PROJECT REPORT

ON
Manufacturing of Turbo generator Stator Bars :
AT B.H.E.L (HARIDWAR)
IN PRACTICAL FULFILLMENT OF THE
REQUIRMENT
OF THE 6th SEMESTER

B.TECH-ELECTRICAL ENGINEERING
OF
DEHRADUN INSTITUTE OF
TECHNOLOGY, DEHRADUN.

UTTARAKHAND TECHNICAL
UNIVERSITY, DEHRADUN.
SUBMITTED BY,
SWATI KATARIA
6TH SEM. E.E.

ACKNOWLEDGEMENT
It gives me immense pleasure to present my
Project Report before you. I thankfully acknowledge
the

staff

of

BHEL,

Haridwar for giving me so much co-operation and

taught lots of new things to me, which I am sure will
help me in my future.
A special thanks to Mr. A.K. Dhiman (Sr.
Engineer) and Mrs. Gyandevi Mehta (Engineer)
for their support during my Industrial Training. I pay
my sincere regards to these two. Without their
support I was not able to accomplish my project
I extend my thanks to my college for giving me
such an opportunity under the supervision of Mr.
GAGAN

(H.O.D.) and Mr. V.R.C PHANIHARAN

(Training and Placement Officer) who are also

an experienced person.
SWA
TI KATARIA
ELECTRI
CAL(3rYEAR)

TABLE OF CONTENTS

CHAPTER

PAGE NO.

1. INTRODUCTION

2. BHARAT HEAVY ELECTRICALS LIMITED THE CORPORATE GIANT

3. BRIEF DESCRIPTION OF MANUFACTURING BLOCKS I, II,III, IV, V,

VI, VII, VIII

16

4. BLOCK IV: MANUFACTURING OF STATOR COIL FOR

TURBOGENERATORS

28

5. MANUFACTURING OF STATORCOIL FOR HYDRO GENERATORS

44

6. MANUFACTURING OF INSULATION

48

B.H.E.L AN OVERVIEW
The Navratanas declared by Indian
government are NTPC, VSNL, ONGC, IOC, HPCL,
SAIL, BHEL, IPCL, BPCL, etc. Therefore, B.H.E.L. is
one of the Navratanas and is the largest engineering
enterprise of its kind in India with an excellent track
record of performance. The company is engaged in
engineering development and manufacturing of a
wide variety of mechanical and electrical equipment
for generation, transmission, and electricity. The
company today enjoys National and International
presence featuring in the Fortunes Internationals
500 and is ranked among the top 12 companies in
the world for manufacturing power generation
equipment.
B.H.E.L. has 14 manufacturing divisions, nine
service centers and four power sectors regional centers and about
180 projects sites enables the company to its customers and
provide them with suitable products, systems and service at
competitive prices. Having attained ISO 9000 certification,
B.H.E.L. is now embarking upon the total quality management.

BACKGROUND OF THE B.H.E.L.

4

Heavy Electrical (India) ltd. [HE (I) L] was set

up in Bhopal in 195 6 with a view to reach self-sufficiency in
power equipments vital for industrialization of the country, then
B.H.E.L. came into existence in 1964. Three plants were stabilized
under B.H.E.L. are as follows:
1) High Pressure Boiler Plant Tiruchy (T.N.)
(MAY 1965)
2) Heavy Power Equipment Plant Hyderabad (A.P. )
(DEC 1965).
3) Heavy Electrical Equipment Plant Hardwar (U.k.)
(JAN 1967).
As there was need for development of power
equipment manufacturing in India and also with a view to
optimally utilize the resources HE (I) L. was merged in B.H.E.L.
PRESENT POSITION OF B.H.E.L.
At present B.H.E.L. have 14 manufacturing units.
The major units are B.H.E.L. Bhopal, B.H.E.L. Hyderabad,
B.H.E.L. Triuchy, and B.H.E.L. Hardwar. The corporate
office is situated in New Delhi and provides necessary top
management leadership, direction, strategic-planning and
operational and management support services.
It also
coordinates the activities, function of various manufacturing,
service divisions and numerous other functional and product
groups. It also looks after the long term planning in regards to
resource and marketing and also planning for marshaling of
human, physical and financial resources.

COMPANY OBJECTIVES:
BUSINESS MISSION :
To maintain a leading position as suppliers of
quality equipment, system and services in the field of conversion,
transmission utilization and conversation of energy for application
in the areas of electric power transportation, oil and gas
exploitation industries utilize companys capabilities and resources
to expand business into allied areas and other sectors of the
economy like defiance, communication and electronics.

GROWTH :
To ensure a steady growth by enhancing the
competitive edge of B.H.E.L. in existing business in new areas and
international operators.
PEOPLE ORIENTATION:
To enable each employee to achieve his potential,
improve is potential, improve his capabilities perceive his role and
responsibilities and success of the company. To invest in human
resources continuously and be alive to there needs.
TECHNOLOGY :
To achieve technological excellence in operations
by development of indigenous technology and efficient absorption
and adoption of imported technologies to suit business needs and
priorities and provide a competitive advantage to the company.
IMAGE :

To fulfill the expectation which stakeholders like

government as owner, employees, customers and the country at
large house from B.H.E.L.

MANUFACTURING UNITS AND PRODUCT PROFILE:

NAME OF PLANT

PLACE

Steamless plant.

Tiruchirappali Steamless steel tubes,

( Tiruchy ).
Sriral finwelded tubes.

