Submitted To:Ms. Neha Tiwari EE Department SGVU,Jaipur(Raj.

INDIAS NAVRATNA COMPANY

B.H.E.L. Has 14 manufacturing divisions, 9 service centers and 4 power sectors regional centers . It works on 180 projects sites enables the company to its customers . Having attained ISO 9001 certification. Company contributes more than 75% of the national grid, share of 45% comes from bhel-haridwar It ranks in fortune 500 companies Ranked among top 12 companies in the world manufacturing power generation equipments Only PSU among 12 indian companies to get position in forbes asia fabulous 50 list

 The

major units are B.H.E.L. Bhopal, B.H.E.L. Hyderabad, B.H.E.L. Trichy, and B.H.E.L. Haridwar. The corporate office is situated in New Delhi.
Committed

Workforce of more employees working at various posts.

than

60,000

 First Heavy electrical equipment plant in bhopal;

Heavy electrical equipment plant in haridwar; Transformer plant in jhansi; Heavy electrical equipment plant in hyderabad; Electro-division plant in banglore; Insulator plant in jagdishpur; Industrial values plant in govindwal; Fabrication plant in rudarpur; Solar cell plant in gurgaon; Heavy electrical equipment plant in varanasi; Electrical machine shop in mumbai;

BHEL
Block-1 (Electric al Machine s) Block-2 (Fabricati on Block) Block-3 (Turbine and Auxiliar y block) Block4 (CIM Block) Block 5( Feeder Block) Block-6 (Stamping Block) Block 7 (Wood Working Block) Block -

8(Hea t Excha nger)

Block-4 (CIM shop)

MANUFACTURING PROCESS OF 500 MW STATOR BAR Conductor drawn from Store. Conductor cutting and end cleaning. Transposition of conductor. Assembly of all conductors to be used in stator bars. Cross over insulation. Consolidation if slot portion of Bar. IS Test (i.e. inter strand test). Forming of Bar (to shape overhang portion). Pickling of bar ends (1) Mounting of Contact sleeve. Brazing of Contact sleeve . Pickling of bar ends (2)

 Mounting of water box leak test. Repacking. Water flow and N2 test. Thermal Shock Application. Helium Leak Test. Reforming of bar (i.e. overhang portion). Insulation of bar on CNC machine. Impregnation and curing of bar insulation. Surface finishing of stator bar. OCP on stator Bar. Preparation of bar for HV and Tan Test. If O.K. Dispatch to Block-1 for laying in the generator.

This process is basically done to consolidate the solid as well as the hollow conductors into a single bar. In this process the bar is pressed both vertically and horizontally in the pressing machine. initial temperature of 100-110 0c. Then the temperature is allowed to rise to the maximum of 160c.

 To remove unwanted particles on the ends of the bar The constituents of the pickling solution are Sulphuric acid (h2so4)-10% Phosphoric acid (h3po4)-5% Hydrogen peroxide (h2o2)-5% Water (h2o)

contact sleeve and water box bottom parts are mounted on both the ends of the bar. Contact sleeve, as clear from the name itself, is a rectangular sleeve which is used to make contact between upper and lower bars

Brazing is basically the process of fixation of both the contact sleeve and water box bottom part i.e. both are properly consolidated using brazing material at high temperature.Two types:(i)Thermal Brazing (ii)Induction Brazing

water is passed through one end of the bar and is allowed to flow through the hollow conductors at the other end of the bar.

Thermal shock test is performed to check whether the bar can withstand extreme conditions.

A pressure of 13.3 kg/cm2 is applied. Pressure is measured by mass spectrometer

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. The bar is provided with 14 layers of insulation. Out of these fourteen layers, 12 layers are provided by using a machine called cnc The rest of the two layers are provided manually.

Heating temperature 65 to70 cen. Create vacuum at temperature 70 to 75 can Then apply nitrogen gas After 24hr process are complete

OCP (Outer Corona Protection)

TAN - TEST H.V TEST