Professional Documents
Culture Documents
REPORT, DEC-2015
PROJECT INCHARGE:
.
SUBMITTED BY:
PANKAJ MODI
3rd YEAR STUDENT
DEPT. OF ELECTRICAL ENGINEERING
MAULANA AZAD NATIONAL INSTITUTE OF
TECHNOLOGY
BHOPAL (M.P.)
TRAINING DURATION:
1
ACKNOWLEDGEMENTS
I would sincerely like to express my gratitude for
BHEL Bhopal, for providing me the opportunity of
pursuing my vocational training in this renowned
industry and endowing me with an unparallel
experience and deep understanding of a wide array
of processes and manufacturing methods taking
place in different workshops of the industry.
I would also take this opportunity to thank our
training in-charge, Mr. A.K. Dhimaan whose
guidance and motivation went a long way in our
understanding of different sections of the industry.
Furthermore, I would thank my institute, MANIT
Bhopal, for giving me opportunity of visiting this
industry and increasing my practical knowledge.
Last, but not the least, I would also like to
acknowledge the immense pleasure, brought about
by my friends as they pursued their training along
with me. We shared some unforgettable moments
together.
3
Vision:
A world class engineering enterprise committed to
enhance stakeholder values.
Mission:
To be an Indian multinational engineering providing
total business solution through quality product system and
services in the field of energy, transportation, industry,
infrastructure and other potential area.
Values:
Zeal to excel.
BUSINESS MISSION
To maintain a leading position as supplier of quality
equipments, system and services in the field of conversion,
transmission, utilization, and conversation of energy for
application in the area of electric power, transportation oil and
gas exploration and industries. To utilize companys capability
and resources to expand busyness in to allied area an priority
sector of economy like defense, communication and
electronics.
BHEL OBJECTIVES
A dynamic organization is one which keeps its aim high,
adopts itself quickly to changing environment, so we are in
BHEL. The objectives of the company have been redefined in
the corporate plane for 90s.
Growth
To ensure a steady growth by enhancing the competitive
edge of BHEL in existing busyness, new area and international
market so as to fulfill national expectation from BHEL.
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Profitability
To ensure a reasonable and adequate return on capital
employed, primarily through improvements in operation,
efficiency, capacity utilization & productivity and to generate
adequate internal resources to finance the companys growth.
Focus
To built a high degree of customer confidence by
providing increased value of his money through international
standards of product quality performance and superior
customer service.
People Orientation
To enable each employee to achieve his potential,
improve his capabilities, understand is role and responsibilities
and participate and contribute to the growth and success of the
company.
Technology
To achieve technological excellence in operation of
indigenous technologies and efficient absorption and adoption
of imparted technologies to suit business.
Image
To fulfill the expectations, which stack holders like
government as owner employee, customer and the country at
large have from BHEL.
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Power
Industry
Transportation
Transmission
Defenses etc.
In, all 700 utility sets of thermal, hydro, gas and nuclear
have been placed on the company as on date. The power plant
equipment manufactured by BHEL is based on contemporary
technology comparable to the best in the world and is also
internationally competitive.
The Company has proven expertise in Plant Performance
Improvement through renovation modernization and up rating
of variety of power plant equipment besides specialized know
how of residual life assessment, health diagnostics and life
extension of plants.
POWER TRANSMISSION AND DISTRIBUTION (T&D)
Cement
Petrochemicals
Fertilizers
Steel papers
Refineries
Mining and telecommunication
TELECOMMUNICATION
BHEL also caters to telecommunication sector by way of
small, medium and large switching system.
Renewable energy
Technologies that can be offered by BHEL for exploiting
non-conventional and renewable resources of energy includes:
wind electric generators, solar power based water pumps,
lighting and heating systems.
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19
20
Prommashexport
RUSSIA
Sulzer Brother
SWITZERLAND
# Electronic Automation System for
Siemens AG.
22
GERMANY
General Electric
CANADA
Baloke Duerr
National Oil
Head
Assemblies, USA
# Steam Turbines , Generators and Axial
Condensers
# Cam Shaft Controllers and Tractions
Current Control Units
Siemens AG.
GERMANY
Siemens AG.
