.

CONTENTS
1. An Introduction to BHEL, Bhopal

2. Switchgear, Control Gear and Rectifier Assy. 2.1 Switch Gear Assembly 2.2 Control Gear Assembly 2.3 Rectifier Assembly 2.4 On-Load Tap Changer Manufacturing 2.5 Electroplating

AN INTRODUCTION TO B.H.E.L.
BHARAT HEAVY ELECTRICALS LMITED was set up in Bhopal in August, 1956, with a view to reach self sufficiency in industrial products and power equipments. This plan was setup in collaboration with M/S AEJ, U.K. More plants were setup at Tiruchi, Hyderabad with Czechoslovakian and Soviet Union assistance in May 1956, Dec. 1965, and Jan. 1967 respectively. Today B.H.E.L. has become the largest engineering plant employing over 45000 employees. Its headquarter is located at New Delhi.

BHEL is the largest engineering and manufacturing enterprise in India in the energy-related/infrastructure sector, today. BHELwas established more than

40 years ago, ushering in the indigenous Heavy Electrical Equipment industry in India - a dream that has been more than realized with a wellrecognized track record of performance. The company has been earning profits continuously since 1971-72 and paying dividends since 1976-77.

The high level of quality & reliability of its products is due to the emphasis on design, engineering and manufacturing to international standards by acquiring and adapting some of the best technologies from leading companies in the world, together with technologies developed in its own R&D centres.

BHEL has: Installed equipment for over 1,00,000 MW of power generation- for Utilities, Captive and Industrial users.

Supplied over 2,25,000 MVA transformer capacity and other

equipment operating in Transmission & Distribution network up to 400 kV (AC & DC)

Supplied over 25,000 Motors with Drive Control System to Power projects, Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants, etc.

Supplied Traction electrics and AC/DC locos to power over 12,000 kms Railway network.

Supplied over one million Valves to Power Plants and other Industries.

BHEL's operations are organised around three business sectors, namely Power, Industry - including Transmission, Transportation and Renewable Energy - and Overseas Business. This enables BHEL to have a strong customer orientation, to be sensitive to his needs and respond quickly to the changes in the market.

BHEL's vision is to become a world-class engineering enterprise, committed to enhancing stakeholder value. The company is striving to give shape to its aspirations and fulfill the expectations of the country to become a global player.

The greatest strength of BHEL is its highly skilled and committed 45,505 employees. Every employee is given an equal opportunity to develop himself and grow in his career. Continuous training and retraining, career planning, a positive work culture and participative style of management all these have engendered development of a committed and motivated workforce setting new benchmarks in terms of productivity, quality and responsiveness.

B.H.E.L: AN OVERVIEW

(Birds Eye view of B.H.E.L., Bhopal)

BHEL is the largest engineering and manufacturing enterprise in India in the energy related/infrastructure sector today. BHEL was established more than 45 years ago when its first plant was set up in Bhopal ushering in the indigenous Heavy Electrical Equipment industry in India, a dream that has been more than realized with a well-recognized track record of performance. The Companys inherent financial strengths can be seen from its net worth, Debt Equity ratio and cash surplus. The Companys cash surplus

stood over Rs 38,55,806 crore cash surplus as on 31st March 2010. The Debt Equity ratio of the Company is at 0%.

BHEL caters to core sector of Indian economy viz. Power Generation and Transmission, Industry, Transportation, Telecommunication, Renewal energy defense etc. The wide network of BHEL 's, 14 manufacturing divisions, 4 Power sector regional centers, 8 service centers ,18 regional office and a large numbers of project sites spread all over India and abroad enable the company to promptly serve its customer and provide them with suitable products, system and services at competitive prices.

BHEL has already attained ISO 9000 and all the major units/divisions of BHEL have been upgraded to the latest ISO-9001: 2000 version quality standard certification for quality management. All the major units/divisions of BHEL have been awarded ISO-14001 certification for environmental management systems and OHSAS-18001

certification for occupational health and safety management systems.

POWER SECTOR: Generation: Power sector comprises of thermal, nuclear and hydro power plant business. Today BHEL supplied sets account for nearly 6473 MW or 68% of the total installed capacity of 99146 MW in company as against nil in 1969-70.

TRANSMISSION: BHEL also provides a wide range of transmission products and systems of upto 400 KV class. These include high voltage power and distributed transformer , capacitor, insulator etc. for economic transmission of bulk power over long distances High voltage Direct Current (HVDC) sys tems are supplied.

