BHARAT HEAVY ELECTRICALS

LIMITED JHANSI

PROJECT REPORT ON

TYPES OF TRANSFORMER MANUFACTURED IN BHEL

JHANSI

SUBMITTED TO: UNDER GUIDANCE OF:

Dr. Mohammad Aftab Alam Mr. Prabhat Katiyar
DEPUTY MANAGER DEPUTY MANAGER
HRD DEPARTMENT BAY-9
BHEL JHANSI BHEL JHANSI

COORDINATOR: SUBMITTED BY:

Mr. Ashok Agnihotri SAKSHI SINGH
HRDC B. tech Electrical Engineering
BHEL JHANSI B.I.E.T JHANSI
ACKNOWLEDGMENT
I am highly thankful and indebted to B.H.E.L. engineers and technical staff for
providing me vital and valuable information about the different facts of an
industrial management system and their respective departments thus helping
me to gain an overall idea about the working of organization.
I am also thankful to Mr. PRABHAT KATIYAR(Sr. Engineer) for giving his precious
time and help me in understanding various theoretical and practical aspects of
power transformer. I also convey my special thanks to all senior executives and
members of BHEL, Jhansi.

I would like to thank my parents who have been a constant source of

encouragement & inspiration during my studies & have always provided me
support in every walk of life.
PREFACE
At very outset of the prologue it becomes imperative to insist that vocational
training is an integral part of engineering curriculum. Training allows us to gain
an insight into the practical aspects of the various topics, with which we come
across while pursuing our B. Tech i.e. Summer training gives us practical
implementation of various topics we already have learned and will learn in near
future. Summer training always emphasizes on logic and common sense instead
of theoretical aspects of subject.
On my part, I pursue four weeks training at B.H.E.L. Jhansi. The training involved
a study of various departments of the organization as per the time logically
scheduled and well planned given to me.
The rotation in various departments was necessary in order to get an overall
idea about the working of the organization.
TABLE OF CONTENT
S. NO TITLE
1. About BHEL Jhansi
ROTATIONAL REPORT
2. STORE
3. FABRICATION
4. BAY-3
5. BAY-4
6. BAY-5
7. BAY-6
8. BAY-7
9. BAY-8
10. BAY-9
11. TRANSFORMER ENGINEERING
12. TECHNOLOGY
13. TRANSFORMER COMMERCIAL
14. LOCOMOTIVE PRODUCTION
15. LOCOMOTIVE MANUFACTURING
16. LOCOMOTIVE COMMERCIAL
17. CENTRAL QUALITY SERVICE
18. TESTING
19. WORK ENGINEERING AND SERVICE
REPORT ON TYPE OF TRANSFORMER
MANUFACTURED IN BHEL JHANSI
20. TRANSFORMER
21. POWER TRANSFORMER
22. CAST RESIN DRY TYPE TRANSFORMER
23. RECTIFIER TRANSFORMER
24. INSTRUMENT TRANSFORMER
25. ESP TRANSFORMER
26. TRACTION TRANSFORMER
ROTATIONAL
REPORT
BHARAT HEAVY ELECTRICALS LIMITED
JHANSI
A BRIEF INTRODUCTION
By the end of the fifth year plan, it was envisaged by the planning
commission that the demand for the power transformer would raise in the
coming years. Anticipating the country’s requirement, in 1974, BHEL
started a new plant in Jhansi which would manufacture power and other
type of transformer in addition to the capacity available at BHEL in
Bhopal. The Bhopal plant was engaged in the manufacture transformers
of large rating and Jhansi unit would concentrate on power transformers,
instrument transformers, traction transformers for railway etc.

This unit of Jhansi was established around 14 km from the city on the
N.H. No 26 on Jhansi Lalitpur road. It is called second-generation plant
of BHEL set up in 1974 at an estimated cost of Rs 16.22 crores inclusive
of Rs 2.1 crores for township. Its foundation was laid by late Mrs. Indira
Gandhi the prime minister on 9 th Jan. 1974. The commercial production
of the unit began in 1976-77 with an output of Rs 53 lacs since then there
has been no looking back for BHEL Jhansi

The plant of BHEL is equipped with most modern manufacturing

processing and testing facilities for the manufacture of power, special
transformer and instrument transformer, Diesel shunting locomotives and
AC/DC locomotives. The layout of the plant is well streamlined to enable
smooth material flow from the raw material stages to the finished goods.
All the feeder bays have been laid perpendicular to the main assembly
bay and in each feeder bay raw material smoothly gets converted to sub
assemblies, which after inspection are sent to main assembly bay.
The raw material that are produced for manufacture are used only after
thorough material testing in the testing lab and with strict quality checks
at various stages of productions. This unit of BHEL is basically engaged
in the production and manufacturing of various types of transformers and
capacities with the growing competition in the transformer section, in
1985-86 it under took the re-powering of DESL, but it took the complete
year for the manufacturing to begin. In 1987-88, BHEL has progressed a
step further in under taking the production of AC locomotives, and
subsequently it manufacturing AC/DC locomotives also.
PRODUCT PROFILE OF B.H.E.L., JHANSI
 MAIN AIM OF ROTATION
Main aim behind the rotation of various departments is that one can understand the working of
each and every department and to see that how people (workers, middle level executives, top
officials) work incorporate environment.
Main departments of BHEL Jhansi are
 Production
 Administration

