BHEL is India's largest power equipment manufacturer. It has several manufacturing blocks, including Block 4 which produces stator bars for generators. The stator bars undergo a multi-step manufacturing process that includes conductor cutting, transposition, stacking, brazing, various tests like water, nitrogen and thermal shock, insulation, varnishing and finishing. The finished bars are then used in power generators manufactured by BHEL.

1. Presented By
Neeraj Varshney
1216521034
Electrical & Electronics Engg.

2. 
 Introduction to BHEL
 Key Features of BHEL
 BHEL mission, vision & values
 Blocks in BHEL, Haridwar
 Layout & study of Block 4
 Manufacturing of 600MW stator bars
 Conclusion
Contents

3. Introduction to
Bharat Heavy Electricals Limited, Haridwar

4. FEATURES DESCRIPTION
INDUSTRY 1. Heavy Electrical Equipment Plant
2. Central Foundry Forge Plant
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, Environmental
Management Company
TOTAL TURNOVER 9.07 billion $
PRODUCTS Turbines, Boilers, Generators, Sensors,
Drives, Circuit Breakers, Switch Gears, Motor
etc.

5. FEATURES DESCRIPTION
CERTIFICATIONS 1. ISO 9001:2000 for Quality Management
2. ISO 14001 for Environmental Management System
3. OHSAS-18001 for Occupational Health & Safety
Management System
CAPACITY 59% in India’s total Installed Generating Capacity.
EMPLOYMENT 49,280
EXPORTS To about 21 countries.

7. HEADQUARTER
MANUFACTURING UNITS
CHECK & REPAIRING
UNIT
NEW DELHI
KOLKATA
VARANASI
GOINDWAL
HARIDWAR
RUDRAPUR
JAGDISHPURJHANSI
BHOPAL
HYDERABAD
BANGALORE
RANIPET
TIRUCHIRAPALLY
CHENNAI

8. BLOCKS DESCRIPTION
Block -1 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

9. BLOCK-4 BAY-2
BAY-1
BAY-3
Bar Winding
Shop
Bars with CNC
machines
Insulation Detail
Shop

12. INSULATION
CHECK
CONDUCTOR
CUTTING
TRANSPOSITION STACK
PRESSING
INTER
STRAND
SHORT
TEST
FORMING
PICKLING
PROCESS
BRAZING
WATER
TEST
NITROGEN
TEST
INTERNAL
PICKELING
BAROSCOPIC
TEST
THERMAL
TEST
HELIUM
LEAKAGE TEST
INSULATION
IMPREGNATION
& BAKING
FINISHING
VARNISH &
COATING

13. Insulation check : Insulated Copper conductors are used:
(1) Solid Cu conductor
(2) Hollow Cu conductor
Conductor cutting :
It is done by C.N.C MACHINE.
LOWER BAR :
UPPER BAR
CONDUCTOR SIZE LENGTH NO. OF CONDUCTORS
9.5*4.4*1.3mm hollow 11053mm Hollow-14
9.5*1.2mm solid 11053 mm Solid-28
CONDUCTOR SIZE Length NO. OF CONDUCTORS
9.5*4.4*1.3mm (Hollow) 10887mm Hollow – 14
9.5*1.2mm (Solid) 10887mm Solid- 28

14. 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.
Bar is pressed both vertically & horizontally.
Inter strand short test :
(1) To check the short circuit between conductors.
(2) No current flow between the conductors.

15. Pickling process : BASIC SOLUTION FOR PICKELING 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.
Forming :
SOLUTION NAME PERCENTAGE
(%)
SULPHURIC ACID 10%
PHOSPHORIC ACID 5%
HYDROGEN
PEROXIDE
5%

16. 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.

17. 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.
4. Determines the strength of the bar.
Internal pickling:
1. Done for cleaning of hollow conductors.
2. Used for removing the impurities from
inside.

18. Insulation : 1. To prevent short circuit, insulation is done.
2. MICALASTIC is used as insulating tape

19. Conductor varnish and Coating
(1) ECP(End corona protection) coating
Grey semiconducting varnish is applied at the end of the bars.
(2) OCP(Outer corona protection)coating
Black semiconducting varnish coating is applied at the core length.
FINISHING
1. BARS ARE SANDED OFF.
2.THE EDGES ARE SMOOTHENED.

20. Manufactured
Bars
Bars used in
generator

21.  The training has proved to be useful as well as faithful.
 Got a chance to encounter with the generators, its
manufacturing units, etc.
 Gives an opportunity to learn about the optimization of
technology.
 It also helped me to have an exposure of the practical
implementation of the theoretical knowledge.