TRAINING REPORT ON INSULATION AND MANUFACTURING PROCESS OF 500MW TURBO GENERATOR BARS

Under the Guidance of Mr. A.K Dhiman (DGM)BHEL, HARIDWAR

SUBMITTED BYSANDEEP KUMAR YADAV (EN-3RD YEAR) NOIDA INSTITUTE OF ENGG. & TECHNOLOGY GREATER NOIDA(U.P.)-201306

ACKNOWLEDGEMENT

An engineer with the theoretical knowledge is not a complete engineer. Practical knowledge is very important to develop and apply engineering skills. It gives me a great pleasure to have an opportunity to acknowledge an to express my gratitude to those who are associated with me during my training at BHEL, Haridwar.

Special thanks to Mr. A.K. Dhiman for providing me with an opportunity to undertraining under his able guidance and offering me a very deep knowledge of practical aspects of industrial work culture...

I express my sincere thanks and gratitude to BHEL authorities for allowing me to undergo the training in this prestigious organization. I will always be indebted to them for their constant interest and excellent guidance in my training work, moreover for providing me with an opportunity to work and gain experience.

Sandeep Kumar Yadav Noida Institute of Engg. & Technology, Greater Noida

CONTENTS:CHAPTER 1 . CHAPTER 2 BHEL - AN OVERVIEW COMPANY PROFILE

CHAPTER3

ABOUT BHEL, HARIDWAR

CHAPTER 4

BLOCKS IN BHEL, HARIDWAR

CHAPTER 5

BRIEF SUMMARY OF CIM SHOP(BLOCK-4 ) MFG. PROCESS FLOW CHART OF500 MW TG STATOR BAR.

CHAPTER 6 -

CHAPTER 7

MANUFACTURING PROCESS OF 500 MW TG STATOR WINDING BARS.

CHAPTER-1
COMPANY PROFILE

The first plant of what is today known as BHEL was established nearly 40 yearsago at BHOPAL and was genius of heavy electrical equipment industry in India. BHELis today the largest engineering enterprise of its kind in India with well recognized track records of performance making profits continuously since 1971-72 it achieved a salesturnover of 1023 crore in 1977-78. BHEL caters to core sectors of the Indian economy in power, industry, transportation,defense etc.

The wide network of BHEL is 14 manufacturing divisions, 9 service centers & 4 power global players.Power sector comprises thermal, nuclear, gas & hydro power plant businesstoday, BHEL supplied sets account for nearly 56, 318 MW or 65% of the total installedcapacity of 86, 636 MW in as against nit till 1969-70.BHEL has proven turnkey capabilities for executing power projectors fromconcept to commissioning. It possess the technology and capability to produce thermal power plant equipments up to 1000 MW rating and gas turbine generator sets up to a unitrating of 240 MW. Cogeneration and combines cycle plants has been introduced toacheve higher plant efficencies. To make efficient use of the higher ash content coilmanufacturers 235 MW nuclear turbine generator sets and has commenced production of 500 MW nuclear turbine generator head discharge combinations are also engineered and manufactured is also competitive.

1.1 Transmission: BHEL also supplies a wide range of transmission products and system up to 400KV class. These include high voltage power and distribution transformer, instrumenttransformers, instrument, transformers, dry type transformers. SF6 switch gear, capacitor and insulator etc series and shunt compensation system have been also developed andintroduced to minimize transmission losses. 1.2 Transportations: A high percentage of trains operated by Indian Railway are equipped withBHELis traction and traction control equipments including the metro at Calcutta anddelhi. The company supplies broad gauge.Electrical locomotive to Indian railway and diesel shunting locomotives to variousindustries 5000/6000 hp ac/dc locomotive developed and manufactured by BHEL have been leased to Indian railway, battery powered road.

1.3 International operations: BHEL is product series and projects have been exported to over so countriesranging from UNITED STATES in the west to NEW ZEALAND in for east INDIA isover 3000 MW. A few motable ones are 150 MW gas turbine to GERMANY, utility boiler and open cycle gas turbine plant to MALAYSIA, Tripoli west, power station inLibya and Turkey. In Cyprus, hydro generator to New Zealand and hydro power plant toThailand , Saudi Arabia, Oman , Greece and Egypt.

