CONTENTS

CHAPTER 1 – BHEL
1.1 Introduction 01
1.2 Heavy Electrical Equipment Plant 02

CHAPTER 2 - Coil & Insulation Manufacturing (CIM) - Block-IV

2.1 Introduction 04
2.2 Flow Chart 05

CHAPTER 3 - Manufacturing Process of 800 MW Bars (Bay I & II)

3.1 Conductor Drawn From Store & Insulation Check 08

3.2 Conductor cutting for Transposition 09
3.3 Crossover insulation 10
3.4 Hydraulic Pressing 11
3.5 Radius Milling 11
3.6 Inter Strand Test (IST) 11
3.7 Water Test 12
3.8 Forming 12
3.9 Pickling & End Cutting of Conductors 13
3.10 Contact Sleeve & Bottom Mounting 13
3.11 Brazing & TIG Welding 13
3.12 Nitrogen Test & Dye Penetration Test 15
3.13 Thermal Shock Test 16
3.14 Helium Leakage Test 16
3.15 Reforming 17
3.16 Main Body Insulation & Impregnation 17
3.17 Pressing Of Bar & Curing 18
3.18 Surface Finishing & OCP 18
3.19 H.V. & Tan Delta Test 19
3.20 Baroscopic & ECP Coating 19
3.21 Packing & Shipment of Bars 20

CHAPTER 4 - Manufacturing of Insulation (Bay III) 21

4.1 Introduction 21

CHAPTER 5 - Summary 23

CHAPTER 6
6.1 Conclusion 24
6.2 References 24

0
CHAPTER-1 BHEL – AN OVERVIEW

1.1 Introduction
BHEL is an integrated power plant equipment manufacturer and one of the largest
engineering and manufacturing company of its kind in India engaged in the design,
engineering, manufacture, construction, testing, commissioning and servicing of a wide range
of products and services for core sectors of the economy, viz. Power, Transmission, Industry,
Transportation (Railways), Renewable Energy, Oil & Gas, Water and Defence with over 180
products offerings to meet the needs of these sectors. BHEL has been the bedrock of India's
Heavy Electrical Equipment industry since its incorporation in 1964.

BHEL's growth has been synchronous with achieving self-sufficiency in the indigenous
manufacturing of heavy electrical equipment. Out of the available 35,000 MW per annum
capacity for power plant equipment manufacturing in the country, BHEL alone constitutes a
mammoth 20,000 MW per annum capacity. A widespread network of 17 Manufacturing
Divisions, 2 Repair Units, 4 Regional Offices, 8 Service Centres, 6 Overseas Offices, 6 Joint
Ventures, 15 Regional Marketing Centres and current project execution at more than 150
project sites across India and abroad corroborates the humungous scale and size of its
operations.

BHEL also has a widespread overseas footprint in 80 countries with cumulative overseas
installed capacity of BHEL manufactured power plants nearing 10,000 MW including
Belarus, Bhutan, Egypt, Indonesia, Iraq, Kazakhstan, Malaysia, New Zealand, Oman,
Rwanda, Sudan, Tajikistan and UAE.

BHEL places strong emphasis on innovation and creative development. The R&D efforts of
the company are aimed not only at improving the performance and efficiency of existing
products, but also developing new products using state-of-the-art technologies and processes.
With its innovation-led growth strategy, BHEL continues to rank among the highest R&D
spenders in the country in the engineering and manufacturing segment. 477 patents and
copyrights were filed during the year 2015-16, enhancing the company's intellectual capital to
3,441.

1
 Fig 1.1 – Rotor of Turbo Generator

1.2 Heavy Electrical Equipment Plant

BHEL's Heavy Electrical Equipment Plant (HEEP) was set up in technical

collaboration with USSR, for the manufacturing of power plant equipment, AC/DC motors of
various rating with associated control equipment and started production in January 1967. In
1976, BHEL entered into a collaboration agreement with M/s Kraftwerk Union, AG of
Germany for design, manufacturing, erection and commissioning of large size steam turbines.
More than 40 per cent of the country's electrical energy is generated from the power
equipment supplied by BHEL, Haridwar. Products manufactured include power transformers,
instrument transformers, dry type transformers, series — and stunt reactor, capacitor tanks,
vacuum — and SF circuit breakers gas insulated switch gears and insulators. The products,
which are manufactured in HEEP, are: - Steam Turbines, Turbo Generators, hydro turbines,
Gas turbines, etc.