GERMANY
Abroad:
TNB,Malaysia
PPC,Greece
MEW,Oman
OCC,Oman
GECOL,Libya
Trinidad & Tobago
New Zealand
Tanzania etc
Italy
Switzerland
USA
USA
China
U.K.
Poland
Russia
Italy
France
Japan
U.K.
USA
Japan
Russia
Japan
Japan
U.K.
USA
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20.
21.
Rolls Royce
Sanghai Electric Co.
Germany
China
DIVISIONS OF BHEL
There are 20 Divisions of BHEL, they are as follows:
HEEP, Haridwar
HPEP, Hyderabad
HPBP, Tiruchi
SSTP & MHD, Tiruchi
CFFP, Haridwar
BHEL, Jhansi
BHEL, Bhopal
EPD, Bangalore
ISG, Bangalore
ED, Bangalore
BAP, Ranipet
IP, Jagdishpur
IOD, New Delhi
COTT, Hyderabad
IS, New Delhi
CFP, Rudrapur
HERP, Varanasi
Regional Operations Division ARP, New Delhi
TPG, Bhopal
Power Group (Four Regions and PEM)
HARIDWAR
HYDERABAD
TIRUCHY
Plant
HARDWAR
TIRUCHY
JAGDISHPUR
Insulator Plant
RUDRAPUR
BANGALORE
EQUIVALENT CIRCUIT
with
secondary
over the active part and cycle this with periods of hot-air
vacuum (HAV) drying. More common for larger transformers is
to use evaporated solvent which condenses on the colder active
part. The benefit is that the entire process can be carried out at
lower pressure and without influence of added oxygen. This
process is commonly called vapour-phase drying (VPD).
For distribution transformers, which are smaller and have
a smaller insulation weight, resistance heating can be used.
This is a method where current is injected in the windings to
heat the insulation. The benefit is that the heating can be
controlled very well and it is energy efficient. The method is
called low-frequency heating (LFH) since the current is
injected at a much lower frequency than the nominal of the
grid, which is normally 50 or 60 Hz. A lower frequency reduces
the effect of the inductance in the transformer, so the voltage
needed to induce the current can be reduced. The LFH drying
method is also used for service of older transformers.
TERMINALS
Very small transformers will have wire leads connected
directly to the ends of the coils, and brought out to the base of
the unit for circuit connections. Larger transformers may have
heavy bolted terminals, bus bars or high-voltage
insulated bushings made of polymers or porcelain. A large
bushing can be a complex structure since it must provide
careful control of the electric field gradient without letting the
transformer leak oil.
BUSHINGS
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Capacitor types
Some of the higher voltage types (layers of conductive
paper, film, ink or aluminum foil are used with an insulating
medium) are called capacitor bushings because they form a low
value capacitor between the conductor and the wall. This is
done to disperse the electrical field stress and thus reduce the
peak stress that could cause breakdown.
BUSHING FAILURE
Bushings
sometimes
fail
due
to partial
discharge degradation in the insulation. There is at present great
interest in the electricity supply industry in monitoring the
condition of high voltage bushings.
APPLICATIONS
back
again
afterward,
transformers
enable
economical transmission of power over long distances.
Consequently, transformers have shaped the electricity supply
industry, permitting generation to be located remotely from
points of demand. All but a tiny fraction of the
world's electrical power has passed through a series of
transformers by the time it reaches the consumer.
Transformers are also used extensively in electronic products to
step down the supply voltage to a level suitable for the low
voltage circuits they contain. The transformer also electrically
isolates the end user from contact with the supply voltage.
Signal and audio transformers are used to couple stages of
amplifiers and to match devices such as microphones and
record players to the input of amplifiers. Audio transformers
allowed telephone circuits to carry on a two-way conversation
over a single pair of wires. A balun transformer converts a
signal that is referenced to ground to a signal that has balanced
voltages to ground, such as between external cables and
internal circuits.
The principle of open-circuit (unloaded) transformer is widely
used for characterisation of soft magnetic materials, for
example in the internationally standardized Epstein
frame method.
MANUFACTURING SECTIONS
INVENTORY
It is the section of storage of raw material.
FABRICATION
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ASSEMBLY SHOP:
It is an assembly shop where different part of tank
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Tank Assembly
Tank cover assembly
End frame assembly
Cross feed assembly
Core Clamp assembly
Pin & pad assembly
2.
3.
4.
5.
