Vocational Training Report: Submitted by:- Rahul Roy S.R.M University Kattankulathur (Electronics &Instrumentation) REG. NO. 1171110153

Bharat Heavy Electricals Limited

Bharat Heavy Electricals Limited (BHEL) is an Indian state-owned integrated power plant equipment

manufacturer and operates as an engineering and manufacturing company based in New Delhi, India. BHEL

was established in 1964, ushering in the indigenous Heavy Electrical Equipment industry in India. The company

has been earning profits continuously since 1971-72 and paying dividends since 1976-77. It is one of the only 7

mega Public Sector Undertakings (PSUs) of India clubbed under the esteemed 'Maharatna' status.On 1

February 2013, the Government of India granted Maharatna status to Bharat Heavy Electricals Limited.

Main manufacturing Units:

Heavy Electrical Equipment Plant, Haridwar, Uttarakhand

Heavy Power Equipment Plant Ramachandrapuram Hyderabad(Andhra Pradesh)

Transformer Plant, BHEL Jhansi(Uttar Pradesh)

High Pressure Boiler Plant and Seamless Steel Tube Plant, Trichy(Tamil Nadu)

Boiler Auxiliaries Plant, Ranipet, Vellore(Tamil Nadu)

Electronics Division and Electro Porcelain Division, Bangalore (Karnataka)

Centralised Stamping Unit & Fabrication Plant  Jagdishpur (Uttar Pradesh)

Insulator Plant Jagdishpur (Uttar Pradesh)

Heavy Electrical Plant Bhopal

Component Fabrication Plant Rudrapur (Uttrakhand)

Industrial Valves Plant, Goindwal(Punjab)

Bharat Heavy Plates and Vessels Limited (Vizag)

BHEL Electrical Machines Ltd., Kasaragod, Kerala

Products Boiler (steam generator)- under collaboration with Combustion Engineering, USA

Gas generator

Hydro generator

Steam turbine - under collaboration with Siemens, Germany

Gas turbine - under collaboration with GE, USA

Hydro turbine

Transportation equipment

Traction machines

AC Motors

Transformer

Switchgear

Oil field equipment (OFE)-under collaboration with National Oilwell Varco.

Boiler drum

Water wall panel, Coils, Super Heaters, Re heaters, SOFA panels, Burner panels, Piping & Headers

Wind mill

Valves

Electrostatic precipitators

SWITCH GEAR

Introduction

Switchgear is the combination of electrical disconnect switches, fuses or circuit breakers used to control, protect and isolate

electrical equipment. Switchgear is used both to de-energize equipment to allow work to be done and to clear

faults downstream.

Location

Switch gear is located anywhere where isolation and protection may be required.These locations include generators, motors,

transformers and substations.

 

1. Substations :Typically switchgear in substations is located on both the high voltage and the low voltage side of large

power transformers. The switchgear on the low voltage side of the transformers may be located in a building, with

medium-voltage circuit breakers for distribution circuits, along with metering, control, and protection equipment. For

industrial applications, a transformer and switchgear line-up may be combined in one housing, called a unitized

substation or USS.

2. 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, although 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.

At small substations, switches may be manually operated, but at important switching stations on the transmission network all

devices have motor operators to allow for remote control.

3.Functions:

We all familiar with low voltage switches and re-wirable fuses in our home. The switch is used to manually open and close the

electrical circuit in our home and electrical fuse is used to protect our household electrical circuit from over current and short

circuit faults. In same way every electrical circuit including high voltage electrical power system needs switching and

protective devices. But in high voltage and extra high voltage system, these switching and protective scheme becomes

complicated one for high fault current interruption in safe and secure way. In addition to that from commercial point of view

every electrical power system needs measuring, control and regulating arrangement. Collectively the whole system is

called Switchgear and Protection of power system. The electrical switchgear have been developing in various forms.

Switchgear protection plays a vital role in modern power system network, right from generation through transmission to

distribution end. The current interruption device or switching device is called circuit breaker inSwitchgear

protection system. The circuit breaker can be operated manually as when required and it is also operated during over

current and short circuit or any other faults in the system by sensing the abnormality of system. The circuit breaker senses

the faulty condition of system through protection relay and this relay is again actuated by faulty signal normally comes

from current transformer or voltage transformer.

CONTROL GEAR

The control gear 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 phase panel, some more instruments are used :

Voltmeter

 

HV side

IV side

LV side

Switch for :

 

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

Current indicator

Voltage indicator

Active power indicator

Reactive power indicator

RECTIFIER

A rectifier is an electrical device that converts alternating current(AC), which periodically reverses direction, to direct current (DC), which flows in only one direction. The process is known as rectification. The rectifier manufacturing department deals with products as displayed below :

PRODUCT PROFILE :

1. Traction Control

Diesel electric locos 700 hp to 3600 hp

Electric locomotives 500hp control cubicles

2.Plant industrial controls

Electronic controllers for electrostatic precipitators (60-80 kv, 250-1600 Ma)

Large current rectifiers (upto 90kamp, 300-900 V )

G40, electrohydraulic governor (upto 165 MW)

Compact automatic voltage regulator with power factor controls( 1.4 MW to 6 MW)

Automatic voltage regulator (1.4 MW to 60 MW)

Static excitation equipment ( 1.4 MW to 60 MW)

Alternator Mounted Recitifier

HIRECT has also designed and developed rectifiers which eliminates self cooling system by integrating the rectifier

cooling with that of main alternator and is mounted on top of the alternator thereby reducing space requirement.

