COIL & INSULATION MANUFACTURING SHOP DETAILS

(BLOCK-IV)

As the complete one peace coil is not practicable so the coils are manufactured in two parts, upper and lower bars. Out of the various BLOCKS as mentioned before the coil and insulation manufacturing block is BLOCK-4. This block is known as the COIL AND INSULATION MANUFACTURING block.Block-4 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. There are three BAYS in this block each bay manufactures stator bars and coils for different machines as mentioned below: 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 No. 3- 464 i.e. Robel bar centre.
BAY-III:         Insulation detail shop: Manufacturing of hard insulation & machining of hares insulation part (Glass Textolite) such as packing, washer, insulation box, wedges etc. & CNC taping machine.
 Bar Shop: This shop is meant for manufacturing of stator winding coils of turbo generator and hydro generator.
 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. Turbo-Generators: The manufacturing of bars of standard capacity such as 100MW, 130MW, 150MW, 210/235MW, 210/250MW, 500MW. The plant has capacity and technology to manufacture 800MW and 1000MW generators.
 Types of generators:- The generator may be classified based upon the cooling system used in the generators such as: THRI, TARI, THDI, THDD, THDF, THFF, and THW.
 

Ø  T => First alphabet signifies the type of generator i.e. turbo- generator or Hydro generator.

Ø  H/A => Second alphabet stands for the cooling media used for the cooling of rotor i.e. hydrogen gas or air

Ø  R/D/F/I => Third alphabet signifies the type of cooling of rotor e.g. radial, indirect, forced, direct etc.

Ø  I/D/F => Last alphabet stands for the type of cooling of stator e.g. indirect cooling, direct cooling, and forced cooling

Ø  W => Cooling media used for cooling of stator coil e.g. water.

 Sections in Block IV

 
(a) Assembly Section

·        Mechanical Assembly Section: - It is equipped with small size drilling machines, welding sets and hydraulic testing equipment for manufacturing turbo-generator mechanical assemblies.
·        Close Cubical Assembly Section
 

(b) Stator Bar Winding Section

·        Conductor cutting, insulation and transposition section having facilities for transposing the bars.
·        Stack consolidation section, forming and lug brazing sections have block type hydraulic press, steel former and induction brazing installations respectively.
·         Insulation taping sections with automatic taping facilities in air-conditioned temperature covering maximum slot portion each overhung ay both ends.
·        Baking and pressing section having baking moulds for simultaneous curving of straight and overhead portion with electrical heating.
 

(c) Armature Winding, Rotor coil and Stator bar Section

Coils are diamond pulled type with Class-B (bitumen) and Class-F (conventional or resin rich discontinuous epoxy insulation) and Class-H Silicon insulation for machines ranging from 5 to 460 KW capacity. This section has the following work centers:-·        Conductors cutting, U- bending and terminal conductor cutting machines, U- bending machines and terminal baths.
·         Forming and Insulation of DC coils.
·        Main and Interpole Winding: - It is having semi-automatic winding machine.
·        Planking, boat pulling and diamond pulling machine.
·        Insulation and pressing of AC coils: - it is equipped with hydraulic presses of 608 T capacities.
 

(d)Impregnation Section :-

It is equipped with impregnation tank, ovens for impregnation of DC pole coils.  

(e) Insulation Section :-

·        Insulating details, machining is equipped with small size lathes, milling and radial drilling machines and jet cutting saw.
·        Press Molding Section: - It has electrical ovens, hydraulic presses, shearing and circular saw cutting machines for manufacturing press molded components of all the electrical machines.
·        Plastic Molding Section: - Is equipped with various presses for plastic molded parts.
·        Bitumen Mica Tape Manufacture: - Is equipped with mica tape manufacturing machine and lathe for slitting mica tape to the required size.

Heavy Electrical Equipment Plant (H.E.E.P.) Blocks Haridwar

H.E.E.P. is further divided into eight different blocks

1.      BLOCK 1 (Electrical Machine Block):- In this block turbo generators , exciter motors (A.C &D.C.) are manufactured and assembled.

2.      BLOCK 2 (Heavy Fabrication Block):- In this block large size fabricated assemblies component for power equipment are manufactured and assembled

3.      BLOCK 3(Turbine Manufacturing Shop):- In this block steam turbine , hydro turbine and gas turbines , turbines blades are manufactured and assembled.

4.      BLOCK 4 (Coils and InsulationManufacturing ):- In this block Turbo and hydro generator winding bar are manufactured.

5.      BLOCK 5 (Condenser Fabrication and Forge Block):- In this block fabricated parts of hydro and steam turbine water box manufactured.

6.      BLOCK 6:- Fabricated oil tanks hollow guides blades, rings, stator frames , rotor spiders are manufactured.

7.      BLOCK 7:- All types of dies including stamping dies, stamplings of generators and motors are manufactured.

8.      BLOCK 8:- LP heaters , ejectors, steam coolers ,oil coolers ,ACG coolers, oil tanks are manufactured.

B.H.E.L. Haridwar

INTRODUCTION TO BHEL HARIDWAR

In 1956, India took a major step towards the establishment of its heavy engineering industry Bharat Heavy Electrical Limited. The first heavy electrical manufacturing unit of the country was setup at Bhopal. It progressed rapidly and three more factories went to production in 1965. The aim of the establishing B.H.E.L was to meet the growing power requirement of country.

