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A Report on industrial training at

BHARAT HEAVY ELECTRICALS LIMITEDHaridwar, India

TURBINE

!nder t"e a#le guidan$e o%

S" Ra& Ma"es" Meena 'SE()lg* + Blo$ -

Su#&itted #.

Ma.an /u&ar

Me$"ani$al Engineering 0rd.ear

Tulas Institute of Engineering & Management, Dehradun


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AC/123LED4EME1T

Practical knowledge means the visualization of the knowledge,

which we read in our books. For this, we perform experiments and get

observations. Practical knowledge is very important in every field. One

must be familiar with the problems related to that field so that he may

solve them and become a successful person.

fter achieving the proper goal in life, an engineer has to

enter in professional life. ccording to this life, he has to serve an

industry, may be public or private sector or self!own. For the efficient

work in the field, he must be well aware of the practical knowledge

as well as theoretical knowledge.

"o be a good engineer, one must be aware of the industrial

environment and must know about management, working in such a

industry, labor problems etc., so that he can tackle them successfully.

#ue to all the above reasons and to bridge the gap between theory

and practical, our engineering curriculum provides a practical training of

$% days. #uring this period, a student works in the industry and gets

all type of experience and knowledge about the working and

maintenance of various types of machinery.

& have undergone my $% days training 'after (& )emester* at

BHARAT HEAVY ELECTRICALS LIMITED. "his report is based

on the knowledge, which & ac+uired during my $% days training period

at the plant.

MAYA1/ /!MAR


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I1DE5

S1o

%. &-"O#/0"&O-

%1. 2345! 2rief Profile

%$. 2345 ! - O(4(&46

%7. 344P8 - O(4(&46

%9. 2&4F )/::; OF "34 2 )3OP

%


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[email protected] 3&=3 (O5"=4 "4)"

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I1TR2D!CTI21

&n A9


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covering individual e+uipment to complete power stations on a turnkey

basis.

&n A>@!>A export earnings reached s. 11 crores, the highest for

any one!year.

2345 has its head+uarters at -ew #elhi. &ts operations are

spread over

manufacturing plants and number of engineering and service divisions

located across the

countryH the service divisions includes a network of regional branch

offices throughout

&ndia.

BHEL(A Brie% )ro%ile


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2345 is the largest engineering and manufacturing enterprise in

&ndia in the energy!related H infrastructure sector, today. 2345 is

ushering in the indigenous 3eavy 4lectrical 4+uipment industry in &ndia!a

dream that has been more than realized with a well!recognized track

record of Performa

widespread network comprising of 7 manufacturing

companies, which have international recognition for its commitment

towards +uality. 6ith an export presence in more than


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&nstalled e+uipment for over A%,%%%:6 of power

generation for /tilities, captive and &ndustrial users.

)upplied over 19%%% :otors with #rive 0ontrol )ystem to power

proDects, Petrochemicals efineries, )teel, luminum, Fertilizer,

0ement plant, etc.

)upplied "raction electrics and 0H#0 locos over

1%%% kms ailway network.

)upplied over one million (alues to Power Plants and other

&ndustries

BHEL ( A1 2VERVIE3


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"he first plant of what is today known as 2345 was established

nearly 7% years ago at 2hopal I was the genesis of the 3eavy 4lectrical

4+uipment industry in &ndia.

2345 is today the largest 4ngineering 4nterprise of its kind in

&ndia with excellent track record of performance, making profits

continuously since A>!>1.

2345 business operations cater to core sectors of the &ndian 4conomy

like.

Power

&ndustry

"ransportation

"ransmission

#efenses etc.

"oday 2345 has

7 :anufacturing #ivisions

A )ervice 0enters

7 Power )ector egional 0enters

9% ProDect sites

2345Gs vision is to become world !class engineering enterprise,

committed to enhancing stakeholder value. "he greatest strength of2345 is its highly skilled and committed 77,%%% employees.


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)pread all over &ndia I abroad to provide prompt and effective

service to customers.

B!SI1ESS SECT2R

2345 operations are organized around business sectors to

provide a strong market orientation. "hese business sectors are Power

&ndus and &nternational operations.

)23ER SECT2R

Power sector comprises of thermal, nuclear, gas and hydro

business. "oday 2345 supplied sets account for nearly


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2345 is a maDor contributor of e+uipment and system to importantindustries like

0ement

Petrochemicals

Fertilizers

)teel paper

efineries

:ining and "elecommunication

"he range of system and e+uipment supplied including captive power

stations

3igh speed industrial drive turbines

&ndustrial boilers and auxiliaries

6aste heat recovery boilers

=as turbines pump, valves, seamless steel tubes

3eat exchangers

Process control etc.