INDUSTRY SECTOR: BHEL is a major contributor of equipment and systems to industries like cement, fertilizers, refinery, petrochemicals, etc.

TRANSPORTATION: Most of the trains operated by the India Railways including Metro in Kolkata are equipped with BHELs traction control equipment.

TELECOMMUNICATION: BHEL also caters to the telecommunication sector by way of small, medium and large switching systems.

RENEWABLE ENERGY: Technologies that can be offered by BHEL for its exploiting nonconventional and renewable sources of energy include: wind-electric generator, solar power based water pumps, lighting and heating systems.

INTERNATIONAL OPERATIONS: BHEL has over the years, established its reference in over 60

countries worldwide, ranging from the USA to New Zealand in the far east.

NATIONAL CUSTOMERS OF BHEL: PUNJAB STATE ELECTRICITY BOARD(PSEB) UTTAR PRADESH STATE ELECTRICITY BOARD(UPSEB) NATIONAL THERMAL POWER CORPORATION(NTPC) APPOLO TYRES BAKCO SAIL BIRLA TYRES AND BIRLA CEMENT GRASIM INDUSTRIES IOC ESSAR OIL ONGC NATIONAL CUSTOMERS OF BHEL(CONTD.): LARSEN AND TURBO JK CEMENT KIRLOSKAR

SIEMENS, etc.

INTERNATIONAL CUSTOMERS OF BHEL:

 M/S ESBARA CORPORATION, JAPAN M/S ZEECO IN CORPORATION, USA SIMMCO INTERNATIONAL SIEMENS, GERMANY SIEMENS, SINGAPORE BIEJI PROJECT, IRAQ LMZ, RUSSIA, etc.

TECHNOLOGICAL UPGRADATION AND RESEARCH & DEVELOPMENT: To remain competitive and meet customers' expectations, BHEL lays great emphasis on the continuous upgradation of products and related technologies, and development of new products. BHEL's commitment to advancement of technology is reflected in its involvement in the development of futuristic technologies like fuel cells and superconducting generators.

BHEL's investment in R&D is amongst the largest in the corporate sector in India. During the year 2010-11, BHEL invested Rs.10,050 Million on R&D

efforts- 21% higher than the previous year.

HUMAN RESOURCE DEVELOPMENT: BHEL's Human Resource Development Institute (HRDI) has skills in the areas of Management training, Research, Consultancy, Organizational Development and Manpower Planning. Over the years, the institute has acquired proficiency in imparting training to professionals in the field of Strategic management, Contract management, Marketing management, Project management, Human Resource management, Activity based costing, Performance management, Emotional Intelligence, Values Laboratory, Human-process Laboratory, Leadership Development, Team Building, Trainer Development, and other functional and behavioral areas of management.

B.H.E.L. OBJECTIVES:

Switch Gears, Control Gears and Rectifiers

The 4th Block of B.H.E.L, Bhopal is the Switch Gear, Control Gear and Rectifier Manufacturing division or it is more conveniently known as the SWM division. In the block, the following devices are manufactured:
1. 2. 3. 4.

Tap Changer (OLTC) Switch Gear Panel(Indoor and Outdoor) Traction Gear Assy. Fabrication Shop

Bay-1,2 Bay-3,4 Bay-5 Bay-6 Bay-7 Bay-8 Bay-1,2

5. Control Gear Panel 6. Rectifier Manufacturing 7. Machine Shop 8. Electroplating

A brief sescription of the manufacturing processes of the above mentiones items is given below:

1.

THE SWITCHGEAR:
INTRODUCTION: The term switchgear, used in association with the electric power system, or grid, refers to the combination of electrical disconnects, fuses and/or circuit breakers used to isolate

electrical equipment. Switchgear is used both to de-energize equipment to allow work to be done and to clear faults downstream. LOCATION: Switchgear is located anywhere where isolation and protection may be required. These locations include generators, motors, transformers and substations.

Substations: Typically, switchgear in substations is located on both the high voltage and the low voltage side of large power transformers. The switchgear located on the low voltage side of the transformers in distribution type substations, now are typically located in what is called a Power Distribution Center (PDC). Inside this building are typically smaller, mediumvoltage (~15kV) circuit breakers feeding the distribution system. Also contained inside these Power Control Centers are various relays, meters, and other communication equipment allowing for intelligent control of the substation.