PRODUCTION UNIT DEPARTMENTS

1. STORE :
It is one of the prime departments of material management department.
There are separate stores for different type of material in the BHEL.
There are three sections in store:
 Control Receiving Section
 Custody Section
 Scrap Disposal Section

Function: Whatever material coming from anywhere as ordered by the purchase

department first comes to central store. The supervisor looks upon all documents and
decide whether material is to be unloaded at central store or at shop directly. A list of
material coming in store is prepared and Quality Control people are called for
inspection. If material is found as per standard, SRV (Store Receipt Voucher) is
issued for each material. A total of 08 SRV’s are prepared. If material is accepted, it is
shifted to custody stores i.e. storing agency. If rejected, material is shifted to rejection
store and vendor is informed either to replace material or to collect it. Some materials
like Silicon oil, Transformer oil, insulating material etc. are directly stored in the
Bays. Scraps are also sold through unit by a MATERIAL SCRAP TRADING –
DELHI.

2. FABRICATION :

Fabrication is nothing but production. This shop deals with the manufacturing of
transformer and locomotive components such as tanks, plates and nuts & bolts. It
comprises of three bays i.e. Bay 0, Bay 1 and Bay 2.
 A. Bay 0 :

This is the preparation shop where according to the required drawings, the cutting
of different components of different materials is done. This section has the
following machines:
 Planer machine – It is used to reduce thickness.
 Cutting machine --
o CNC/ANC Flame cutting machine – To cut complicated shaft using Oxy-
Acetylene flame. This is fully computerized. The figure is loaded into a
computer attached to machine and flame thus cuts figure accordingly.
o Pantograph flame cutting machine.
o PUG cutting
 Shearing machine- This machine is used for metal sheet. Cutting range is 2mm to
6mm. Suitable materials for use are Al, Standard steel and Cu. It cuts material just like
a scissor.
 Bending machine- It is hydraulically operated. Pressure gauge is used to the pressure
applied. Stopping mechanism is used by screw to prevent the collapsing the ram blade
with bending grooves (Die). It consists of a ramp (tool) for up-down motion and the
item is leveled on it.
 Rolling machine- It is used to reduce the roll thickness. The roller material used is
High Carbon Steel. It consists of 3 rollers. The upper roller is fixed whereas below 2
rollers are used for up-down motion.
 Flattening machine-It is used to straighten or to flattening the job using power
hammer.
 Radial Drilling machine- In this machine, tool can move radically. In this cutting oil
mixed with water is used to cool the drill tool is used as the material to be drilled.
Different drill tools are used from 2mm to 100mm dia.
 Nibbling machine- Used for straight cutting, circle cutting, nibbling, circular and
square punching.
 Plano milling machine
 Plasma cutting machine- Used for non-ferrous metals.
 Hydraulic guillotine shear- used to cut the sheet which has maximum cross-sectional
area (3200*13 sq. mm).
 Pacific hydraulic shear &pressure- hydraulically operated machine to cut the sheet
of different thickness.
 Hydraulic power press- has the capacity of 100 tones and used for flattening the
objects.
 Butler machine- for facing, taping and shot cutting.
 B. BAY 1 :
It is an assembly shop where different parts of tank come from bay 0. Here
welding processes are used for assembly, after which a rough surface is obtained
which is eliminated by Grinder operating at 1200 rpm.

C. BAY 2 :

It is also assembly shop dealing with making different object mentioned below:

 Tank assembly
 Tank cover assembly
 End frame assembly.
 Foot assembly.
 Cross feed assembly.
 Core clamp assembly.
 Pin and pad assembly.

The various process of assembly are fitting, welding and testing.

Fitting- In this section, different components are fit according to the drawing requirements.
Welding- In this section , welding of the different components of different drawings by
permanent joints is done.
Testing- When the tank for transformers is completed, then we check the leakage tests on the
tanks. There are two types of leakage tests, which we have to perform on the transformer.
 AT(Air leakage test)- In this, tank is filled by compress compressed air and dip the tank
in the shop solution for bubble test.
 VT(Deflection test)

Shot blasting-It is firing of small materials with the high pressure of 7 kg i.e. acid picking. It
is done on different parts of jobs for removing carbon layer from its surface before painting.
Painting- After shot blasting, the tank is painted for corrosion resistant.
After assembly some tests known as NONDESTRUCTIVE TESTS are carried out. They are:
 Ultrasonic Tests: To detect the welding fault on the CRO at the fault place high
amplitude waves are obtained.
 Die Penetration Tests: Red solution is put at the welding & then cleaned. After some
time white solution is put. Appearance of a red spot indicates a fault at the welding.
 Magnetic Crack Detection: Magnetic field is created & then iron powder is put at the
welding. Sticking of the iron powder in the welding indicated as a fault.
 X-Ray Test-It is same as human testing and fault is seen in X-ray film.

3. TRM BAY – 3 :
It is split in two parts, half consists of machine shop and the other half consists of winding of
dry type transformer.
Here are basically three sections:
1. Machine Section.
2. Copper Section.
3. Tooling Section.

a. MACHINE SECTION :
The operations to form small components of Power & Traction Transformers are done in
section. The shop consists of following machines:
1. Lathe machine
 Central lathe machine- It consist one tailstock, headstock low part of tailstock is fixed
& tailstock spindle is moving. On this machine facing, turning & threading is done. It
is used for light work and its range is 20mm to 200mm.
 Turret lathe-Its function is same as central lathe but it is used for mass production.
Here turret lathe is used in presence of tailstock because turret lathe contains many
tailstocks. It is used for heavy duty and its range is 250mm to 300 mm.
 Capstone lathe-It is belt drive. Used for light work and its range is 20mm to 150mm.

