MANUFACTURING PROCESS OF 500 MW TURBO GENERTOR STATOR WINDING BAR AT BHEL HARIDWAR

Tushar Shukla (0803221054)

INTRODUCTION
In 1956 India took a major step towards the establishment of its heavy engineering industry when BHEL, the first heavy electrical Manufacturing unit of the country was set up at Bhopal. BHEL's Heavy Electrical Equipment Plant (HEEP) was set up in technical collaboration with USSR, for the manufacturing of power plant equipment.

More than 40 percent of the country's electrical energy is generated from the power equipment supplied by BHEL, Haridwar.

MANUFACTURING BLOCKS:
BLOCK I
BLOCK II

:
:

Electrical Machine Block

Fabrication Block

BLOCK III
BLOCK IV

:
:

Turbine Blade Block

Coil & Insulation Manufacturing Block

BLOCK V
BLOCK VI BLOCK VII

:
: :

Fabrication And Forge Block

Stamping And Dies Manufacturing Block Woodworking Block Heat Exchanger Block

BLOCK VIII :

COIL & INSULATION MANUFACTURING SHOP (BLOCK-IV)

Block-4 is a feeder block for insulating items, winding with class-B Bituminous insulation and sheet metal components for all the products of Block-1 i.e. Turbo-generators, Hydro-generators, A.C. and D.C. machines There are three BAYS in this block each bay manufactures stator bars and coils for different machines

Sections in Block IV
1) Assembly Section It is equipped with small size Drilling machines Welding sets Hydraulic testing equipment for manufacturing turbogenerator mechanical assemblies. 2) Stator Bar Winding Section It is equipped with Conductor cutting, insulation and transposition section. Stack consolidation section, forming and lug brazing sections. Insulation taping sections with automatic taping facilities in airconditioned 3) Impregnation Section It is equipped with Impregnation tank Ovens for impregnation of DC pole coils.

Layout of CIM, Block-IV

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, and THW
Stands for type of generator T- Turbo Generator H- Hydro Generator Stands for the cooling media for Rotor H- Hydrogen gas A- Air Stands for the type of cooling for Rotor R- Radial D- Direct F- Forced I- Indirect Stands for type of cooling for Stator I- Indirect D- Direct F- Forced

Stands for cooling media used for Stator coil

W- Water

No. of Bars in current products

Set Type Upper Upper Lower Lower Ordinary Terminal Ordinary Terminal 42 54 6 6 42 54 6 6 Total Bars 96 120 No. of Bus Bars 6 9

500MW THDF 210MW THW

250MW THRI

48

12

48

12

120

For making ONE bar

FOURTY SOLID CONDUTOR ARE USED TWENTY HOLLOW CONDUTOR ARE USED LENGTH OF UPPER BAR & LOWER BAR =10,500mm

FOR 500 MW TOTAL 96 BARS ARE USED

Manufacturing process a of bar:

COPPER CUTTING TRANSPOSITION CROSS OVER INSULATION STACK MACHINE IST TEST FORMING LUG MOUNTING LUG BRAZING

Cont
NITROGEN TEST THERMAL SHOCK TEST HELIUM TEST BODY INSULATION IMPERGNATION BAKING FINISHING HV TEST DISPATCH FOR LAYING IN STATOR

INSULATION CLASSIFICATION:
Upto 90 C Class Cotton, Silk, or Paper. Y
Class Reinforced Class-Y materials with impregnated varnish. A

Upto 105 C Upto 120 C

Class Cotton lamination & Paper lamination. E

Upto 130 C Class Inorganic material is hardened with adhesives. B

Class Class-B materials that are upgraded with adhesives. F

Upto 150 C

Upto 180 C Class Made of inorganic material glued with silicone resin. H > 180 C Upto 220 C Class Made of 100% inorganic material C

500 MW Turbo generators at a glance

2-Pole machine with the following features: Direct cooling of stator winding with water. Direct hydrogen cooling for rotor. Micalastic insulation system. Spring mounted core housing for effective transmission of vibrations. Brushless Excitation system. Vertical hydrogen coolers

Salient technical data: Rated output: 588 MVA , 500 MW Terminal voltage: 21 KV Rated stator current: 16 KA Rated frequency: 50 Hz Rated power factor: 0.85 Lag Efficiency: 98.55% Important dimensions & weights: Heaviest lift of generator stator : 255 Tons Rotor weight : 68 Tons Overall stator dimensions [L*B*H] : 8.83m*4.lm*4.02m Rotor dimensions(Dia. and length) : 1.15m and 12.11m Total weight of turbo generator : 428 Tons

Picture Of Bars

THANK YOU