Housing: Switchgear for low voltages may be entirely enclosed within a building. For transmission levels of voltage (high voltages over 66 kV), often switchgear will be mounted outdoors and insulated by air, though this requires a large amount of space. Gas insulated switchgear used for transmission-level voltages saves space compared with air-insulated equipment, although it has a higher equipment cost. Oil insulated switchgear presents an oil spill hazard.

A piece of switchgear may be a simple open-air isolator switch or it may be insulated by some other substance. An effective although more costly form of switchgear is gas insulated switchgear (GIS), where the conductors and contacts are insulated by pressurized sulfur hexaflouride gas (SF6). Other common types are oil or vacuum insulated switchgear.

FUNCTIONS: One of the main basic functions of switchgear is protection: discrimination between circuit breakers enhances availibility, that is to say continuity of service. The overall approach is termed coordination: the standars provide a framework for discriminationand cascading that protects the integrity of the power system and minimises the scope of downward outafes. Protecton is needed along high degree of reliability for system operations. A power system has to be protected from fauls such as overloads, undervoltage, overvoltage etc. so we need switching devices for the making and breaking of the circuit.

RANGE OF SWITCHGEAR PRODUCTS MANUFACTURED AT B.H.E.L.

S. No. 1.

Discription Metal enclosed indoor vacuum circuit breaker switch board

Type VM12

Rating Upto 12kV, 3000 amp, 44 kamp

Applications Power stations and process industry aux. Distribution duty(width 700mm)

2.

Metal enclosed indoor vacuum circuit breaker switch board Outdoor metal enclosed VCB switch board Metal clad

BVM12

Upto 12 kV, 1250 amp, 26.3 kamp

Distribution duty(width 550 mm)

3.

VMN12

Upto 12 kV, 1600 amp, 25 kamp 24kV/36

Distribution duty

4.

VM24/36

Distribution duty

indoor VCB switchboard 5. Outdoor structure mounted porcelain clad VCB PVN12A

kV, upto 2500 amp, 25 kamp 12 kV, Distribution duty upto 1250 (the circuit amp, 25 breakers can be kamp provided with outdoor relay panel, outdoor structure mounted instrument transformer and isolator). Suitable for 8MVAR/capacitor switching 36 kV, Distribution duty upto 2000 (the circuit amp, 25 breakers can be kamp provided with outdoor relay panel, outdoor structure mounted instrument transformer and isolator)Suitable for 44 MVAR/ capacitor bank switching. 12 kV, 400 Auto reclosing

6.

Outdoor structure mounted porcelain clad VCB

PVN36

7.

Outdoor pole

PMVN

mounted auto recloser with microprocess or based control 8. Outdoor pole mounted vacuum type capacitor switch PMVC

amp, 12.5 unattended rural kamp feeders built in CT and aux. trasformer is provided. 12 kV, 200 amp, 6 kamp Swtching of capacitors. The switch is provided with electronic control unit for switching command based on the load currents.Built in aux. transformer and CT provided.

9.

Outdoor pole mounted vacuum auto sectionaliser Outdoor porcelain clad VCB Outdoor porcelain clad VCB Indoor metal clad SF6 gas

PMVS

12 kV, 400 Sectionalinzing amp of faulty feeders

10.

PVTI

25 kV, 800 amp, 8 kamp 25 kV, upto 1600 amp,20 kamp 36 kV, upto 1600

Traction substation duty Traction substation duty

11.

PVTB

12.

GVM36

Distributin duty

insulated vacuum swithcgear 13. Outdoor metal clad skid mounted switchgear Outdoor metal clad kiosk Spark Gap MVM12

amp,25 kamp Upto 12 kV, 1250 amp, 25 kamp

(width 650 mm)

Electric distribution substations for open cast mines

14.

VN12

12 kV, Distribution duty 1250 amp, 25 kamp 220 kV, 3, 50 Hz., STC 31.5 kamp Series Compensation

15.