2. Radial arm drilling machine-It is used for drilling & boring.

3. Horizontal boring machine-It is computerized and used for making bore, facing etc.
4. Milling machine:
 Horizontal milling machine – It is used for making gear and cutting operations.
 Vertical milling machine – By this machine facing, cutting & T slot cutting is done
5.Grinder:
 Tool cutter grinder- Used for cutting tools and also grind them.
 Hydraulic surface grinder- It consist of magnetic platform. Cooling oils are used as
coolant.
 Vertical grinder machine-Used for grinding purpose.
6. Hydraulic power press- Used for straightening the material. The capacity of this machine
is 25 tons.
7. Resistance brazing machine- used for overlap connections.
8. Bend saw machine- Bit is used for cutting circular object. In this machine blade width is
inch and thickness is ¾ inch.
9. Electric furnace-Used for heating the object.
10. Hydraulic punching machine-Used for making small pieces of material for desire
purpose. Range of this machine is 12mm to 250mm.
11. Hydraulic shearing machine-Used for cutting the material in range between 12mm to
25mm.

b. COPPER SECTION :
This part is only with copper cutting, bending, tinning etc. Machine used are as listed below.

Tube slitting machine-This machine is developed here & is used for cutting the tube along its
length & across its diameter. Its blade thickness is 3 mm.
Shearing machine-It is operated hydraulically & its blade has V-shape & a thickness of 15
mm.

Die and punching machine-It is also hydraulically operated & has a die & punch for making
holes.

Hydraulic bending machine-It is used for bending job up to 90 degree.

Fly press machine- It is used to press the job. It is operated mechanically by a wheel, which
is on the top of the machine.

Bend saw machine -This machine is used for cutting job having small thickness. It is
circularly operated blade, around 1.5 m long.

Water cooled brazing machine-It contain two carbon brushes. The sheet is put along with a
sulfas sheet & the carbon brushes are heated. A lap joint is formed between the sheets as the
sulfas sheet melts.

Linking belt machine- It creates a smooth surfaces.

Hydraulic press machine-To press the job.

Solder pot machine-It has a pot that contains solder. Solder has a composition of 60% Zn &
40% Pb.

c. TOOLING SECTION:
In this section the servicing of tools is done.
Blade shape machine-It sharpens the blade using a circular diamond cutter. Blade of CNC,
cropping line machine is sharpened here.
Mini surface grinder machine-It serves grinding purposes. It has a grinding wheel made of
Aluminium Oxide.
Tool & surface grinding machine-This is specially used to grind the tool used in Bay 7.
Drill grinding machine-To grind the drills.

4. TRM BAY 4 :
It is the power transformer winding section.

TYPES OF WINDING
1) Reverse section winding.
2) Helical winding
3) Spiral winding.
4) Interleaved winding.
5) Half Section winding
There are four types of coils fixed in a transformer.
1) Low voltage coil (LV)
2) High voltage coil (HV)
3) Tertiary coil.
4) Tap coil.

The type of winding depends on job requirement also the width and thickness of the conductors
are designed particulars & are decided by design department. Conductors used for winding is
in the form of very long strips wound on a spool, the conductor is covered by cellulose paper
for insulation.
For winding, first the mould of diameter equal to inner diameter of required coil is made. The
specifications of coils are given in drawing. The diameter of is adjustable as its body is made
up of wooden sections that interlock with each other. Interlocking can be increased or decreased
to adjust the inner diameter of coil.
The Moulds are of following types:
1. Belly types.
2. Link types.
3. Cone types.

5. TRM BAY 5 :
It is core and punch section. The lamination used in power, dry, ESP transformer etc. for
making core is cut in this section.

CRGO (Cold rolled grain oriented) silicon steel is used for lamination, which is imported in
India from Japan, Korea, U.K. or Germany. It is available in 0.27 & 0.28 mm thick sheets, 1 m
wide & measured in Kg. The sheets are coated with very thin layer of insulating material called
“carlites” to avoid short circuiting.
Core is the basic requirements of transformer in this bay various type of lamination of core is
made, they are:
a) Side leg- this lamination is at the extreme ends of the core which stand vertical. They
are isosceles trapezium in shape with angle of 45 o.
b) Central leg- This as the name suggests is central vertical portion of the core. It is a
diamond shaped with vertical edges longer. At the narrower edge one side is kept longer
than the other for making a well fixed joint; the angles are kept 45 0.
c) Yoke- The horizontal lamination of the core is called yoke. They are also isosceles
trapezium in shape with angles of 45 0.

For the purpose of cutting & punching the core three machines are installed in shop.
1. Slitting machine: It is used to cut CRGO sheets in different width. It has a circular
cutter whose position can be changed as per the requirement.
2. CNC cropping line pneumatic: It contains only one blade, which can rotate 90 degree
about the sheet. It is operated pneumatically.
 CNC cropping line hydraulic: It is all so used to cut the CRGO Sheet. It contains
two blades, one is fixed and the other rotates 90 degree above the sheet. It is operated
hydraulically. M4 quality sheet 0.23-0.33 mm thickness is used

Core
Transformer
CRGO sheet

6. TRM BAY 6 :
4 different types of Transformers are manufactured in this section :
i. 3-phase Freight loco Traction Transformer
ii. 1-phase Freight loco Traction Transformer
iii. 3-phase ACEMU
iv. 1-phase ACEMU

Single – traction transformer for AC locomotives is assembled in this section. These Freight
locomotive transformers are used where there is frequent change in speed. They are basically
used in locomotives. In this bay core winding & all the assembly & testing of transformer is
done.
These three phase transformer for ACEMU are also manufactured in this section. The supply
lines for this transformer are of 25 KV & power of the transformer is 6500 KVA.