CHAPTER-2 BHEL-AN OVERVIEW BHEL is the largest engineering and manufacturing enterprise in India in theenergy related sector. BHEL was established more than 40 years ago, ushering in theindigenous Heavy Electrical Equipment industry in India, a dream which has been morethan released with a well-recognized track record of performance.BHEL caters to core sectors of the India economy viz. Power Generation andTransmission, Renewable Energy, Defence etc. The wide network of BHEL is 14manufacturing divisions, 4 power sector regional centers, 8 service centers, 15 regionaloffices and a large number of Projects sites spread all over India and abroad enables thecompany to promptly serve its customer and provide them with suaitable products,systems and services- efficiently and at competitive prices.BHEL has attained ISO 9001 certification for quality management and all themanufacturing units/divisions of BHEL have been upgraded to the latest ISO 9001:2000version. All the major units/divisions of BHEL have been awarded ISO 14001certification for Environmental Management System and OHSAS-18001 certification for Occupational Health and Safety management System. BHEL become the first PublicSector Company in the country to win the coveted PRIZE for its Haridwar unit under the CII Exim Award for business excellence as per the globally recognized model of European Foundation for Quality Management. BHEL is the only PSU among the 12Indian Companies to figure in Forbes Asia Fabulous 50 list. It has also won theBusiness Standard Star Public Sector Company Award 2006. The company receivedMoU Excellence Award for 2004-2005 and Merit Certificate for MoU Excellence for 2005-2006.

2.1 Power Generation: Power generation Sector comprises Thermal Gas, Hydrogen, Nuclear power plant business. As of 31.3.2007. BHEL supplied sets accounts for 80,781 MW or nearly 65% of the total

install capacity of 1, 25,414 MW in the country.Significantly these sets contribute 73% of the total power generated in the country. 2.2 Heavy Electrical Equipment Plant: BHEL's Heavy ElectricalEquipment Plant (HEEP) was set up in technical collaboration with USSR, for themanufacturing of power plant equipment, AC/DC motors of various rating withassociated control equipment and started production in January 1967. In 1976, BHELentered into a collaboration agreement with M/s Kraftwerk Union, AG of Germany for design, manufacturing, erection and commissioning of large size steam turbines. Morethan 40 percent of the country's electrical energy is generated from the power equipmentsupplied by BHEL, Haridwar. The products, which are manufactured in HEEP, are: -Steam Turbines, Turbo Generators, hydro turbines, Gas turbines, etc.

2.3 Vision:

World-class , innovative, competitive and profitable engineering enterprise providing total global business solutions. 2.4 Mission: The leading Indian engineering enterprise providing quality products systems andservices in the fields of energy, transportation, infrastructure and other potential areas. 2.5 Values: Meeting commitments made to external and internal customers.Foster learning creativity and speed of response.Respect for dignity and potential of individuals.Loyalty and pride in the company.Team playing. Zeal to excel.

3.1 Products of BHEL: Heaps product & capacity ratings PRODUCT CAPACITY RATING 1. Thermal/nuclear set 2.Hydro set 3.Generator 5. Heat exchangers, condenser 6. AC/DC electrical machine 210 MW 1000 MW 115 MW Acc. To Requirement Up to 800 MW 5 KW 2000 KW

(a) AC (250 KW 1600 KW) (b) DC (7KW 1000 KW)

3.3 DESCRIPTION OF 8 BLOCKS OF HEEP: BLOCK-1:

This is the main block of HEEP named as Electrical MachineShop. The main products of this block 1 are turbo generators, hydro generators & ACand DC motors.

BLOCK-2: This is a Heavy Fabrication Shop in which fabrication of all typeof parts of turbines as well as generators are done. In this block work is divided into four steps namely Bay-1, Bay-2, Bay-3, and Bay-4.In Bay-1 Preparatory work is been donei.e. cutting, shaping, grinding, pressing etc. In Bay 2 & Bay-3 assembly work is done.Bay-4 is called HMS (Heavy Machine Shop) in which all types of components of turbine,generators and motors are manufactured. BLOCK-3: This block is called Turbine Manufacturing Block . This block contributes maximum in terms of turnover. Here steam, Gas & Hydro all three types of turbines are manufactured.

This Block also divided into 4 Bays. And these bays arefurther divided into several sections and shops. BLOCK-4: Block-4 is called as CIM (COILS & INSULATION) BLOCK

. Inthis block coils of Generators & motors are made & assembled. Also insulation of all DC& AC motors and Generators are done. BLOCK-5: Block-5 is called as CONDENSER FABRICATION & FORGE BLOCK. Alltype of condenser used for refrigeration purpose in turbines are fabricated here.

BLOCK-6: Block 6 is divided into 3 parts Fabrication shop, Die shop, Stamping shop BLOCK-7: This Bock is called as CARPENTRY SHOP . In this Block all carpentry work isdone such as making of wood pattern for casting purpose, making of fixtures, large woodcontainer used for packing of several jobs like different components of Turbines,Generators, motors etc. BLOCK-8: This is the last block of Heavy Electrical Equipment Plant (HEEP) named as HEAT EXCHANGER SHOP. In this Block all type of Heat Exchanger of Steamturbines are manufactured. CHAPTER-4COIL & INSULATION MANUFACTURING SHOP(BLOCK-IV) 4.1 Introduction: As the complete one peace coil is not practicable so the coils are manufactured in two parts, upper and lower bars. Out of the various BLOCKS as mentioned before the coil andinsulation manufacturing block is BLOCK-4. This block is known as the COIL ANDINSULATION MANUFACTURING (CIM) block.