SG

SWITCHGEAR APPLICATION RATED VOLTAGE FAULT LEVEL:

TYPE VM BVM VN12 PVN12 VN36 PVN36 INDOOR INDOOR OUTDOOR OUTDOOR OUTDOOR OUTDOOR kV 7.2/ 12 7.2/ 12 12 12 36 36 kA 25/31.5/40/44 18.4 18.4/31.5 18.4/25 25 25 Current, Amp(rated) 630/800/1250/1600/2000/2500 630/800/1250 630/800/1250/1600 630/800/1250 630/800/1250 630/1250

11 kV SWITCHGEAR ASSEMBLY: In a power system SWGR serves two purposes: For switching during normal conditions for maintenance For switchig during faulty conditions for protection

Switchgear is a modified form of MCB(Miniature Circuit Breaker) which is used for higher voltages. The 11 kV assembly is used for indoor purposes. It has a fixed and a moving contact. It has the following chambers: Breaker Chamber: It is the main part of the SWGR where the circuit makes and breaks. It has a moving portion called Truck. The mechanism used for the operation of VCB has a universal D.C. motor, limiting switches for operation, position indicators etc. Instrument Chamber: It consists of controlling devices. It is a low voltage chamber having relays, fuses etc. CT Chamber: 3 Current Transformers are used to measure current. Busbar Chamber: It is welded sheet steel construction and covers busbars of aluminium or copper electroplated with silver.

(An assembly of Switch gears)

OPERATION: When the coil is dischargerd, the limiting switch becomes ON. This switch conducts current to universal motor and it starts operating. The spring is charged by the motor. When we have to close the breaker, we push the close button, the spring disharges with force and gives motion to shaft, lever and drive link. This makes contact with fixed and moving contacts of the breaker. The movement charger the tripping spring and contact pressure springs are charged. The recharging of closing spring is done as above in a similar manner.

INDOOR METAL CLAD VACUUM CIRCUIT BREAKER(TYPE VM12): 12 kV indoor metal clad vacuum switchgear type VM12 withg maximum fault breaking capacity of 44 kV is ideal for installation in power stations, industries and other electrical networks for switching of power supplies to the auxillaries. It can also be deployed in the design of panels and clearances has been established for system voltages from 3.3 kV to 12 kV.

VACUUM CIRCUIT BREAKERS FROM B.H.E.L.:

(Outdoor VCB type PVN-11/36 kV)

B.H.E.L started manufacturing oil and air-blast circuit breakers during early sixties and since then the firm has continued its ceaseless search for new know-how and technology through its own R&D programme and to suppliment its effortsin this direction, BHEL has entered into collaboration with the worlds reputed manufacturers- AEI, ASEA, BBC and Siemens. BHEL has supplied more than 25000 switchgears, in the volatge range up to 36 kV and there are in operation all over the country. Keeping pace in the latest in the field is a regular policy of BHEL, the first VCB designed and developed indigenously was successfully tyoe tested at Kema, Netherlands way back in

1979. Due to various inherent advantages of the VCB, the technology has been accepted all over the world. In 1981-82, BHEL entered into collaboration with M/S Siemens, West Germany , for the manufacturing of 3AF gesign of the VCB. BHEL since then introduced a wide range of vacuum switchgears for indoor as well as outdoor applications in medium voltage range. Extensive testing and certification test at Cenral Power Researc Institute(CPRI), Bhpal and BHELs Ultra High Voltage(UHV) testing laboratory proved the accuracy and ruggedness of these designs. Special tests lie Seismic tests at Universty of Roorkee and motor switching test at IIT, Bombay and in house, qualify the switchgear for special applications. The 3AF technology from Siemens has been with our long and unmatched experience in the switchgear field and this has resulted in a wide variety of new products for complex market needs.

WHY VACUUM CIRCUIT BREAKERS ARE THE BEST CHOICE: Freedom from oil, gases eliminate the arcing and fire hazards. Sealed for life design of vacuum interrupters make the vacuum interrupters and the VCBs practically maintenance free. Low arc energy and arcing time results in very long contact life. Rapid dielectricrecovery requirementsresult in quite and low vibration operations. Reduced number of components impart simplicity to the operating mechanism. No change in contact resistance because of contact pressure applied. The very low contact resistance remains practically

constant regardless of number of switching operations carried out. Furthermore, the fact that contacts cannot oxidize in vacuum ensures that they remain metallically clean even after years of operation No capital cost on maintenance accessories. Switching in vacuum does not produce any by-products. The hermetically sealed vacuum ensures that there is no interaction with the environment and this results in a sutable dielectric medium Conventional sealing arrangement has been dispensed with. All the sealing joints are brazed by a special technique tus evolig leak free interrupters. Vast operational experience gained couples with strict quality control measure make the VCB the right choice for all switching duties.

