each bar from the rotor is same so they cut same amount of flux and
thereby producing equal emf. If transposition is not done then the
conductors nearer to the rotor generates more emf and therefore, its life
is reduced and after sometimes nearly half of the conductors get damaged
due to heating.
LOWER BAR’S:
COMB OF SETTING: Die 1st Die 2nd Die 3rd
2200.2mm 3735.3mm 6586.2mm
UPPER BAR’S:
COMB OF SETTING: Die 1st Die 2nd Die 3rd
2109mm 3602.2mm 6496.2mm

3. Cross over insulation

The pre insulation of the copper conductor may get damaged due to
mechanical bending in die during transposition, hence the insulating
spacers are provided at the crossover portion of the conductors. A filter
material (insulating putty of molding micanite) is provided along the
height of the bar to maintain the rectangular shape and to cover the
difference of level of conductors.

SPACER SIZE: 1ST Band 2nd Band 3rd Band

146mm 219mm 292mm
Fix the insulation in cross portion & fix MICA bonded spacer in
light portion.
 4. Pressing or 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 degree
Celsius for a given period. The consolidated stack is withdrawn from the
press and the dimensions are checked.

 Half bar press (Tapped with transparent file pressed on machine-4

no.)
 Remove the transparent film & calibrate the 4 no.s of bars and
cleaning with sand paper, spirit, searchbrite.

5. Inter Strand Short Test

The consolidated bar stack is tested for the short circuit between any two
conductors in the bar, if found then it has to be rectified. 300V is applied
for both THRI & TG generators. For IST testing Series Testing Lamb
Machine is used. This 300V is applied between two conductors one by
one to all conductors, if the conductors are short then the bulb glows.

IInd Pressing
Attach full slots separator between two half bar with NOMEX paper and tapped
with transparent film. After pressing remove the transparent film and calibrate
sand etc.
Radius Milling
In slot portion, corner of bar should be cleaned by Radius Miling Machine.
 6. Forming
The straight bar stack is formed as per overhang profile( as per
design). The overhang portion is consolidated after forming.

Pickling
Pickling is the process of cleaning of component by chemical like:
PICKLING SOLUTION:-
 Water- 100 parts by weight 140 Kg
 Sulphuric acid -10 parts by weight 14Kg
 Phosphoric acid-5 parts by weight 7 Kg
 Hydrogen per oxide-5 parts by weight 7 Kg
These chemicals are heated upto 50-60 degree Celsius.
Dip the components in solution. 10-15 min after that, clean the
component with brass brush and water. Dip Ammonia solution for
neutralization of acidic property. Ammonia solution is the
combination of liquid Ammonia 10 parts by weight with 100 parts by
weight and clean with water and then dipping in Ethyl Alcohol. After
this dry the solution with nitrogen pressure before pickling all types
of components like bar, contact sleeves, bottom and top part of water
box, wedge plane and profile etc.
 7. Brazing of Coil Lugs
For water cooled generator bars, the electrical connection contact and
water box for inlet and outlet of water are brazed.

LUG MOUNTING:
1. Stand by bars for setting of lug.
2. Set up the conductors in each row as per drawing.
3. Insert contact sleeve with the setting of plane row wise wedge then
tapper wedge fix up for tightening with copper thin strip as per
marking.

MAIN BRAZING:
1. Stand by bars of setting for brazing used Resistone for that area
which will not braze.
2. Heating the lug joint by two inductors at 65 C use brazing alloy L
Ag-15P by 4 persons.
3. Then cooled with air and water.
 Deveering
20 no.s of hollow conductors should be deveered in lug braze with the
help of special machine. After deveering water flow is checked,
whether all hollow conductors are allowing equal amount of water or
if not, then may be due to improper hammering during lug brazing,
then the bar has to be repaired.

8. Nitrogen Leak Test

The bar is tested for water flow test, nitrogen leak test & pressure test
for given duration.

9. Thermal Shock Test

The cycle of hot (80 degree celsius) & cold (30 degree celsius) water
are flown through the bar to ensure the thermal expansion and
contraction of the joints. Then we apply vacuum tubes for 1 hr so that
all the moisture is absorbed.

10. Helium Leak Test

After thermal shock test bar is tested for any leakage with the help of
helium gas at 12 Kg/cm^2 pressure hr 11min. For helium testing Mass
Spectrometer machine is used.
 11. Insulation
The bar is insulated with the given no. of layers to build the wall
thickness of insulation subjected to the generating voltage of the
machine.

12. Impregnation and Baking

 Thermo reactive system: In case of rich resin insulation the bar
is pressed in closed box in heated condition and baked under
pressure and temp. as per requirement for given period.
 Micalastic system : in case of poor resin system the insulated
bar are heated under vacuum and the impregnated (dipped) in
heated resin so that all the air gaps are filled , layer by layer ,
with resin . Then the extra resin is drained out and bars are
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 temp. for given duration.
VIP MICALASTIC SYSTEM:- The individual (separate) bar is heated in
vacuum and impregnated in resin . Then bar is taken out and pressed
in closed box fixture and then baked at given temp. for given duration.

13. Finishing
The baked and dimensionally correct bars are sanded of to smoothen
the edges and the surfaces is calibrated, if require, for the dimension.
 14. Conducting Varnish Coating
 OCP (Outer Corona Protection) Coating:- The black
semiconducting varnish coating is applied on the bar surface on
the core length.
 ECP (End Corona Protection) Coating:- The Grey semiconducting
varnish coating is applied at the bend outside core end of the
bars in gradient to prevent from discharge in minimize the end
corona.

15. Testing
 Tan α test: - This test is carried out to ensure the healthiness
of dielectric (insulation) i.e. dense or rare and measure the
capacitance loss.
 HV test: - Each bar is tested momentarily at high voltage
increased gradually to 3 times higher than rated voltage.
FORMULA USED:
Hv = 1.5(2un + 1)
Up = 2Un + 1
Un = working voltage

16. Dispatched for winding

The bar preserved with polythene sleeves to protect from dust, dirt,
oil, rain, etc are send for winding.