BAY-I: Bar winding shop:

manufacturing of stator winding bars of generator.BAY-II:

Manufacturing of heavy duty generator stator bars.BAY-III: Insulation detail shop:

Manufacturing of hard insulation & maching of hares insulation part (Glass Textolite) such as packing, washer, insulation box,wedgesetc.Bar Shop:

This shop is meant for manufacturing of stator winding coils of turbo-generator and hydro generator.Why do we call it bar?

It is quite difficult (rather impossible) to manufacture, handle and wind in thestator slot of generator of higher generation capacity because of its bigger size and heavyweight. That is why we make coil in two parts. One part its bottom part of coil called bottom or lower bar and other part of coil is called top bar or upper bar.The manufacturing of bars of standard capacity such as 100MW, 130MW,150MW, 210/235MW, 210/250MW, 500MW. The plant has capacity and technology to manufacture 800MW and 1000MW generators. 4.2 MFG. Process flow chart of 500MW TG stator bar: 1. Insulation check. 2. Conductor cutting and end cleaning. 3. Transposition of conductor. 4. Assembly of all conductors to be used in stator bars. 5. Cross over insulation. 6. Consolidation if slot portion of bar. 7. I.S Test (i.e. inter strand test). 8. Forming of bar (to shape overhang portion). 9. Pickling of bar ends (1). 10. Mounting of contact sleeve & bottom part of water box. 11. Brazing of contact sleeve & bottom part of water box. 12 . Pickling of bar ends (2) 13. Mounting of water box leak test.

14. Re-Pickling.15. Water flow and Nitrogen test. 16. Thermal Shock Application. 17. Helium leak test.18. Reforming of bar (i.e. overhang portion). 19. Insulation of bar on CNC machine. 20. Impregnation & curing of bar insulation. 21. Surface finishing of stator bar. 22. OCP on stator bar. 23. Preparation of bar for HV and Tan test.

24. If O.K. Dispatch to Block-1 for lying in the generator.

CHAPTER-5MANUFACTURING PROCESS OF BARS

BAY-1 Some points of manufacturing process is in brief as below 1.Insulation Check: For the manufacturing of stator bars insulated copper conductors are brought fromBangalore, it is of two type is i.e. solid copper conductor & hollow copper conductors which are used in water cooled stator layer glass insulation. 2. Conductor cutting: This process is done by automatic CNC machine. In this process the pre-insulatedcopper conductor is cut into number of pieces of required length (length given in drawingas per design) insulation is removed from both ends of the copper conductor out. Lower Bar: Conductor Size 8*4.6*1.5mm(Hollow) 8*2.8mm(Solid) Upper Bar: Conductor Size 8*4.6*1.5mm(Hollow) 8*1.3mm(Solid) Length 10500 mm 10500 mm Number of conductors Hollow - 20 Solid - 40 Length 10200 mm 10200 mm Number of conductors Hollow- 20 Solid - 20

Conductor cutting

3. Transposition: Transposition means changing/shifting of position of each conductor in activecore(slot) part. After cutting the required number of conductors, the conductors arearranged on the 12 comb in staggered manner and then bends are given to the conductorswith the help of bending die at required distance. Then the conductors are taken out fromthe 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 aspacer is placed between the two halves.1. To reduce eddy current losses.2. Equalize the voltage generator.3. To minimize skin effect of ac current, small cross section of conductor is usedan also hollow conductors are used to effect cooling by D.M.water

4. Crossover 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 thecrossover portion of the conductors. A filler material (insulating putty of moldingmicanite) is provided along the height of the bar to maintain the rectangular shape and tocover the difference of level of conductors. To eliminate inter turn short at bends duringedge wise bending and leveling of bars in slots portion for proper stack pressing

5. Stack Pressing: This process is basically done to consolidate the solid as well as the hollowconductors into a single bar. In this process the bar is pressed both vertically andhorizontally in the Pressing Machine. The pressing machines are also provided with theheaters Each bar is loaded on each tier of heating plate and it is then provided with aninitial pressure of 355 kg per cm2 and an initial temperature of 100-110 C. then thetemperature is allowed to raise to the maximum of 160C, this temperature is kept for atleast one hour with a final pressure of 8010 kg per cm2 vertically and 7010 kg per cm2horizontally. After pressing the bar at specified pressure and maximum temperature for onehour, the bars are then cooled placing them on cooling plates through which water isallowed to follow below 50C. Then the ends of both the bars are cleaned with rectifiedspirit and sand paper for the inter strand test.

Conductor Presssing

6. Inter Strand Short test: The consolidation bar stack is tested for the short between any two conductors inthe bar, if found then it has to be rectified. This is done to ensure that no local current isflowing due to short circuit between conductors. (300V A/C supply). For this test all the bare conductors at both the ends are separated from each other so that they do not shortcircuit. Then a live wire is connected to a conductor and received from it consecutiveconductor to light a lamp. Hence if the lamp lights up it shows short circuit between thetwo conductors due to improper insulation between them. It shows insulation failure between the conductors, these conductors are then replaced and bar is followed throughall the previous processes. Similarly all the conductors are checked for any short circuit.After passing both the half bars from I.S.T. the bars are combined together and pressedinto a single bar. A sheet of mica glass insulation is provided between the two halves asthe insulation also has some gluing property to consolidate the two halves into a single bar. All the steps of pressing are again followed for the complete bar and then it isallowed to cool.