Boiler auxiliaries.

Industrial
plant .

Ranipet.

vavles Govindwal.

PRODUCT

Electrostatic precipitation ,
Air preheater ,
Fans ,
Wind elctric generators ,
Desalination plants.
Industrial vavles and
Fabrication .

Heavy
electrical Haridwar.
equipment plant.

Steam turbines ,
Hydro turbines ,
Gas turbine ,
Turbo generators ,
Control panels,
Light aircrafts ,
Eletrical machines.

Central
foundry Haridwar .
forge plant .

Heavy casting and forging.

Heavy
plant.

electrical Bhopal .

Transformer plant.

Jhansi.

Heavy
power Hyderabad.
equipment plant.

Steam turbines ,
Turbo generators ,
Hydro sets ,
Switch gear controllers,
Transformers ,
Diesel shuntless ,
AC locos ,
AC EMU.
Power generating set ,
Industrial turbo sets,
Compressors ,
Pumps and heaters ,
Bow mills ,
8

Heat exchangers oilrings ,

Gas turbines ,
Switch gears.
Electronic division.

Banglore.

Energy meters ,
Water meters ,
Control equipment ,
Capacitors ,
Piotovoltaic panels and
Electronic private automatic
branch exchange.

Insulator plant.

Jagdishpur.

Insulators and bushing.

Electronic
system Banglore.
division, electronic
city.

Simulator,
Telecommunication system ,
Other advanced
micro
processor based control
system.

Electro porcelain Banglore.

division.

Insulator and bushing ,

Creamic liners.

Component
fabrication plant.

Windmill ,
Solar water heating system.

Amerphass

Rudrapur.

silicon Guragaon.

Solar cells ,
9

solar cell plant.

Solar lanterns chargers ,

Solar clocks.

Heavy
equipment
plant.

Repair
shop for power
generating equipment.

eletrical Varanasi.
repair

Electrical machine Mumbai.

repair shop.

Repair
of
machines.

electrical

TECHNICAL COLLABORATORS:
NAMES OF
COLLABORATOR

Seimens.

Germany.

National oil well.

General
company.

COUNTRY

U.S.A.

electrical U.S.A.

PRODUCT

Steam turbines ,
Generators ,
Lateral / Arial condensers.
Christmas tree and
Well head assembled.
Gas turbines.

10

Asian brown boveri.

May & christe gumbh.

Seimens AG.

National oil well.

Nordex A/S .
Energy technics.

Siemens AG.

High
voltage
directs
Switzerland. current system (HVDC).

Germany.

Germany.

U.S.A.

Denmark.

Dry type transformer.

Large size gas turbines.

Composite block valves,

Sub sea well ,
Head assembly ,
Caring support machine
suspension equipment.

Wind electricgenerators.

Germany.

Bed combustion boiler.

Germany.

Electrical machines

Super rapid.
11

Melara SPA.

Italy.

COMPETITORS:
SEMENS

GERMANY

WESTING HOUSE
GENERAL ELECTRIC COMPANY
(GEC)
ANSAELU
GEC AISTHAM
MITSHUBISHI
CMZ
MAROBENI
ITTOCHU
ANRON
RAYTHEON
BEETHES
CUSTAIN
ROLLS ROYEE
BROWN AND ROUTE
SARGENT AND LUNDRY
STONE AND WELSTER
ASIAN BROWN BOVERI ( ABB )

U.S.A.
U.S.A
ITALY
FRANCE
JAPAN
RUSSIA
JAPAN
U.S.A.
U.S.A.
U.S.A.
U.S.A.
U.K.
U.K.
U.S.A.
U.S.A.
U.S.A.
SWITZERLAN
D

12

B.H.E.L. (HARDWAR): A PROFILE

B.H.E.L. Hardwar, one of the keys manufacturing

units of B.H.E.L. is located between Shivalik Mountains and Holy
River GANGA. Its manufacturing plant includes two factories at
Hardwar.
On the northern side is heavy electrical equipment
plant (H.E.E.P.), which commenced production in 1967 with
knowhow from M/S Kraft-work union, AG of Germany.

Now

H.E.E.P. has a technical collaboration with M/S Siemens

Germany. For manufacturing of large size gas turbine.

13

Located immediately to the south of H.E.E.P. is the

central foundry forge plant (C.F.F.P.) which was primarily set up
for manufacture of alloy steel casting and forging required for
industry and power generation equipment. It was established in
technical collaboration with M/S Crensot Loire of France. .

PROFILE OF HEEP

ESTABLISHMENT AND DEVELOPMENT STAGES :

Establishment in 1960's under the Indo soviet

Agreement of 1959 and 1960 in the area of
Scientific, technical and industrial cooperation.
DRP prepared in 1963 64 , construction started
From Oct.1963.
Initial product of electric motors started from Jan.
1967.

14

 Major contribution /election /commissioning completed

By 1971 72 as per original DRP scope.

Motor manufacturing technology up dated within

siemens collaboration during 1984 87 .
Facilities being
Replacement,

modernized continually through

reconditioning,
retrofitting,

technological, operational balancing .

HEEP PRODUCT PROFILE

1. THERMAL SETS :
Steam turbines and generators up to 500 MW
capacity for utility and combined cycle applications; capability to
manufacture up to 1000 MW unit cycle.

15

2. GAS TURBINES:
Gas turbines for industry and utility application; range3 to 200 MW (ISO).
Gas turbines based co-generation and combined cycle
system.

