A Report on industrial training at

BHARAT HEAVY ELECTRICALS LIMITED

Haridwar, India
TURBINE
!nder t"e a#le guidan$e o%
S" Ra& Ma"es" Meena 'SE()lg* + Blo$, -
Su#&itted #.
Ma.an, /u&ar
Me$"ani$al Engineering 0
rd
.ear
Tulas Institute of Engineering & Management, Dehradun
AC/123LED4EME1T
Practical knowledge means the visualization of the knowledge,
which we read in our books. For this, we perform experiments and get
observations. Practical knowledge is very important in every field. One
must be familiar with the problems related to that field so that he may
solve them and become a successful person.
fter achieving the proper goal in life, an engineer has to
enter in professional life. ccording to this life, he has to serve an
industry, may be public or private sector or self!own. For the efficient
work in the field, he must be well aware of the practical knowledge
as well as theoretical knowledge.
"o be a good engineer, one must be aware of the industrial
environment and must know about management, working in such a
industry, labor problems etc., so that he can tackle them successfully.
#ue to all the above reasons and to bridge the gap between theory
and practical, our engineering curriculum provides a practical training of
$% days. #uring this period, a student works in the industry and gets
all type of experience and knowledge about the working and
maintenance of various types of machinery.

& have undergone my $% days training 'after (& )emester* at
BHARAT HEAVY ELECTRICALS LIMITED. "his report is based
on the knowledge, which & ac+uired during my $% days training period
at the plant.

MAYA1/ /!MAR
I1DE5
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%1. 2345! 2rief Profile
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I1TR2D!CTI21
&n ,A9<, &ndia took a maDor step towards the
establishment of its heavy engineering industry when 2harat
3eavy 4lectrical 5td., the first heavy electrical manufacturing unit
of the country was setup at 2hopal. &t progressed rapidly and three more
factories went into production in ,A<9. "he main aim of establishing
2345 was to meet the growing power re+uirement of the country.
2.3.4.5 appeared on the power map of &ndia in ,A<A when the first
unit supplied by it was commissioned at the 2asin 2ridge "hermal
Power )tation in "amil -adu. 6ithin a decade, 2345 had
commissioned the ,%% unit at )antaldih. 6est 2engal.
2345 had taken &ndia from a near total dependence on imports to
complete self!reliance in this vital area of power plant e+uipment
2345 has supplied A>E of the power generating e+uipment. 2345
has already supplied generating e+uipment to various utilities capable
of generating over ,@%%% :6 power. "oday 2345 can produce
annuallyF e+uipment capable of generating <%%%:6. "his will grow
further to enable 2345 to meet all of &ndiaGs proDected power e+uipment
re+uirement. s well as sizeable portion of export targets.
Probably the most significant aspect of 2345Gs growth
has been itGs
diversification. "he constant reorientation of the organization to meet the
varied needs in
time with time a philosophy that has led to the development of a
total capability from concepts to commissioning not only in the field
of energy but also in industry and transportation.
&n the world power scene, 2345 ranks among the top ten
manufactures of power plant e+uipment and in terms of the spectrum of
products and services offered, it is right on top. 2345Gs technological
excellence and turnkey capabilities have won it worldwide recognition.
Over 7% countries in the world over have placed orders with 2345
covering individual e+uipment to complete power stations on a turnkey
basis.
&n ,A>@!>A export earnings reached .s. ,11 crores, the highest for
any one!year.
2345 has its head+uarters at -ew #elhi. &ts operations are
spread over ,,
manufacturing plants and number of engineering and service divisions
located across the
countryH the service divisions includes a network of regional branch
offices throughout
&ndia.