The tap changer of rectifier transformer is also assembled in this bay. Rectified transformer is
used in big furnace like the thermal power stations/plants (TPP).

7. TRM BAY 7 :
This is the insulation shop. Various types of insulation which are to be used in
transformers are prepared in this bay.

MATERIALS USED:
 1) AWWW: All Wood Water Washed press paper The paper is 0.2-0.5 mm thick
cellulose paper & is wound on the conductors for insulation.
2) Pre-compressed board: This is widely used for general insulation & separation of
conductors in the forms of block.
3) Press board: This is used for separation of coils e.g. L.V. from H.V. It is up to 38
mm thick.
4) UDEL: Undemnified Electrical Laminated Wood or Perm wood. This is special type
of plywood made for insulation purposes.
5) Fiber glass: This is a resin material & is used in fire prone areas (Used in DTT)
6) Bakelite: Size 4mm to 25 mm.
7) Gasket: It is used for protection against leakage.
8) Silicon rubber: It is used for dry type transformer.
9) Perma wood: Size 4mm to 25mm.
10) N.B.C. (Naporeniom Bonded Cork) sheets: Size 3mm, 6mm 10mm and 12mm.

The machine used for shaping the insulation material are-

1) Cylindrical machines.
2) Circle cutting machine- Used for cutting the circular objects
3) Scarping machine (used for taper cutting) & Lines in machines (to remove burrs).
4)Punching Press and Drilling machine.
5) Bench saw (specially for OD)
6) Jig saw (specially for ID)
7) Circular saw
8) Rolling machines-Used to roll the press board.

8. TRM BAY 8 :
Basically two types of transformers are assembled in this bay:
1) Electrostatic Precipitator (ESP)
2) Instrument Transformers
a) Current Transformer (CT) up to 400kV class.
b) Electromotive Voltage Transformer (EMVT) up to 220kV class.

INSTRUMENT TRANSFORMER:
These are used for measurement. Actual measurement is done by measuring instruments but
these transformers serve the purpose of stepping down the voltage to protect the measuring
instrument. They are used in AC system for measurement of current voltage and energy and
can also be used for measuring power factor, frequency and for indication of synchronism.
They find application in protection of power system and for the operation of over voltage,
over current, earth fault and various other types of relays.
In power lines current & voltage handled is very large & therefore direct measurement are not
possible as these current & voltage are for too large for any other of reasonable size & cost.
The solution lies in steeping down the current & voltage with instrument transformers that
would be mattered with instruments of moderate size. The transformers are also used for
protective purpose.
Body:
 The main body is a bushing which also acts as insulators in which the winding is placed.
 It has a top and bottom chamber.
 The top chamber is the cylindrical tank of mild steel. It has terminals for connection of
HV coils.

a) Current transformer: It is a step down transformer. The body is divided in to three

parts – top chamber, bushing, bottom chamber. Top chamber is the cylindrical tank of
mild steel. It has terminal for connection of HV coil. It also has oil window to indicate
the oil level. Below it is bushing which houses the winding and also act as insulator. It
has several folds or rain sheds to provide specific electric field distribution and long
leakage path. Some bushings are cylindrical while modern ones are conical, as the
amount of oil porcelain used is reduced without any undesirable effects. Bottom
chamber houses the secondary winding. There is also a connection box to which the
connection of low voltage coil is made.

b) Voltage Transformer: It is also an step down transformer and outer construction is same
as that of CT. the difference is only in winding.

ESP TRANSFORMER:
The Electrostatic Precipitator transformer is used for environmental application. It is used to
filter in a suspended charge particle in the waste gases of an industry. They are of particular
use in thermal power stations and the ash is used in cement industry.
The ESP is a single-phase transformer. It has a primary and secondary. The core is laminated
and is made up of CRGOS. It is a step up transformer. An AC reactor is connected in series
with primary coil. The output of the transformer must be DC this is obtained by rectifying AC
using a bridge rectifier (bridge rectifier is a combination of several hundred diodes). A radio
frequency choke (RF choke) is connected in series with the DC output for the protection of the
secondary circuit and filter circuit. The output is chosen negative because the particles are
positively charged. The DC output from the secondary is given to a set of plates (electrodes)
arrange one after the others. Impurity particles being positively charged stick to these plates,
which can be jerked off. For this a network of plates has to be setup all across the plant. This
is very costly process in comparison with the transformer cost. A relive vent is also provided
to prevent the transformer from bursting it higher pressure develops, inside it. It is the weakest
point in the transformer body. An oil temperature indicator and the secondary supply spark
detector are also provided.
One side of the transformer output is taken and other side has a ‘marshalling box’ which is the
control box of the transformer.
ESP is of two types.
 1. Si oil type.
2. Transformer oil type.

It is also known as Rectifier Transformer as it converts AC into DC.

