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PROFILE OF HEEP

ESTABLISHMENT AND DEVELOPMENT STAGES:

DRP prepared in 196364 , construction started from Oct 1963. Initial product of electric motors started from Jan 1967. Major contribution /election /commissioning completed by 1971 72 as per original

DRP scope.

Establishing in 1960s under the Indo- soviet agreement of 1959 and 1960 in the areaof scientific, technical and industrial co-operation.

Motor manufacturing technology up dated within siemens collaborationduring 198487 .

Facilities being modernized continually through Replacement, reconditing,retrofitting, technological, operational balancing

HEEP PRODUCT PROFILE

1. THERMAL SETS:

Steam turbines and generator up to 500MW capacity for utility and combined cycleapplications; capability to manufacture up to 1000MW unit cycle.

2. GAS TURBINES:

Gas turbines for industry and utility application; range-3 to 200 MW (ISO).

Gas turbines based co-generation and combined cycle system.3. HYDROSETS :

Custombuilt 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 .

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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 steeland other grades of alloy meeting stringent international specifications.

6. DEFENCE PROCEDURE:

Naval guns with collaboration of Italy.

BRIEF DESCRIPTION OF

MANUFACTURING BLOCKSI, II, IV, V,VI, VII AND VIIIBlock- I

Block-I, also known as Electrical Machines Block, is designed to manufacture

Hydro generators, Turbo generators and Testing facilities for Turbo generators. There

is also a special Test Bed for testing of turbo generators of capacity of 500 MW and

above. Apart from facilities and equipment for manufacture of turbo generators, the

Block also has a Bebitting Section.Bebitting of bearing liners for Turbo generators,

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Turbines, Hydro generators, is carried out in this section. The Block has its own over

speed balancing installation; where the dynamic balancing of Turbo generator-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 Turbo

generators, Hydro generators 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.

Rotor Winding

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Generator Testing

BlockII

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

Steam Turbines, Hydro Turbines, Turbo generators, Hydro generators, 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.

BlockIII

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It 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 block. Blades of

different stages are also manufactured here in this block.

Block- IV

Block-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 Turbo generators, Hydro generators and Class

F and H insulation for AC and DC motors. It also supplies all insulation

components for Turbo generators, Hydro generators, and motors. Control panels for

Turbo generators, Hydro generators, Industrial drives for motors, and Turbo

generators auxiliaries, contactor relays and master controllers are also manufactured

in this Block.

Block -V

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, Hydro generator and motor assemblies and components. Forging of

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carbon, alloy and stainless steels are manufactured in this block. It is equipped with

pneumatic hammers, gas-fired furnaces and hydraulic manipulators.

Block -VI

Block-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 Turbo generators, Hydro generators and motors are manufactured

in other bay. The Block is equipped with Welding, Drilling, Shot Blasting and CNC

Flame cutting facilities. The tems manufactured in this block are Condensers, Steam

Turbine components (Oil Tanks and Hollow Guide Blades), Hydro Turbine

components (Stay Rings), Hydro generator and motors

(Stator Frames) etc.

Block -VII

Block-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, Turbo generators, Hydro

generators 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 Tanks, Bearing Covers,

Turbine shaft Covers, Oil Bath and Thrust Bearings.

Block1:-

Block-I, also known as Electrical Machines Block, is designed to manufacture Hydro

generators, Turbo generators and Testing facilities for Turbo generators. There is also

a special Test Bed for testing of turbo generators of capacity of 500 MW and above.

Apart from facilities and equipment for manufacture of turbo generators, the Block

also has a Bebitting Section. Bebitting of bearing liners for Turbo generators,

Turbines, Hydro generators, is carried out in this section. The Block has its own over

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speed balancing installation; where the dynamic balancing of Turbo generator-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 receivedfrom CFFP and other sources for

Turbo generators, Hydro generators 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.

Manufacturing process of turbo generator:-

1.Stator Frame Fabrication:-

Firstly the cutting, bending, welding and N.D.T testing of stator

frame and End Shield is done in block 2.Material used for stator frame and End Shield

is Carbon Steel.

CUTTING:-

CNC Gas and CNC Plasma is used for cutting at 6000 *C.Gas used for Gas cutting is

Oxygen and Acetylene and for Plasma cutting it is Argon, Hydrogen and Nitrogen.

DRILLING:-

After cutting drilling of material is done.

BENDING:-

Three Roll Bending is used for Bending the sheets.

WELDING:-

Arc welding is used to weld the parts and bend material and For some parts gas

welding is also used.

N.D.T :-After the welding NON DESTRUCTIVE TESTING (N.D.T) Of the material

is done.

2.Stator Frame Machined:-

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HOLES:-

Holes are formed of dia 36 where End Shield Is to be Bolted.

INTERNAL DIA.:-

Internal dia is formed according to The drawing.

COOLING WINDOW:-

Cooling windows are also Formed during machining.

3.Hydraulic Testing:-

After the drilling hydraulic testing of frame is done at high Pressure of 2, 5,

8,10kg/cm2.

4.Core Building:-

Than frame send to the core department in block-1

Process of Core Department:-

1. Elastic Property of Body is Checked.

2. Baskets are formed:-

Total 7 Baskets in one stator body and in one Basket 3 Spring 2 vertical and 1horizontal.

Vertical springs are to bear the load Horizontal spring is to control the vibration.

