[TYPE

THE
COMPAN
Y NAME]

VOCATIONAL TRAINING
REPORT ON TRANSFORMERS

BHARAT HEAVY ELECTRICALS

LIMITED

DURATION: 02-JUNE-16 TO 13-JULY-16

SUBMITTED
BY-

SUBMITTED TOMr. Sumit Kumar

SR. ENGINEER
(MM-MOD)
BHEL, BHOPAL

Ajay Kumar
Rai
B.Tech. 6th
Sem.
Dr. BR
Ambedkar
NIT Jalandhar

CERTIFICATE

This is to certify that Mr. Ajay Kumar Rai of VIth semester

B.Tech. Electrical engineering has successfully completed
her four week vocational training in Bharat Heavy
Electrical Limited, Bhopal in the duration from 02-06-16
to 13-07-16.

This training report is hereby approved for submission

towards partial fulfilment for the award of degree in BE
(Electrical Engineering) from

NATIONAL
JALANDHAR.

INSTITUTE

Mr . Sumit kumar
SR. ENGINEER (MM-MOD)
Bhel, Bhopal

DR. BR AMBEDKAR

OF

TECHNOLOGY

Acknowledgement
The extensive training program at BHARAT HEAVY
ELECTRICALS LIMITED (BHEL), Bhopal was a great
opportunity and an exceptional learning experience for
me. It is first hands on experience and an exposure of
practical world.

I got opportunity to work under the esteemed

supervision of MR. SUMIT KUMAR, SR. ENGINEER(MMMOD). It was great privilege for me to work under him. I
am thankful to him for his extremely patient gesture, to
make training program fruitful for me and for rendering
every possible help to carry out this research project. I
offer my gratitude to the management and staff that
have spent their precious time, expressed keen interest
and given continued encouragement throughout the
study and enabled the successful completion of my
practical at BHEL, Bhopal.

I am indebted to my parents, teachers and friends who

helped and encouraged me to work hard, move ahead
and inspired me with words. Their blessings made this
work possible.

INDEX
1)
2)
3)
4)
5)
6)

COMPANY OVERVIEW
PRODUCT PROFILE
BASIC KNOWLEDGE
BUSHING PROCESSING & ASSEMBLY
CAPACITOR VOLTAGE TRANSFORMER
MACHINE SHOP,TOOL ENGGINEERING &

DEVLOPMENT
SHOP
7)
VERTICAL WINDING MACHINE
8)
HORIZONTAL WINDING MACHINE
9)
CORE AND COIL ASSEMBLY
10) COOLING SYSTE
11) PROCESSING
12) ACCESSORIES
13) TESTING
14) MANUFACTURING FACILITIES
15) CONCLUSION

Company Overview

BHARAT HEAVY ELECTRICALS

LIMITED, BHOPAL

BHEL, BHOPAL is the mother plant of Bharat Heavy Electricals

Limited, the largest engineering and manufacturing enterprise
in India in the energy-related and infrastructure sector, today. It
is located at about 7 kms from Bhopal Railway station, about 5
kms from Habibganj Railway station and about 18 kms From
Raja Bhoj Airport. With technical assistance from Associated
Electricals (India) Ltd., a UK based company, it came into
existence on 29th of August, 1956. Pt. Jawaharlal Nehru, first
Prime minister of India dedicated this plant to the nation on 6th
of
November,1960.
BHEL, Bhopal with state-of-the-art facilities, manufactures wide
range of electrical equipments. Its product range includes
Hydro, Steam, Marine & Nuclear Turbines, Heat Exchangers,
Hydro & Turbo Generators, Transformers, Switchgears, Control
gears, Transportation Equipment, Capacitors, Bushings,
Electrical Motors, Rectifiers, Oil Drilling Ring Equipments and
Diesel Generating sets.

BHEL Bhopal's strength is it's employees. The company

continuously invests in Human Resources and pays utmost
attention to their needs. The plant's Township, well known for
its greenery is spread over an area of around 20 sq kms. and
provides all facilities to the residents like, parks, community
halls, library, shopping centers, banks, post offices etc. Besides,
free health services are extended to all the employees through
350 beddeg Equipments and Diesel Generating sets60 d
(inclusive of 50 floating beds) Kasturba Hospital and chain of
dispensaries.

Bharat Heavy Electricals Limited (BHEL)

BHEL is the largest engineering and manufacturing enterprise
in India in the energy-related/infrastructure sector, today. BHEL
was 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 well-recognized
track record of performance. The company has been earning
profits continuously since 1971-72 and paying dividends since
1976-77.