7. Forming: This process of forming is very important as in this process the bars are bendingfrom both the ends of the bar i.e. at exciter side and turbine side at specific angles andshape as per design. This process is done manually. First the former is set according tothe design making different angles at different positions. Each bar of a variant is bent or formed at same angle.

8. End Conductor Cutting: Both the solid and hollow conductors are cut and from both the sides of the bar.Also this process of cutting of the hollow conductors helps in opening of vents of hollowconductors from both the ends of the bar. 9. Pickling Process: After the forming and cutting process of the bar and due to the transportation of the bar, there accumulate very minute particles of dust on the ends of the bar. These particles may cause hindrances at the time of brazing and may create some air gaps. So,in order to remove these unwanted particles, basically the oil particles pickling process is performed. The basic solution used for this process is called pickling solution. Theconstituents of the pickling solution are

Sulphuric acid (H2SO4)-10%

Phosphoric acid (H3PO4)-5% Hydrogen peroxide (H2O2)-5% Water (H2O) Sulphuric acid (H2SO4)-10%Phosphoric acid (H3PO4)-5%Hydrogen peroxide (H2O2)5%Water (H2O)There are many other solutions used in this process, these are:AmmoniaThinner Water Rectified spirit NitrogenIn this process the following steps are involved:(A)

The end of the bar is dipped in thinner to remove the dust or oil particles.(B)

The end is then dried with the help of N2 gas.(C)

Then the bar end is dipped in pickling solution for 5 to 10 minutes.(D)

This is then followed with dipping in water.As there is acid in the pickling solution, so accordingly to neutralize the acidiceffect of the acid it has to be treated with some base, so the bar is then dipped inAmmonia (10%).It is then followed with dipping in water.As water takes a lot of time to evaporate, it may let the tiny chemical particles onthe bar to react with it and leave spots on the bar, this may weaken the insulation at those particular points and thus damage it, further it may lead to poor brazing. So in order toavoid such a damage the bar is dipped in rectified spirit to make the water contentsevaporate as soon as possible.The bar is then dried with N2 gas.Finally it is wrapped with cotton cloth to avoid any manual touch. 10. Contact Sleeve Mounting: After the pickling process is complete, contact sleeve and water box bottom partsare mounted on both the ends of the bar. Contact sleeve, as clear from the name itself, itis a rectangular sleeve which is used to make contact between upper and lower bars whenlaid out in the generator to form a complete coil. All the solid conductors are cut from theends of the bar after the contact sleeve except the outer solid conductors. None of theconductor is cut before the contact sleeve so that to make proper contact between theupper and the lower bars. The water box is mounted in two halves; first the water box bottom part is mounted after the contact sleeve keeping some distance between them.Both the ends of the bar are then again pickled along with contact sleeve and water box bottom part following the same procedure of pickling.

11. Brazing of coil lugs: For water cooled generator bars, the electrical connection contact and water boxfor inlet and outlet of water are brazed. The contact sleeves, which are used to makecontact between the upper bar and the lower bar to form a complete coil and the water box bottom part, both together are called Coil Lug, so the brazing of these two parts atthe end of a bar is called Coil Lug Brazing. Brazing is basically the process of fixation of both the contact sleeve and water box bottom part or we can say both are properlyconsolidated using brazing material at high temperatures. Consolidation is properly doneso that no air gap is left which would adversely affect the conducting properties of thecontact sleeve and the bar. The two types of brazing processes are:Thermal brazing (using LPG)Induction brazingAs induction brazing is more beneficial than thermal brazing as it does not requiresany inflammable gas for heating. So now a day is Induction brazing process is used. For brazing as we use very high temperature so that is possible due to carbon strips fixed onthe brazer. Carbon has very high resistance and when the current is allowed to passthrough it due to induction the material to be brazed i.e. Contact Sleeve gets super heated.Induction heating is hence faster and even more efficient than thermal heating. When thecontact sleeve becomes red hot at 750C, the brazing material is then pushed to fill the air gaps and to consolidate the contact sleeve on the bar. It is then allowed to cool. The typesof brazing materials used are:LAG 15P ( Alloy Silver 15 Phosphorous)LAG 40Cd ( Alloy Silver 40 Cadmium)Same process of brazing is then repeated for the water box bottom part. After the brazing of water box bottom part the bar is then allowed to cool at room temperature 12. End Conductor Cutting: As is clear from the name itself this is the process of cutting of extra conductorsi.e. the hollow conductors left after the water box bottom part are cut from both the endsof the bar. These conductors are required to be cut so that water box top part with anozzle is to be mounted on the water box bottom part. The vents of the hollow conductorsare visible from the ends of the water box bottom part. The openings of the vents of thehollow conductors are then checked to be uniform After cutting of extra conductors from both the ends of the bar, pickling processis done. Same pickling process as mentioned before is then done at both the ends of the bar for removing the dust particles, oil particles and other unwanted impurities which weassume to be there after the brazing process of the contact sleeve and water box bottom part. After pickling the bar ends are then wrapped in cotton cloth until the water test is performed. 13. Water Test: Water test is performed so that there not any blockage in the vents and also tocheck the flow of water. Flow should be uniform i.e. all the vents should have same water flow. In this test water is supplied from one side of the bar and is collected from the other side of the bar in a tank and is supplied back to the first end. Flow of the water is checked by measuring the distance of the flow of water. If there is any kind of blockage inside thehollow