9. TRM BAY 9:
In this bay, power transformers are assembled. After taking input from different bays 0-8,
assemblies are done.
Power Transformer is used to step up & step down voltages at generating & sub-stations.
There are various ratings 11 KV, 22 KV etc. manufactured, they are:
a) Generator Transformer
b) System Transformer
c) Auto Transformer

A transformer in a process of assemblage is called a job. The design of the transformer is done
by the design department & is unique for each job; depends on the requirement of customer.
The design department provides drawing to the assembly shop, which assembles it accordingly.
The steps involved in assembly are:
A. Core Building: It is made of cold rolled grain oriented steel CRGO. The punch core is
sent to this shop from core punching shop. Here it is assembled with the help of drawing
a set of 4 laminations is called a packet. The vertical portion of a core is called a leg.
The horizontal one is caller a yoke. Packets of both are interlinked. It is undesirable to
keep the X section of core circular to provide low reluctance part without air space. A
perfect circle cannot be made so the core is steeped to achieve a near circle. Wherever
the spaces are left, are fitted with thin wooden rod. After core building the end frames
are bolted. The bolts are insulated from the core.
B. Core Lifting: The core is lifted by a crane & is placed vertical. The rest of the assembly
is done on the core in this portion.
C. Unlacing & Core Coil Assembly: The yoke of this core is removed using crane.
Bottom insulation in form of 50 mm thick UDEL sheets is placed. PCB & press board
are also used for filling the gap & to provide a good base for the coil to rest. The coil
are then lowered primary, secondary, tertiary & tap in that sequences.
The following tests are done during relacing:
Megger test
Ratio test
High voltage
Testing at this stage is called pre-testing.

D. Replacing & End-frame mounting: After lowering a coil the top insulation similar to
the bottom one is provided. The removed yoke is placed end-frame bolted back into its
position. The connections are then made as per drawing. All the conductors are
insulated using crepe paper. Brazing copper makes the connections. For brazing sulfas
is used.

E. H.V.T.G. & L.V.T.G.: Terminals gears are accessories provided at high voltage and
low voltage. Main device used is tap changer. Tap changers can be on-load or off-load.
 In off-load type the supply has to be tripped, then the tapings changes but in on-load
type the tapings can be changed while the supply. .The upper portion of the OLTC
contains mechanism by which tapping is changed .There is switch which changes tap
in very small time (Microseconds). But there is a possibility of sparking. To get rid of
it, OLTC is filled with oil. The bottom part houses the terminals and the mechanism,
which makes automatic connections. The terminals are made of thick Al strops.
F. Vapour Phasing & Oil Soaking: It is well known fact that water (impure) is a good
conductor electricity. Therefore, moisture presence in transformer will affect
insulation; the process of moisture removal from transformer is called vapour phasing.
The job is put in dummy tank and place in a vacuum vessel. It is an airtight chamber
with heating facilities. A solvent vessel is released is the chamber which enters all
transformer parts and insulations. It absorbs water rapidly. The job is heated in
vacuum. All the solvent vapour is sucked out with moisture and if not taken care of,
may burst the job.
After moisture removal tank is filled with transformer oil & soaked for at least three
hours, so that every part gets wet with oil.
The job remains in vessel for three days during phasing. It is then taken out of the vessel
& also out of the dummy tank.

G. Final Servicing & Tanking: After taking the job out of dummy tank all the parts
retightened any other defects are rectified and the job is retimed in mild steel tank. After
this the tanking oil is filled.

H. Case Fitting: The accessories are fixed and final touches given the job. The accessories
included tank cover, fixing bushing, fixing valves etc. The terminals are marked and R
and D (rating and diagram) plate is fixed by bolting and not riveting because it may
require maintenance while opening and closing the tank. The bottom chamber is mild
steel tank with a steel frame attached to its base for earthing.

10. TRE (TRANSFORMER ENGINEERING):

The transformers manufactured in BHEL Jhansi range from the 100MVA to 315MVA and up
to 400kV.The various transformers manufactured in this unit are:
Power Transformer
 Generation transformer
 System transformer
 Auto transformer

Special Transformer
 Freight loco transformer
 ESP transformer
 Dry Type Transformer

All above types are oil cooled except dry type, which is air cooled.
The designing of all these transformers is done by the TRE department according to the
specifications of the customers’ i.e.
1. The input/output voltage.
 2. The KVA rating.
3.The weight of iron and copper.
The basic design factors are:
1. The amount of copper and iron losses.
2.The rise in temperature of coils.
3.The ambient condition.

The designer has to keep rise between the design factors and selects the optimization of the
core yoke winding etc.
Functioning of TRE
a) Tendering/Submission of offer with EFC
i. Study of customer specifications
ii. Designing
iii. Preparation of material sheet
iv. EFC(Estimated Factory Cost)
v. Guaranteed technical particulars with tender drawings
vi. Type test reports of similar equipments
vii. Deviation/clarification etc.
b) Contract execution
i. Designing
ii. Electrical Specification
iii. Guaranteed technical particulars*
iv. Testing schedule*
v. Customer Drawings*
vi. Components Drawings etc.
vii. Indenting of Materials
viii. Manufacturing information to shops
ix. Shipping instruction for transportation
*Approval required from customer

Basically there are 4 sections of the TRE department :

a. Estimation
b. Tendering
c. Design
d. Drawing Office
The Estimation section calculates all ratings related to power transformer , number of jobs to
be prepared ,etc. As per the customer requirement , Tendering section decides materials
required and estimates the cost involved in manufacturing. Using T146 software for power
transformer actual designing takes place considering actual amount of material and scrap.
The designing of core windings, type of tank assembly, etc. all work under guidelines. The
drawing office section issues all drawings of related customer demand are issued to various
shops and accordingly final product is made.
 11. TECHNOLOGY:
This department analysis the changes taking place in the world and suggest changes and
upgrades accordingly. This section mainly deals with continuous modification in the operations
to be performed for the completion of the job. It gets the PSR (Performa of Specification &
routine Sheet) from PPC.
This is very important department because the product must not get obsolete in the market
otherwise they will be rejected by the customer.
This section gives the sequence of operations, time for operations, no. of labors etc., according
to the given standards; it can be modify the above things to obtain best results.