BHEL manufactures over 180 products under 30 major product

groups and caters to core sectors of the Indian Economy viz.,
Power Generation & Transmission, Industry, Transportation,
Telecommunication, Renewable Energy, etc. The wide network
of BHEL's 14 manufacturing divisions, four Power Sector
regional centres, over 100 project sites, eight service centres
and 18 regional offices, enables the Company to promptly serve
its customers and provide them with suitable products, systems
and services efficiently and at competitive prices. 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 acquired certifications to Quality Management

Systems (ISO 9001), Environmental Management Systems (ISO
14001) and Occupational Health & Safety Management
Systems
(OHSAS 18001) and is also well on its journey
towards Total Quality Management.
BHEL has Installed equipment for over 90,000 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,
Aluminium, 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:
1. Power
2. Industry- including Transmission, Transportation,
Telecommunication & Renewable Energy
3. 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 full fill the expectations of the country to become a global
player. The greatest strength of BHEL is its highly skilled and
committed 42,600 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.

BHEL, ranking among the major power plant equipment

suppliers in the world, is one of the largest exporters of
engineering products & services from India. Over the years,
BHEL has established its references in around 60 countries of
the world, ranging from the United States in the West to New
Zealand in the Far East.
BHEL's export range covers individual products to complete
Power Stations, Turnkey Contracts for Power Plants, EPC
Contracts, HV/EHV Sub-stations, O&M Services for familiar
technologies, Specialized after-market services like Residual
Life Assessment (RLA) studies and Retrofitting, Refurbishing &
Overhauling, and supplies to manufacturers & EPC contractors.
All these have engendered development of a committed and
motivated workforce setting new benchmarks in terms of
productivity, quality and responsiveness.

PRODUCT PROFILE:
With an export presence in more than 60 countries, BHEL is
truly Indias industrial ambassador to the world. This list is
intended as a general guide and does not represent all of
BHEL's products and systems.

Thermal Power Plants

Steam turbines and generators of up to 500MW capacity for
utility and combined-cycle applications; capability to
manufacture steam turbines with super critical steam cycle
parameters and matching generator up to 1000 MW unit size.

Gas based Power Plants

Gas turbines of up to 260MW (ISO) rating.
Gas turbine based co-generation and combined-cycle systems
for industry and utility applications.

Hydro Power Plants

Custom-built conventional hydro turbines of Kaplan, Francis
and Peloton types with matching generators, pump turbines
with matching motor-generators. Mini/micro hydro sets.

Spherical, butterfly and rotary valves and auxiliaries for hydro

station DG Power Plants
HSD, LDO, FO, LSHS, natural-gas/biogas based diesel power
plants, unit rating up to 20MW and voltage up to 11kV, for
emergency, peaking as well as base load operations on turnkey
basis.

Industrial Sets
Industrial turbo-sets of ratings from 1.5 to 120MW.

 Gas turbines land matching generators ranging from 3 to

260MW (ISO) rating.
Industrial stream turbines and gas turbines for drive
applications and co-generation applications.

Boilers and Auxiliaries

Steam generators for utilities, ranging from 30 to 500MW
capacity, using coal, lignite, oil, natural gas or a combination of
these fuels: capability to manufacture boilers with super critical
parameters up to 1000 MW unit size.

Steam generators for industrial applications, ranging from 40

to 450t/hour capacity using coal, natural gas, industrial gases,
biomass, lignite, oil, bagasse or a combination of these fuels.
Pulverized fuel fired boilers.
Stoker boilers.
Pressure vessels.

Heat Exchangers and Pressure Vessels

Air-cooled heat exchangers.
Surface condensers.
Steam jet air ejectors.
LPG/propane storage bullets.
Feed water heaters.

Power Station Control Equipment

Microprocessor-based distributed digital control systems.
Sub-station controls with SCADA.
Static excitation equipment/automatic voltage regulator.

 Electro-hydraulic governor control.

Turbine supervisory system and control.
Controls for electrostatic precipitators.
Controls for HP/LP bypass valves.

Switchgears
Switchgear of the various types for indoor and outdoor
applications and voltage ratings up to 400 kV.
Minimum oil circuit breakers (66K 132kV).
SF6 circuit breakers (132 kV 400 kV).
Vacuum circuit breakers (3.3 kV 33 kV).
Gas insulated switchgears (36 kV).

Transformers

Power transformers for voltage up to 400 kV.

HVDC transformers and reactors up to + 500 kV rating.