conductors of the bar then it is indicated by flow of water i.e. flow of water will be not uniform and the bar is assumed to be chocked. Then cocked conductors arechanged or repaired and the bar is reformed and water test is again performed to check the flow of water. 14. Brazing Of Water Box Top Part: Brazing of water box top part is done with water box bottom part in brazingsection of Block4.For this it should be kept in mind that water box bottom part shouldhave same material as that of water box top part. The difference in previous brazing andthis brazing is that, now flux is also introduced with brazing material and also flux ismixed with copper chips. Copper chips are added to make the electrical contact betweenthe top and bottom part without the copper chips this will be not possible. In this brazingmaterial is formed in the shape as that of water box side where it has to be brazed.Brazing material is formed in square shape for top and bottom part and in ring shape for the brazing of nozzle for water flow. Then both the parts are heated with induction brazer as done earlier. It is heated until they become red hot then the brazing material melts dueto its low melting temperature then the melting temperature of the water box top and bottom part. Brazing material is also introduced at the boundaries until it is completelyconsolidated that is the entire air gap is completely filled. After the brazing of water boxtop part the bar is then allowed to cool at room temperature.

15. Checking Of Threads and Pickling Process: As mentioned earlier that water box top part has got nozzle for flow of water, italso has got threads which is provided for the proper fixation of water supply throughwater pipe to the bar. These threads are checked for its uniformity by fixing water pipe tothe nozzle. If threads are not found satisfactory than the nozzle is replaced with new oneand again its threads are checked. Also the pickling process is again done for the removal of any dust particles and lubricants etc. the detail of this process is same as mentionedearlier in pickling process. 16. Nitrogen leak test: As the name suggests Nitrogen gas is the main constituent of the test. This test issimilar to puncture test that is inflated tube is dipped in water for any leakage, the air bubbles gives us the exact position of the puncture. Similarly on the same steps this test is performed. Basically this test is performed to check any leakage in bar i.e. to check the brazing. In this test nitrogen at a pressure of 10Kg/Cm2 is forced from one end of the bar and other end of the bar is blocked then the pressure of 10Kg/Cm2 is maintained and boththe ends of the bar are dipped in water. The bubbles if there any tells us that brazing isweak or not done properly. So if bubbles appear then brazing is done again and same testis performed for the proper brazing of water box top and bottom part.Then both the ends of the bar wrapped in cotton cloth so that it is not disturbed i.e. toavoid any manual touch which may deposit any

dust particle on it until it is ready for brazing. 17. Internal Pickling: After various test performed on the bar the pickling process i.e. removal of anydust particles lubricants etc is done only on outer surface of the bar (ends). But frominside it is assumed that there must be some impurities, foreign material must be present.For this purpose inside pickling is done. As mentioned earlier same process is repeated but from inside of the hollow conductors this time. In this process the following steps areinvolved:The thinner is passed through the bar to remove the dust or oil particles.The dried with the help of N2 gas.Then the pickling solution is passed for 5 to 10 minutes.Then water is flowed in the bar As there is acid in the pickling solution, so accordingly to neutralize the acidiceffect of the acid it has to be treated with some base, so the bar is filled with Ammonia(10%).It is then followed flowing of water again.As water takes a lot of time to evaporate, it may let the tiny chemical particles inthe bar to react with it and leave spots in the bar, this may weaken the insulation at those particular points and thus damage it, further it may lead to poor brazing. So in order toavoid such a damage the rectified spirit is flowed in the bar to make the water contentsevaporate as soon as possible.The bar is then dried with N2 gas.Finally it is wrapped with cotton cloth to avoid any manual touch which maydeposit any dust particle on it until it is ready for brazing.

