Unit - I AN ISO 9001 : 2008 COMPANY

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2 Unit - I 2

3 Mission GMC is committed to serving customers with products that incorporate innovative and new technologies and to fully satisfy all customer needs and requirements. Our goal is to maintain leadership in the design, manufacture and marketing of coil products and services. This goal is achieved while operating as a competitive, entrepreneurial company, dedicated to quality, good business practices and superior customer service. Vision To be one of the world s principal coil manufacturing company, with the best quality, service, Price and delivery on it. 3

4 Introduction GMC Unit - I is situated 35 Kms from Bangalore city on the Bangalore Mysore Highway. This facility has a working area of 35,000 Sq Ft (3,500 Sq Mtrs). GMC Unit - II is situated 20 Kms from Bangalore city on the Hosur Highway. This facility has a working area of 20,000 Sq Ft (2,000 Sq Mtrs) Both the above facilities have all modern machines and testing equipments for manufacturing coils to International Standards. 4

5 Bangalore - A Strategic Location Based out of Bangalore, GMC has leveraged some distinct benefits such as - Up to date technology and trained manpower from the city s major electrical equipment manufacturers Bangalore City boasts of manufactures of insulated copper conductors for electric machines as well as for mica paper insulation for high voltage machines. Central Power Research Institute, A Government of India undertaking is located in Bangalore. We utilize their facilities in order to carry out Special Tests like DLA, tan delta test, Impulse Test and partial discharge test. Products and Services Coils can be manufactured and supplied with voltages upto 11 KV for VPI coils, 7.2 KV for soft cell coils, 18 KV for hot moulded resin rich coils and roebel bars, resin rich with maximum rating upto 210 MW& resin poor (VPI cured coils) upto 100 MW. 5

6 Our Manufacturing Capabilities Resin-Rich Coils [Diamond] Upto 30 MW, 18 KV Roebel Stator Bars (Resin Rich) Upto 210 MW, 18 KV Roebel Stator Bars (Resin Poor, uncured or green) Upto 100 MW Soft Cell Coils Upto 7.2 KV Interpole Coils Including Strip on Edge AC Traction Coils Upto Any Capacity Insulated Rotor Coils For Slipring Motor Rotor Field Poles Upto 20 MW Diamond VPI Resin-poor Coils ( Green Coils) Upto 20 MW DC Armature Coils Upto Class H, Any Capacity DC Traction Coils Upto Any Capacity DC Field Pole Coils Rotor C- Coils For Turbo Alternators Upto 120 MW We Supply Copper Strips & Round Wire Enameled, En-glass Covered, Kapton Taped, En- Daglass Squirrel Cage Rotor Bars & Short Circuit Rings RTD Thermistor and Thermostats HV Winding Cable (Flexible Silicon Rubber) LV Winding Cable (Flexible Silicon Rubber) All Kinds of HT and LT Insulation Tapes Glass Epoxy Laminates to Nema G11/G10 Specs Magnetic Sheets for Slot Wedges Wedges of any Shape and Size Carbon Brushes and Brush Holders All Transformer Spares Upto 20 MVA Slipring Commutator AVR Upto 20 MVA Stator Rotor Stampings 6

7 Quality Control GMC Manufactures coils and winding kits for rotating electrical machines is committed to enhance customer satisfaction by supplying high quality coils and winding kits on time through the involvement of all the employees and continual improvement of processes in the organization. Coils Testing Facility HV Test AC Upto 100KV HV Test DC 80KV Tan delta upto 18KV Inter turn Testing upto 30KV Partial discharge Test Impulse Testing We test all our coils for any standard specified by customer, eg. ESI 44/5, ESI 44/7 Etc.. Coils Testing Lab - I Inspection of Coils on Dummy Stator / Rotor Coils Testing Lab - II 7

8 We Export to Middle East Africa Americas Asia Europe Saudi Arabia Egypt U.S.A. Singapore U.K. U.A.E. Algeria Mexico Malaysia Italy Kuwait Nigeria Coloumbia Indonesia Holland Qatar Argentina Philippines Norway Bahrain Thailand Turkey Bangladesh Portugal Spain Sweden 8