FUNCTIONS:
Technology functions can be classified as:
 Processing Sequence: The sequence of process of manufacturing is decided for timely
and economic completion of the job.
 Operation Time Estimate: It includes incentive scheme management.
 Allowed Operation Time: It includes incentive amount.
 Facilities Identification: It includes looking for new equipment or plant or tools to
increase productivity.
 Special Process Certification: special processes are the ones requiring expertise for
example identifying errors, cracks, air bubbles in the welding.
 Special Tools Requirement: special tools are allotted, if possible, when required else
the design has to be reconsidered.
 Productivity Projects compilation: It includes the initial analysis of the problem and
their appropriate solution to enhance productivity

Recently it has modified the operation of crimping in which it advised the use of tungsten
carbide thus reducing the work time to three hours instead of 27 hours with HSS; this also
relieved the workers from maintenance of different dies for different jobs.
The principle of working is that
“IF YOU DO NOT MAKE THE CHANGES IN YOUR COMPANY, THE
CUSTOMER WILL CHANGE YOU”.

BUS DUCT :

Bus ducts are conductors for high power application. They are used in power connections
over 150 MW. The bus ducts consist of a mild steel casing and Aluminium conductors held
within the casing with electro-porcelain insulators. The bus ducts are installed with hot air
blowing fans to keep the conductors moisture free at the time of operation. Two types of bus
ducts are manufactured:
 Segregated Bus Ducts (SBD)
 Isolated Bus Ducts (IBD)

In segregated bus ducts , one casing is divided into three chambers through which Aluminium
conductors for three phases pass.
In isolated bus ducts, each phase is provided with its own casing. The bus ducts also have
cubicles in which circuits and controls are installed.
The mild steel casings of bus ducts are mostly procured as pre-fabricated items. Aluminium
bars are also main raw material for the manufacturing of bus ducts.

12. TRC (TRANSFORMER COMMERCIAL):

The objective of this department is to interact with the customers. It brings out tenders &
notices & also responds to them. It is department that places the contracts of building the
transformers & after delivery further interacts with the customer regarding faults, this
department does failure & maintenance. All such snags are reported to them & they forward
the information to the concerning department.
The works of the commercial department are:
 Tenders and Notices.
 Interaction with design department
 Place of work
 Approximate cost of work
 Earnest money
 Place and time where document can be seen.
 Amount if any to be paid for such document.

Tenders and notices: The department response to the tenders calls of

companies/organization, which requires transformers. Contracts are bagged through
also notices. Before inviting tenders it must be sure that BHEL is ready to undertake
the contract and before full knowledge of scope of work is essential.
The main functioning of this department is divided in 3 parts :
a) Tendering
b) Execution
c) Closing
The Tendering section bring orders from different sectors of market viz power sector,
industry sector, etc. After bringing of order it comes under execution section which
ensures timely delivery of order. The contract execution group ensures to fulfill all the
terms on which they have agreed with the customer. At last , contract closing group
measures performance. Also meetings with customer are conducted and bank guarantee
and money for completing job is asked from customer.

LOCOMOTIVE DEPARTMENT

This unit was started in 1985.

A locomotive is a rail vehicle that provides the motive power for a train.
“LOCO” means from a place.
“MOTIVE” means causing motion.
A locomotive has no payload capacity of its own. It is used to move a train.
This department of Jhansi consists of two sections the first is manufacturing & other is
design. The diesel, AC, AC/DC locomotives are manufactured here.

1. THE DIESEL LOCOMOTIVE:

Salient features:
a) Flat bed under frame.
b)All pneumatic valves provides in single panel.
c)All electrical Equipments provided in single panel.
d)Improved filtration system.
e)Brush less traction alternators.
f)Fault display on control desk with alarm.
g)Simple driving procedure.
h)Automatic wheel slip detection & correction.
i)Multiple unit operation up to three locomotives.
j)Air & vacuum brakes.

2. THE AC LOCOMOTIVE
Salient features:
a)Operate on 25 KV AC Single-phase lines.
b)Driving cab at both ends.
c)Corridors on both sides for maintenance.
d)All pneumatic valves at one place.
e)Automatic wheel slip detection & correction.
f)Multiple unit operation up to three locomotives.
g)Fault display on driver’s desk.
h)VCB in AC circuit.
i)Air & Vacuum brakes.

3. THE AC/DC LOCOMOTIVE

Salient features:
a) Designed to operate both in 1500 V DC & 25 KV AC lines.
b) Driving cab at both ends.
c) High adhesion bogie.
d) Corridors on both sides for maintenance.
e) All pneumatic valves at one place.
f) Automatic wheel slip detection & correction.
g) Multiple unit operation up to three locomotives.
h) Fault display on driver’s desk.
i) Static inverter for auxiliary supply.
j) FRP control desk.
k) VCB in AC circuit.
l) Air & Vacuum brakes.
m) Air dryer for brake system.