BHEL(A Brie% )ro%ile
2345 is the largest engineering and manufacturing enterprise in
&ndia in the energy!related H infrastructure sector, today. 2345 is
ushering in the indigenous 3eavy 4lectrical 4+uipment industry in &ndia!a
dream that has been more than realized with a well!recognized track
record of Performa
widespread network comprising of ,7 manufacturing
companies, which have international recognition for its commitment
towards +uality. 6ith an export presence in more than <% countries,
2345 is truly &ndiaGs ambassador to the world. 2345Gs vision is to
become world class engineering enterprise, committed to enhancing
stakeholder value.
BHEL "as6(
&nstalled e+uipment for over A%,%%%:6 of power
generation for /tilities, captive and &ndustrial users.
)upplied over 19%%% :otors with #rive 0ontrol )ystem to power
proDects, Petrochemicals .efineries, )teel, luminum, Fertilizer,
0ement plant, etc.
)upplied "raction electrics and 0H#0 locos over
,1%%% kms .ailway network.
)upplied over one million (alues to Power Plants and other
&ndustries
BHEL ( A1 2VERVIE3
"he first plant of what is today known as 2345 was established
nearly 7% years ago at 2hopal I was the genesis of the 3eavy 4lectrical
4+uipment industry in &ndia.
2345 is today the largest 4ngineering 4nterprise of its kind in
&ndia with excellent track record of performance, making profits
continuously since ,A>,!>1.
2345 business operations cater to core sectors of the &ndian 4conomy
like.
Power
&ndustry
"ransportation
"ransmission
#efenses etc.
"oday 2345 has
,7 :anufacturing #ivisions
A )ervice 0enters
7 Power )ector .egional 0enters
,9% ProDect sites