Rectifiers are also supplied for AC-DC locomotives.

BoilerA boiler is a closed vessel in which water or other fluid is heated. The fluid does not necessarily boil. The heated or

vaporized fluid exits the boiler for use in various processes or heating.

Material used: The pressure vessel of a boiler is usually made of steel (or alloy steel), or historically of wrought iron.

Cast iron may be used for the heating vessel of domestic water heaters.

WATER TURBINE

A water turbine is a rotary engine that takes energy from moving water.

Now they are mostly used for electric power generation. Water turbines are mostly found in Embankment dams to

generate electric power from water kinetic energy

Types: Kaplan Francis

VALVES:

This kind of valve is generally used in the hydroelectric power plants as a turbine protection to guarantee the emergency shutoff of the pressurized water flow of the penstock. It’s placed immediately before the turbine and works automatically to shut off the water flow in case of any turbine malfunction, lack of power or any specified condition.

SPHERICAL VALVES

A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing various passageways.

Butterfly valvesButterfly valves are equipped with either a lens type or a lattice door (through-flow) type. These door types were optimized in model tests to achieve a minimum flow head loss coefficient. This type of valve is mainly used as safety valve, turbine inlet valve, and pump valve for low to medium design pressures.

Cone valvesCone valves are installed for flow regulation from 0 to 100%, for energy dissipation, and as pressure relief valves. They are often installed in combination with an upstream guard valve (e.g. butterfly valve) for maintenance and emergency shut-down purposes.

•Butterfly valves up to a diameter of 6,000 mm and design pressure of 64 bar•Cone valves up to a diameter of 2,200 mm and design pressure of 64 bar

TRANSFORMER Coil Winding is of two types:-

High Voltage Coils: H.V. Coils are the components of finished transformers. They are made on automatic layer setting winding machines.

A solid cylindrical former of predetermined diameter and length is being used as hase over which is made.

Generally round insulated wire of either copper (Cu) or Aluminium (Al) is used as basic raw material.

The coils are made in number of layers.

The starting and finishing leads of each coil are terminated on either side of the coil.

These leads are properly sleeved and locked at number of points.

Low Voltage Coils:

L.V. Coils are also one of the components of transformer. The procedure of making low voltage coil is generally same as described earlier.

The shape of the basic raw-material (Al or Cu) is rectangular.

The Test: The "Turn Test" is carried out on the H.V. Coils as per the specifications.

The manufacturing process of Transformer cover the following departments:-

Coil Winding

Core Assembly

Core-Coil Assembly

Tank-up

Transformer Tank

Painting & Finishing

MOTORS

At BHEL Bhopal, manufacturing of following motors are done:

SQUIRREL CAGE INDUCTION MOTORS SLIPRING INDUCTION MOTORS SYNCHRONOUS MOTORS INDUSTRIAL ALTERNATORS VARIABLE FREQUENCY DRIVE MOTORS PRESSURISED MOTORS  FLAME PROOF MOTORS INDUCTION GENERATORS WIND ELECTRIC GENERATOR 

   Product Range  

SQUIRREL CAGE INDUCTION MOTORS UP TO 21000 KW(4POLE) LOW VOLTAGE, 3.3-11KV 50 AND 60 HZ 4 POLE TO 24 POLE 2 POLE MOTORS UP TO 4500KW

  SLIP RING INDUCTION MOTORS UP TO 10000 KW (4 POLE) LOW VOLTAGE, 3.3-11 KV 50 & 60 HZ 4 POLE TO 12 POLE

 

 SYNCHRONOUS MOTORS UPTO 21000 KW (4 POLE) CYL. ROTOR 4 POLE TO 10 POLE CYL. ROTOR UPTO 4500 KW ( > 12 POLE) SALIENT POLE ROTOR 3.3 – 11  KV

  ALTERNATORS  UPTO 3 MW, 4 POLE  LT (420 V) UPTO 25000 KVA , 4 POLE  CYLINDRICAL ROTOR UPTO 20000 KVA, 12 POLE SALIENT POLE ROTOR 3.3 – 11  KV

VARIABLE  FREQUENCY  MOTORS  UPTO 21000 KW (4 POLE) CAGE INDUCTION MOTOR UPTO 15000 KW (4 POLE) SYNCHRONOUS MOTOR 

  

PRESSURIZED  MOTORS UPTO 21000 KW,  4 POLE VFD SYN. MOTOR UPTO 21000 KW, 4 POLE INDUCTION MOTOR UPTO 4500 KW, 18 POLE INDUCTION MOTORUPTO 4500 KW,18 P  SALIENT POLE  SYN. MOTORUPTO 13000 KW, 4 POLE CYL. ROTOR SYN. MOTOR

 FLAME PROOF  MOTORS UPTO 1200 kW, 4POLE TETV

INDUCTION GENERATORUPTO 5000 kW, 4 POLE

   WIND ELECTRIC GENERATORS UPTO 2500kW

 

Totally Enclosed Tube Ventilated Sq. Cage Cyl. Rotor Syn. machine Induction Motor

Vertical Sq. Cage Induction Motor

Flame Proof Sq. Cage Induction Motor

THANK YOU