ARC QUENCHING: When the contacts separate, the currents to be interrupted initiate a metal vapour arc discharge and flows through its plasma until the current reduces to zero. The arc is then extinguished and the conductive metal vapour condenses on the metal surface within a matter of microseconds. As a result, the dielectric strength in the breaker builds up very rapidly. The metal vapour arc discharge can only be maintained if a certain minimum current flows. A current that does not attain this level is chopped off prior to current zero. The chopping current is kept to a minimum between 4 to 5 amps in order to prevent unduly high voltages building up when inductive circuits are switched with the special contact material. The contacts are so designed that the self generated field makes the arc not to remain stationary and it keeps moving. This

prevents the contact from local overheating when interrupting large currents. VCBs need not have separate main and arcing contacts. Contact errosion is low, because of short contact stroke, low arc voltage and short arcing time. Contact resistance remains low and there is no chemical reaction on the contact surface. Extremely high number of switching operations are possible. A contact material of copper and chromium used in vacuum interrupters lowers the maximum chopping current value, as compared to pure copper. The distribution of chopping current obtained from copper chromium represents a compromise between sufficiently low chopping currents and high breaking currents. VCBs using low chop vacuum interrupters are capable of switching out motors under normal load or no load condition without producing any significant over voltages. VCBs need much less mechanical energy as compared to other conventional breakers. This is because of two salient reasons. Firstly, the arc quenching in vacuum does not require any mechanical energy at all, the reason being that no quenching medium flow needs to be produced. Secondly, low contact stroke, from 6 to 20 mm compared to 175-225mm for oil. This fact has resulted in design of simple spring mechanism with high reliability. The operating mechanism of the VCB is of modular design. The manual, motor wound spring mechanism is of the stored energy type. In the closed state of the breaker, the closing spring can perform 0-0.3 sec operation. The closing spring of the motor mechanism is automatically recharged after a closing operation within 15 sec. Manual charging of the closed spring is possible in vent of supply failure. The operating mechanism is designed to match the life of the interrupter. Maintenance free 30,000 operations are guaranteed.

RELIABILITY THROUGH QUALITY PROGRAMME: A very high reliabilty of VCB is ensured through kit quality programme enveloping the activities, starting from conception to execution milestones. Following the meticulous checks at each stage to ensure a high quality has been made an integral part of all design and manufacturing activities. Routine and type tests verify the high reliability of VCBs. VCBs have been subjected to a wide variety of tests covering practically all the severe duties likely to be imposed during service. Short time current tests Short circuit making and breaking tests High voltage tests Temperature rise tests Mechanical endurance tests Low inductive current tests Capacitor switching tests Auto enclose duty tests Seismic test Motor switching tests

Special switching and voltage tests carried out with loss of vacuum, temperature rise on eroded contacts and arc behavioural studies during faults inside the cubicle have generated immense data to back the operational reliability.

AVAILABILITY: The simplicity in the design and the operation and high degree of reliability makes the vacuum circuit breakers trouble free. With neglible failure rate these breakers have minimum outage tume when in service. Maintenance is now a thing of the past. VCBs are maintenance free for most of their life. With proper selection of vacuum interrupter capability to interrupt the rated operation current 30,000 times and the rated breaking current times is possible. A continuous operation of VCB is ensured because the operating mechanism need only be lubricated after 10 years or 10,000 mechanical operations. The life of the operating mechanism is 60,000 mechanical operations. VCBs not only last longer but also cost less in operation. Maintenance is very easy to carry out.

SAFETY: With no fire hazers and low mechanical energy requirements, VCBs are the safest to operate. No oil or gas keeps the operation area clean.

SALIENT FEATURES: Conforms to IS-14118/3427 and iec-56/298/694 Metal-clad, horizontally drawable, dust and verin proof Extensible, modular construction

 Ceramicinterrupter for better electrical and mechanical properties. Low chopping current possible with special contact materials High reliability Fully tropicalised modern insulating system Optimum mechanical stability and uniform distribution of electromagnetic forces Fully interlocked for operational safety Test psition of VCB truck within house, door locking possible in this condition High dielectric grade heat shrinkable busbar sleeves

DETAILS OF TYPE SWITCHGEAR VM12: Technical Data Type VM12 Rated voltage upto 12 kV Rated normal upto 25 kamp Rated STC-3 sec upto 44 kamp rms Rated short circuit breaking (symm) upto 44 kamp rms

Rated breaks time 80+5 msec

Rated closing time 75+5 msec Mechanical 30,000 operations At load current 20000-30000 At full short circuit current 30-100 operations depending upon current

33 kV SWITCHGEAR ASSEMBLY: A 33 kV assembly is used for the same purpose as the 11 kV SWGR. It is used for outdoor applications and only constructional differences are there.