2345Gs vision is to become world !class engineering enterprise,
committed to enhancing stakeholder value. "he greatest strength of
2345 is its highly skilled and committed 77,%%% employees.
)pread all over &ndia I abroad to provide prompt and effective
service to customers.
B!SI1ESS SECT2R
2345 operations are organized around business sectors to
provide a strong market orientation. "hese business sectors are Power
&ndus and &nternational operations.
)23ER SECT2R
Power sector comprises of thermal, nuclear, gas and hydro
business. "oday 2345 supplied sets account for nearly <9E of the
total installed capacity in the country as against nil till ,A<A!>%.
2345 has proven turnkey capabilities for executing power proDects
from concept to commissioning and manufactures boilers,
thermal turbine generator set and auxiliaries up to 9%%:6.
&t possesses the technology and capability to procure thermal
power generation e+uipment up to ,%%%:6.
0o!generation and combined cycle plants have also been introduced.
For efficient use of the high ash content coal!2345 supplies
circulating fluidized boiler.
2345 manufactures 1$9:6 nuclear sets and has also commenced
production of 9%%:6 nuclear set.
0ustom!made huge hydro sets of Francis, 4lton and ?aplan types for
different head! discharge combinations are also engineered and
manufactured by 2345.
I1D!STRY SECT2R
2345 is a maDor contributor of e+uipment and system to important
industries like
0ement
Petrochemicals
Fertilizers
)teel paper
.efineries
:ining and "elecommunication
"he range of system and e+uipment supplied including captive power
stations
3igh speed industrial drive turbines
&ndustrial boilers and auxiliaries
6aste heat recovery boilers
=as turbines pump, valves, seamless steel tubes
3eat exchangers
Process control etc.
TRA1S)2RATI21 6(
2345 supplies a wide e+uipment and system to &ndian .ailways.
4lectric locomotive
"raction electric and traction control e+uipment
TELEC2MM!1ICATI216(
2345 also caters to "elecommunication sector by way of
small, medium and large switching system.
2345 has been divided into many blocks8!
-* Blo$,(-6(
&n block one turbo generator, generator, exciter motors
'.0I#.0* are manufactured I assembled
7* Blo$,(76(
&n block two large size fabricated assembliesJcomponent for power
e+uipment are manufactured I assembled.
0* Blo$,(06(
&n block !$ steam turbine, hydro turbines, and gas turbines,
turbines blade are manufactured I assembled
8* Blo$,(86(
&n block !7winding for turbo generator, hydro generator, insulation of
.0I#.0 motors insulating component for turbo generator,
hydro generator motors are manufactured I assembled
9* Blo$,(96(
&n block !9 fabricated parts of steam turbine water box, hydro
turbine turbines parts are manufactured I assembled
:* Blo$,(:6(
&n block !< fabricated oil tanks hollow guide blades, rings,
stator frames rotor spiders are manufactured I assembled
;* Blo$,(;6(
&n block !>all types of dies including stamping dies, stamping
for generators Imotors are manufactured I assembled
<* Blo$,(<6(
&n block !@ 5P heaters, eDectors, steam coolers, oil coolers, 0=
coolers, oil tanks are manufactured I assembled
MA1!=ACT!RI14 DIVISI21S
3eavy 4lectrical Plant, Piplani, 2hopal
4lectrical :achines .epair Plant '4:.P*, :umbai
"ransformer Plant P.O. 2345, Khansi.
2harat 3eavy 4lectrical 5imited 8
0entral Foundry Forge Plant., .anipur, 3ardwar
3eavy 4+uipment .epair Plant, (aranasi.
&nsulator Plant, Kagdishpur, #istt. )ultanpur.
3eavy Power 4+uipment Plant, .amachandra Puram, 3yderabad
3igh Pressure 2oiler Plant I )eamless )teel "ube Plant,
"iruchirappalli.
2oiler uxiliaries Plant, &ndira =andhi &ndustrial 0omplex, .anipet.
&ndustrial (alves Plant, =oindwal.
4lectronics #ivision 8
4lectronics )ystems #ivision.
morphous )ilicon )olar 0ell Plant '))0P*.
4lectro porcelains #ivision.
HEE)6 A1 2VERVIE3
Over the years, 2harat 3eavy 4lectrical 5imited has emerged
as world class engineering and &ndustrial giant, the best of its kind in
entire )outh 4ast sia. &ts business profile cuts across various sectors
of engineeringHpower utilities and industry. "he company today
enDoys national and international presence featuring in the L fortune
international!9%%M and is ranked among the top ,1 companies of the
world, manufacturing power generation e+uipment. 2345 has now ,7
manufacturing division, @ service centers and 7power power sectors
regional centers besides a large number of proDect sites spread over
&ndia and abroad.
"he company is embarking upon an ambitious growth path through
clear vision, mission and committed values to sustain and augment its
image as a world!class enterprise.
VISI21
world!class innovating, competitive and profitable
engineering enterprise providing total business solution.
MISSI21
"o be the leading &ndian engineering enterprise providing +uality
products system and services in the field of energy, transportation,
infrastructure and other potential areas.
VAL!ES
:eeting commitments made to external I internal customers
Foster learning creative and speed of response
.espect for dignity and potential of individual
5oyalty and pride in the company
"eam playing
MA1!=ACT!RI14 )R2CESS 2= T!RB2
4E1ERAT2R > STAT2R BAR
BRIE= S!MMARY6 AB2!T THE BAR SH2)
"his shop is meant for manufacturing of stator winding coils of
generator that may be turbo generator or hydro generator.
HR BARS
:anufacturing of bars of different capacity depends upon the
water head available at site. "he hydro generator is air called
generator of lesser length.
T!RB2 4E1ERAT2R BAR
For the turbo generator the manufacturing of bars of standard
capacity such as ,%% :6, ,$%:6, ,9%:6, 1,%H1$9:6,
1,%H19%:6. "his plant has capacity and technology to
manufacturing @%% :6 generators.
TY)ES 2= 4E1ERAT2RS
"he generator may be classified based upon the cooling system
used in the generators such asF
"3.&, ".&, "3#&, "3##, "3#F, "3FF, "36
" Ni.e. "urbo =enerator or 3ydro =enerator.
3H Ni.e. 3ydrogen =as or ir.
.H#HFH& Ni.e. .adial, indirect, forced, direct etc.
&H#HF Ni.e. &ndirect cooling, direct cooling, forced cooling.
6 Ni.e. cooling media used for cooling of stator coil e.g.
water.
MATERIAL CHEC/I14
First we check the material of the conductor. nd the total
insulation upon the conductor. "he width of the copper conductor
should be8
a For 5ower bar N @ x 1.@mm ')olid*
# For /pper bar N @ x ,.$mm ')olid*
$ For 3ollow conductor N @ x 7.< x ,.9mm ')olid*
C21D!CT2R C!TTI14 A1D E1D CLEA1I14
"his process is done by the automatic 0-0 machine, in this
process the length of lower bar I upper bar is decided as
following as per drawing!
Lower Bar
a )olid conductor length N ,%,1%%mm ',% Plates*
# 3ollow conductor length N ,%,1%%mm',% Plates*
!pper Bar
a )olid conductor length N ,%,%9%mm ',% Plates*
# 3ollow conductor length N ,%,%9%mm',% Plates*
"his insulation is removed from both ends after the cutting of conductor
i.e. 9%%mm for both lower I upper bar.
TRA1S)2SITI21 2= C21D!CT2R
"ransposition means changing or shifting of position of each
conductor in active care 'slot* part. fter cutting the re+uired
number of conductors are arranged on the comb in staggered
manner and than bands are given to the conductor with the help of
bending die at re+uired distance.
Setting o% die
a 0omb of setting for lower barGs
#ie ,
st
#ie 1
nd
#ie $
rd

