MANUFACTURING PROCESS OF 500 MW TURBO GENERTOR STATOR WINDING BAR

Tushar Shukla(0803221054)

AT BHEL HARIDWAR

INTRODUCTIONINTRODUCTIONIn 1956 India took a major step towards the establishment of its heavy engineering industry when BHEL, the first heavy electrical Manufacturing unit of the country was set up at Bhopal.

BHEL's Heavy Electrical Equipment Plant (HEEP) was set up in technical collaboration with USSR, for the manufacturing of power plant equipment.

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

MANUFACTURING BLOCKS:

   

BLOCK I : Electrical Machine Block

BLOCK II : Fabrication Block

BLOCK III : Turbine Blade Block

BLOCK IV : Coil & Insulation Manufacturing Block BLOCK V : Fabrication And Forge Block

BLOCK VI : Stamping And Dies Manufacturing Block

BLOCK VII : Woodworking Block

BLOCK VIII : Heat Exchanger Block

COIL & INSULATION MANUFACTURING SHOP

(BLOCK-IV)Block-4 is a feeder block for insulating items, winding with class-B Bituminous insulation and sheet metal components for all the products of Block-1 i.e. Turbo-generators, Hydro-generators, A.C. and D.C. machines

There are three BAYS in this block each bay manufactures stator bars and coils for different machines

Sections in Block IV 1) Assembly Section

It is equipped with small size• Drilling machines• Welding sets• Hydraulic testing equipment

for manufacturing turbo-generator mechanical assemblies.

2) Stator Bar Winding Section It is equipped with• Conductor cutting, insulation

and transposition section.• Stack consolidation section,

forming and lug brazing sections.

• Insulation taping sections with automatic taping facilities in air-conditioned3) Impregnation Section  

It is equipped with• Impregnation tank• Ovens for impregnation of DC pole coils.

Layout of CIM, Block-IV

Types of GeneratorsThe generator may be classified based upon the cooling

system used in the generators such as: THRI, TARI, THDI, THDD, THDF, THFF, and THW

Stands for type of

generator

• T- Turbo Generator

• H- Hydro Generator

Stands for the cooling media for

Rotor

• H- Hydrogen gas

• A- Air

Stands for the type of cooling for

Rotor

• R- Radial• D- Direct• F- Forced• I- Indirect

Stands for type of

cooling for Stator

• I- Indirect• D- Direct• F- Forced

Stands for cooling

media used for Stator coil

• W- Water

Set Type Upper Ordinary

Upper Terminal

Lower Ordinary

Lower Terminal

Total Bars

No. of Bus Bars

500MW THDF

42 6 42 6 96 6

210MW THW

54 6 54 6 120 9

250MW THRI

48 12 48 12 120 9

No. of Bars in current products

For making ONE bar

FOURTY SOLID CONDUTOR ARE USED

TWENTY HOLLOW CONDUTOR ARE USED

LENGTH OF UPPER BAR & LOWER BAR =10,500mm

FOR 500 MW TOTAL 96 BARS ARE USED

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

Manufacturing process a of bar:

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

Cont…

INSULATION CLASSIFICATION:

Class Y

•Upto 90 °C

•Cotton, Silk, or Paper.

Class A

•Upto 105 °C

•Reinforced Class-Y materials with impregnated varnish.

Class E

•Upto 120 °C

•Cotton lamination & Paper lamination.

Class B

•Upto 130 °C

•Inorganic material is hardened with adhesives.

Class F

•Upto 150 °C

•Class-B materials that are upgraded with adhesives.

Class H

•Upto 180 °C

•Made of inorganic material glued with silicone resin.

Class C

•> 180 °C Upto 220 °C

•Made of 100% inorganic material

2-Pole machine with the following features:

Direct cooling of stator winding with water.Direct hydrogen cooling for rotor.Micalastic insulation system.Spring mounted core housing for effective transmission of

vibrations.Brushless Excitation system.Vertical hydrogen coolers

500 MW Turbo generators at a glance

 Important dimensions & weights:Heaviest lift of generator stator : 255 Tons Rotor weight : 68 Tons Overall stator dimensions [L*B*H] : 8.83m*4.lm*4.02m Rotor dimensions(Dia. and length) : 1.15m and 12.11m Total weight of turbo generator : 428 Tons

Salient technical data:

Rated output: 588 MVA , 500 MW Terminal voltage: 21 KV Rated stator current: 16 KA Rated frequency: 50 Hz Rated power factor: 0.85 Lag Efficiency: 98.55%

Picture Of Bars

THANK YOU