Transformer
Transformer
Transformer
ELECTRICALS LIMITED
JHANSI
INSTRUMENT
TRANSFORMER
A - BRIEF INTRODUCTION
1
SUBMITTED TO- GUIDED BY-
DR. DHRUVA BHARGAVA SH. CBS BUNDELA
SUBMITTED BY-
VANDNA RAJPUT
S.G.S.I.T.S INDORE(M.P.)
CONTENTS
2 An Overview of BHEL 4
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7 Health, Safety & Environment 26
VISION
A global engineering enterprise providing solutions for a better tomorrow.
MISSION
Providing sustainable business solutions in the fields of Energy, Industry &
Infrastructure.
VALUES
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GOVERNANCE: We are stewards of our shareholders investments and we take
that responsibility very seriously. We are accountable and responsible for delivering
superior results that make a difference in the lives of the people we touch.
LOYALTY: We are loyal to our customers, to our company and to each other.
TEAM WORK: We work together as a team to provide best solutions & services
to our customers. Through quality relationships with all stakeholders we deliver value to
our customers.
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BHEL is the largest engineering and manufacturing enterprise in India in the
energy/infrastructure sector today. BHEL was established more than 40 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.
BHEL caters to core sectors of the Indian Economy viz., Power Generation &
transmission, Industry, Transportation, Telecommunication, Renewable Energy,
Defense, etc. The wide network of BHEL’s 17 manufacturing divisions, four Power
Sector regional centers, over 100 project sites, eight service centers 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. BHEL has
already attained ISO 9000 certification for quality management, ISO 27000 for
Information Technology and ISO 14001 certification for environment management.
POWER GENERATION
Power generation sector comprises thermal, gas, hydro, and nuclear power plant
business.
TELECOMMUNICATION
BHEL also caters to Telecommunication Sector by way of small, medium and large
switching systems.
BHEL offers wide-ranging products and systems for T&D applications. Products
manufactured include: power transformers, instrument transformers, dry type
transformers, series &shunt reactors, capacitor banks, vacuum &SF6 circuit breakers,
gas-insulated switchgears and insulators.
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INDUSTRIES
BHEL is a major contributor of equipment and systems to industries, cement, sugar,
fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and other process
industries. The range of systems & equipment supplied includes: captive power plants,
co-generation plants, DG power plants, industrial steam turbines, industrial boilers and
auxiliaries, waste heat recovery boilers, gas turbines, heat exchangers and pressure
vessels, centrifugal compressors, electrical machines, pumps, valves, seamless steel
tubes, electrostatic precipitators, fabric filters, reactors, fluidized bed combustion boilers,
chemical recovery boilers and process controls.
TRANSPORTATION
BHEL is involved in the development, design, engineering, marketing,
production, installation, and maintenance and after-sales service of rolling stock
and traction propulsions systems. BHEL manufactures electric locomotives up to
5000 HP, diesel electric locomotives from 350 HP to 3100 HP, both for mainline
and shunting duty applications. It also produces rolling stock for special
applications viz. overhead equipment cars, special well wagons, and Rail-cum
road vehicle.
RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional and
renewable sources of energy include: wind electric generators, solar photovoltaic
systems, solar heating systems, solar lanterns and battery-powered road
vehicles.
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OIL AND GAS
BHEL’s products range includes Deep Drilling Oil Rigs, Mobile Rigs, Work Over
Rigs, Well Heads and X-Mas Trees, Choke and Kill Manifolds, Full Bore Gate
Valves, Mudline Suspension System, Casing Support system Sub-Sea Well
Heads, Block valves, Seamless pipes, Motors, Compressor, Heat Exchangers
etc.
INTERNATIONAL OPERATIONS
BHEL is one of the largest exporters of engineering products & services from
India, ranking among the major power plant equipment suppliers in the world.
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(3) VARIOUS BHEL UNITS
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Haridwar : Central Foundry and Forge Plant.