13. LOCOMOTIVE PRODUCTION (LMP):

There are following products are manufactured at Loco shops
 Alternating Current Locomotive (ac Loco)
  WAG-5H
 AC./D.C. Loco
 WCAM-2P
 WCAM-3

W-broad gauge A-running in AC mode

C-running in DC mode G-hauling goods train
P-hauling passenger train M-hauling passenger& goods train
 Diesel Electric Locomotive Shunting (DESL)
 350 HP
 700 HP
 Single Power Pack (SPP): One 700 HP m/c is made as a single
 Unit. It is a meter gauge locomotive
 Twin Power Pack (TPP): 2 350HP m/cs are combined in 1 engine & can be operated
individually or in combination depending on the load.
 450 HP
 1400 HP
 1150 HP
 1350 HP
 2600 HP
 1150 HP and 1350 HP DESL s are non-standard locomotives and are modified
versions of 1400 HP DESL based on requirement of customer.

Under mention are the new non-conventional products designed and developed for Indian
Railways based on their requirement.

 OHE (Overhead electric) recording and testing cars

 UTV(Utility vehicle )
 RRV(Rail cum road vehicle)
 DETV( Diesel electric tower car)
  BPRV(Battery power road vehicle)
 BCM(Blast cleaning machine)
 200 T Well wagon for BHEL Haridwar
 Metro Rake-Kolkata Metro Railways

14. LMM (LOCOMOTIVE MANUFACTURING):

This section deals with manufacturing of locomotives. The main parts of the
locomotive are -
 Under frame: The frame on which a locomotive is built
 Super structure: The body of locomotive is called superstructure or Shell and is made
of sheet of Mild steel
 DC motor
 Alternator
 Compressor: When air pressure is 5kg/cm2 , it will lift up pantograph.
 Flower
 B.D.Panel : It will control and power low power equipments.
 Static Rectifier-MSR : converts 1-phase AC supply to 110V DC to charge battery.
 Static Converter-SC : converts 1-phase 1000V AC supply from overhead
extension(OHE) to 3-phase 440V AC supply .
 Exchanger
 Blower-MVMT : It will suck air through 3 ducts. These ducts are directly connected to
Traction motor for cooling it.
 ATFEX : It is braking transformer.
 Bogie-The wheel arrangement of a loco is called a bogie. A bogie essentially contains

1-wheel axle arrangement

2-Suspension
3-Brake rigging
Traction transformer: It is fixed on under frame and gets supply from an overhead line by
equipment called pantograph. The type of pantograph depends on supply. This transformer
steps down voltage and is fitted with a tap changer. Different taps are taken from it for
operating different equipment. One tap is taken and is rectified into DC using MSR and is fed
to the DC motor.
Railways has two types of power supplies – 25 KV , 1 Phase ,50hz AC and1500 V DC
An AC/DC loco is able to work on both of these supplies. For e.g. WCAM-3.
 15. LMC (LOCOMOTIVE COMMERCIAL):

This department is divided into 3 sections :

a) Tendering
b) Execution
c) Service after sales

The Tendering section Looks upon requirements of customer , estimate cost of project
and other information of tender. On receipt of tender forms formal tender enquiries are
issued to engineering dept., production planning and control , central dispatch cell. If tender
is technically acceptable then offer is submitted to customer. Offer includes technical ,
commercial details and other terms and conditions. On opening of technical bid the
commercial bid of technically qualified tenderers is opened and order is placed on lowest
value tender.
The Contract Execution section on receipt of purchase order issue internal work orders
for execution of work as per the contract. To maintain the key dates of the contract internal
meetings with concerned departments are held on regular basis to monitor the progress. After
the supply of equipments and other materials and billing the major responsibility of this
section is to collect the payment from customer. After the dispatch of full material and
collection of full payment and fulfilling all other requirements , the contract is formally
closed by this section.
The after sales service section looks upon 2 types of work :
a) Within Warranty period – free of cost service and replacement of material on account
of failure of material due to faulty material or bad workmanship.
b) Beyond Warranty – services and material on chargeable basis.

16. CQS (CENTRAL QUALITY SERVICES) :

First we get acquainted with a few terms concerning this department.
Quality: It is the extent to which products and services satisfy the customer needs.
Quality Assurance: All those plants and systematic action necessary to provide
adequate confidence that a product or service will satisfy the given requirement is called
quality assurance.
Quality control: The operational techniques and activities that are used to fulfill
requirement for quality are quality controlled.
Quality Inspection: Activities such as measuring, testing, gauging one or more
characteristics of a product or service and comparing these with specified
requirements to determine conformity are termed as Quality Inspection.
 17. TESTING :
In this shop testing on the transformer is carried out in one section and for loco in other
section.
In transformer testing section there are for MG sets. The electrical specifications of the entire
test are given. These tests are done on demand of customer on transformer manufactured.