9 9

10 Our Strengths We are committed to Quality, while ensuring a Quick Turn Around Time and Competitive Pricing. Packing We pack all coils suitable for Road, Air and Sea transport with fumageted wood, thermocol & air bubble sheet. 10

11 Product Range RESIN RICH ROEBEL BARS FOR TURBO GENERATOR RESIN RICH ROEBEL BARS FOR HYDRO GENERATOR WAVE WINDING DIAMOND SHAPED RESIN RICH STATOR COILS DIAMOND SHAPED VPI STATOR COILS DIAMOND SHAPED SOFT CELL STATOR COILS DC ARMATURE COILS 11

12 Product Range INSULATED ROTOR COILS AC TRACTION STATOR COILS DC TRACTION ARMATURE COILS DC TRACTION TRANSPOSED ARMATURE COILS DC ARMATURE COIL WITH CONTINUOUSLY TRANSPOSED COPPER 12

13 Product Range TRANSPOSED DIAMOND STATOR COIL TURBO ROTOR COIL DC AUXILIARY POLES DC TRACTION FIELD POLE COILS 13

14 Product Range SYNCH. M/C FIELD POLE COIL CONCENTRIC STATOR COIL LARGEST DIAMOND STATOR COIL MANUFACTURED MVA 11.KV 4P EQUIPOTENTIAL WINDING EQUIPOTENTIAL WINDING WINDING KIT MATERIALS 14

15 Coil Manufacturing Equipment LOOPING MACHINE UP TO 1.5 MTRS LOOP LENGTH AND 8 PARELLEL CONDUCTORS LOOPING MACHINE UP TO 3 MTRS LOOP LENGTH AND 16 PARELLEL CONDUCTORS LARGE LOOPING MACHINE UP TO 5 MTRS LOOP LENGTH AND 24 PARELLEL CONDUCTORS COIL STRETCHING MACHINE PLC CONTROLLED mm LOOP LENGTH HYDRAULIC COIL STRETCHING MACHINE mm LOOP LENGTH COIL STRETCHING MACHINE mm LOOP LENGTH COIL STRETCHING MACHINE mm LOOP LENGTH COPPER BUFFING, STRAIGHTENING AND CUTTING MACHINE ROEBELING MACHINE UP TO 8 MTRS CORE LENGTH ROEBELING MACHINE UP TO 8 MTRS CORE LENGTH CLEAN TAPING ROOM TAPING MECHINE UP TO 5 MTRS STRAIGHT LENGTH TAPING MECHINE UP TO 3 MTRS STRAIGHT LENGTH HYDRAULIC PRESSING MACHINE 16 HEADS PLC CONTROLLED - UP TO 7 MTRS STRAIGHT LENGTH HYDRAULIC PRESSING MACHINE 16 HEADS PLC CONTROLLED - UP TO 7 MTRS STRAIGHT LENGTH HYDRAULIC PRESSING MACHINE 12 HEADS UP TO 7 MTRS STRAIGHT LENGTH HYDRAULIC PRESSING MACHINE 12 HEADS PLC CONTROLLED - UP TO 7 MTRS STRAIGHT LENGTH SURFACE GRINDING MECHINE MTRS BED LENGTH OVEN 10Ft X 10Ft X 10Ft 60 KW OVER HEAD CRANE - 35 TONS CAPACITY 15

16 Field Service REWINDING OF 115MVA, 13.8 KV, 3600 RPM BBC MAKE GENERATOR - SAUDI ARABIA REWINDING OF 115MVA, 13.8 KV, 3600 RPM BBC MAKE GENERATOR - SAUDI ARABIA REWINDING OF 107 MVA, 13.8 KV, 3600 RPM GE MAKE FRAME 7 GENERATOR (PARTIAL REPAIR AT SITE ONLY) - SAUDI ARABIA REWINDING OF 25MW, 11 KV, 3000 RPM SIEMENS MAKE GENERATOR - INDIA 16