3. HYDRO SETS :

Custom built conventional hydro turbine of kaplan,

Francis and Pelton with matching generators upto 250
MW unit size.

Pump turbines with matching motor-generators.

Mini / micro hydro sets.
Spherical butterfly and rotary valves and auxiliaries for
hydro station .

16

4. EQUIPMENT FOR NUCLEAR POWER PLANTS:

Turbines and generators upto 500MW unit size.

Steam generator upto 500MW unit size.
Reheaters / separators .
Heat exchangers and pressure vessels.

5. CASTING AND FORGINGS:

Sophisticated heavy casting and forging of creep
resistant alloy steels, stainless steel and other grades of alloy
meeting stringent international specifications.

17

6. DEFENCE PROCEDURE: Naval guns with collaboration of

Italy.

BRIEF DESCRIPTION OF
MANUFACTURING BLOCKS I, II, IV, V,
VI, VII AND VIII
Block IBlock-I, also known as Electrical Machines Block, is designed
to manufacture Hydrogenerators, Turbogenerators and Testing
facilities for Turbogenerators. There is also a special Test Bed for
testing of turbogenerators of capacity of 500 MW and above. Apart
from facilities and equipment for manufacture of turbogenerators,
the Block also has a Babitting Section. Babitting of bearing
liners for Turbogenerators, Turbines, Hydrogenerators, is carried
18

out in this section. The Block has its own overspeed balancing
installation; where the dynamic balancing of Turbogenerator-rotors
of less than 500 MW rating is done. Rotors having higher rating
are balanced in OSBT of Block-III.
Fabricated components are received from fabrication blocks
(Block-II, IV, VI, VIII), while other castings, forgings are received
from CFFP and other sources for Turbogenerators,
Hydrogenerators and Electrical motors. Stampings are received
from Stampings manufacture section; Block-VI and coils, bars,
insulating details and sheet metal components are received from
Block-IV. These are then machined, assembled, tested and
dispatched.

Block IIBlock-II, also known as Fabrication Block, is a feeder block for

various products- Steam Turbines, Hydro Turbines,

19

Turbogenerators, Hydrogenerators, Electrical Machines, Apparatus

and Control Gear, Aircraft and SRGM (Smooth Recoil Gun
Mounting). The main processes in this Block are cutting, bending
and welding of metal sheets etc. to form fabricated structures. The
Block also has useful equipments like Hydraulic Bending Presses
and Straightening Rollers. Other notable facilities include a CNC
six-spindle drilling machine, a plasma-flame cutting machine,
shot-blasting apparatus and various furnaces. The Block also has
facilities for NDT (Non Destructive Testing) of various
components. The following Non-Destructive tests can be
conducted DP Test (Die Penetration Test), MPI (Magnetic
Particle Inspection), UT (Ultrasonic Testing) and Radiography
which includes X-ray and -ray testing.

Block III
Known as the TURBINE BLOCK, this is the major block for
manufacturing turbines. All types of Hydro, Steam, Gas and
Nuclear Turbines are manufactured and dispatched from this
20

block. Blades of different stages are also manufactured here in this

block.

Block IVBlock-IV, also called as CIM&ACM (Coil and Insulation

Manufacturing & Apparatus and Control Gear Manufacturing), is a
feeder block to Block-I. It is a feeder block for Class F windings
for Turbogenerators, Hydrogenerators and Class F and H
insulation for AC and DC motors. It also supplies all insulation
components for Turbogenerators, Hydrogenerators, and motors.
Control panels for Turbogenerators, Hydrogenerators, Industrial
drives for motors, and Turbogenerators auxiliaries, contactor relays
and master controllers are also manufactured in this Block.

Block V-

21

Block-V, also called as Fabrication and Forge Block is again a

feeder block. Fabrication work being done in this block is of Steam
Turbine parts like Condenser, Water Box (Front and Rear),
assemblies of LP cylinder, Storage Tanks etc.; Hydro Turbine parts,
Hydrogenerator and motor assemblies and components. Forging of
carbon, alloy and stainless steels are manufactured in this block. It
is equipped with pneumatic hammers, gas-fired furnaces and
hydraulic manipulators.

Block VIBlock-VI, also called as Fabrication Block, is also a feeder

block. Manufacturing of all types of dies, including stamping dies
and press forms is carried out in one bay, while stamping for
Turbogenerators, Hydrogenerators and motors are manufactured in
other bay. The Block is equipped with Welding, Drilling, Shot
Blasting and CNC Flame cutting facilities. The items manufactured
in this block are Condensers, Steam Turbine components (Oil
22

Tanks and Hollow Guide Blades), Hydro Turbine components

(Stay Rings), Hydrogenerator and motors (Stator Frames) etc.

Block VIIBlock-VII, also called as Woodworking section, is also a

feeder block. Bay-I, known as Packaging section manufactures
packages for packaging and dispatch of various products.

Block VIII.
Block-VIII, also called as Heat Exchanger Block, is designed to
manufacture Heat Exchanger Units for Steam Turbines, Hydro
Turbines, Turbogenerators, Hydrogenerators etc. Blanks cut to size
and shape are received from Block-II and Block-VI. These are
assembled, welded and machined. The items manufactured here
are LP Heater, Ejectors, Gland Steam Coolers, Oil Coolers, Oil

23

Tanks, Bearing Covers, Turbine shaft Covers, Oil Bath and Thrust
Bearings.

