BHEL Haridwar block 2 heavy fabrication, training report Summer Training Project Report on EMPLOYEE MOTIVATION OF BHEL EMPLOYEES. This project report has been made as a part of the industrial training the least; I would like to thank all the staff members of B.H.E.L. Block-4, Ranipur, Haridwar. Training Report on Manufacturing of Turbo Generator at BHEL Haridwar .. BLOCK-4 CIM (Coil & Insulation Manufacturing) & ACG (Apparatus control Gear) v. .. undertaken summer training in Bharat Heavy Electricals Limited, Haridwar.

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I would like to extend sincere thanks to Mr. Dhiman, deputy manager for his prodigious guidance throughout my training and I would specially like to thank Mr.

Vinod Bharadwaj and Mrs. Kapoor for their immensely helpful, painstaking attitude and suggestion during the training. Efforts have been made to make the report as succinct as possible. Quantitative sunmer has been presented through tables, charts and suitable bloco. The project would not have been possible without the help and cooperation of the aforementioned officials. Last but not the least; I would like to thank all the staff members of B. The company has been earning profits continuously since blokc paying dividends since It is engaged in the design, engineering, manufacture, construction, testing, commissioning and servicing of a wide range of products and services for the core sectors of the economy, viz.

It has 15 manufacturing divisions, two repair units, four regional offices, eight service centres, eight overseas offices and 15 regional centres and currently operates at more than project sites across India and abroad.

It is the 7th largest power equipment manufacturer in the world.

In the yearit was ranked ninth most innovative company in the world by US business magazine Forbes. BHEL is the only Indian Engineering company on the list, which contains online retail firm Amazon at the second position with Apple and Google at fifth and seventh positions, respectively.

Bhel Haridwar- Training report – 800 MW bar CIM block 4 (EEE)

It is also placed at 4th place in Forbes Asia’s Fabulous 50 List of The company has been earning profits continuously since and paying since This would add six million units of electricity on a daily basis. BHEL, completely owned by the Government of India is an integrated engineering complex consisting of several plants of India, where about 70, workers are employed in the design and manufacturing of heavy electrical equipment. Hydro set MW 3. Generator according to requirement 4.

Cogeration and combine cycle plants have been introduced to achieve higher plant efficiencies. To make efficient use of the higher ash content crash coil manufacturers MW nuclear turbine generator sets and has commenced the generation of MW nuclear turbine generator head discharge combinations are also engineered and manufactured is equally competitive.


These include high voltage power, distribution transformers, instrument transformers, dry type transformer,SF6 switch gear, capacitor and insulator,etc.

Bhel Haridwar- Training report – MW bar CIM block 4 (EEE) – PDF Free Download

Series and shunt compensation systems have been also developed and introduced to minimize transmission losses. This shop is meant for manufacturing of stator winding coils of generator that may be turbo-generator or hydro-generator. Why do we call it bar: It is quite difficult rather impossible to manufacture, handle and wind the coil in 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 is Bottom part of coil called bottom or tower bar and other part of coil is called top bar or upper bar. The manufacturing of bars of standard capacity such as: In this process the pre- insulated copper conductor is cut into number of required length.

Insulation is removed from both ends of the conductor cut. After cutting the required number of conductors, the conductors are arranged on the comb in staggered manner and then bends are given to the conductors with the help of bending die at required distance. Then the conductors are taken out from the comb and die and placed with their ends in a line and transposition is carried out. The two halves of the bar are overlapped over each other and a spacer is placed between the two -halves.

To reduce eddy current losses. Equalize the voltage generator 3. To minimize skin effect of ac current, small cross section of conductor is used and also hollow conductors are used to effect cooling by D.

Crossover Insulation The pre insulation of the copper conductor may get damaged due trainihg mechanical bending in die during transposition, hence the insulating spacers are provided at the crossover portion of the conductors.

A filler material insulating putty or molding micanite is provided along the height of the bar to maintain the rectangular shape and to cover the difference of level of conductors. To fraining inter turn short at bends during edges wise bending and leveling of bars in slots portion for proper stack pressing. Stack Consolidation The core part of the bar stack is pressed in press closed box under pressure varies from product to product and temperature of C for a given period.

The consolidated stack is withdrawn from the press and the dimensions are checked. Inter Strand Short Test The consolidated oar stack is tested for the short between any two conductors in the bar, if found then it has to be rectified.

This is bhdl to ensure that no local current is flowing due to short circuit between conductors. Forming The straight bar stack is formed as per overhang profile as per designthe overhang portion is consolidated after forming. Brazing of coil lugs For water cooled generator bars, the electrical connection contact and water box for inlet and outlet of water are brazed. Helium leakage test After thermal shock test bar is tested for any leakage with the help of helium gas.

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Insulation The bar is insulated with the given number of layers to build the wall thickness of insulation subjected to the generating voltage of the machine. Impregnation and baking hqridwar Thermoreactive system In case of rich resin insulation the bar is pressed in closed box in heated condition and baked under pressure and temperature as per requirement for a given period.

Then extra resin is drained out and bars are heated and baked under pressed condition in closed box fixture. The bars already laid in closed fixture and full fixture is impregnated dipped in resin and then fixture with box is baked under given temperature for given haridawr. The individual separate bar is heated in vacuum and impregnated in resin. Then bar is taken out and pressed in closed box fixture and then baked at given temperature for given trainint.

Finishing The baked and dimensionally correct bars are sanded-off to smooth the edges and the surface is calibrated, if required, traininy the dimension.

The black semi-conducting varnish coating is applied on the bar surface on the core length. 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. The raw materials are ready to use and require preservation and working on temperature ‘: Its shelf life is one year when kept at temperature 20 C which could be increased when kept at temperature of 5 C. The temperature control need not required. The insulating material is applied on job and then the same is impregnated fully dipped bhwl the resin.

This test is carried out to ensure the healthiness of dielectric Insulation i. High Voltage Test each bar is tested momentary at ssummer voltage increased sunmer to three times higher repkrt rated voltage.

This gave me, a chance to have an encounter with such heavy machines like turbo generator TG MW. The architecture of B. It has provided an opportunity to learn that optimization of technology used at proper place bjel time can save a lot of labour.

The training has proved traininf be immensely helpful as it has helped me to have an exposure of the practical implementation of the theoretical knowledge that I have gained till date. Remember me on this computer. Enter the email address you signed up with and we’ll email you a reset link.

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