B.H.E.L. appeared on the power map of India in 1969 when the first unit supplied by it was commissioned at the Basin Bridge Thermal Power Station in Tamil Nadu within a decade, B.H.E.L. had commissioned the 100th unit at Santaldih, West Bengal.
 B.H.E.L. had taken India from a near total dependence on imports to complete self reliance in this vital area of power plant equipment B.H.E.L. has supplied  97% of the power generation equipment B.H.E.L. has already supplied generating equipment to various utilities capable of generating over 1800MW power. Today B.H.E.L. can produce annually equipment capable of generating 6000MW. This will grow further to enable B.H.E.L. to meet all India’s projected power equipment requirement as well as sizeable portion of export targets.
 Probably the most significant aspect of BHEL’s growth has been its diversification. The constant reorientation of the organization to meet the varied need in time with time a philosophy that has led to the development of a total capability from concept to commissioning not only in the field of energy but also in industry and transportation.
 In the world power scene, B.H.E.L. ranks among the top ten manufacturers of power plant equipment and in terms of spectrum of product and service offered. It is right on top B.H.E.L.’s technological excellence and turnkey capabilities have won it worldwide recognition. Over 40 countries in the world have placed orders with B.H.E.L. covering the individual equipment to complete power station on a turnkey basis.
 B.H.E.L. Haridwar has two manufacturing plants :

(1) Heavy Electrical Equipment Plant (H.E.E.P.)
(2) Central Foundry Forge Plant (C.F.F.P.)

Awards and Recognition of B.H.E.L.

Awards and Recognition :-

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

v  BHEL was adjudged the Best Power Equipment Manufacturing Organization by CBIP.

v  The company won the prestigious ‘Golden Peacock Award for Occupational Health & Safety 2011’ for significant achievements in the field of Occupational Health and Safety.

v  The company bagged PSE Excellence Award 2014 for R&D & Technology Development.

v  BHEL received the National Intellectual Property Award 2014 and WIPO Award for Innovative Enterprises.

v  BHEL received two Awards in CII-ITC Sustainability Awards 2012 from President of India.

v  Bharat Heavy Electricals Limited signed a Memorandum of Understanding (MoU) with Govt. of India outlining the performance targets for the year 2018-19 in New Delhi.

v  BHEL has been awarded the CBIP Award 2018 for 'Best Power Equipment Manufacturing Organisation'.

v  BHEL has been conferred the India Pride Award 2017-18 for Excellence in Heavy Industries in the Maharatna category.

v  Bharat Heavy Electricals Limited  has won the EEPC INDIA National Award for Export Excellence for the year 2016-17, as 'Star Performer - Project Exports (Large Enterprise)'.

Shareholders of B.H.E.L.

BHEL’s equity shares are listed on Exchange and National Stock Exchange of India. Central Government of India and State Government of India hold majority of the shares of BHEL.

Shareholders (as on 31 March 2017)	Shares (in percentage)
Central Govt. & State Govt. of India	63.06%
Foreign Institutional Investors(FIIs)	15.89%
Insurance Companies	10.38%
Banks, FI and Mutual Funds	6.05%
Individual Shareholders	3.09%
Others	1.53%
Total	100%

Above data is given as per the BHEL 31 March 2017 released report.

Bharat Heavy Electricals Limited(BHEL)

INTRODUCTION ABOUT BHEL

Bharat Heavy Electricals Limited(BHEL), owned by Government of India, Is a power plant equipment manufacturer and operates as Engineering and manufacturing company based in New Delhi. Established in 1964, BHEL is India’s largest engineering and manufacturing company of its kind. The company has been earning profits continuously since 1971-72 and paying dividends uninterruptedly since 1976-77.

BHEL was established in 1964. Heavy Electricals Limited(India) was merged with BHEL in 974. In 1982, It entered into power equipment, to reduce its dependence on power sector. It developed the capability to produce a variety of electrical, electronic and mechanical equipments for all sectors, including transmission, transportation, oil and gas and other industries. In 1991, It was converted into public limited company.

The wide network of BHEL’s 17 manufacturing division, 2 repair units, 4 regional offices, 8 service centers, 8 overseas offices, 15 regional centers, 7 joint ventures, and infrastructure allowing it to execute more than 150 projects at sites across India and abroad. The company has established the capability to deliver 20,000 MW p.a. of power equipment to address the growing demand for power generation equipment.

BHEL has attained ISO 9001:2000 certification for quality management and all the manufacturing units divisions of BHEL have been upgraded to the latest ISO:2000 version. All the major divisions of BHEL have been awarded ISO-14001 certification for Environment Management System and OHSAS:18001 certification for Occupational Health and Safety Management System. BHEL become the first public sector company in the country to win the coveted prize for Haridwar Unit under the CII Exim Award for the management. BHEL is the only PSU among the 12 Indian companies to figure in “Forbes Asia Fabilous 50” list. The company received MoU excellence for 2005-06. Bharat Heavy Electricals Limited signed a Memorandum of Understanding (MoU) with Govt. of India outlining the performance targets for the year 2018-19 in New Delhi. BHEL has been awarded the CBIP Award 2018 for 'Best Power Equipment Manufacturing Organisation'. It has been conferred the India Pride Award 2017-18 for Excellence in Heavy Industries in the Maharatna category.