11%%.1mm $>$9.$mm <9@<.1mm
# 0omb of setting for /pper barGs
#ie ,
st
#ie 1
nd
#ie $
rd

1,%Amm $<1%.1mm <7A<.1mm
"his process is repeated to making another half of the bar.
CR2SS 2VER I1S!LATI21
0ross over insulation is give to the conductor for the protection in
which the insulating spacer are provided at the cross over portion. &n
this insulation the -o!max paper is used.
3ere the filter material 'insulating putty of moulding micanite*
spacer is provided along the high of bar to maintain the rectangular
shape. "he size of spacer should be O
,
st
2and N ,7<mm
1
nd
2and N 1,Amm
$
rd
2and N 1A1mm
STAC/ C21S2LIDATI21 2R )RESSI14
"he core part of the bar stack is pressed in press under the pressure
between >%kg to @%kg 'various from product to product* and the
temperature between A% #eg.0 to ,<% #eg.0 for a given period.
3ere four bars is pressed in one time and six to eight plates are used
for pressing. fter that the consolidated stack is withdrawn from the
press.
I1TER STA1D SH2RT TEST 'ISSTest*
&n this test first we make the distance to the non insulating portion of
the bar. 3ere we check the short between any two conductor. fter
this test the bars are again go for the second pressing. &n which
attached full slot separator between two half bar no!max paper and
tapped with transparent film. &n this test if any error is found then it
has to be rectified.
=2RMI14 2= BAR
&n this operation the straight bar stack is formed as per overhang
profile. &n this process bars should be formed on universal former
and marked for the thermal space. fter it they are moved for cutting
of extra conductor.
?ER2 )IC/LI14 2= BAR E1D
Pickling is the process of the cleaning of components by the
chemicals. "he pickling solutions are8
a 6ater N ,%% parts by weight
# )ulphuric cid N ,% parts by weight
$ Phosphoric cid N 9 parts by weight
d 3ydrogen per Oxide N 9 parts by weight
"he temperature should be maintain 9% #eg.0 to <% #eg.0. "he end
portion of bar is dipping in this solution upto ,% to ,9 min.
#uring this pickling process some aciditic properties are effected to
the end portion of bar. )o to neutralization of it dipped the bars again in
the ammonia solution. For the shining of end part the bars are dipped in
ethyal alcohol '0139O3* solution and dry with nitrogen Pressure.
C2IL L!4 M2!1TI14
&n this process contact sleeve and the bottom part of the water box
are adDust at the give dimensions. "he operation of mounting of
contact sleeve and bottom part of water box is complete in following
steps!
a 0heck the dimension of contact sleeve and water box bottom part.
# )tand by bar for setting of lug.
$ )etup to the solid conductor in each row as per drawing.
d "hen insert the contact sleeve upon the solid and hollow conductor
and temporally installed to it. nd also installed the bottom part of
water box.
e :aintain the gap between contact sleeve and bottom part of water
box approx 1%mm.
fter the lug mounting cutting of extra solid conductor.
MAI1 BRA?I14
"here are the following steps to brazed the lug.
a )tand by bar of setting for brazing.
# "hen heated the lug point through the two indictor at the temperature
of >%% #eg.0 .
$ For brazing use brazing alloy 5!g!,9P by four person. "his is the
silver platinum alloy wire of melting point >%% #eg.0 to >9% #eg.0.
d "his "emperature is give through the laser rays.
C21D!CT2R C!TTI14, =ACE MILLI14 A1D DEBBERI14
fter the main brazing bars is moved for cutting of extra part of
conductors as per drawing. 3ere cut the end part of the bottom part
of water box and taken for face milling.
&n this process the conductor is given the accurate shaped as per the
measurement and it is taken in account that any part of the surface is
not left uneven and dull.
"hen in #ebbering, the bars edges are many a time left with twigs
and sharp needle type mettle cutting known as bar and this process
of removing is known as #ebbering.
=IRST )IC/LI14
"his is the same process of pickling which is done before the lug
mounting or zero pickling. fter this pickling process the bar is
moved the brazing of top part of water box in both side.
BRA?I14 2= T2) )ART
"hought the induction process the top part of water box is brazed in
both side.
s per the previous main brazing first we stand by bars of setting for
brazing then we attached the top part from the bottom part of water