2
(1.2) -TG Stator (1.3) - Internal of stator (Front view)

(1.4)- Block-1 (1.5) - Rotor on Lathe M/c

**FACTS**

The generator may be classified based upon the cooling system used in
them such as: THRI, TARI, THDI, THDD, THDF, THFF and THW.
T(First alphabet) >>> Type of generator i.e. Turbo-generator or Hydro-
generator.
H/A(Second alphabet) >>> Cooling media used for the cooling of rotor i.e.
Hydrogen gas or Air.
R/D/F/I(Third alphabet) >>> Type of cooling of rotor e.g. Radial, Indirect,
Forced and Direct.
I/D/F(Fourth alphabet) >>> Type of cooling of stator e.g. Indirect, Direct and
Forced.
W >>> Cooling media used for cooling of stator coil e.g. water.
3
CHAPTER-2 Coil & Insulation Manufacturing (CIM)

2.1 Introduction

Coil & Insulation manufacturing Block 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.

. (2.1) (2.2)

Fig. (2.1) - Layout of CIM Block –IV; (2.2) - Main Products of CIM block

There are four BAYS in this block each bay manufactures stator bars and coils for different
machines i.e. BAY-0, BAY-I, BAY-II, BAY-III.

4
 800 MW STATOR BAR PROCESS FLOW CHART

Conductor Drawn
From Store

Conductor Cutting For

Transposition

Crossover Insulation

First Pressing I.S.T Repair

Inter Strand
NOT OK
Test (I.S.T)

Final Pressing

Radius Milling

I.S.T

NOT OK
Water Flow

NOT OK
Forming

Pickling &End Cutting

5
 Contact Sleeve &
Bottom Mounting

TIG Welding Of Tubes

With Sheet
(Automatic)

Main Brazing

Water Box- Top Part

Welding (TIG)

Nitrogen NOT OK
Test

Die Penetration Test

NOT OK

Thermal Shock

Mat Filling

Helium Leak Test

NOT OK

Inner Corona
Protection (ICP)

Main Body
Insulation
6
 Impregnation

Wagon Setting &

Pressing Of Bar

Curing

Surface Finishing &

Calibration

Outer Corona Protection

Inter Corona
Protection (ICP)
High Voltage & Tan
Delta Preparation

H.V. & Tan

Delta Test

Borescope

Marking & End Corona

Protection Coating
(ECP)

Protection Warping Of
ECP

Conductive Wrapping
of Slot

Packing Of Bar

Send the Bar to

Block 1

7
 CHAPTER – 3 Manufacturing Process of 800 MW Bars

3.1 Conductor Drawn From Store & Insulation Check

For the manufacturing of stator bars, insulated solid Copper
conductors are brought from Bangalore and hollow Steel conductors are brought from
Germany\England.

 Hollow Steel conductors use for both conduction as well as to facilitate the flow of
coolant (e.g. Water).
 Insulating materials and the conductors are ensured to be certified.
 The insulation is checked by the respective agencies.

3.2 Conductor cutting for Transposition

This process is done by automatic CNC machine (Roebel Machine).
In this process the pre-insulated copper conductor is cut into number of pieces of required
length (length given in drawing as per design) insulation is removed from both ends of the
copper conductor.

**FACT**

Why do we call it bar?

It is quite difficult (rather impossible) to manufacture, handle and wind in the stator
slot of generator of higher generation capacity because of its bigger size and heavy
weight. That is why we make coil in two parts. One part its bottom part of coil
called bottom or lower bar and other part of coil is called top bar or upper bar.

Upper Bar:-

Type of Conductor Size Length (mm) Number of

conductor (mm) conductor
*
Solid Copper 14 1.8 11282 50

8
 *
Hollow 14 4 11282 10
hollow

Lower Bar:-

Type of Conductor Length (mm) Number of

conductor Size (mm) conductor
*
Solid Copper 14 1.8 11077 50
*
Hollow hollow 14 4 11077 10

Transposition means changing/shifting of position of each conductor in active core (slot) part.

Here Roebel CNC Machine (3-464) automatic cut the conductor of required length and also
clean the ends of conductor by vertical and horizontal brushes. Each conductor pick by the
manipulator (having sensor) of machine and bends are given with the help of bending die at
required distance by the machine. After bends are given, machine automatically arrange the
conductors (i.e. for 800MW 2-solid then 1- hollow steel followed by 5- solid then 1-hollow
steel so on). Then the arranged conductors are taken out from magazine and transposition is
carried out. This process is repeated for making another half of the bar which would be
mirror image of the first half. The two halves of the bar are overlapped over each other and
an insulating spacer (mica) is placed between the two halves.