TRA1S)2RATI21 6(

2345 supplies a wide e+uipment and system to &ndian ailways.

4lectric locomotive

"raction electric and traction control e+uipment


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TELEC2MM!1ICATI216(

2345 also caters to "elecommunication sector by way ofsmall, medium and large switching system.

2345 has been divided into many blocks8!

-* Blo$(-6(&n block one turbo generator, generator, exciter motors

'.0I#.0* are manufactured I assembled

7* Blo$(76(

&n block two large size fabricated assembliesJcomponent for power

e+uipment are manufactured I assembled.

0* Blo$(06(&n block !$ steam turbine, hydro turbines, and gas turbines,

turbines blade are manufactured I assembled

8* Blo$(86(

&n block !7winding for turbo generator, hydro generator, insulation of

.0I#.0 motors insulating component for turbo generator,

hydro generator motors are manufactured I assembled

9* Blo$(96(

&n block !9 fabricated parts of steam turbine water box, hydro

turbine turbines parts are manufactured I assembled

:* Blo$(:6(

&n block !< fabricated oil tanks hollow guide blades, rings,

stator frames rotor spiders are manufactured I assembled


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;* Blo$(;6(

&n block !>all types of dies including stamping dies, stamping

for generators Imotors are manufactured I assembled


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4lectro porcelains #ivision.

HEE)6 A1 2VERVIE3

Over the years, 2harat 3eavy 4lectrical 5imited has emerged

as world class engineering and &ndustrial giant, the best of its kind in

entire )outh 4ast sia. &ts business profile cuts across various sectors

of engineeringHpower utilities and industry. "he company today

enDoys national and international presence featuring in the L fortune

international!9%%M and is ranked among the top 1 companies of the

world, manufacturing power generation e+uipment. 2345 has now 7

manufacturing division, @ service centers and 7power power sectorsregional centers besides a large number of proDect sites spread over

&ndia and abroad.

"he company is embarking upon an ambitious growth path through

clear vision, mission and committed values to sustain and augment its

image as a world!class enterprise.

VISI21

world!class innovating, competitive and profitable

engineering enterprise providing total business solution.

MISSI21

"o be the leading &ndian engineering enterprise providing +uality

products system and services in the field of energy, transportation,

infrastructure and other potential areas.

VAL!ES

:eeting commitments made to external I internal customers


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Foster learning creative and speed of response

espect for dignity and potential of individual

5oyalty and pride in the company

"eam playing

MA1!=ACT!RI14 )R2CESS 2= T!RB2

4E1ERAT2R > STAT2R BAR

BRIE= S!MMARY6 AB2!T THE BAR SH2)

"his shop is meant for manufacturing of stator winding coils of

generator that may be turbo generator or hydro generator.

HR BARS

:anufacturing of bars of different capacity depends upon the

water head available at site. "he hydro generator is air called

generator of lesser length.

T!RB2 4E1ERAT2R BAR

For the turbo generator the manufacturing of bars of standard

capacity such as %% :6, $%:6, 9%:6, 1%H1$9:6,

1%H19%:6. "his plant has capacity and technology to

manufacturing @%% :6 generators.


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TY)ES 2= 4E1ERAT2RS

"he generator may be classified based upon the cooling system

used in the generators such as

"3&, "&, "3#&, "3##, "3#F, "3FF, "36

" Ni.e. "urbo =enerator or 3ydro =enerator.

3H Ni.e. 3ydrogen =as or ir.

H#HFH& Ni.e. adial, indirect, forced, direct etc.

&H#HF Ni.e. &ndirect cooling, direct cooling, forced cooling.

6 Ni.e. cooling media used for cooling of stator coil e.g.

water.

MATERIAL CHEC/I14

First we check the material of the conductor. nd the total

insulation upon the conductor. "he width of the copper conductor

should be8

a For 5ower bar N @ x 1.@mm ')olid*

# For /pper bar N @ x .$mm ')olid*

$ For 3ollow conductorN @ x 7.< x .9mm ')olid*


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C21D!CT2R C!TTI14 A1D E1D CLEA1I14

"his process is done by the automatic 0-0 machine, in this

process the length of lower bar I upper bar is decided as

following as per drawing!

Lower Bar

a )olid conductor length N %,1%%mm '% Plates*

# 3ollow conductor length N %,1%%mm '% Plates*

!pper Bar

a )olid conductor length N %,%9%mm '% Plates*

# 3ollow conductor length N %,%9%mm '% Plates*

"his insulation is removed from both ends after the cutting of conductor

i.e. 9%%mm for both lower I upper bar.