Series and shunt reactors of up to 400 kV rating.
Current transformers up to 400 kV.
Electro-magnetic voltage transformers up to 220 kV.
Capacitor voltage transformers up to 400 kV.
Special transformers,earthing,furnace, rectifier, electrostatic
precipitator; freight loco and AC EMU and traction transformers.

Insulators
Disc/suspension insulators for AC/DC applications, ranging
from 45 to 400 kn electro- mechanical strength, for clean and
pollute atmospheres.
Pin insulators of up to 33 kV.

BASIC KNOWLEDGE
Transformer

- A transformer is a static piece of apparatus

used for the transferring power from one circuit to the other
without change in frequency. It can raise or lower the voltage
with a corresponding decrease or increase in current.
Normal components of transformer are:
Primary winding
Secondary winding
Linkage of the two by Mutual Inductance

Capacitor

This
is
a passive two-terminal electrical
component used to store energy in an electric field. The forms
of practical capacitors vary widely, but all contain at least
two electrical conductors separated by a dielectric (insulator).
:-

Bushing:- This is a hollow insulating liner through which a

conductor
may
pass.
on switchgear, transformers, circuit
voltage equipment.

Bushings
breakers and

appear
other high

BUSHING PROCESSING &

ASSEMBLY
A bushing is a hollow insulating liner through which a
conductor
may
pass.
Bushings
appear
on switchgear, transformers, circuit breakers and other
high voltage equipment.
Bushings are often made of wet-process fired porcelain
and is often filled with oil (TRE158) to provide additional
insulation.
The inside of the bushing consists of paper insulation
either made with OIP or SRBP
Hollow bushing consist of alternate layers of aluminium
foil and insulated paper
For testing purpose one coil is taken out from 67 th layer &
another coil (earth coil) is taken out from 64th layer
The highest rated bushing made in BHEL is of 420 kv
For lower rated bushings earth coil is not used for testing

BUSHING WINDING
Bushing winding consist of alternate layers of
aluminium foil and insulated paper
Paper insulation used are of two types
Oil Impregnated paper(OIP)
Synthetic Resin Bounded Paper(SRBP)
OIP is in the form of coil whereas SRBP is full width
type insulation
OIP has less strength whereas SRBP has more
strength

CAPACITOR VOLTAGE
TRANSFORMER
CVT is a transformer used in power systems to step
down extra high voltage signals and provide a low
voltage signal, for measurement or to operate
a protective relay.
It consists of three parts: two capacitors across which
the transmission line signal is split, an inductive
element to tune the device to the line frequency, and
a transformer to isolate and further step down the
voltage for the instrumentation or protective relay
The tuning makes the overall division ratio less
sensitive to changes in the burden of the connected
metering or protection devices.
The device has at least four terminals: a terminal for
connection to the high voltage signal, a ground
terminal, and two secondary terminals which connect
to the instrumentation or protective relay
CVTs are typically single-phase devices used for
measuring voltages in excess of one hundred kilovolts
where the use of wound primary voltage transformers
would be uneconomical

In
practice,
capacitor
often

C1 is

constructed as a stack of smaller capacitors

connected in series. This provides a large voltage
drop across C1 and a relatively small voltage drop
across C2.

 CVT is also useful in communication systems

MACHINE SHOP,TOOL
ENGGINEERING & DEVLOPMENT
SHOP
This bay consist of machines for drilling, threading,
shapping etc
RADIAL DRILLING MACHINE is used for all functions such
as drilling, counter boring, spot facing, lapping, and
screwing reaming, tapping and boring. Radial drilling
machines work well with a variety of material such as cast
iron, steel, plastic etc.

RADIAL DRILLING MACHINE

MACHINE

SHAPER

SHAPPER MACHINE is used to machine surfaces. It can cut

curves, angles and many other shapes. It is a popular
machine in a workshop because its movement is very
simple although it can produce a variety of work.
LATHE MACHINE is a machine tool which rotates the
workpiece on its axis to perform various operations such
as cutting, sanding, knurling, drilling, or deformation with
tools that are applied to the workpiece to create an object
which has symmetry about an axis of rotation.