box. "hen healed the top part by top inductors at the temperature of
7%%#eg.c.
For this type of brazing use 5!g!7%0d. "his is the alloy silver
academy which have 7%E cadmium and the melting point is 7%% #eg.0
to 9%% #eg.0. "his brazing is done for both end.
fter the brazing the bars is go for second pickling which is the same
process as previously explain.
3ATER =L23 TEST
"hought this test check the flow water e+uivalently in the hollow
conductor of the bar. "here is the following steps of checking!
a 6ater should be exit all the total hollow conductor.
# &f some burrs are Dammed it should be removed to give very high
pressure of water and clean with the help of solid wire.
$ "he main point of testing is that the water flow into the bar and exit
from the water box fall down approximately to cover , :tr. From
each conductor.
1ITR24E1 LEA/ TEST
&n this test the bar is tested for leakage into the components of bar. &n
this test flow of nitrogen gas with pressure of ,%kgH0m
1
to check the
leakage in to the hollow conductor. &f leakage found the bar is
reDected.
THERMAL SH2C/ TEST
"he cycles of hot '@% #eg.0* and cold '$% #eg.0* water are flew
thought the bar to ensure the thermal expansion and contraction of
the Doints. "he time of low of hot I cold water should be approx $1
to 7%min and give the time between to flow of hot I cold water is 9
min. this process is applied atleast @ hours.
HELI!M LEA/A4E TEST
&n this test the barGs end is tested to flow of helium gas with the
given pressure if the end part of the bar is leakage then the helium
gas is covered the surface of water box and indicator indicate the
point of leakage.
I1S!LATI21
For the insulation sunmika therm tape or sunmika pleese tape is used
which is the combination of mica P glass P varnish. &t is used for
corona protection. &n this insulation to layer of pleese tape P to layer
of therm tape and after them again to mica pleese tape is used.
)ro$ess o% Insulation
a 0lean the bar.
# 0lean with chemical or thinner.
$ "aping
d .ealizing film from the mica plastic section.
&n insulation the wall thickness of insulation is subDected to the generating
voltage of the machine.
IM)RE41ATI21 A1D BA/I14
- T"er&orea$ti@e s.ste&6 &n case of rich resin insulation the bar is
pressed in closed box in heated condition and baked under pressure
and temperature as per re+uirement for a given period.
7 Mi$alasti$ s.ste&6 &n case of poor resin system the insulated bars
are heated under vaccum and impregnated 'dipped* in heated resin
so that all the air gaps are filled, layer by layer with resin then extra
resin is drained out and bars are heated and baked under pressed
condition in closed box fixture.
V)I Mi$alasti$ S.ste&
"he bars already laid in closed fixture and full fixture is impregnated
in resin and then fixture with box is baked under given temperature
for the given duration.
VI) Mi$alasti$ S.ste&
"he individual bar is heated in vaccum and impregnated in resin.
"hen bar is taken out and pressed in closed box fixture and then
baked at given temperature for given duration.
=I1ISHI14
"he baked and dimensionally correct bars are sanded!off to
smoothen the edges and surface calibrated if re+uired for the
dimension.
C21D!CTI14 VAR1ISH C2ATI14
2C) '2uter Corona )rote$tion* Coating6 "he black semi!
conducting varnish coating is applied on the bar surface on the core
length.
EC) 'End Corona )rote$tion* Coating6 "he 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.
TESTI14
,. Tan Test6 "his test is carried out to ensure the healthiness of
dielectric 'insulation* i.e. dense or rare and measured the capacitance
loss.
1. HV Test6 "he each bar is tested momentarily at high voltage
increased gradually to three times higher than rated voltage.
DIS)ATCHED =2R 3I1DI14
&f the bar is passed in all the operation and testing after completing
then the bar is send for stator winding.
T!RB2 4E1ERAT2RS
'a* Air Cooled 4enerators !pto 7AA Mw Range 'T.pe6
TARI * Salient Design =eatures
)tator core and rotor winding direct
air!cooled
&ndirect cooling of stator winding
3orizontally split casing design of
stator
(ertically side mounted coolers in a
separate housing
:icalastic bar type insulation system
)eparately assembled stator core and
winding for reducing the manufacturing cycle
2rushlessHstatic excitation system