18. Thermal Shock Test: Thermal shock test is performed to check whether the bar can withstand extremeconditions i.e. when the generator is working or running at about 3000 Rpm. This isachieved by thermal shock test. Thermal shock test consist of series of hot water & coldwater cycles alternatively. So firstly hot water at temperature of about 90C is passedthrough the bar and then cold water at about room temperature 27C approx. is flowedinside the bar alternatively.This process is repeated for about 26 times i.e. it has 26 cyclesof hot and cold water. So this test tells us the strength of the bar so that it can withstandthe working conditions of the generator. 19. Helium Leakage Test: Helium test is the most important test of all, because helium test is performed tocheck any minute leakage within the bar and at the brazed portion. Any minute leakagewhich couldnt be checked by water test can easily be observed by helium test becausehelium is one of the lightest gases. So this is also the customers check point, before performing this test customer is by called and they see themselves the test being performed and if They find the test all right then only the bar is send to next process. Inhelium test, whole of the bar is wrapped in the polythene excluding the end points. Thehelium gas at pressure of 11Kg/Cm2 is passed through the bar and a probe connected tothe gauge is inserted inside the polythene at different places. The gauge will show deflection if there is any helium atom present. Gauge will show reading even if 1 heliumatom in 100000 atoms is present. This test checks the strength of brazing and insulation.

20. Reforming: After all the previous processes which had undergone on the bar it is assumed thatthe shape of the bar is deformed from its original shape due to handling of the bar fromone place to another for different processes. So to keep the shape of the bar as per design,the bar is checked if it is found distorted then it is reformed in the previous former machine by placing the bar on the former and malleting. 21. Insulation: The bar is insulated with the given number of layers to build the wall thickness of insulation subjected to the generating voltage of the machine. Insulation is basically doneto prevent any kind of short circuit between the bar and the stator core when the bar isassembled in the stator of the machine. The stator bars are insulated with Micalastic insulation. High quality mica, selected epoxy resins and a matching vacuumimpregnation process are the characteristic features of the micalastic insulation for largeturbo generators.The bar is provided with 14 layers of insulation. Out of these fourteen layers, 12layers are provided by using a machine called CNC TAPPING MACHINE. The rest of the two layers are provided manually.

22. Micalastic Insulation, Impregnation, Baking : Micalastic System : In case of poor resin system the insulated bars are heatedunder vacuum and the impregnated (dipped) in heated resin so that all the air gaps arefilled, layer by layer, with resin. Then extra resin is drained out and bars are heated and baked under pressed condition in closed box fixtureFor insulation with micalastic, the conductor strands are arranged together to forma compact assembly and set to the required shape. This assembly is then baked withepoxy resin to give it mechanical strength required for further processing. The bars arethen dried under vacuum and impregnated with synthetic resin, which by reason of itslow viscosity penetrates the insulation thoroughly and eliminates all voids. After impregnation under vacuum, the bars are subjected to pressure, with nitrogen being usedas pressurizing medium. The impregnated bars with direct conductor cooling are then brought to the required dimensions in moulds and cured in an oven at a high temperature This complete process involves pressing of the bars, drying by heating, impregnation inresin and finally curing. These processes are discussed briefly below: (a).Pressing: The bars are pressed to bring them back to the original dimensions. (b)Drying:

The stator windings are to be dried under vacuum 0.1 m bar at (605) C for 15 hours, minimum. The drying temperature is to be increased to (652) C if the initialviscosity of the impregnating resin mixture is high.The temperature distribution should be as uniform as possible. The drying under vacuum can be stopped if the pressure rises, 10 minutes after closing of vacuum valve isless than 0.06 m bar. (c).Impregnation: The impregnation resin mixture is to be heated in the workingtank, to (603) C or in case of higher initial viscosity. At a temperature of 50C, theimpregnating resin mixture is to be degassed with 1-5 m bar vacuum. Subsequently thestator windings are to be dipped continuously in resin hardener mix such that the highestlocations of the windings are at least 100 mm below the resin level.After 10 minutes of resin stabilization, pressure is increased by application of nitrogen. Pressure is to be gradually increased in uniform stages within 80 minutes to 4 bars and to be maintained for 120 minutes in the impregnation tank.The impregnation of the stator winding is to be monitored continuously. Further it is to be decided whether to increase the pressure or to stop the impregnation process,however the total period of nitrogen pressure cycle shall in any case not exceed 4 hours.The impregnation tank during shut down is to be closed and kept either filled withnitrogen (1.1bar) or low vacuum.

(d)Curing: To prevent heating in the overhang portion, the curing of the impregnatedstator winding is to be done with a maximum 160C hot air. The curing period isextended for such a long time till the measurement positions in the core indicate (1405)C for minimum 8 hours. 23. Finishing: The baked and dimensionally correct bars are sanded - off to smoothen the edgesand the surface is calibrated, if required, for the dimension. 24. Conducting varnish coating: (a) OCP (Outer Corona Protection) Coating: The black semi-conducting varnishcoating is applied on the bar surface on the core length. (b) ECP (End Corona Protection) Coating: The grey semi-conducting varnish isapplied at the bend outside core end of bars in gradient to prevent from discharge andminimize the end corona 25.Testing: When the bar is dried it is wrapped with aluminum sheet to make outer surface of the bar

