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BHARAT HEAVY ELECTRICAL LTD Industrial Training Taken At B.H.E.L. Haridwar Presented By: - Sajal Kr. keshri EE 7th Sem Submitted To:- Ms. Neha Tiwari EE Department SGVU,Jaipur (Raj.)

introduction 1.BHEL is the largest engineering &manufacturing enterprise in India. 2.First plant was setup in BHOPAL about Established 50 years ago. :

introduction 1. BHEL is the largest engineering &manufacturing enterprise in India . 2. First plant was setup in BHOPAL about Established 50 years ago.

Bhel an overview :

Bhel an overview INDIA’S “NAVRATNA” COMPANY B.H.E.L. Has 14 manufacturing divisions, 9 service centers and 4 power sectors regional centers . It works on 180 projects sites enables the company to its customers . Having attained “ISO 9001” certification. Company contributes more than 75% of the national grid, share of 45% comes from bhel-haridwar It ranks in “ fortune 500 companies” Ranked among top 12 companies in the world manufacturing power generation equipments Only PSU among 12 indian companies to get position in “ forbes asia fabulous 50” list

Present position of bhel:

Present position of bhel The major units are B.H.E.L.– Bhopal, B.H.E.L.– Hyderabad, B.H.E.L. – Trichy , and B.H.E.L. – Haridwar . The corporate office is situated in New –Delhi. Committed Workforce of more than 60,000 employees working at various posts.


MANUFACTURING OF PRODUCT First Heavy electrical equipment plant in bhopal ; Heavy electrical equipment plant in haridwar ; Transformer plant in jhansi ; Heavy electrical equipment plant in hyderabad ; Electro-division plant in banglore ; Insulator plant in jagdishpur ; Industrial values plant in govindwal ; Fabrication plant in rudarpur ; Solar cell plant in gurgaon ; Heavy electrical equipment plant in varanasi ; Electrical machine shop in mumbai ;

BHEL Classification:

BHEL Classification

PowerPoint Presentation:

Conductor drawn from Store. Conductor cutting and end cleaning. Transposition of conductor. Assembly of all conductors to be used in stator bars. Cross over insulation. Consolidation if slot portion of Bar. IS Test (i.e. inter strand test).   Forming of Bar (to shape overhang portion). Pickling of bar ends (1) Mounting of Contact sleeve. Brazing of Contact sleeve .   Pickling of bar ends (2) Block-4 (CIM shop) MANUFACTURING PROCESS OF 500 MW STATOR BAR

PowerPoint Presentation:

Mounting of water box leak test.   Repacking.   Water flow and N 2 test.   Thermal Shock Application.   Helium Leak Test. Reforming of bar (i.e. overhang portion). Insulation of bar on CNC machine. Impregnation and curing of bar insulation.   Surface finishing of stator bar. OCP on stator Bar. Preparation of bar for HV and Tan δ Test. If O.K. Dispatch to Block-1 for laying in the generator.

Conductor cutting :

Conductor cutting Transposition form of conductor

Stack Consolidation:

Stack Consolidation This process is basically done to consolidate the solid as well as the hollow conductors into a single bar. In this process the bar is pressed both vertically and horizontally in the pressing machine. initial temperature of 100-110 0 c. Then the temperature is allowed to rise to the maximum of 160°c. Inter Strand Short Test


Forming Pickling Process To remove unwanted particles on the ends of the bar The constituents of the pickling solution are Sulphuric acid (h2so4)-10% Phosphoric acid (h3po4)-5% Hydrogen peroxide (h2o2)-5% Water (h2o)

Mounting of Contact Sleeve:

Mounting of Contact Sleeve contact sleeve and water box bottom parts are mounted on both the ends of the bar. Contact sleeve, as clear from the name itself, is a rectangular sleeve which is used to make contact between upper and lower bars Brazing of contact sleeve Brazing is basically the process of fixation of both the contact sleeve and water box bottom part i.e. both are properly consolidated using brazing material at high temperature. Two types:- ( i )Thermal Brazing (ii)Induction Brazing


WATER FLOW TEST water is passed through one end of the bar and is allowed to flow through the hollow conductors at the other end of the bar. Nitrogen Testing

Thermal Shock Testing :

Thermal Shock Testing Thermal shock test is performed to check whether the bar can withstand extreme conditions. A pressure of 13.3 kg/cm2 is applied. Pressure is measured by mass spectrometer Helium Leakage Testing

Reforming Of Bar Insulation Of Bar:

Reforming Of Bar Insulation Of Bar 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 14 layers of insulation. Out of these fourteen layers, 12 layers are provided by using a machine called cnc The rest of the two layers are provided manually.

Impregnation tank:

Impregnation tank Heating temperature 65 to70 cen. Create vacuum at temperature 70 to 75 can Then apply nitrogen gas After 24hr process are complete Finishing


TESTING OCP ( Outer Corona Protection) TAN - ∆ TEST H.V TEST Dispatched to Block 1

Thank you! :

Thank you!

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