The construction is divided into five parts: Interrupter Chamber Interrupter Housing Mechanism Housing Support Structure Earth Stud

Interrupter Chamber or Housing pole Assembly: This chamber consists of VCB coveredby insulator. Top and middle of chamber contains two conducting plates which works as inputand output and ouput of SWGR. The whole part is supprted

over insulator. It has a fixed rod and insulated moving rod for closing and opening operations.

Interphase Housing: Three individual pole assemblies are mounted on common base frame. It has interphase shaft supported on bearing bracjets at both sides to which insulated pull rods of all the three poles are connected to spring charging mechanism.

Mechanical Housing: It has necessary equipments for operating the VCB. It has motor charged spring, trip and closing mechanism, auxillary switch, terminal blocks and secondary wiring, push buttons for local operation, manual spring discharge, indicator are provided in weather proof housing.

Support Structure: It supports stucture supports all assembly used for switching and protecting.

Earth Stud: It is used to earth the whole equipment. Modes of operation: Charging spring with circuit breaker in open condition. Closing operation

 Opening operation Manual operation for spring charging Rated Voltage Rated normal current Rated power frequency withstand voltage Rated lightening withstand impulse voltage Rated Short circuit breaking Rated short time withstand Duration Rated short circuit making current kV A kV kVP 36 1250/160 0 70 170

kAm 25 p kAm 25/40 p sec 3/1 kAm 63/100 p

2.

THE CONTROLGEAR

(A GENERATOR CONTROL PANEL)

The controlgear assembly is used for the control over equipments. Various control panels are made in BHEL, Bhopal. Some of them are: Remote tap changer and control panel(RTCC) for both single and three phase. Line Control panel Relay Control panel

The RTCC panel consists of: Tap position indicator Alarm annunciator Indicator for: Out of step Tap change in process Tap changer control supply on Switches for: Tap position lower Tap position raise

 Sequence selector Switch for OFF Alarm for: Out of step Fault Alarm The above instrument is used in single phase panel. In a three pahse panel, some more instruments are used: Voltmeter HV side IV side LV side

Switch for: Cooler control isolator Voltmeter switches for HV, IV, LV side Auto/Manual control selector Automatic voltage regulator Indicator for Fan running Pump running Switch for lamp test

Line control panel consists of: Alarm annunciator Current Indicator Voltage Indicator Active Power Indicator Reactive Power Indicator Switches as: Alarm silence PBS Alarm accept PBA Alarm reset PBR Alarm Test PBT

Switches for isolators and indicators.

(A PARALLEL CONTROL PANEL)

3.

THE RECTIFIER

(6-PULSE RECTIFIER UNIT)

The Rectifier manufacturing department deals with products as displayed below:

PRODUCT PROFILE: Plant Industrial Controls Electronic controllers for electrostatic precipitators(60-80kV, 250-1600 mA) Large current rectifiers (upto 90 kAmp, 300 -900 V) G40, electrohydraulic governer (upto 165MW) Compact automatic voltage regulator with power factor controls(1.4 MW to 6 MW)

Automatic Voltage Regulator(1.4 MW to 60MW)

Static excitation equipment(1.4 MW to 60 MW)

Oil Rig control E-3000 AC SCR RIG (drilling upto 10 km)

E-2000 AC SCR RIG (drilling upto 6 km) E-1400 AC SCR RIG (drilling upto 4.5 km) E-700 AC SCR RIG (drilling upto 3 km)

Traction Controls Diesel electric locos 700 hp to 3600 hp Pressurized control cubicles for export Pressurized control cubicles for Indian Railways E-type excitation controls Voltage Regulators Power Rectifiers(100 kV, 4000 Amp) Electric locomotives 5000 hp control cubicles Dynamic braking resistor (4 MW) Power rectifiers(1100 V, 5500 amp) Master controllers Reversr