VERTICAL WINDING MACHINE

Vertical winding machine is used making high voltage
winding for transformer
High voltage winding has large number of turns & less
current
Disc coil are the best choice for the high voltage winding
where single disc can have higher number of turns
This coils are self supporting
Each disc is mechanically strong & exibits good withstand
of axial forces against short circuit
Each disc can have fractional or integral number of turns

HORIZONTAL WINDING MACHINE

Horizontal winding machine is used making low voltage
winding for transformer
Low voltage winding has less number of turns & high
current
To carry high current the area of cross section of
conductors will be large.This is accomplished by adopting
more number of parallel conductors per turns
Helical and spiral winding which is spring like is more
suitable for low voltage winding
Helical winding has radial ducts whereas spiral winding
has no radial ducts

CORE AND COIL ASSEMBLY

At this stage of manufacturing, the coil and the core are
brought and assembled together. The insulation system is so
designed that the terminal major insulation and internal coil
insulation are probably co-ordinated to minimise the effect of
surge voltages. Immediately after coil and core assembly,
preliminary ratio and resistance test are carried out before
doing further work on transformers.
Experimental investigations are sometimes carried out to
determine magnitude and nature of impulse stress which are
not distributed linearly along the legs as they are under power
frequency conditions. The voltages that would be appearing
between the various parts of winding under the surge
conditions are found out at this stage with the help of surge
oscilloscope.

COOLING SYSTEM
NATURAL AND AIR BLAST COOLING
Detachable radiators are used to provide adequate cooling
surface mounted directly on the tank side or Built up in one or
two bank placed adjacent to the transformer and connected to
it by pipe work. The radiator element is made from specially
treated sheet steel plates. Two rolled and pressed plates are
welded together along the outer edges and along the troughs
between flutes. A number of each element is welded into a mild
steel header.
For increased cooling, fans are provided beneath the radiators.
The fans are operated automatically when the winding reaches
a pre-set temperature by means of mercury switch contacts
provided in the winding temperature indicator .

WATER COOLING
The water cooler is usually of condenser type. Top oil is pumped
around a set of tubes through which cooling water circulates.
This type of cooling reduces the space requirement
considerably, and is recommended specially for generator
transformers where plenty of cooling water is available. To
prevent any possible leakage of water into the transformer oil,
oil pressure is always maintained higher than the circulating
water pressure.

FORCED OIL COOLING

Hot oil from the top of the tank is pumped into compact cooler
with built in fans, and returned to the tank at the bottom.
Alternatively a pump can be introduced to force the oil
circulation between the top and bottom main radiator headers (
where radiators are mounted in a separate bank).

PROCESSING
The quality of transformer, and consequently its performance
and life, depends essentially on the factor processing, which is
carried out at various stages of manufacturing.
All the coils are preshrink before assembly. After the coils are
assembled on the core, the whole assembly is heated in an
oven for extraction of moisture, and also the coils are reduced
to proper dimensions.
After final assembly, the core and coils are placed in their own
tanks, and the whole unit placed in a vacuum chamber for final
drying. The chamber is heated up to about 100 oC and a vacuum
of very high degree is maintained during dry out. Sometimes
vacuum drying is done by drawing vacuum in its own tank and
keeping the whole transformer inside the oven.
Besides this conventional method of drying, most modern
vapour phase drying method is used alternatively.

Much importance is attached to proper dry out, as otherwise

coils would become loose in service and may get distorted
under short circuit conditions.
The oil is treated separately in the filtering and degenerating
plant, and is kept constantly under vacuum at a temperature of
80oC, so that moisture free degassed oil is always available. Ten
thousand gallons of oil can be treated in the plant at a time. Oil
is tested for electrical strength, and moisture content before
the same is let in to the transformer. The oil impregnation of
winding insulation is also done under high vacuum conditions.
The dryness of insulation is measured in terms of insulation
resistance.

ACCESSORIES
OIL CONSERVATOR:All power transformers are invariably provided with an
expansion vessel called conservator. This is to take care of
changes in the oil volume due to change in ambient
temperature, or as consequences of changes in load on the
transformer. The oil level in conservator thus rises or falls,
results in a phenomenon called Breathing .
The conservator is fitted with an oil preservation system
calledAircell, which is a bag made of nitrile rubber and it floats
on the oil surface inside the conservator. The air cell inflates or
deflates as the oil level in the conservator falls or rises.

OIL LEVEL GUAGE:A magnetic oil level gauge is fitted to indicate oil level in the
conservator, float of which is always beneath the air cell. This
gauge is also provided with a switch which gives alarm when oil
level falls below the minimum oil level or when air cell is
damaged and sinks.

BREATHER:A breather is connected to the air cell and is used to dry the air
that enters in the air cell when the transformer breathes. The
breather contains an absorbent material like silica gel for
absorbing the moisture present in the atmospheric air. Air
entering the breather is first drawn through an oil seal at the
bottom, and passes upwards through the silica gel crystals to
the connecting pipe at the top of air cell.
During the upwards passage of air, any moisture present is
absorbed by the dry silica gelz. The oil seal at the bottom
ensures that the gel absorbs moisture only when the
transformer is breathing in.

