A Report on industrial training atBHARAT HEAVY ELECTRICALS LIMITEDHaridwar, India.Manufacture and assembly of Turbo Generators and Exciter motorsUnder the able guidance ofSh. P.S. Jangpangi (Sr. DGM) Block 1Submitted byUtsav Goyal B. Tech 4th year Department of Electrical & Electronics Engineering Naraina College of Engineering & Technology, Kanpur Uttar Pradesh, IndiaACKNOWLEDGEMENTPractical 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.UTSAV GOYALINDEXS.No. 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. 16. 17. `18. 19 INTRODUCTION BHEL-A Brief Profile BHEL - AN OVERVIEW HEEP: AN OVERVIEW BRIEF SUMMARY OF THE BAR SHOP TYPES OF TURBOGENERATORS MATERIAL CHECKING CONDUCTOR CUTTING AND END CLEANING TRANSPOSITION OF CONDUCTORS CROSSOVER INSULATION PRESSING ISS- TEST FORMING OF BAR ZERO PICKLING OF BAR END COIL LUG MOUNTING MAIN BRAZING CONDUCTOR CUTTING, DEBBERING AND FACE MILLING FIRST PICKLING BRAZING OF TOP PART20. 21. 22 23 24. 25. 26. 27. 28.WATER FLOW TEST NITROGEN LEAK TEST THERMAL SHOCK TEST HELIUM LEAKAGE TEST INSULATION IMPREGNATION AND BAKING FINISHING CONDUCTING VARNISH COATING TESTING 28.1 TAN-DELTA TEST 28.2 HIGH VOLTAGE TEST29. 30. 31.DISPATCHED FOR WINDING MOTOR WINDING CONCLUSIONINTRODUCTIONIn 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 Indias projected power equipment requirement. As well as sizeable portion of export targets. Probably the most significant aspect of BHELs growth has been its 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. BHELs technological excellence and turnkey capabilities have won it worldwide recognition. Over 40 countries in the world over have placed orders with BHELcovering 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 ProfileBHEL 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 Indias ambassador to the world. BHELs vision is to become world class engineering enterprise, committed to enhancing stakeholder value.BHEL has:- Installedequipmentforover90,000MWofpowergeneration 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 12000 Traction electrics and AC/DC locos over kms Railway network. Supplied over one million Values to Power Plants and other IndustriesBHEL - AN OVERVIEWThe 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 TransmissionDefenses etc.Today BHEL has 14 Manufacturing Divisions 9 Service Centers4 Power Sector Regional Centers 150 Project sitesBHELs 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 TelecommunicationThe 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 equipmentTELECOMMUNICATION:BHEL also caters to Telecommunication sector by way of small, medium and large switching system.BHEL has been divided into many blocks:1). Block-1:In block one turbo generator, generator, (A.C&D.C) are manufactured & assembled exciter motors2). Block-2:In block two large size fabricated assembliescomponent 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 & assembledMANUFACTURING 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.HEEP: AN OVERVIEWOver 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 engineering enterprise providing total business solution. profitableMISSION 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 responseRespect for dignity and potential of individual Loyalty and pride in the company Team playingMANUFACTURING PROCESS OF TURBO GENERATOR & STATOR BARBRIEF 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.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 T H/A R/D/F/I I/D/F W 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 b. For Upper bar = = 8 x 2.8mm (Solid) 8 x 1.3mm (Solid) 8 x 4.6 x 1.5mm (Solid) =i.e. Turbo Generator or Hydro Generator. =i.e. Hydrogen Gas or Air. =i.e. Radial, indirect, forced, direct etc. =i.e. Indirect cooling, direct cooling, forced cooling. =i.e. cooling media used for cooling of stator coil e.g.c. For Hollow conductor =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 b. Hollow conductor length Upper Bar a. Solid conductor length b. Hollow conductor length = = 10,050mm (10 Plates) 10,050mm (10 Plates) = = 10,200mm (10 Plates) 10,200mm (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 bars Die 1st 2200.2mm Die 1st 2109mm Die 2nd 3735.3mm Die 2nd 3620.2mm Die 3rd 6586.2mm Die 3rd 6496.2mmb. Comb of setting for Upper barsThis 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 2nd Band 3rd Band = = = 146mm 219mm292mmSTACK CONSOLIDATION OR PRESSINGThe 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 b. Sulphuric Acid c. Phosphoric Acid = = = 100 parts by weight 10 parts by weight 5 parts by weight 5 parts by weightd. Hydrogen per Oxide =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 stepsa. 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 checkinga. 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 TESTIn 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 bars 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 BAKING1.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. 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.2.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 COATINGOCP (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 semi-conducting varnish is applied at the bend outside core end of bars in gradient to prevent from discharge and minimize the end corona.TESTING1.Tan Test: loss.This test is carried out to ensure the healthiness ofdielectric (insulation) i.e. dense or rare and measured the capacitance 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.2.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 cycleBrushless/static excitation system(b)Hydrogen Cooled Turbogenerators Of 140-260 Mw Range (Type: THRI ) Salient Design FeaturesStator 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 WINDING9.1 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 WINDING9.2 Winding dataNO. OF PHASE NO. OF POLES PHASE CONNECTION NO. OF PARELLEL PATH NO. OF COIL GROUP 3 6 Y 2 189.3 Connection of motor windingCONCLUSIONThe 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.