TRA1S)2SITI21 2= C21D!CT2R

"ransposition means changing or shifting of position of each

conductor in active care 'slot* part. fter cutting the re+uirednumber of conductors are arranged on the comb in staggered

manner and than bands are given to the conductor with the help of

bending die at re+uired distance.


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Setting o% die

a 0omb of setting for lower barGs

#ie st #ie 1nd #ie $rd

11%%.1mm $>$9.$mm


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STAC/ C21S2LIDATI21 2R )RESSI14

"he core part of the bar stack is pressed in press under the pressure

between >%kg to @%kg 'various from product to product* and the

temperature between A% #eg.0 to


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?ER2 )IC/LI14 2= BAR E1D

Pickling is the process of the cleaning of components by the

chemicals. "he pickling solutions are8

a 6ater N %% parts by weight

# )ulphuric cid N % parts by weight

$ Phosphoric cid N 9 parts by weight

d 3ydrogen per Oxide N 9 parts by weight

"he temperature should be maintain 9% #eg.0 to


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# )tand by bar for setting of lug.

$ )etup to the solid conductor in each row as per drawing.

d "hen insert the contact sleeve upon the solid and hollow conductor

and temporally installed to it. nd also installed the bottom part of

water box.

e :aintain the gap between contact sleeve and bottom part of water

box approx 1%mm.

fter the lug mounting cutting of extra solid conductor.

MAI1 BRA?I14

"here are the following steps to brazed the lug.

a )tand by bar of setting for brazing.

# "hen heated the lug point through the two indictor at the temperature

of >%% #eg.0 .

$ For brazing use brazing alloy 5!g!9P by four person. "his is the

silver platinum alloy wire of melting point >%% #eg.0 to >9% #eg.0.

d "his "emperature is give through the laser rays.

C21D!CT2R C!TTI14, =ACE MILLI14 A1D DEBBERI14

fter the main brazing bars is moved for cutting of extra part of

conductors as per drawing. 3ere cut the end part of the bottom part

of water box and taken for face milling.


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&n this process the conductor is given the accurate shaped as per the

measurement and it is taken in account that any part of the surface is

not left uneven and dull.

"hen in #ebbering, the bars edges are many a time left with twigs

and sharp needle type mettle cutting known as bar and this process

of removing is known as #ebbering.

=IRST )IC/LI14

"his is the same process of pickling which is done before the lug

mounting or zero pickling. fter this pickling process the bar is

moved the brazing of top part of water box in both side.

BRA?I14 2= T2) )ART

"hought the induction process the top part of water box is brazed in

both side.

s per the previous main brazing first we stand by bars of setting for

brazing then we attached the top part from the bottom part of water

box. "hen healed the top part by top inductors at the temperature of

7%%#eg.c.


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For this type of brazing use 5!g!7%0d. "his is the alloy silver

academy which have 7%E cadmium and the melting point is 7%% #eg.0

to 9%% #eg.0. "his brazing is done for both end.

fter the brazing the bars is go for second pickling which is the same

process as previously explain.

3ATER =L23 TEST

"hought this test check the flow water e+uivalently in the hollow

conductor of the bar. "here is the following steps of checking!

a 6ater should be exit all the total hollow conductor.

# &f some burrs are Dammed it should be removed to give very high

pressure of water and clean with the help of solid wire.

$ "he main point of testing is that the water flow into the bar and exit

from the water box fall down approximately to cover :tr. From

each conductor.

1ITR24E1 LEA/ TEST

&n this test the bar is tested for leakage into the components of bar. &n

this test flow of nitrogen gas with pressure of %kgH0m 1 to check the

leakage in to the hollow conductor. &f leakage found the bar is

reDected.


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THERMAL SH2C/ TEST

"he cycles of hot '@% #eg.0* and cold '$% #eg.0* water are flew

thought the bar to ensure the thermal expansion and contraction of

the Doints. "he time of low of hot I cold water should be approx $1to 7%min and give the time between to flow of hot I cold water is 9

min. this process is applied atleast @ hours.

HELI!M LEA/A4E TEST

&n this test the barGs end is tested to flow of helium gas with the

given pressure if the end part of the bar is leakage then the helium

gas is covered the surface of water box and indicator indicate the

point of leakage.

I1S!LATI21

For the insulation sunmika therm tape or sunmika pleese tape is used

which is the combination of mica glass varnish. &t is used for

corona protection. &n this insulation to layer of pleese tape to layer

of therm tape and after them again to mica pleese tape is used.


