Lokesh Training report from BHEL
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Lokesh Training report from BHEL

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Training from BHEL, Haridwar

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

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Lokesh Training report from BHEL Lokesh Training report from BHEL Presentation Transcript

  • A PRACTICAL TRAINING SEMINAR ON MANUFACTURING PROCESS OF 500 MW STATOR BAR AT BHARAT HEAVY ELECTRICALS LIMITED, HARIDWAR SUBMITTED TO SHRI S C MITTAL SHRI M K LALVANI SUBMITTED BY LOKESH KHATRI ELECTRICAL ENGG. UNIVERSITY COLLEGE OF ENGINEERING ,KOTA(RAJASTHAN)
  • Table of contents  About the organization  B.H.E.L Haridwar: A Glance  Over view of 500 MW stator bar  Manufacturing process of 500 MW Stator Bar
  • About the organization : BHARAT HEAVY ELECTRICALS LIMITED ,HARIDWAR
  • KEY FEATURES OF BHEL : FEATURES DESCRIPTION INDUSTRY 1. HEAVY ELECTRICAL EQUIPMENT PLANT 2. POWER GENERATION ESTABLISHED IN 1964 HEADQUARTER NEW DELHI,INDIA AWARDS & RANK 1. LARGEST PSU WITH ‘MAHARATNA STATUS’ 2. 4TH RANK IN FORBES 50 LIST 3. QUALITY ,SAFETY, ENVIORMENTAL MANAGEMENT COMPANY TOTAL TURNOVER 9.07 billion $ PRODUCTS TURBINES, BOILERS, GENERATORS, SENSORS, DRIVES, CIRCUITBREAKERS, SWITCHGEARS, MOTOR etc.
  • TYPE DESCRIPTION DIVISIONS 15 MANUFACTURING, 2 REPAIR, 8 REGIONAL, 8 SERVICE CENTERS CAPACITY 59% IN INDIA’S TOTAL INSTALLED GENERATING CAPACITY EMPLOYMENT 49,280 EXPORTS TO ABOUT 21 COUNTRIES BHEL MISSION,VISION & VALUES :
  • LOCATION SHOWING THE PLANTS OF B.H.E.L OVER INDIA : GOINDWAL NEW DELHI HARIDWAR RUDRAPUR JAGDISHPUR JHANSI VARANASI BHOPAL KOLKATA HYDERABAD BANGALORE CHENNAI RANIPET TIRUCHIRAPALLY HEADQUARTER MANUFACTURING UNITS CHECK & REPAIRING UNIT
  • B.H.E.L HARIDWAR : A GLANCE : BHEL Hardwar divided into 8 blocks. these blocks are. Blocks Block -1 Description of block Machine block(Turbo generators & Exciter manufactured ) Block-2 Power equipment manufactured & Assembled Block-3 Turbine section Block-4 Coil & insulation manufacturing block Block-5 Water box & turbine parts Block-6 Stator frames & rotor blades manufactured Block-7 Stampings & Dies for motor & generator Block-8 Coolers & oil tanks
  • BAY-1 BLOCK-4 MANUFACTURE OF STATOR BAR OF TURBO GENERATORS BAY-2 MANUFACTURE OF STATOR BAR OF HYDRO GEN,AC BAY-3 MANUFACTURE OF Insulation MATERIAL ACC DESIGN
  • MANUFACTURING OF 500 MW STATOR BAR : Why we call it bar? It is difficult to wind a large capacity generator with a specific gauge of Cu conductor or a wire. In large capacity generators we use bunch of Cu conductors is used after pass through a process. Those Cu strips called as bar. Bar may be 210MW,500MW,600MW etc. STATOR BARS
  • Overview of manufacturing process : INSULATION CHECK CONDUCTOR CUTTING TRANSPOSITION STACK PRESSING BRAZING PICKLING PROCESS FORMING INTER STRAND SHORT TEST WATER TEST NITROGEN TEST INTERNAL PICKELING BARSCOPIC TEST IMPREGNATI ON & BAKING INSULATION HELIUM LEKAGE TEST THERMAL TEST FINISHING WARNISH & COATING
  • Insulation check : Insulated Cu conductors are used: (1) Solid Cu conductor (2) Hollow Cu conductor Conductor cutting : It is done by C.N.C MACHINE. LOWER BAR : CONDUCTOR SIZE LENGTH NO. OF CONDUCTORS 8*4.6*1.5mm hollow 10200 mm Hollow-20 8*2.8mm solid 10200 mm Solid-20 CONDUCTOR SIZE Length NO. OF CONDUCTORS 8*4.6*1.5mm(Hollow) 10500mm Hollow – 20 8*1.3mm(Solid) 10500mm Solid- 40 UPPER BAR
  • Transposition 1). To reduce eddy current in bar. 2). Done manually Stack pressing : This is done for hollow & solid conductors to make a one unit. Inter strand short test : (1) To check the short circuit between conductors. (2) No current flow between the conductors.
  • Forming : 1). Done on Universal forming Machine. 2). A bend is given to the bar, both side . 3). Bend use for terminal connections. FORMING FIG. Pickling process : 1). For cleaning job (oily, dirty and dusty job) and for remove acidic properties. 2).Solution is heat upto 50˚ C. 3). Then our job is dipped in pickling solution for 15 minutes. BASIC SOLUTION FOR PICKELING PROCESS SOLUTION NAME PERCENTAGE (%) SULPHURIC ACID 10% PHOSPHORIC ACID 5% HYDROGEN PEROXIDE 5%
  • Brazing : 1). Brazing is basically the process of fixation of both the contact sleeve and water box bottom part to bar. 2).It is done by Induction machine. Water test : 1). To check any blockage and vent in the bar. 2). Also check the flow of water in the bar. Nitrogen test : 1). To check any puncture in the bar. 2). If there is any puncture air bubble give us exact location of puncture.
  • Internal pickling : 1). Done for cleaning of hollow conductors. Thermal shock test : (1) To check the bar at extreme condition. (2) Process repeated at 26 times. (3) 26 hot water & 26 cold water cycle. Thermal shock fig.
  • Helium leakage test : (1)Test is done in front of customer (2) By passing the helium inside the bar. (3). It pass at presssure of 11kg/cmsq. Insulation : (1) To prevent short circuit, insulation is done. (2) MICALASTIC is used as insulating tape
  • Impregnation: (1) Thermo reactive system(Rich Resin System) (2) Micalastic system(Poor Resin System) Finishing : Smooth the edges of impregnated bars
  • Conductor varnish and Coating (1) ECP(End corona protection) coating (2)OCP(Outer corona protection)coating
  • THANK YOU
  • ANY QUERIES ?