3. Stator body placed in Core pit vertically.

5. Stator Winding: - During this process Electrical winding of the stator like bars are

Inserted with insulation and total 24 core bars are inserted which are formed of

stainless steel at the Turbine end and core bar of Mild Steel at the Exciter end and one

core bar is of 6 mt.Headers are also inserted during winding which are used for the

entry of cold water and exit of the hot water.

Stamping are inserted in the stator which are Formed of Silicon Steel. It is of .5mm inwidth and 70mm Stamping used in one package and after each package Ventilation is

used for the flow of Hydrogen as a coolant and total 87 Packages are used.

Dove Tails Bars are inserted and then pressing of packages isdone.

At the ends of packages End Stampings are used for the external Support.

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A Core building of stamping is formed and coil are inserted during winding and thanthis core building is transfer to impregnation plant.

Impregnation Process:-

Pre-heating in curing oven for about one hour. Drying under vacuum (

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11.Rotor Winding:-In this process Electrical winding of 250 MW,500MW AND 600

MW of the Rotor is done.

Process of Rotor Winding:-

1.Insertion of coil is done in two parts i.e two poles are there and in each pole 7 coil

in each pole and total 14 coils in two pole and one coil is formed by the 11 long strips

and they are joined by the insulating material called as Texolite.

2.Than four pins are formed at the exciter side end for the current supply.

3.Now heating is done at 130 C for insulation and again heating is done at 160 C.

4.Than Ritter ring is used to cover the winding.

5.At last Rotor balancing is done at 3600 rpm in Balancing

Tunnel.

12.Final Assembly:-Now final assembly of generator is done.

Process ofFinal assembly:-

1.Wound Stator and Wound Rotor are assembled at testing bed.2.Wound Rotor is inserted in the wound Stator with the help of high capacity cranes.3.After the insertion of Rotor following products are inserted for the smooth and safe

running of Generator.

Primary water tank at the top of the Generators. Bearings in the End Shield. Inner oil catchers. Outer oil catchers. Air gap seal rings. Seal body +Seal rings. Baffels rings for circulation of Hydrogen. Terminal box. Terminal bushings. Hydrogen coolers in End shield. Support ring used at the Exciter End. Magnetic shunt used at Exciter and Turbine End to reduce the leakage of flux.

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Support Ring for the over hang winding of wound Stator. At last End Shields are fitted.

Now the Generators Testing is done.

ENGINEERING CAPABILITIES

-EXTENDING LIMITS WITH LATEST TECHNIQUES

BHEL possesses very strong engineering base, R&Dinfrastructure, very precise CNC & conventional machine tools, sophisticated

technologies and capabilities to produce hydro-generators of capacity up to 300 MW

based on customers requirements as per national /international standards.

BHEL has the latest hardware and computer software for design development of largecapacity (> 250 MW) and large size hydro-generators.

Latest computational techniques for design analysis andintegrated manufacturing like CAD, FEM, CAM etc. are

used.

Use of solid modelling, finite element modelling and further down stream applicationsfor solution of design structure, heat transfer, electro-magnetic applications etc. for

optimisation.

The computer software is also used for thermal networksolutions and ventilation system, which are vital

parameters for large capacity machines

HYDROGEN AND WATER COOLED TURBO GENERATORS OF 500 MW

RANGE (TYPE: THDF)

SALIENT DESIGN FEATURES

1 Stator winding directly water- cooled

2 Rotor winding directly hydrogen cooled (axial)

3 Leaf spring suspension of stator core

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4 Micalasticinsulation system

5 End shield mounted bearings

6 Support ring for stator over hang

7 Magnetic shunt to trap end leakage flux

8 Ring type shaft seals with double flow

9 Multistage compressor and vertical coolers on turbine end

10 Brushless/static excitation

11 Integral coupling of rotor

HYDROGEN COOLED TURBOGENERATORS OF 140-260 MW RANGE (TYPE:

THRI)

SALIENT DESIGN FEATURES

1. Stator core and rotor winding directly hydrogen cooled

2. Indirect cooling of stator winding

3. Micalastic insulation system

4. End shield mounted bearings

5. Ring type shaft seals

6. Symmetrical ventilation.

7. Brushless/static excitation

8. Integral coupling of rotor

HYDROGEN AND WATER COOLED

TURBOGENERATORS OF 500 MW RANGE (TYPE: THDF-115/59)

SALIENT DESIGN FEATURES

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Stator winding directly water-cooled

Rotor winding directly hydrogen cooled (axial)

Leaf spring suspension of stator core

Micalastic insulation system

End shield mounted bearings

Support ring for stator over hang

Magnetic shunt to trap end leakage flux

Ring type shaft seals with double flow

Multistage compressor and vertical coolers on turbine end

Brushless/static excitation

Integral coupling of rotor

HYDROGEN AND WATER COOLED TURBOGENERATORS

OF 200-235 MW RANGE (TYPE: THW)

SALIENT DESIGN FEATURES

Stator winding directly water- cooled

Rotor winding directly hydrogen cooled by gap pickup method

Resiliently mounted stator core on flexible core bars

Thermo reactive resin rich insulation for stator winding

Top ripple springs in stator slots

Enclosed type slip rings with forced ventilation

Ring/thrust type shaft seals

Two axial fans for systematic ventilation and four Hydrogen

Coolers

Static excitation

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TURBO GENERATOR