. (3.2.1) (3.2.2)

9
. (3.2.3) (3.2.4)

Fig - (3.1) & (3.2)-Roebel Machine, (3.3)-Bends in Bar, (3.4)-Transposition

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.

I. To reduce eddy current losses.

II. Equalize the voltage generator & prevent current circulation.
III. To minimize skin effect of ac current, small cross section of conductor is used and
also hollow conductors are used to effect cooling by water.

3.3 Crossover insulation

The pre insulation of the copper conductor may get damaged due to
mechanical bending in die during transposition, hence the insulating spacers are provided at
the crossover portion of the conductors. A filler material (insulating putty of moulding
micanite) is provided along the height of the bar to maintain the rectangular shape and to
cover the difference of level of conductors.

10
3.4 Hydraulic 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 35±5 kg/cm2 and an initial temperature of 100°-110° C. Then the temperature is allowed to
raise to the maximum of 160°C, this temperature is kept for at least one hour with a final
pressure of 80±10 kg/cm2 vertically and 70±10 kg/cm2 horizontally.

Then the bars are cooled and both ends of bars are cleaned with rectified spirit and sand paper
for the inter strand test.

3.5 Radius Milling

After hydraulic pressing of bar, the bar is brought for radius milling.
Due to hydraulic pressing, the bar’s edges become sharp. In this process the sharp end of bar
is grinded to give a smooth finish of uniform radius.

3.6 Inter Strand Test (IST)

The pressed bar is tested for the short between any two conductors in
the bar, if found then it has to be rectified. This is done to ensure that no local current is
flowing due to short circuit between conductors which damage the side conductor and its
insulation thus damage whole bar when it place in stator. For this test all the bare conductors
at both the ends are separated from each other by putting them in comb so that they do not
short circuit.

Then testing knob is connect to an adjacent conductor and check for whether it is short or not
by glow of bulb (which is series connected).Same is done for up- down conductors. If the
lamp lights up it shows short circuit between the two conductors due to improper insulation

11
between them. It shows insulation failure between the conductors, these conductors are then
replaced and bar is followed through all the previous processes.

3.7 Water Test- Water test is performed so that there not any blockage in the hollow
steel conductor. In this test water is supplied from one side of the bar and water profile
is checked at other end. Profile must be same for every hollow conductor.

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 or profile is disturbed so the bar is
assumed to be chocked. Then chocked conductors are repaired and water test is again
performed to check the flow of water.

3.8 Forming
In this process the bars are bending 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 tools (e.g. mallet,
clamper etc.) from both the ends.

While forming, the bars are assumed to get loosen. Thus the formed portion of the bar are
clamped at different places and provided with heaters to reconsolidate the formed portion.
After few hours the bar is then allowed to cool at room temperature.

3.9 Pickling & End Cutting of Conductors

After giving a required shape through forming process the bars are
marked up to required length. Only solid conductors are clip out with the help of Top Cutting
Plier.

12
Due to forming, cutting of the bar and 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, pickling process is performed. The solution
used for this are constituents of Sulphuric acid (10%), Phosphoric acid (5%), Hydrogen
peroxide (5%) and Water.

The end of the bar is dipped in thinner to remove the dust or oil particles then dried with the
help of N2 gas. After that the bar end is dipped in pickling solution for 5 to 10 minutes
followed by dipping in water. Then the bar is dipped in rectified spirit to make the water
contents evaporate as soon as possible also dried with N2 gas.

3.10 Contact Sleeve & Bottom Mounting

After the pickling process and end cutting is done, contact sleeve
and water box bottom parts are mounted on both the ends of the bar. Contact sleeve - it is a
rectangular sleeve which is used to make contact between upper and lower bars when laid out
in the generator to form a complete coil.

All the remaining hollow Steel conductors are cut after the contact sleeve is fitted leaving 2
mm for TIG welding (automatic).

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.

3.11 Brazing & TIG Welding

The water box bottom part is welded on contact sleeve through TIG
welding using Helium as shielding gas. 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.

The contact sleeve (coil lug) which house conductors of bar is brazed through the process of
Brazing (Induction Brazing).