conducting so that tan and H.V. (High voltage test) can be performed. After these tests the coating of red gel is applied at both the ends of the bar. (a)Tan test : Test is performed to find the capacitance of the bar because bar will act ascapacitor when it is laid in the stator of the generator. In this test Schearing Bridge whichworks on the principle of wheat-stone bridge is used to find the unknown capacitance of the bar. For good efficiency, capacitance of the bar should be high but we never approach pure capacitance. In this test also same bar which is wrapped with aluminum is used tomake the bar conductive throughout the outer surface of the bar. The two conductingmaterial i.e. the aluminum sheet and the conductors of the bar act as two plates of thecapacitor and the insulation on the bar act as dielectric medium for the capacitor. Thecapacitance of the bar is found and of angle of deviation due to impurity in the insulationis obtained from the formula: C4 * R4 * 10-4 = Tan For different ratings of the bar theacceptable value of Tan test is fixed according to their insulation requirement as per designconsiderations. (b)H.V. (High Voltage) Testing : This test is also known as insulation test because this test is performed to check the insulation of the bar. In this test the bar which is already wrapped with aluminum isused. High voltage is applied to the bar using auto-transformer and it is increased in stepsaccording to the working voltage of the generator. If the insulation is weak the bar will puncture at the place of weaker insulation. For 500 MW the working voltage of the bar is64.5 KV & for 210 MW the working voltage of the bar is 63 KV. If any of the bar failsthis test i.e. bar is punctured at any point then the bar is sent back for re-insulation and allthe processes are repeated again. 26. Dispatched for Winding : The bars preserved with polythene sleeves to protect from dust, dirt, oil,rain etc are send to Block-I (Electric Machines Production Block I, Turbo Generatorsand Hydro Generators) for winding 500MW Generator characteristics Rating Rating MVA Cooling 500MW 588MVA H2 and primary water Gen Self Excitation Generator Voltage 340V, 4040A 21KV

H.V. Test Voltage / Duration of test for 500MW stator bars: Formula for HV test =1.5 Up Un = working voltage of generator. Working voltage of 500 mw generator = 21kw 1 Up = 2Un+1

HV testing voltage of 500mw generator = 64.5kw

Maximum Tan limit for 500MW stator bar:-

Tan Delta is measured al 0.2 Un , 0.4 Un,0.6 Un,0.8 Un, 1.0 Un,01.2 Un,1.2 Un, 1.4 Un The difference of tan delta between two adjacent values should not be more than 1x10-3 up to 1.0Un i.e. .. a) 0.4Un -0.2 Un </ 1x10-3 b) 0.6Un 0.4 Un </ 1x10-3 c) 0.8Un 0.6 Un </ 1x10-3 d) 1.0Un 0.8 Un </ 1x10-3

CHAPTER-6 BAY-2 6.1 Introduction: Bay 2 is the manufacturer of stator bars of hydro generators, stator coils of ACmotors and stator coils of DC Exciter. The stator coils of AC motors of up to 11 KV,stator bars of Hydro generators of 200 MW and DC Exciters of all the 500 MW THRIgenerators are manufactured in this bay. The processes involved in the manufacturing of AC motors are as follows: 6.2 Insulation Check:

For the manufacturing of stator coils of AC motors, insulated copper conductorsof specific dimensions rolled on the drums are brought from Bangalore. Before performing any process on that conductor, the insulation of the conductor is checked.Insulating materials and the conductors are ensured to be certified.If required the insulation is checked by the respective agencies. 6.3 Conductor Tapping: The copper conductor is first provided with two layers of insulation, this is alsoknown as double layer tapping. The insulation tape used in this is Micafabriglass Tape. Inthis process the copper drums are loaded on the stand and tapping rolls on taping heads of the Tapping machine. The copper conductor is insulated with two layer of tape in butt as per design and hence the insulated copper conductor is again rolled on the drum fromother side of the machine. The insulation on the copper is checked, which is provided bythe automatically moving tapping rolls with some tension. 6.4 Winding Boat Coil :

The next process is forming a boat shape coil with the insulated copper conductor.In this process the former of the boat shape coil, which is adjustable in length, is first setas per length of the coil required according to the design. The number of conductors per turn and the total number of turns in a coil are all set according to the design. The insulated copper conductor drums are loaded on stand on one side of the former, theformer is then rotated and hence a boat shaped coil of specified length and specificnumber of turns is formed. The boat coil is then checked for its length and number of turns. 6.5 Boat Insulation: The boat coil is then sending to the insulation block for its insulation. Here thecomplete boat coil is insulated with single layer of polythene and then the stack consolidation length of the coil is marked and the coil is send for the next process. 6.6 Stack Pressing : In this process the press plank is first cleaned then the boat coil is loaded in the press. The boat coil is cured for 35 minutes at 155 5 C under high pressure (to ensureclosing of box) after attaining the temperature. 0.1 mm filler gauge should not go insidethe box. The stack length and width of the boat coil is checked at slot portions. The pressing of the boat coil is done for the consolidation of the coil. The length of heating plates should be approximately equal to the stack consolidation length of coil.