MACHINE SECTION:
To operation to form small components of power and
traction transformer are done is this section. The shop consists
of following machines.
MILLING MACHINE:
a.
b.
COPPER SECTION:
o
o
o
o
TOOLING MACHINING:
In this section the servicing of tools is done.
Blade sharp machine
Mini surface grinding Machine(used for grinding
purpose)
Tool and surface grinding Machine(used to grind the
tool)
Drill grinding Machine (to grid the drills)
Helical winding
Spiral winding
Interleaved winding
Half section winding
Belly type
Link type
Cone type
Cylindrical machine
Circular cutting machine
Bending machine
Punching press machine
Drilling machine
Guillotine machine
Bench saw
Jig saw
Circular saw
MANUFACTURING PROCESS
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CORE ASSEMBLY
All cores utilize the step lap principle in the corner joints to
reduce losses, magnetizing current and sound level. The
cores are fully-mitered on all joints in order to improve the
flux distribution.
45
The exposed edges of all finished cores are bonded with low
viscosity, high-strength epoxy resin on the legs and bottom
yoke to help lower the sound level. The temperature rise of
the core is designed to be low and is controlled, if necessary,
by careful placement of vertical oil ducts within the core
packets.
47
TESTING
Impulse Testing
A state-of-the-art digital impulse recording system, the Haefely
HIAS system, provides the most accurate analysis of impulse
results available today. Electronic recording of the impulse
current and voltage waveforms allows quick mathematical
comparisons to be made, including the difference between the
two waveforms under scrutiny. Accurate printed and plotted
final results are quickly available. If required, photographic
transparencies from the impulse oscilloscope can be supplied.
The construction of the test area incorporates a complete
copper mesh ground mat system, with extensive grounding
points provided. This eliminates high impedance grounds and
provides exceptionally clean test records. The impulse
generator is rated at 200 kV per stage for a total of 2.8 MV,
with 210 kJ total stored energy. For precise triggering, this
generator is equipped with a pressurized polytrigatron gap in
each stage. For chopped wave tests, a Haefely multiple
chopping gap is used. Our plants are fully capable of
performing lightning impulse, switching impulse and front-ofwave tests as required.
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Induced Testing
For induced testing, a variable voltage alternator, rated
1500/1000 kVA, 3/1-phase, 170/240 Hz, is used. Voltage
control is by solid state automatic voltage regulator, and solid
state speed control of the 1000 kW DC driving motor. During
the induced test, partial discharge measurements both in pC and
V are taken and equipment is available to locate internal
partial discharges by the triangulation method.
Loss Measurement
Power is provided to the loss measuring system by a 5/10 MVA
regulating transformer feeding three single-phase 10 MVA
variable ratio transformers and a 110 MVAR capacitor bank.
Losses are measured by an automated system using CTs for
current and gas capacitors for voltage. This system has a fully
automated digital readout and printer.
AC Testing
A test supply with an output voltage infinitely adjustable from
3-350 kV is available for high voltage AC testing. To measure
the applied voltage level, a digital peak-responding RMS
calibrated voltmeter capable of measuring up to 1600 kV is
used.
WATER TURBINE
A water turbine is a rotary engine that converts kinetic and
potential energy of water into mechanical work.
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THEORY OF OPERATION
Flowing water is directed on to the blades of a turbine runner,
creating a force on the blades. Since the runner is spinning, the
force acts through a distance (force acting through a distance is
the definition of work). In this way, energy is transferred from
the water flow to the turbine
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STEAM TURBINE
A steam turbine is a device which extracts thermal energy
from pressurized steam and uses it to do mechanical work on a
rotating output shaft. Its modern manifestation was invented by
Sir Charles Parsons in 1884.
Because the turbine generates rotary motion, it is particularly
suited to be used to drive an electrical generator about 90% of
all electricity generation in the United States (1996) is by use of
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blades may damage the thrust bearings for the turbine shaft. To
prevent this, along with controls and baffles in the boilers to
ensure high quality steam, condensate drains are installed in the
steam piping leading to the turbine.
Maintenance requirements of modern steam turbines are simple
and incur low costs (typically around $0.005 per kWh); their
operational life often exceeds 50 years.