13
Fig (3.11.1) – Brazing Process

Brazing is a metal-joining process in which two or more metal items are joined together by
melting and flowing a filler metal into the joint, the filler metal having a lower melting point
than the adjoining metal.

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 in BHEL, induction brazing process is used. 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 750°C, the brazing material (alloy of
Ag+Cu+Au+Brass) is then pushed to fill the air gaps and to consolidate the contact sleeve on
the bar. It is then allowed to cool.

The hollow Steel conductors are welded with water box bottom part
through process of TIG welding. This is done by CNC Machine. Before welding, the opening
hole of conductors are adjust with help of chisel. Heat generated by Tungsten melt down the
hollow steel conductor (2mm) and water box bottom part, due to this both join to each other,
thus no filler material use here.

Voltage (V) Current (Amp) Feed (mm/min) Time (sec)

8-9 55-70 102 20-30
Table 3.9.a – TIG welding of tubes with water box bottom part.

14
The top water box is also welded on water box bottom part through the method of TIG
welding. For this it should be kept in mind that water box bottom part should have same
material as that of water box top part. Shielding gas use here is Argon gas and filler material
use here is stainless steel.

Tungsten Inert Gas (TIG) welding, is an arc welding process that uses a non-consumable
tungsten electrode to produce the weld. The weld area is protected from atmospheric
contamination by an inert shielding gas (Ar & He), and a filler metal is normally used.

(3. 9.1)

Fig. (3.9.2) - TIG Welding

3.12 Nitrogen Test & Dye Penetration Test

This test is performed to check any leakage in bar i.e. to check the
TIG welding. 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. Similarly, this test is
performed with the help of Nitrogen gas.

In this test, nitrogen at a pressure of 10Kg/cm2 is forced from one end of the bar and other
end of the bar is blocked then the pressure of 10Kg/cm2 is maintained and both the ends of
the bar are dipped in water. If bubbles appear then welding is done again and same test is
performed to ensure TIG welding of water box top and bottom part is done properly.

Dye Penetration Test used to locate surface-breaking defects in all non-porous materials.
Liquid with certain dye is applied on water box and check for breaks on surface.

15
3.13 Thermal Shock Test
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.

Thermal shock test consist of series of hot water & cold water cycles alternatively. So firstly
hot water at temperature of about 80-90°C is passed through the bar and then cold water at
about room temperature 25-30°C approx. is flowed inside the bar alternatively. This process
is repeated again and again. This process is repeated for about 6 times i.e. it has 6 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.

.Fig (3.13.1) – Layout for thermal shock of bar.

3.14 Helium Leakage Test

Helium test is the most important test of all, because this test is
performed to check any minute leakage within the bar and at the welded portion. Any minute
leakage which couldn't be checked by water test can easily be observed by Helium test
because Helium is one of the lightest gases.

In this test, end of the bar is wrapped in the polythene. The Helium gas at pressure of
11Kg/cm2 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.

16
If the test is failed then the bar again go under the welding process and whole process.

3.15 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 do the forming process again.

3.16 Main Body Insulation & Impregnation

The bar is insulated with the specific number of layers to build the
wall thickness of insulation subjected to the generating voltage of the machine. 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 many layers of insulation which is done by
machine called CNC TAPPING MACHINE.

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 further 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.

 Impregnation:

The impregnation resin mixture is to be heated in the working tank,

to (60±3) °C. At a temperature of 50°C, 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

17
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 impregnation process, however the
total period of nitrogen pressure cycle shall in any case not exceed 4 hours.

3.17 Pressing Of Bar & Curing

After impregnation under vacuum, the impregnated bars then
brought to the required dimensions in moulds and cured in an oven at a high temperature.

 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 (60±5) °C for
15 hours, minimum. The drying temperature is to be increased to (65±2) °C if the
initial viscosity of the impregnating resin mixture is high. The temperature
distribution should be as uniform as possible.

 Curing: To prevent heating in the overhang portion, the curing of the impregnated
stator winding is to be done with a maximum 160°C hot air. The curing period is
extended for such a long time till the measurement positions in the core indicate
(140±5) °C for minimum 8 hours

3.18 Surface Finishing & OCP

The baked and dimensionally correct bars are sanded-off to
smoothen the edges and the surface is calibrated as per requirement of the dimension.

OCP (Outer Corona Protection) Coating: - The black semi-conducting varnish coating is
applied on the bar surface on the core length.