Power contractor

DEMU 700 HP to 1400 HP Electronic load control module Switcg group and controls Drivers desk METRO/EMU- 25 kV Microprocessor based TCCU Camshaft controller

Switch group

Static Invertor upto 180 kVA and 300 kVA 25 kVA force cooled for AC coaches 25 kVA natural cooled for ac coaches 3*100 kVA force cooled on board for 3-phase loco EMU-3- AC/DC, 25 kV/1500 V Power convertor GTO based Aux. convetor(20 kVA, 50 kVA)

Control Gear equipment

Plant and Industrial Contro Group

Excitation equipment Digital static excitation equipment: Excitation control equipment is the equipment providing excitation power, regulation, control and protection for a synchronous machine. The primary function of the equipment is to provide eld current. Equally important is the regulation, control and protection aspects of a modern excitation system. These functions are accomplished automatically by appropriate changes in the level of machine excitation. A modern excitation system not only maintains steady-state response but also maintains continuity of service during a severe power system disturbance or equipment malfunctionthat would threaten to damage thegenerating unit or system. The voltage regulator and excitationsystem functions to control the output of an ac generator or synchronous motor by varying the machines eld voltage. Voltage regulation is accomplished by control of thyristor power ampliers. The excitation may be controlled either manually by a base or dc regulator adjuster or automatically by the ac voltage regulator in response to the generator terminal voltage. The system may be congured to provide var or power factor control instead of terminal voltage regulation.

Automatic Voltage Regulator: The automatic voltage regulator or AVR, as the name implies, is a device intended to regulate voltage automatically: that is to take a varying voltage level and turn it into a constant voltage level. There is tremendous diversity in the size and type of devices that could qualify to be called an automatic voltage regulator. To get a sense of the degree of diversity among AVRs, consider an analogy

about the term spotlight which can mean pixel-sized all solid state elements found in display devices to truck-mounted, power guzzlers to illuminate the night sky. AVRs range in size from small ones that can be mounted on printed circuit boards to those the size of a small house. This discussion looks at automatic voltage regulators typical for AC applications of about 1,000 VA (roughly the requirement of a handheld hair dryer) and larger. The diversity of automatic voltage regulators in size and design is reflected in the tremendous variety of names for AVRs: Ferroresonant transformer Constant voltage transformer Ferro CVT Ferroresonant voltage regulator Constant voltage regulator Mechanical tap changing regulator Electromechanical voltage regulator Tap changer Electromechanical voltage stabilizer Tap-switching voltage regulator Motorized variable transformer Servo voltage regulator Magnetic induction voltage regulator Servo voltage stabilizer

 Magnetic induction voltage stabilizer

Motorized variac Motor-driven variable autotransformer Variable autotransformer Line voltage regulator Line drop compensator On load tap changer LDC OLTC Step voltage regulator Electronic tap switching voltage regulator Auto-boost regulator Double conversion electronic voltage regulator Electronic voltage regulator

Excitation Control Product Range: Compact AVR(for LT generators) MOD compact AVR with power factor controller AVR type VXB22M AVR type VXB32M AVR type VXD12 for warship generators

 Static excitation equipment(analog) Digital AVR Digital Static Excitation equipment

LARGE CURRENT RECTIFIER:

(TRANSFORMER RECTIFIER UNIT)

The two basic units consisting of a regulating transformer , one or two rectifier transformers having configuration of double star with IPT or 3-phase bridge connection, transducers having variable voltage characteristics or one or two rectifier cubicle. The voltage range required for starting and controlling the output of the process is obtained with the help of transducer in conjunction with an on-load tap changer mounted on regulating transformer. The

large current is obtained by power diodes connected in parallel on a heat sink for

each phase. The heat sinks are either forced air cooled or forced demineralized water cooled depanding on rating and application. The equipment comprises of an assembly of silicon diodes on heat sink together with protection components , all suitably enclosed and a separately mounted transformer. Additional items such as inter connections, control cubicles, switchgear, AC/DC measuring system, AC/DC busbars are included to specification, when required. For large current applications above 25 kamp, important advantages are gained by mounting the rectifier assembly in close association, with the trnsformaer known as rectiformer. The choice of connection depends upon the DC voltage required, efficiency and cost considerations.