All blocks have a most modern and streamlined layout with mechanized
material handling facilities like inter-bay and inter-block transfer bogies,
rail tracks connecting the main blocks with railway system, Electric
Overhead Travelling (EOT) cranes etc. An open gantry connecting all major
manufacturing blocks for ease of inter-block material movement is also
provided.

To Study the Manufacturing of Turbogenerator Stator

Bars :
General Aspects of Turbogenerators :
With the increasing pace of industrial & technological developments,
powerful and high speed machines have become a common feature of many
industries. Electric motors, turbogenerators, high speed turbines &
compressors have become an integral and indispensable components of
modern industry.
Turbogenerator is an A.C synchronous machine. These are the
Synchronous Generators driven by steam turbines at high speeds, 3000 rpm.
They have ratings as high as 1000 MW. The basic operation principle
involves the conversion of mechanical energy into electrical energy. It is
necessary to remove the generated losses (heat) in the machine from a point
24

as close as possible to the heat source. So the designer aims at the removal
of the heat losses in the most efficient way.
Here in BHEL Turbogenerators are manufactured having capacity up to
660 MW. Their latest projects going on are the manufacturing of 500 MW
Turbogenerators. BHEL is the leading manufacturer of high capacity
Turbogenerators up to 660 MW in India. All modern Turbogenerators are 2pole machines and their speed is 3000 rpm corresponding to a frequency of
50 Hz.
Turbogenerators are characterized by long lengths & short diameters. This
is because it is not possible to increase the rotor diameter beyond a certain
value 1.2 m) owing to the limitations imposed by mechanical considerations
like centrifugal force, deflection of shaft and the critical speed. The diameter
being limited, the only way to raise the rating is to increase the length; the
active core length must be of the order of 10 mm per MVA.
The generator is provided with a fast acting fully static/ brushless
excitation system & dependable services to give prolonged trouble-free
operation over the years. 500MW Turbogenerator is a three phases,
horizontally mounted 2 pole cylindrical rotor type machine driven by a
directly coupled steam turbine at 3000 rpm.
With large lengths of core, it is very difficult to cool the machine,
especially its central portions. Infect the cooling of turbo generators is the
most complex engineering problems.
All the materials that go into the manufacture of this machine are subjected
to rigorous tests and each sub-assembly or component undergoes a series of
stage wise tests. Every Turbogenerator is fully tested at the plants test bed
as per National Electro technical Commission Standards

25

Fig. 1. Stator of the largest air cooled turbogenerator tested at 500 MVA

26

Fig. 2. Directly cooled braided stator bars with insulated cooling ducts

27

Fig. 3. Hydrogen-cooled turbogenerator of the 500 MVA class in standard

steam turbine arrangement

Fig. 4. Braided bars

28

BLOCK-4
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 and insulation manufacturing block
is BLOCK-4. This block is known as the COIL AND INSULATION
MANUFACTURING block. 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 as mentioned below:
BAY 1: Manufactures stator coils for various turbo generators
THRI, TARI, TWRI of different ratings (500 MW, 210 MW).
BAY 2: Manufactures stator coils of AC, DC machines and hydro
generators.
BAY 3: Insulation Material Manufacturing.
The manufacturing facilities available in this block are:
(a) Assembly Section
It has the following sub-sections:
---Mechanical Assembly Section
It is equipped with small size drilling machines, welding sets
and hydraulic testing equipment for manufacturing turbo-generator
mechanical assemblies.
---Close Cubical Assembly Section
(b)Stator Bar Winding Section
29

It is equipped with machines to manufacture bars for turbo-generators

up to 500 MW Hydro-generators.
It comprises of the following sub-sections:
- Conductor cutting, insulation and transposition section having
facilities for transpositioning the bars.
- Stack consolidation section, forming and lug brazing sections have
block type hydraulic press, steel former and induction brazing
installations respectively.
- Insulation taping sections with automatic taping facilities in airconditioned temperature covering maximum slot portion each
overhung ay both ends.
- Baking and pressing section having baking moulds for simultaneous
curving of straight and overhead portion with electrical heating.
(c) Armature Winding, Rotor coil and Stator bar Section :It is equipped with coils for AC and DC machines.
AC Machine : Coils are diamond pulled type with Class-B ( bitumen )
and Class-F (conventional or resin rich discontinuous epoxy insulation)
and Class-H Silicon insulation for machines ranging from 5 to 460 KW
capacity.
This section has the following work centers :- Conductors cutting, U- bending and terminal conductor cutting
machines, U- bending machines and terminal baths.
- Forming and Insulation of DC coils.
- Main and Interpole Winding :- It is having semi-automatic winding
machine.
- Planking, boat pulling and diamond pulling machine.
- Insulation and pressing of AC coils :- it is equipped with hydraulic
presses of 608 T capacities.
(d)Impregnation Section :30

It is equipped with impregnation tank, ovens for impregnation of DC

pole coils.
(e) Insulation Section :It comprises of the following sub-sections :- Insulating details, machining is equipped with small size lathes,
milling and radial drilling machines and jet cutting saw.
- Press Moulding Section :- It has electrical ovens, hydraulic presses,
shearing and circular saw cutting machines for manufacturing press
moulded components of all the electrical machines.
- Plastic Moulding Section :- Is equipped with various presses for
plastic moulded parts.
- Bitumen Mica Tape Manufacture :- Is equipped with mica tape
manufacturing machine and lathe for slitting mica tape to the required
size.