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)ro$ess o% Insulation

a 0lean the bar.

# 0lean with chemical or thinner.

$ "aping

d ealizing film from the mica plastic section.

&n insulation the wall thickness of insulation is subDected to the generating

voltage of the machine.

IM)RE41ATI21 A1D BA/I14

- T"er&orea$ti@e s.ste&6 &n case of rich resin insulation the bar is

pressed in closed box in heated condition and baked under pressure

and temperature as per re+uirement for a given period.

7 Mi$alasti$ s.ste&6 &n case of poor resin system the insulated bars

are heated under vaccum and impregnated 'dipped* in heated resin

so that all the air gaps are filled, layer by layer with resin then extra

resin is drained out and bars are heated and baked under pressed

condition in closed box fixture.

V)I Mi$alasti$ S.ste&


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"he bars already laid in closed fixture and full fixture is impregnated

in resin and then fixture with box is baked under given temperature

for the given duration.

VI) Mi$alasti$ S.ste&

"he individual bar is heated in vaccum and impregnated in resin."hen bar is taken out and pressed in closed box fixture and then

baked at given temperature for given duration.

=I1ISHI14

"he baked and dimensionally correct bars are sanded!off to

smoothen the edges and surface calibrated if re+uired for the

dimension.

C21D!CTI14 VAR1ISH C2ATI14

2C) '2uter Corona )rote$tion* Coating6 "he black semi!

conducting varnish coating is applied on the bar surface on the core

length.

EC) 'End Corona )rote$tion* Coating6 "he grey semi!conducting

varnish is applied at the bend outside core end of bars in gradient toprevent from discharge and minimize the end corona.


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TESTI14

. Tan Test6 "his test is carried out to ensure the healthiness of

dielectric 'insulation* i.e. dense or rare and measured the capacitance

loss.

1. HV Test6 "he each bar is tested momentarily at high voltage

increased gradually to three times higher than rated voltage.

DIS)ATCHED =2R 3I1DI14

&f the bar is passed in all the operation and testing after completing

then the bar is send for stator winding.

T!RB2 4E1ERAT2RS

'a* Air Cooled 4enerators !pto 7 Mw Range 'T.pe6

TARI * Salient Design =eatures

)tator core and rotor winding direct

air!cooled

&ndirect cooling of stator winding

3orizontally split casing design of

stator


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(ertically side mounted coolers in a

separate housing

:icalastic bar type insulation system

)eparately assembled stator core and

winding for reducing the manufacturing cycle

2rushlessHstatic excitation system

'b* H.drogen Cooled Tur#ogenerators o% -8(7: Mw Range 'T.pe6

THRI * Salient Design =eatures

)tator core and rotor winding directly

hydrogen cooled

&ndirect cooling of stator winding

igid core bar mounting

:icalastic insulation system

4nd shield mounted bearings

"op ripple springs in stator slots

ing type shaft seals

)ymmetrical ventilation.


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M2T2R 3I1DI14

- Te$"ni$al Reuire&ents

'* 0ount the coil groups in the anti clock wise direction locking from the

connection end.

'1* 5eads of the coils groups lying on the outer periphery of the overhang

position shall be the finish and those lying on the inner periphery shall be

the start to coil groups.

'$* 5eads shall be taken form the coil side lying at inner periphery of slot

-o..

'7* "he coil group -o. shall 5ie at top with its axes coinciding with the

vertical axis of the frame.


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'9* "ake out terminal leads %1 /1, (1, 61 for left hand side terminal box

and %1 /, (, 6 for right hand side terminal box. 6hen looking

form the connection end.

Circuit diagram:-

WINDING DIG!M "# M"T"! WINDING

7 3inding data

12 2= )HASE 0

12 2= )2LES :

)HASE C211ECTI21 Y

12 2= )ARELLEL )ATH 7

12 2= C2IL 4R2!) -


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0 Conne$tion o% &otor winding


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C21CL!SI21

"he second phase of training has proved to be +uite faithful.

&t proved an opportunity for encounter with such huge machines like

turbine etc.

"he architecture of 2.3.4.5., the way various units are linked

and the way working of whole plant is controlled make the students

realize that 4ngineering is not Dust structural description but greater part

is planning and management. &t provides an opportunity to learn tech.

/sed at proper place and time can save a lot of labour.

2ut there are few factors that re+uire special mention. "raining is

not carried in true spirit. &t is recommended that there should be proDectors

especially for trainees where presence of authorities is ensured.

3owever, training has proved to be satisfactory. &t has allowed us an

opportunity to get an exposure of the practical implementation of

theoretical fundamentals.

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