DIFFERENT CONNECTIONS: 3-phase bridge(6-pulse): The double way connection gives a rectification with a 120 degree conduction angle . This is most commonly used for industrial power supply. Double Star(6-pulse): With this connection 6-phase secondary windings are separated into two opposite star groups, the neutral points of which are connected through an interphase transformer. The voltage equalizing effect of the IPT enables the two star groups to share the currents and 120- degree conduction occurs.

12 pulse circuit: For 12 pulse working, two 6- pulse rectifier circuits, two equipments, or two groups of equipment to be phase shifted by 30 degrees from each other. This is usually achieved by having star-delta primaries. N very large installations, pulse numbers greater than 12 can be obtained by suitable phase shifting a number of 6/12 pulse rectifiers.

INDUSTRIAL CONTROL PRODUCT RANGE: Electronic controller for electrostatic precipitators (60-80 kV, 250-1600 mA) Large current rectifier Forced air cooled type 22 kamp, 100 V dc Water cooled type 120 kamp, 200 V dc

E.M.U.(Electrical Multiple Units): The EMUs are classified broadly under the following categories: AC EMU(Broad gauge and meter gauge) DC EMU(Broad gauge)

DEMU(Broad gauge and meter gauge)

Metro Rail

The AC EMUs are powered by 25 kV ac traction line, DC EMU is powered by 1500 V DC traction line(in Bombay region only), DEMU is powered by diesel engines, metro ril is powered by 750 V dc.

A multiple unit traction train is more commonly known as local passenger train. Each unit of a multiple unit consists of 1 power unit + 2-3 trailer units resulting in a 3-4 coach formation. When more coaches are requires then another set of power unit + trailer coaches are added. The simultaneous operations of the power coaches are trailer coaches gives the name multiple units.

OIL RIG CONTROL: SCR devices provides controlled rectification hence a fixed voltage AC supply is converted into variable voltage DC supply. By applying this variable voltage to a DC motor armature.

THE ON-LOAD TAP CHANGER:

(On-Load Tap Changer for transformer)

The type-M OLTC are used to vary the ratio of oil immersed transformer under load. It comprises of a divertor switch and tap selector. To make the output voltage constant, tap changers are used. OLTCs have the following parts:

Motor drive unit: All parts of the motor drive unit operate at 110 V except the motor shaft which operates at 415 V. This unit contains limiter switches for operating motor, transformer, switches for trippeng, raising, lowering of tap disc counter for indicating the tap position, manual operating shaft for tap changing, MCB etc

Selector and Divertor: Divertor and Selector select the tap position for and lowering of tap. The divertor is installed into a pressure tight oil chamber or compartment separated from transformer oil and tap selector mounted below it. Oil Chamber: This contains oil at high pressure and divertor is dipped into it.

Drive Shaft and Bevel Gear: The square driving shaft is a mechanical connection between the motor drive and the tap changer head. The bevel gear connects the vertical and horizontal parts of the shaft above.

(Dry Vacuum OLTC)

Precautions that have to be taken while using OLTC: After the process the tap changer must not be operated without oil.

Do not operate the motor drive until the divertor switch is properly inserted and the drive shaft is coupled.

Ensure same position position on load tap changer and motor drive before coupling.

The rotational lag is to be equalized during commissioning i.e. difference in raise/lower rotation of hand crank up to red

mark after diverter switch operation should not be more than 2 rotations. For lubrication of control gear, limit switch level transmission ger and position gear grease gem EP2 or equivalent to be used.

ELECTROPLATING:
Electroplating is a plating process in which metal ions in a solution are moved by an electric field to coat an electrode. The process uses electrical current to reduce cations of a desired material from a solution and coat a conductive object with a thin layer of the material, such as a metal. Electroplating is primarily used for depositing a layer of material to bestow a desired property (e.g., abrasion and wear resistance, corrosion protection, lubricity, aesthetic qualities, etc.) to a surface that otherwise lacks that property. Another application uses electroplating to build up thickness on undersized parts.

TYPES OF ELECTROPLATING: According to the polarity of charge: Anodic Cathodic

A general process carried out in plant: Loading Knock of degreasing Degreasing Water rinse Water rinse Activation Phosphate Water rinse Water rinse De-ionised water rinse E coat Permeate rinse Permeate rinse De-ionised water rinse Oven

A Flow chart of electroplating is shown below:

RAW PART LOADING

ACID CLEANING

ETCHING

ELECTROLESS PLATING

COPPER PLATING

NICKEL PLATING

CHROME PLATING

DRYING

UNLOADING