TEMPERATURE INDICATOR:Each transformer is provided with dial type thermometers for

oil and winding temperature indication. The bulb is placed in an
oil filled pocket screwed into the transformer tank cover. The
pocket or the below for winding temperature indicator has a
heating coil around it.
The expansion of the liquid in the bulb is transmitted through a
capillary tube to an indicating instrument. The dial type
thermometer is also provided with mercury switches for alarm
and trip circuit operations in the event of excessive
temperature rise and also for operation of cooling fans and oil
pump motors of certain pre-set temperatures. A potentiometer
device can also be provided for remote temperature indication.

BUCHHOLZ RELAY:The oil and gas actuated relay serves as a protection against
any loss of oil, discharge inside the tank and intern short circuit
and insulation defects. Indications for the above faults are
available from this relay even when the fault current is too
small to operate the overcurrent and earth fault relay. This
device is usually mounted in the connecting pipe between the
highest point in the transformer and the oil conservator. The

device accommodates two floats, of which the upper float is

actuated by a build-up of gas and the lower float by a sudden
oil surge. The contacts for the first float normally give an alarm
signal and those of a second cause tripping. Gas sample can be
collected from the upper part of the device, and analysis of the
gas gives an indication as to the nature of fault.

MARSHALLING BOX:A weather proof marshalling box is fitted on the side of the
transformer tank or mounted separately. This accommodates
the oil and winding temperature indicators, starters, etc. for
various fan and pump motors, and terminal connectors from
various alarm and trip circuits provided in the transformer. A
heater is provided is provided inside the transformer in order to
avoid condensation.

PRESSURE RELIEF VALVE:This is a spring loaded safety valve mounted on the tank cover
for protection of the transformer in case of sudden over
pressure. Valve diaphragm is sealed against gaskets by springs.
Valve operation is effected when pressure inside the tank
exceeds opening pressure established by springs. The
transformer pressure is then rapidly reduced to normal valve
and spring returns the diaphragm to closed position.

CONTROL EQUIPMENTS:The tap changer can be provided with local electrical, remote
electrical
independent
and
remote
electrical
non
automatic/automatic parallel operation. Outdoor weather proof
kiosk for mounting of local electrical control equipment and
indoor control cubicle for the mounting of the remote control
equipment can also be supplied.

TESTING
Testing facility at BHEL works is well established for conducting
routine as well as type test as per international or Indian
standards. The test on transformer can in general be dividing
into following categories:
Test requiring sine wave voltage at variable frequencies:

No-load loss test and over potential test (with partial discharge
measurement) fall in this category. These tests require a large
sine wave generator. A short time rated 4 MVA generator
having a continuous rating of 2 MVA, with a frequency variation
from 25 to 180 hertz has been installed for this purpose. It may
be mentioned here, especially with regard to iron loss test, that
application of sine wave voltage is absolutely important to get
a form factor as close as possible.

Tests requiring power frequency voltage at full power for a

transformer under test:

Load loss test, impedance voltage measurement test and

temperature rise test fall in this category. For these tests, a
large power output at varying voltage is necessary, to enable
feed full copper and iron losses at the impedance voltage of the
transformer under test.

A 40 MVA motor generator set and a matching transformer

have been installed for this purpose, which can give full output
at voltages from 6 to 37 KV, thus enabling testing of even large
transformer at full load.
Test requiring
switching.

impulse

voltages

such

as

lightening

and

Special tests such as RIV, noise level, vibration, stress

measurement etc.

MANUFACTURING FACILITIES
SALIENT FEATURES:Slitting line for CRGO steel (width of roll 1100mm)
Hydraulic & pneumatic cropping line (lamination size-750mm)
CNC cropping line(lamination size-1050mm)
200T core building platform.
20T vertical winding machine.
16 T horizontal winding machine.
High frequency brazing machine.
300 T hydraulic press.
250 T crane lifting facilities.

CONCLUSION:During the Vocational Training in Transformer

Engineering Department at BHEL, Bhopal Studied about
the Design requirement for Power Transformer to meet
the Thermal & Hydro Power station rating(MVA) demand.
It is also involve the correct vision of manufacturing
stages of Transformer and its accessories.
It is also involve the overview of High voltage Testing
availability in india for High Rating Transformer.
(800KV,1200KV Class)