31

BAY-1
Introduction :
Bay 1 is the manufacturer of stator bars of turbo generators of rating up to
500 MW and 210 MW both hydrogen cooled as well as water cooled. Bay-1
is the main manufacturer of all the bays in Block-4. Bay-1 also includes the
stack pressing and consolidation of hydro generator stator bars. Bay-1 is the
main feeder of the block-4.
All the steps involved in the manufacturing of stator bars are as
follows:1. Insulation check
2. Conductor cutting
3. Transposition
4. Cross over insulation
5. Stack Pressing
6. I.S.T. Testing
7. Forming
8. Coil Lug Brazing
9. Nitrogen & Helium Testing
10.Thermal Shock Test
11.Insulation
12.Insulation Baking
13.Finishing
14.Conductor varnish Coating
15.Tan and H.V. Test
16.Dispatch to Block-1 for laying

Insulation Check

32

For the manufacturing of stator bars insulated copper conductors are

brought from Bangalore, its of two types i.e. solid copper conductor &
hollow copper conductors which are used in water cooled stator layer glass
insulation.
Insulating materials and the conductors are ensured to be certified.
If required the insulation is checked by the respective agencies.
Conductor Cutting
This process involves straightening of conductor, removing insulation at
ends of the conductor and length cutting. All the functions are performed by
a CNC machine. Conductor cutting also involves end cleaning i.e.
deinsulation of the ends of the conductors at specified distances. The waste
glass insulation is collected in a chamber in which the powdered glass is
mixed with water and the waste is obtained in the form of paste.
Transposition
Transposition is a process in which the conductors are transposed i.e. the
conductors are bend at certain angles at different lengths along the conductor
as per design and then all the conductors are overlapped on each other.
Transposition is done in two ways
Half Pitch Transposition :- In this transposition, the first conductor at
one end of the bar becomes the last conductor at the other end of the
bar.
Full Pitch Transposition :- In this method of transposition, the first
conductor at one end of the bar becomes the last conductor in the mid
of the bar and then again becomes the first conductor at the other end
of the bar.
Transposition is basically done for the following purposes :

33

 Mechanical strength(as the conductors are gripped with each other)

Equalizing losses in each conductor.
Cross over insulation
It is assumed that the portion at which the conductors are bent during
transposition, the insulation of the conductors got week due to bends. As for
transposition the conductors are required to crossover on each other at the
bends so to equalize the insulation of the conductor throughout the bar, an
extra insulation is provided between the cross overed conductors. The
insulation hence provided is known as CROSSOVER INSULATION.
The material of the insulation used is Mica Glass Insulation and it also
has some gluing properties.
Stack Pressing
This process is basically done to consolidate the solid as well as the hollow
conductors into a single bar, the insulating material provide at crossover
positions which has gluing properties melts and helps in the proper
consolidation of the bar. In this process the bar is pressed both vertically and
horizontally in the Pressing Machine. The pressing machines are also
provided with the heaters.
Each bar is loaded on each tier of heating plate and it is then provided with
an initial pressure of 355 kg per cm 2 and an initial temperature of 100-110
C. then the temperature is allowed to raise to the maximum of 160C, this
temperature is kept for at least one hour with a final pressure of 8010 kg
per cm2 vertically and 7010 kg per cm2 horizontally.
After pressing the bar at specified pressure and maximum temperature for
one hour, the bars are then cooled placing them on cooling plates through
which water is allowed to follow below 50C. The cooled bars are checked
for their heights and widths at pressed portion of the bar.
This complete process performed above is for one half of the bar. The
same process is then repeated for the other half of the bar similarly and then
checked for bars height and width at pressed portions as done before. Then
the ends of both the bars are cleaned with rectified spirit and sand paper for
the inter strand test.

34

I.S.T. Testing
I. S. T. is the Inter Strand Testing. This testing is basically done to check
any short circuit between ant two consecutive conductors of a bar. For this
test all the bare conductors at both the ends are separated from each other so
that they do not short circuit. Then a live wire is connected to a conductor
and received from it consecutive conductor to light a lamp. Hence if the
lamp lights up it shows short circuit between the two conductors due to
improper insulation between them. It shows insulation failure between the
conductors, these conductors are then replaced and bar is followed through
all 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 pressed into a single bar. A sheet of mica glass insulation is provided
between the two halves as the 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 is allowed to cool.
Forming
In heavy generators each stator coil is very large in size and hence its
manufacturing is difficult as it will be very difficult to handle and process
the complete coil. So each coil is manufactured in two halves i.e. Upper half
and Lower half. The bars which are processed till this process are straight
and hence they are required to be formed into the upper half or the lower
half. Hence this process of forming is very important as in this process the
bars are bend from both the ends of the bar i.e. at exciter side and turbine
side at specific angles and shape as per design.
This process is done manually. First the former is set according to the
design making different angles at different positions. Each bar of a variant is
bent or formed at same angle. Once the former is set, the bar is mounted on
it and formed manually by melleting it from both the ends.
After forming the formed portion of the bars are assumed to get loose
creating air gaps between the conductors due to such a heavy melleting.
Thus the formed portion of the bar are clamped at different places and

35

provided with heaters to reconsolidate the formed portion. After few hours
the bar is then allowed to cool at room temperature.