LARGE ELECTRICAL MACHINES
The academic study of electric machines is the universal study
of electric motors and electric generators. By the classic
definition, electric machine is synonymous with electric motor
or electric generator, all of which are electromechanical energy
converters: converting electricity to mechanical power (i.e.,
electric motor) or mechanical power to electricity (i.e., electric
generator). The movement involved in the mechanical power
can be rotating or linear.
Although transformers do not contain any moving parts they
are also included in the family of electric machines because
they utilise electromagnetic phenomena.
CLASSIFICATIONS:
Permanent magnet machines:
PM machines have permanent magnets in the rotor which set
up a magnetic field. The magnetomotive force in a PM (caused
by orbiting electrons with aligned spin) is generally much
higher than what is possible in a copper coil. The copper coil
can, however, be filled with a ferromagnetic material, which
gives the coil much lower magnetic reluctance. Still the
magnetic field created by modern PMs (Neodymium magnets)
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57
Reluctance machines
Reluctance machines have no windings in rotor, only a
ferromagnetic material shaped so that "electromagnets" in
stator can "grab" the teeth in rotor and move it a little. The
electromagnets are then turned off, while another set of
electromagnets is turned on to move stator further. Another
name is step motor, and it is suited for low speed and accurate
position control. Reluctance machines can be supplied with
PMs in stator to improve performance. The electromagnet is
then turned of by sending a negative current in the coil.
When the current is positive the magnet and the current
cooperate to create a stronger magnetic field which will
58
TRACTION MOTOR
A traction motor is an electric motor used for propulsion of a
vehicle, such as an electric locomotive or electric roadway
vehicle.
Traction motors are used in electrically powered rail vehicles
such as electric multiple units and other electric vehicles such
as electric milk floats, elevators, conveyors, and trolleybuses,
as well as vehicles with electrical transmission systems such as
diesel-electric, electric hybrid vehicles, and battery electric
vehicles.
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Mounting of motors
Usually, the traction motor is three-point suspended between
the bogie frame and the driven axle; this is referred to as a
"nose-suspended traction motor". The problem with such an
arrangement is that a portion of the motor's weight is unsprung,
increasing unwanted forces on the track. In the case of the
famous Pennsylvania Railroad GG1, two bogie-mounted
motors drove each axle through a quill drive. The "Bi-Polar"
electric locomotives built by General Electric for the
Milwaukee Road had direct drive motors. The rotating shaft of
the motor was also the axle for the wheels. In the case of
French TGV power cars, a motor mounted to the power cars
frame drives each axle; a "tripod" drive allows a small amount
of flexibility in the drive train allowing the trucks bogies to
pivot. By mounting the relatively heavy traction motor directly
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for a little bit longer until the motor catches up. This can be
heard and felt in older DC trains as a series of clunks under the
floor, each accompanied by a jerk of acceleration as the torque
suddenly increases in response to the new surge of current.
When no resistors are left in the circuit, full line voltage is
applied directly to the motor. The train's speed remains constant
at the point where the torque of the motor, governed by the
effective voltage, equals the drag - sometimes referred to as
balancing speed.
Rating
Electric locomotives usually have a continuous and a one-hour
rating. The one-hour rating is the maximum power that the
motors can continuously develop over a one hour period
without overheating the motors. Such a test starts with the
motors at +25 C (and the outside air used for ventilation also
at +25 C). In the USSR per GOST 2582-72 with class N
insulation, the maximum temperatures allowed for DC motors
were 160 C for the armature, 180 C for the stator, and 105 C
for the collector.[3] The one-hour rating is typically about ten
percent higher than the continuous rating, and limited by the
temperature rise in the motor.
In diesel-electric and gas turbine-electric locomotives, the
horsepower rating of the traction motors is usually around 81%
that of the prime mover. This assumes that the electrical
generator converts 90% of the engine's output into electrical
energy and the traction motors convert 90% of this electrical
energy back into mechanical energy. Calculation: 90% 90% =
81%.
INSULATION
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up to 90 C
Class A
up to 105 C
Class E
up to 120 C
Class B
up to 130 C
Class F
up to 150 C
Class H
up to 180 C
Class C
180 C up to 220 C.
INSULATION TESTING
Insulation:The bar is insulated with the given number of layers to build the
wall thickness of insulation subjected to the generating voltage of
the machine.
Impregnation and baking:a) Thermo reactive system:63
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