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    Manufacturing Process of TG 800 MW, Stator Winding Bar BHEL, Production Block-4, HEEP

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    Prashant Tiwari
    Block 4 of BHEL's Heavy Electrical Equipment Plant (HEEP) manufactures stator winding bars for generators. The 28 step manufacturing process for stator winding bars of an 800 MW turbo generator begins with drawing conductor from storage. The bars undergo processes like insulation, pressing, radius milling, welding, and testing before final packaging and shipment to Block 1 for final assembly into the stator and generator. Block 1 is where the main electrical components like the stator, rotor, and exciter are assembled and tested to produce a completed 800 MW turbo generator.

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    © All Rights Reserved
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    Manufacturing Process of TG 800 MW, Stator Winding Bar BHEL, Production Block-4, HEEP

    Uploaded by

    Prashant Tiwari
    94 views26 pages
    Block 4 of BHEL's Heavy Electrical Equipment Plant (HEEP) manufactures stator winding bars for generators. The 28 step manufacturing process for stator winding bars of an 800 MW turbo generator begins with drawing conductor from storage. The bars undergo processes like insulation, pressing, radius milling, welding, and testing before final packaging and shipment to Block 1 for final assembly into the stator and generator. Block 1 is where the main electrical components like the stator, rotor, and exciter are assembled and tested to produce a completed 800 MW turbo generator.

    Original Description:

    training report on manufacturing of 800MW stator bars

    Original Title

    Industrial Training

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    Block 4 of BHEL's Heavy Electrical Equipment Plant (HEEP) manufactures stator winding bars for generators. The 28 step manufacturing process for stator winding bars of an 800 MW turbo generator begins with drawing conductor from storage. The bars undergo processes like insulation, pressing, radius milling, welding, and testing before final packaging and shipment to Block 1 for final assembly into the stator and generator. Block 1 is where the main electrical components like the stator, rotor, and exciter are assembled and tested to produce a completed 800 MW turbo generator.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    94 views26 pages

    Manufacturing Process of TG 800 MW, Stator Winding Bar BHEL, Production Block-4, HEEP

    Uploaded by

    Prashant Tiwari
    Block 4 of BHEL's Heavy Electrical Equipment Plant (HEEP) manufactures stator winding bars for generators. The 28 step manufacturing process for stator winding bars of an 800 MW turbo generator begins with drawing conductor from storage. The bars undergo processes like insulation, pressing, radius milling, welding, and testing before final packaging and shipment to Block 1 for final assembly into the stator and generator. Block 1 is where the main electrical components like the stator, rotor, and exciter are assembled and tested to produce a completed 800 MW turbo generator.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 26

    Manufacturing Process of TG 800 MW ,

    Stator Winding Bar


    BHEL, Production Block-4, HEEP
     BHEL is a
    • Type - State-owned
    enterprise
    • Industry - Electrical
    equipment
    • Areas served – Worldwide

    • Products - Includes (Gas


    and Steam Turbines),
    Boilers, generators, Heat
    Exchangers, Pumps, circuit
     INTRODUCTION TO HEEP

    • Block-1:- (Electrical Machine Final Assembly)


    • Block-2:- (Gas & Steam Turbine Fabrication Block)
    • Block-3:- (Gas & Steam Turbine Manufacturing Block)
    • Block-4:- [CIM (Coil & Insulation Manufacturing)Block]
    • Block-5:- (Heat Exchangers Fabrication Block)
    • Block-6:- (Stampings Block)
    • Block-7:- (Wooden Packing works Block)
    • Block-8:- (Heat Exchanger Tubes Block)
    MAIN PRODUCTS OF CIM/ACM BL-4
    BAY’S IN CIM BL-4
    BAY-I: Bar winding shop:
    Manufacturing of stator winding bars of generator
    BAY-II:
    Manufacturing of heavy duty generator stator bars with
    New CNC M/c
    BAY-III: Insulation detail shop:
    Manufacturing of hard insulation & machining of hares
    insulation part (Glass Textolite) such as packing, washer,
    insulation box.
    Manufacturing Process of TG 800MW,
    Stator Winding Bar
    1.Condutor drawn from store.
    2.Conductor cutting and transposition.
    3. Cross over insulation

    4. Pressing

    5. I.S.T.

    6. Final Pressing

    7. Radius Milling
    8. Water Flow

    9. Forming

    10. End cutting

    11. Contact Sleeve And Bottom Mounting

    12. Tig Welding & Brazing


    13. Nitrogen test
    slot portion

    14. D.P. test overhang portion


    15. 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.
    16. Helium Leak Test
    17. Reforming

    18. CNC tapping

    19. I.C.P

    20. O.C.P

    21. E.C.P
    22.(A) Impregnation Plant

    Wagon Setting & Pressing of bar

    (B) Curing

    Patent by Cemens Company


    23. Surface Finishing

    24. H.V. & TAN Delta Preparation


    26. Boro scope

    27. Final Finishing

    28. Packing of Bar

    Send the Bar Block -1


    1) Block-1 (Electrical Machine Final Assembly)

    • Mainly Block-I is designed to manufacture Turbo


    Generators.

    Products

    Stator frame Rotor & Rotor


    Stator core Windings Exciter
     STATOR CORE & STATOR FRAME
    » Finishing of Rotor & Finished Rotor
     ROTOR AFTER FINAL ASSEMBLY
    .Coils are placed
    in the gaps which
    allows the flow
    of current when
    the rotor rotates.

    .The hydrogen
    gas is circulated
    within the rotor
    enclosure, and
    cooled by a gas-
    to-water heat
    exchanger.
    Final assembly of Turbo Generator 800 MW.
    TG 800 MW , View from the Exciter end.
    Fuses and the
    capacitors
    mounted on
    the exciter
    part to
    generate
    starting toque
    and fuse to
    prevent from
    the over
    current.

    Exciter enables the synchronous generator to


    generate its own reactive energy. The exciter also
    regulates its own power.
     TURBINES MANUFACTURED IN BHEL

    Steam Turbine
    Gas Turbine
    LP Turbine

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