End Conductor Cutting

Due to heavy malting of the bar for forming it from both the side i.e.
exciter side and turbine side, the conductors of the bar are produced at the
ends of the bar. Therefore to bring all the conductors of the bar in a plane
End Conductor Cutting is required to be done. 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 hollow
conductors from both the ends of the bar.
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.
The constituents of the pickling solution are:
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:
Ammonia
Thinner
Water
Rectified spirit
Nitrogen

36

In this process the following steps are involved:

The end of the bar is dipped in thinner to remove the dust or oil
particles.
The end is then dried with the help of N2 gas.
Then the bar end is dipped in pickling solution for 5 to 10 minutes.
This is then followed with dipping in water.
As there is acid in the pickling solution, so accordingly to neutralize
the acidic effect of the acid it has to be treated with some base, so the
bar is then dipped in Ammonia (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 on the 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 to avoid such a
damage the bar is dipped in rectified spirit to make the water contents
evaporate 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 may deposit any dust particle on it until it is ready for brazing.
The same process of pickling is then preformed on the other end of
the bar.
Contact Sleeve Mounting
After the pickling process is complete, contact sleeve and water box
bottom parts are mounted on both the ends of the bar. Contact sleeve, as
clear from the name itself, it is a rectangular sleeve which is used to make
contact between upper and lower bars when layed out in the generator to
form a complete coil. All the solid conductors are cut from the ends of the
37

bar after the contact sleeve except the outer solid conductors. None of the
conductor is cut before the contact sleeve so that to make proper contact
between the upper 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.
Coil Lug Brazing
The contact sleeves, which are used to make contact 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 at the 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 properly consolidated using brazing material at high temperatures.
Consolidation is properly done so that no air gap is left which would
adversely effect the conducting properties of the contact sleeve and the bar.
The two types of brazing processes are:
Thermal brazing (using LPG)
Induction brazing
As induction brazing is more beneficial than thermal brazing as it does not
requires any inflammable gas for heating. So now a days Induction brazing
process is used. For brazing as we use very high temperature so that is
possible due to carbon strips fixed on the brazer. Carbon has very high
resistance and when the current is allowed to pass through 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 the contact 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 types of brazing materials used are:

38

 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.
End Conductor Cutting
As is clear from the name itself this is the process of cutting of extra
conductors i.e. the hollow conductors left after the water box bottom part are
cut from both the ends of the bar. These conductors are required to be cut so
that water box top part with a nozzle is to be mounted on the water box
bottom part. The vents of the hollow conductors are visible from the ends of
the water box bottom part. The openings of the vents of the hollow
conductors are then checked to be uniform.
After cutting of extra conductors from both the ends of the bar, pickling
process is 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 we assume 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.
Water Test
Water test is performed so that there not any blockage in the vents and also
to check 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 the hollow 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 are changed
or repaired and the bar is reformed and water test is again performed to
check the flow of water.

39

Brazing Of Water Box Top Part

Brazing of water box top part is done with water box bottom part in
brazing section of Block-4.For this it should be kept in mind that water box
bottom part should have same material as that of water box top part.
The difference in previous brazing and this brazing is that, now flux is also
introduced with brazing material and also flux is mixed with copper chips.
Copper chips are added to make the electrical contact between the top and
bottom part without the copper chips this will be not possible.
In this brazing material 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 due to 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 completely consolidated that is all the air gap is completely filled.
After the brazing of water box top part the bar is then allowed to cool at
room temperature.
Checking Of Threads and Pickling Process
As mentioned earlier that water box top part has got nozzle for flow of
water, it also has got threads which is provided for the proper fixation of
water supply through water pipe to the bar. These threads are checked for its
uniformity by fixing water pipe to the nozzle. If the threads are not found
satisfactory than the nozzle is replaced with new one and 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 mentioned
earlier in pickling process.
Nitrogen Testing
As the name suggests Nitrogen gas is the main constituent of the test. This
test is similar 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.
40

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 on end of the bar and
other end of the bar is blocked then the pressure of 10Kg/Cm 2 is maintained
and both the ends of the bar is dipped in water. The bubbles if there any tells
us that brazing is weak or not done properly. So if bubbles appear then
brazing is done again and same test is 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. to avoid any manual touch which may deposit any dust particle
on it until it is ready for brazing.
Internal Pickling
After various test performed on the bar the pickling process i.e. removal of
any dust particles lubricants etc is done only on outer surface of the bar
(ends). But from inside 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 are involved:
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 acidic effect 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.

41

 As water takes a lot of time to evaporate, it may let the tiny chemical
particles in the 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 to avoid such a
damage the rectified spirit is flowed in the bar to make the water
contents evaporate 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 may deposit any dust particle on it until it is ready for brazing.
Boroscope Testing
This test is performed to check the impurities or foreign material inside the
bar. To look inside the with naked eye is not possible so we use boroscope
for this purpose.
So after internal pickling we use a boroscope to look inside the bar.
Boroscope is having a probe having a LED (light emitting diode). LED is
used to provide light inside the bar.
The probe of the boroscope is
inserted from one end of the bar and seen from a magnifying lens. The probe
gives a light which is reflected by the sides of the bar (inside) and with the
help of magnifying lens we get a clear image that what is there in the bar.
If impurities are present then these are removed then only after the bar is
send to next operation.
Water Test
Here again water test is performed. In earlier water test water flow was
checked without the water box top part
. But now the top part is brazed
to the bottom part and to check its flow this test is performed.
Also to check the proper flow from the nozzle this test is performed. In
this test water is forced or pushed from one end of the bar and flow of water
is checked from other end of the bar. This test tells us the presence of any
choke vents of water box top part. If any choke vent is present then it is
repaired or whole of the water box top part is changed with new one.