H.V. & Tan Delta Test

When the bar is dried it is wrapped with aluminium sheet to make

outer surface of the bar conducting so that tan δ 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.

18
  Tan δ test

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 Schering Bridge
which works on the principle of wheat-stone bridge is used to find the unknown capacitance
of the bar.

When the bar wrapped with aluminium there are two conducting material i.e. the aluminium
sheet and the conductors of the bar, which 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 * 104 = tan δ

 H.V. (High Voltages 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 aluminium is used. High voltage is applied to the bar using auto-transformer and it is
increased three times the working voltage of the bar. If the insulation is weak the bar will
puncture at the place of weaker insulation.

The bar is tested to three times the rated voltage. If any of the bar fails this test i.e. bar is
punctured at any point then the bar is sent back for ICP and along with re-insulation all the
processes are repeated again.

3.19 Baroscopic & ECP Coating

This test is performed to check the impurities or foreign material
inside the bar (hollow conductors). To look inside with naked eye is not possible so we use
baroscopic for this purpose.

Baroscopic is having a probe having a LED (light emitting diode). LED is used to provide
light inside the bar. The probe of the baroscopic 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 they are removed.

19
ECP (End Corona Protection) Coating: The grey semi-conducting varnish is applied at the
bend outside core end of bars in gradient to prevent from discharge and minimize the end
corona.

Packing & Shipment of Bars

When the bars under goes all the previous step successfully then
they are packed and ready for shipment i.e. sending of the bars to BLOCK -1. There they are
going to place in stator core of Turbo Generator.

20
 CHAPTER 4 MANUFACTURING OF INSULATION

4.1 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 moulded to different shapes as per
design.

The raw materials used in this bay are:

 Glass based Textile Sheet

 Cotton based Textile Sheet
 Paper based Textile Sheet
 Mica Glass sheet
 Teflon Sheet
 Mica Sheet
 Nylon Sheet
 Ebonite
 Perspex Glass Sheet
 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 high, 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.

21
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 fibres is first
pressed into blocks in a pressing machine with the help of heaters and hydraulic pressure.
Fibres are made into blocks because if fibre 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
moulded in the shape as that of the mould by applying sufficient pressure and temperature.

22
CHAPTER 5 SUMMARY

 Construction —

Each bar consists of solid as well as hollow conductor with cooling water passing through the
latter. Alternate arrangement hollow and solid conductors ensure an optimum solution for
increasing current and to reduce losses. The conductors of small rectangular cross section are
provided with glass lapped strand insulation.

A separator insulates the individual layers from each other. The transposition provides for
mutual neutralization of voltage induced in the individual strands due to the slots cross field
and end winding field. The current flowing through the conductor is uniformly distributed
over the entire bar cross section reduced.

To ensure that strands are firmly bonded together and give dimensionally stability in slot
portion, a layer of glass tape is wrapped over the complete stack. Bar insulation is done with
epoxy mica thermosetting insulation. This insulation is void free and posses better
mechanical properties. This type of insulation is more reliable for high voltage. This
insulation shows only small increases in dielectric dissipation factor with increasing test
voltage. The bar insulation is cured in an electrically heated process and thus epoxy resin fill
all voids and eliminate air inclusions.

 Insulation —

Bar is tapped with several layers of thermosetting epoxy tape. This is applied continuously
and half overlapped to the slot portion. The voltage of machine determines the thickness of
insulation. The tapped bar is then pressed and cured in electrical heated press mould for
certain fixed temperature and time.

23
 CHAPTER 6 CONCLUSION

6.1 Conclusion

I would like to say that this training program is an excellent opportunity for us to get to the
ground level and experience the things that we would have never gained through going
straight into a written material.

The main objective of the industrial training is to provide an opportunity to undergraduates to

identify, observe and practice how engineering is applicable in the real industry.

The architecture of B.H.E.L., the way various units are linked and the way working of whole
plant is controlled make the students realize that Engineering is not just structural description
but greater part is planning and management.

It proved an opportunity for encounter with such huge machines with their working. Overall
this training is totally satisfactory for me.

6.2 References

 Bharat Heavy Electricals Limited (2018). About BHEL

http://www.bhel.com/about.php
 Bharat Heavy Electricals Limited (2018). About Research & Development
http://www.bhel.com/about_rd.php
 Wikipedia, the free encyclopaedia (2018). About TIG welding, Brazing etc.
https://en.wikipedia.org
 Google Images (2018). Various Pictures https://www.google.co.in

24