Here basically there are basically following tests conducted on power transformers:

1. ROUTINE TEST- It is conducted on all transformers. They are:

a) Ratio test: To determine the Voltage Transformation ratio on each tapping between HV
and LV.
b) Vector Group: To verify the internal connection of the coils(Windings) and the
connection to the terminal.
c) Winding Resistance measurement: To check the healthiness of various joints, internal
connection of the coil and connection to the terminals/Bushings.
d) Magnetizing Current: To measure No load current at low voltage (Supply voltage)
e) Magnetic Balance: To measure flux distribution in each winding by exciting (by
applying voltage)one winding only.
f) Insulation Resistance measurement: To check the healthiness of the insulations
provided on each winding in turn to all other windings, core and frame or tank.
g) Separate source test: To check the healthiness of the insulation of each winding in turn
to all other windings, core and frame or tank with applies single phase voltage.
h) No-load loss measurement: To calculate the Power consumption during No load
condition of the Transformer itself.
i) Load loss & impedance measurement: To calculate the Power consumption during full
Load condition of the Transformer itself.
j) Induced overvoltage test: To verify the A.C. voltage withstands strength of each line
terminal and it’s connected winding to earth and other windings, withstand strength between
phases and along the winding under test.
k) 02 KV core isolation test: To check the isolation of core.

2. TYPE TEST- These are to be conducted only on one unit of same design.
a) Temperature rise test: To observe the maximum temperature when the transformer is
running on continuous full load.
b) Impulse test: To verify the A.C. voltage withstands strength of each line terminal and
it’s connected winding to earth and other windings, withstand strength between phases and
along the winding under test. This test is conducted at a voltage even higher than induced
overvoltage.
c) Auxiliary loss test: To measure the power taken by cooling gear like Fans & pumps.
d) Acoustic Noise level measurement: To measure average sound level generated by the
Transformer when energized at rated voltage and rated frequency at no load.
e) Zero sequence impedance measurement: To calculate the impedance when all three
phase are symmetric.
f) Short time current test (STC test)

Tests conducted on INSTRUMENT TRANSFOTMERS :-

1. ROUTINE TEST
 a) Polarity test:
 Instrument used: Polarity meter analog multimeter.
One of the winding is supplied with 1.5V D.C. supply and the other is connected to
ammeter. If the direction of the deflection is correct implies the connections are correct else
it is wrongly connected.

b) Accuracy test:
It is the test for checking the turn ratio steps:
 A standard transformer primary is connected across the primary of the job.
 As the no. of turns of the secondary transformer is known the no. of turns of secondary
of job is calculated.
 The ratio is taken and the max permissible error should be not more than that specified
by the design.
 Even the phase angle is checked for this max permissible limit.

c) Inter turn insulation test:

Checks for the insulation of the transformer
 Current is given to primary and secondary is open circuited.
 Either of the rated primary current or the 4.5KV peak secondary voltages whichever
appears first is allowed to withstand for 1 min.
 Then if the insulation can withstand then it is said to be okay.

d) Winding resistance:
Error in winding resistance appears if the conductors of different length are used if the
conductors are joined in between to check this winding resistance is checked and if it
appears then the internal points of connections is changed.
e) One minute power frequency (dry) withstand test-It is the high voltage test used
to check the insulations on primary and secondary. It depends upon the line voltage
system for primary. And for secondary it is 3 or 5 kVrms as applicable.
f) Tan d test- It is conducted to justify the quality of insulation. Its limit is 0.005 at
Um/√3 .
g) Partial discharge test- It is used to justify the manufacturing process. Its limit is 10
pc at 1.1Um/ √3.

2. TYPE TESTS
a) Temperature rise test
b) Short time current test (STC test)-It is conducted only on CT.
c) Short time withstand capability test- It is conducted only on VT.
d) Impulse test
One minute power frequency wet withstand test- It is conducted in rainy
conditions to check the external insulations.

18. WE&S (WORK ENGINEERING AND SERVICES) :

As the name suggest this section deals with services & maintenance. It has following sections:
a) Plant equipment: This has electronics & elect/mech. Maintenance.
b) Services: This section deals with air, steam & Power equipments.
c) Telephone Exchange.
d) Township Electrical Maintenance.
 e) W.E. & S Planning.

This sections deals with stores & new machines procurement & other general things. There are
three maintenance centers at bay-2, substation 1 & Loco. This section is also responsible for
Power distribution in B.H.E.L.
The power distribution is of two types:
1)HT Power Distribution: This is at 11 KV, OCB are used for protection. There are four
substations for this distribution.
2) LT Distribution: This is for the auxiliary in each shop & other section of B.H.E.L. It uses
OCB/OVC/BHEL BHOPAL, 800 KVA 415V Transformer & ACB (English Electro).

This department looks after the commissioning and maintenance of all the machinery used
in the factory. It also has 3 two-stage air compressors for supplying compressed air to the
various bays.
The department has 03 different divisions:
 Electrical Engg
 Electronics Engg
 Mechanical Engg

ELECTRICAL ENGINEERING:
This division looks after all the electrical machinery and power distribution of the factory.
Snags detected in the system are immediately reported to this dept by the concerning dept.
WE&S takes prompt action to rectify it.
The factory has a feeder of 11KV .The total load sanctioned for the factory is 2500MVA But
the maximum demand reaches the range of 1700-2000 MVA.
Here are various sub-stations (SS) inside the factory, for distribution of power to different
sections.
SS -1 Supplies Bay-6 to Bay –9
SS -3 Supplies Bay 1to Bay-4
SS -4 Supplies Boiler and loco plant
SS -5 Supplies Bay -5
SS -6 Supplies Administrative building
 REPORT ON
TYPE OF TRANSFORMER
MANUFACTURED IN BHEL
JHANSI