42

Thermal Shock Testing

Thermal shock test is performed to check whether the bar can withstand
extreme conditions i.e. when the generator is working or running at about
3000 Rpm. This is achieved by thermal shock test.
Thermal shock test consist of series of hot water & cold water cycles
alternatively. So firstly hot water at temperature of about 90C is passed
through the bar and then cold water at about room temperature 27C approx.
is flowed inside the bar alternatively. This process is repeated again and
again.
This process is repeated for about 26 times i.e. it has 26 cycles of hot and
cold water. So this test tells us the strength of the bar so that it can withstand
the working conditions of the generator. Temperature of the bar is taken in
account according to the working temperature of the generator.

Helium Testing
Helium test is the most important test of all, because helium test is
performed to check any minute leakage within the bar and at the brazed
portion. Any minute leakage which couldnt be checked by water test can
easily be observed by helium test because helium is one of the lightest gas.
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.
In helium test, whole of the bar is wrapped in the polythene excluding the
end points. The helium gas at pressure of 11Kg/Cm 2 is passed through the
bar and a probe connected to the 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 helium atom in 100000 atoms is
present. This test checks the strength of brazing and insulation.

43

Reforming
After all the previous processes which had undergone on the bar it is
assumed that the shape of the bar is deformed from its original shape due to
handling of the bar from one 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.
Insulation
Insulation is basically done to prevent any kind of short circuit between
the bar and the stator core when the bar is assembled in the stator of the
machine. The stator bars are insulated with Micalastic (trade name)
insulation. High quality mica, selected epoxy resins and a matching vacuum
impregnation process are the characteristic features of the micalastic
insulation for large turbo generators.
The bar is provided with 14 layers of insulation. Out of these fourteen
layers, 12 layers are provided by using a machine called CNC TAPPING
MACHINE manufactured by a company named MICAMATION. The rest of
the two layers are provided manually.
The insulating material varies as according to the rating of the machines as
follows:
For 500 MW
: Mica Splitting Tape
For THRI
: Mica Glass
During machine taping in the slot portion the transition from machine to
hand taping is
adjusted at the start of the bend for a tape width for every layer from bar
center. After about half the number of layers, the taping is to be started
furthur at the bend.
The mica tape consists of a thin high strength baking material to which the
mica is bonded by synthetic resin. The number of layers i.e. the thickness of
insulation is determined by the voltage of the machine.

44

Micalastic Insulation and Impregnation

For insulation with micalastic, the conductor strands are arranged together
to form a compact assembly and set to the required shape. This assembly is
then baked with epoxy resin to give it mechanical strength required for
furthur processing. The bars are then dried under vacuum and impregnated
with synthetic resin, which by reason of its low viscosity penetrates the
insulation thoroughly and eliminates all voids. After impregnation under
vacuum, the bars are subjected to pressure, with nitrogen being used as
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 in resin and finally curing. These processes are discussed
briefly below:
Pressing : The bars are pressed to bring them back to the original
dimensions.
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 initial viscosity 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 is less than 0.06 m bar.
Impregnation: The impregnation resin mixture is to be heated in the
working tank, to (603) C or in case of higher initial viscosity. At a
temperature of 50C, the impregnating resin mixture 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 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

45

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 with nitrogen (1.1bar) or low
vacuum.
Curing: To prevent heating in the overhang portion, the curing of the
impregnated stator winding is to be done with a maximum 160C hot
air. The curing period is extended for such a long time till the
measurement positions in the core indicate (1405) C for minimum 8
hours.
Properties of micalastic
Class F, highly reliable micalastic insulation has the following advantage :
Micalastic is an extremely dependable winding insulation system
developed for high voltage Turbo-generates.
The insulation is applied end to end on the stator bars providing
effective protection against over-voltages arising during normal and
against the high stresses that may occur at the slot ends when HIGH
TEST VOLTAGES are applied.
Micalastic has a long electrical life.
Micalastic is a good conductor of heat by reason of the high mica
content and void-free synthetic resin. Efficient heat transfer is
particularly important in machines having thick insulation and having
indirect cooling.
Micalastic owes insensitivity to high temperatures.
Micalastic does not burn. The flammability is so low that it does not
continye to burn after the arc is extinguished &therefore CO 2 fire
extinguisher systems are not necessary for this.
Micalastic has elasticity and accommodates thermo-mechanical
stresses.

46

 Micalastic provides high resistance to moisture and chemical action.

Corrosive gases, vapours, lubricating oil and weak acids, to which the
winding may be subjected during operation, do not attack the
insulation.
Micalastic retains outstanding properties even after years of operation.
Finishing
This process contains removal of extra material from the bar, applying
varnish to the bar, drying up of varnish, Tan test, High voltage test and
then packing. The dimensions of the bar are first checked in the finishing
section. Then the bar is bought to its desired dimensions as per design by
removing the extra resin material manually from the bar. After that the bar is
finished by rubbing it with sand paper before sending it for varnishing.
Hence the proper dimensions of the bar are obtained. The bar is then
varnished with different varnish at different portions of the bar. The slot
portion is varnished with a layer of conducting varnish which is black in
color. The exciter side and the turbine side are varnished with a layer of
semi-conducting varnish it is grey in color.
After proper coating of the varnish on the bar, the bar is kept for drying
Varnish is dried with help of 200 W bulbs. There are number of bulbs which
dry the bar from the bottom and both the ends of the bar. The bar is kept at
this position until the varnish is dried completely.
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.
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 is used. High voltage is applied to the bar using autotransformer and it is increased in steps according 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 is 64.5 KV &
for 210 MW the working voltage of the bar is 63 KV. If any of the bar fails