'b* H.drogen Cooled Tur#ogenerators o% -8A(7:A Mw Range 'T.pe6
THRI * Salient Design =eatures
)tator core and rotor winding directly

hydrogen cooled
&ndirect cooling of stator winding
.igid core bar mounting
:icalastic insulation system
4nd shield mounted bearings
"op ripple springs in stator slots
.ing type shaft seals
)ymmetrical ventilation.
M2T2R 3I1DI14

B- Te$"ni$al ReCuire&ents

',* 0ount the coil groups in the anti clock wise direction locking from the
connection end.
'1* 5eads of the coils groups lying on the outer periphery of the overhang
position shall be the finish and those lying on the inner periphery shall be
the start to coil groups.
'$* 5eads shall be taken form the coil side lying at inner periphery of slot
-o.,.
'7* "he coil group -o., shall 5ie at top with its axes coinciding with the
vertical axis of the frame.
'9* "ake out terminal leads %1 /1, (1, 61 for left hand side terminal box
and %1 /,, (,, 6, for right hand side terminal box. 6hen looking
form the connection end.
Circuit diagram:-


WINDING DIG!M "# M"T"! WINDING
B7 3inding data
12 2= )HASE 0
12 2= )2LES :
)HASE C211ECTI21 Y
12 2= )ARELLEL )ATH 7
12 2= C2IL 4R2!) -<

B0 Conne$tion o% &otor winding




C21CL!SI21

"he second phase of training has proved to be +uite faithful.
&t proved an opportunity for encounter with such huge machines like
turbine etc.
"he architecture of 2.3.4.5., the way various units are linked
and the way working of whole plant is controlled make the students
realize that 4ngineering is not Dust structural description but greater part
is planning and management. &t provides an opportunity to learn tech.
/sed at proper place and time can save a lot of labour.

2ut there are few factors that re+uire special mention. "raining is
not carried in true spirit. &t is recommended that there should be proDectors
especially for trainees where presence of authorities is ensured.

3owever, training has proved to be satisfactory. &t has allowed us an
opportunity to get an exposure of the practical implementation of
theoretical fundamentals.