pressing

6.7 Forming: The forming of the boat coil is done in an automatic machine i.e. SchumannPulling Machine. The machine is first set, and then the forming plates are mounted for overhang on the machine. The forming plates mounted are according to the overhangdesign of the coil. The required variant of boat coil is pulled into the diamond shape.The loading of boat coil should be as per the variant of boat coil given in thedesign. The coil dimensions and geometry of the coil is then checked on the UniversalModel. The terminals of the coil are set according to the design and also the first bendsand the overhang portions are marked. 6.8 Insulation: In this process the slot portion and the first bends of the coil are insulated withaccelerator treated Mica Tape as per design. For the stator coil of 11 KV AC motor, total8 layers of insulation tapping are provided i.e. three layers at the slot portion and the restfive layers all over the coil. Generally for the stator coils of low rating motors total fivelayers of insulation tapping is provided. The insulation tape used is Epoxy Mica Paper tape. Red tape is the finishing tape provided at the overhang portions of the coil. The black colored insulation tape in conducting in nature and it is provided at the slot portionof the coil. The insulation tape at the bend portions of the coil is grey in color and is semiconducting in nature. Then the perimeters and width of the insulated coil is checked at theslot portion of the coil. A release film is to be provided on the entire coil including coilterminals. On slot portion two layers of release film is provided. The coil is now sendingfor the next process.

6.9 Impregnation: For impregnation pressing strips are mounted on the coil. The pressing strips arechecked to be closed properly. The coils are then impregnated in micalastic resin as per design. The impregnation resin mixture is to be heated in the working tank, to (603) Cor in case of higher initial viscosity. At a temperature of 50C, the impregnating resinmixture is to be degassed with 1-5 m bar vacuum. Subsequently the stator windings are to be dipped continuously in resin hardener mix such that the highest locations of thewindings are at least 100 mm below the resin level. After 10 minutes of resinstabilization, pressure is increased by application of nitrogen. Pressure is to be graduallyincreased in uniform stages within 80 minutes to 4 bars and to be maintained for 120minutes in the impregnation tank.The impregnation of the stator winding is to be monitored continuously. Further it is to be decided whether to increase the pressure or to stop the impregnation process,however the total period of nitrogen pressure cycle shall in any case not exceed 4 hours.The impregnation tank during shut down is to be closed and kept either filled withnitrogen (1.1bar) or low vacuum.

6.10 Curing: After the impregnation of the coil it is then cured at 140 10 C for 18 hoursafter attaining the required temperature. Curing of the coil is done for the proper consolidation of the coil. The regime is then required to be checked. The pressing stripsare disassembled after the curing of the coil. The dimensions of the coil are then checked. 6.11 Finishing: In this process the release film is removed and the coil is finished with sand paper.The straight length of the coil is marked. The coil is then coated with corona protectionvarnish as per design and then the coil is allowed to dry properly for 6 hours. The slot portion dimensions and the quality coating varnish are then checked. The coil is checkedfor its insulation using tan and H.V. (High Voltage) Test.

CHAPTER-7 BAY -3 7.1 Introduction:

Bay 3 is the manufacturer of insulating material of different shapes and sizes asrequired according to the design. This bay is also called as I.D. Section (InsulationDesign Section). For the manufacturing of insulations, different raw materials havinginsulating properties are brought by this section. The raw materials having differentinsulating properties are then processed in this section and molded to different shapes as per design. The raw materials used in this bay are: Glass based Textolite Sheet Cotton based Textolite Sheet Paper based Textolite Sheet Mica Glass sheet Teflon Sheet Mica Sheet Nylon Sheet Perpex Glass Sheet Nomex Paper

7.2 Insulation Classification:Thermal classification of insulation depends upon the temperature Withstand capabilityof the insulation.

Class Y Class A Class E Class B Class F Class H Class C

up to 90 up to 105 C up to 120 C up to 130 C up to 150 C up to 180 C 180 C up to 220 C.

CHAPTER-8 CONCLUSION Engineering students will have to serve in the public and private sector industries,laboratories and workshops based training & teaching in classroom has its own limitations.The lack of exposure to real life, materials processes and functioning of industrialorganization is the measure hindrances in the student employment. The training has proved to be quite faithful. It proved an opportunity for encounter with such huge machines like turbo-generator hydro generator etc. Thearchitecture 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 structuraldescription but greater part is planning and management. It provides an opportunity tolearn tech. Used at proper place and time can save a lot of labor. However, training has proved to be satisfactory. It has allowed us an opportunity to get an exposure of the practical implementation of theoretical fundamentals. In the open economy era of fast modernization and tough competition, technicalinstitutes should procedure pass outs as near to job function as possible. Practical training is one major step in this direction. This training helped me ingaining in depth knowledge of the working of a telephone exchange. At last I would only say that this training was helpful for my future prospects.