47

this test i.e. bar is punctured at any point then the bar is sent back for reinsulation and all the processes are repeated again.
Tan Testing
This test is performed to find the capacitance of the bar because bar will
act as capacitor when it is laid in the stator of the generator. In this test
Schearing Bridge which works 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 to make
the bar conductive throughout the outer surface of the bar. The two
conducting material i.e. the aluminum sheet and the conductors of the bar act
as two plates of the capacitor and the insulation on the bar act as dielectric
medium for the capacitor. The capacitance of the bar is found and of angle of
deviation due to impurity in the insulation is obtained from the formula:
C4 * R4 * 10-4 = tan
For different ratings of the bar the acceptable value of tan is fixed
according to their insulation requirement as per design considerations.
This completes all the process of the manufacturing of stator bars of turbogenerator. This completes the functioning of BAY-1. So the bars are packed
and dispatched to Block-1 for its assembly in the generator.

BAY-2
Introduction :

48

Bay 2 is the manufacturer of stator bars of hydro generators, stator coils

of AC motors 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 THRI generators are manufactured in this bay.
The processes involved in the manufacturing of AC motors are as follows:
Insulation Check
For the manufacturing of stator coils of AC motors, insulated copper
conductors of 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.

Conductor Tapping
The copper conductor is first provided with two layers of insulation, this is
also known as double layer tapping. The insulation tape used in this is
Micafabriglass Tape. In this 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 from other side of
the machine. The insulation on the copper is checked, which is provided by
the automatically moving tapping rolls with some tension.

Winding Boat Coil

49

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 set as 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, the former is then
rotated and hence a boat shaped coil of specified length and specific number
of turns is formed.
The boat coil is then checked for its length and number of turns.

Boat Insulation
The boat coil is then send to the insulation block for its insulation. Here
the complete 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.
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 ensure closing of box) after attaining the temperature. 0.1 mm
filler gauge should not go inside the 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.
Forming
The forming of the boat coil is done in an automatic machine i.e.
Schumann Pulling 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 overhang design 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 the design. The coil
dimensions and geometry of the coil is then checked on the Universal
50

Model. The terminals of the coil are set according to the design and also the
first bends and the overhang portions are marked.

Insulation
In this process the slot portion and the first bends of the coil are insulated
with accelerator treated Mica Tape as per design. For the stator coil of 11
KV AC motor, total 8 layers of insulation tapping are provided i.e. three
layers at the slot portion and the rest five layers all over the coil. Generally
for the stator coils of low rating motors total five layers 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
portion of the coil. The insulation tape at the bend portions of the coil is grey
in color and is semi conducting in nature.
Then the perimeters and width of the insulated coil is checked at the slot
portion of the coil. A release film is to be provided on the entire coil
including coil terminals. On slot portion two layers of release film is
provided. The coil is now send for the next process.

Impregnation
For impregnation pressing strips are mounted on the coil. The pressing
strips are checked 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) C or in case of higher initial viscosity. At a temperature of 50C, the
impregnating resin mixture 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 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
51

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 with nitrogen (1.1bar) or low
vacuum.

Curing
After the impregnation of the coil, it is then cured at 140 10 C for 18
hours after 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 strips are disassembled after the curing of the coil.
The dimensions of the coil are then checked.
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 protection varnish 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 checked for its insulation using tan and H.V. (High Voltage)
Test.

52

BAY -3

Introduction :
Bay 3 is the manufacturer of insulating material of different shapes and
sizes as required according to the design. This bay is also called as I.D.
Section (Insulation Design Section). For the manufacturing of insulations,
different raw materials having insulating properties are brought by this
section. The raw materials having different insulating 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
Ebonite
Perpex Glass Sheet
53

 Nomex Paper
Asbestos Sheet
Asbestos Paper

All the insulating raw materials mentioned above are in the decreasing order
of their insulating property. The insulating materials used in the
manufacturing of insulation moulds are categorized according to their laying
requirement in the machine i.e. if an insulation mould is to be fixed in the
place where the risk of fire is more then at those places moulds of Glass
based Textolite sheet are preferred because cotton based or paper based
textolite sheet could catch fire at those places.
Teflon Sheet has an important property and i.e. Teflon is non heat
transferring material. So an insulating mould of Teflon is placed above the
bearings of the rotor so that is any fault in the bearings of the rotor produces
any heat then it is prevented by this material to get transferred to the rotor,
and hence prevents the rotor of the machine.
For the manufacturing of insulation moulds, the glass insulation raw
material in fibers is first pressed into blocks in a pressing machine with the
help of heaters and hydraulic pressure. Fibers are made into blocks because
if fiber is used as it is then volume of the material will be very large. So
blocks are placed on weighing machine and then weighed equal to the
product required according to design. So then these blocks are placed in the
mould and heated and molded in the shape as that of the mould by applying
sufficient pressure and temp.

54

BIBLIOGRAPHY
www.google.com (for searching about turbine
and its parts)
www.cadcim.com
BHEL Turbine Manuals
BHEL Pro/E Manuals
Daily Diary

55