17 Rewinding Activities REWINDING OF 35.4MVA, 13.8KV, 2POLE BRUSH MAKE TURBO GENERATOR IN EAST MALAYSIA REWINDING OF 26.5MVA, 13.8KV, 3600RPM ALSTOM MAKE GENERATOR IN INDONESIA REWINDING OF MVA, 11KV, 4POLE PARSON AND PEEBLES MAKE GENERATOR AT SITE IN INDONESIA PARTIAL REWINDING OF 27MVA, 11KV, 300RPM BHEL MAKE HYDRO GENERATOR IN EAST MALAYSIA 17

18 Rewinding Activities REWINDING OF 9.5MW, 11KV, 4POLE AEG MAKE GENERATOR STATOR IN MALAYSIA REWINDING OF 9.5MW, 11KV, 4POLE AEG MAKE GENERATOR ROTOR IN MALAYSIA REWINDING OF 18MW, 11KV, 4POLE ABB MAKE GENERATOR - TURKEY (COILS SUPPLY ONLY) REWINDING OF 2POLE TURBO ROTOR OF 32 MW, SIEMENS MAKE GENERATOR AT OUR WORKS REWINDING OF 1800KW, 13.8KV, 2POLE MOTOR - MEXICO (COILS SUPPLY ONLY) REWINDING OF 3000KW, 6.6KV, 994RPM CHINA MAKE MOTOR ROTOR AT OUR WORKS 18

19 On Site Testing Following tests can be conducted during rewinding & overhauling of Generators / Motors Stator Windings Wedge Tightness Check (Mapping) Winding Insulation Resistance Over Voltage Proof Test (AC / DC) Dissipation Factor and Tip-Up (Tan Delta and Capacitance Measurement) Partial Discharge Test (Computerized) Corona Probe / PD / TVA Test (Slot Discharges) Surge Comparison Test DC Winding Resistance Natural Frequency (Bump) Test Contact Resistance Core Visual Inspection Electromagnetic Core Imperfection Detection (ELCID) / Low Energy Core Test Loop Test / High Energy Core Test Core Tightness Inspection Rotor Visual Inspection Voltage Drop Test Impedance DC Winding Resistance Insulation Resistance Recurrent Surge Oscillograph (RSO) Metallurgical Tests on retaining rings (DP & UT) On - Line Tests Partial Discharge Analysis (Testing, Installation and Commissioning) Current / Electrical Signature Analysis Vibrations Acoustic Emission IR Thermography Harmonic Analysis Measurements 19

20 Contract Manufacturing Job MANUFACTURING OF VPI GREEN STATOR COILS FOR 1300KW, 6.6KV, 6POLE MOTOR - 10 SETS PER MONTH WINDING OF VPI GREEN STATOR COILS ON TO THE STATOR CORE FABRICATION OF TRANSPORTATION STANDS AND PLACING OF WOUND STATORS TESTING OF WOUND STATORS 20

21 Contract Manufacturing Job WOUND STATOR OF 560KW, 6.6KV, 6POLE MOTOR WOUND STATOR OF 325KW, 3.3KV, 6POLE MOTOR MANUFACTURE OF VPI GREEN STATOR COILS FOR 2.1MW, 690V, 4POLE WIND TURBINE GENERATORS 10 SETS PER MONTH WINDING OF VPI GREEN STATOR COILS ON TO STATOR OF 2.1MW, 690V, 4POLE WIND TURBINE GENERATORS 21

22 Shop Floor Views Unit - I & Unit - II UNIT - I : ROEBEL BAR SHOP UNIT - I : ROEBEL BAR SHOP UNIT - I : DIAMOND COILS AND DC COILS SHOP UNIT - II : ROEBEL BAR SHOP 22

23 Unit - II 23

24 UNIT - I : 35,000 Sq Ft (3,500 Sq Mtrs) UNIT - II : 20,000 Sq Ft (2,000 Sq Mtrs) GEN MOT COILS Unit - I : No. 29/B, Bidadi Industrial Area, Bidadi, Ramanagaram Taluk/Dist, Karnataka, India Unit - II : No. 102, 4th Phase, Jigani Link Road, Bommasandra Industrial Area, Bommasandra, Bangalore , INDIA Mr. A. K. Mahesh Mobile : mahesh@genmotcoils.com Mr. A. M. Vinay Mobile : vinay@genmotcoils.com Tel / Fax : Website :

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