BHEL is growing concern to meet the changing needs of the nation has taken it beyond
power into the total gamut of energy, industry and transportation BHEL is able to offer a
service in each of this fields. It;s manufacturing capability is supported by a corporate
R&D division at Hyderabad works closely with the research and development cells at
various units and Welding Research Institute at Tiruchinapalli.
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Air pre heaters.
Nuclear power equipments.
Hydro sets and Auxiliaries.
Motors.
Transformers.
Rectifiers.
Pumps.
Heat Exchangers.
Capacitors.
Porcelain/Ceramics insulators.
Seamless steel tubes.
Casting and forging.
SYSTEMS/SERVICES
TRASPORTATION SECTOR
INDUSTRY SECTOR
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Boilers.
Valves.
T.G. sets.
Power devices.
Solar Cells.
Photo Voltaic cells.
Gas Turbines.
Compressors.
Drive Turbines.
Oil rigs.
Blow out preventers.
Wind mills.
Control systems for electric devices.
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A BRIEF INTRODUCTION
By the end of 5th five-year plan, it was envisaged by the planning commission that the
demand for power transformer would rise in the coming years. Anticipating the country’s
requirement BHEL decided to set up a new plant, which would manufacture power and
other types of transformers in addition to the capacity available in BHEL Bhopal. The
Bhopal plant was engaged in manufacturing transformers of large ratings and Jhansi unit
would concentrate on power transformer upto 50 MVA, 132 KV class and other
transformers like Instrument Transformer s, 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 9th 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
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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.
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BHEL PERFORMANCE (CORPORATE LEVEL)
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DIVISION 2011 – 12 2012 – 13
(Actual) (Provisional
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One of the major tasks of this department is to earn decent profits over all negotiations.
Transformer industry has become very competitive. The company offering the lowest
price gets the contract but this process may continue does the work on very low profits.
To avoid such a situation, a body by the name of India Electrical and Electronics
Manufactures Association (IEEMA) was set up. This association helps to maintain a
healthy competitive atmosphere in the manufacturing of electrical appliances.
The transformer manufactured in BHEL Jhansi range from 10 MVA to 250 MVA and up
to 400 KV. The various transformers manufactured in this unit are:-
POWER TRANSFORMER
a) Generator transformer
b) System transformer.
c) Auto transformer.
SPECIAL TRANSFORMER
a) Freight loco transformer.
b) ESP transformer.
c) Instrument transformer.
d) Dry type transformer.
.
BAY-00 & 0:
It is a sub part of Fabrication. It is the preparation shop while the other two bays
form the assembly shop. This section has the following machines:
Planner machine – To reduce thickness
Shearing machine
CNC / ANC Flame Cutting machine – To cut Complicated shaft items
using Oxy-Acetylene flame
Bending machine
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Rolling machine
Flattening machine
Drilling machine
Nibbling machine
Pantograph flame cutting machine
BAY-1
BAY-2
4-foot assembly
Before assembly, short blasting (firing of small materials i.e., acid pickling) is done on
different parts of jobs to clean the surface before painting.
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1 Ultrasonic test to detect the welding fault on the CRO at the fault place high
amplitude waves are obtained.
2. Die Penetration test Red solution is put at the welding and then cleaned. After
some time white solution is mixed. Appearance of a red spot indicates a fault at the
welding.
3. Magnetic crack detection Magnetic field is created and then iron powder is put
at the welding. Sticking of the iron powder in the welding indicated a fault.
4. X-Ray Test: It is same as human testing and the fault is seen in X-ray film.
BAY-3
Machine section
Copper section
Tooling section
BAY 4
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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 dia meter of required coil is made
.The specification of coil are given in drawing. The diameter of mould is adjustable as
its body is made up of wooden sections that interlock with each other. This interlocking
can be increased or decreased to adjust the inner diameter of coil.
1. Belly types
2. Link types
3. Cone type
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, U.K. Germany. It is available in 0.27 and 0.28 mm thick sheets,
1mt wide and measured in Kg.The sheet s are coated with very thin layer of insulating
material called “carlites”.
For the purpose of cutting and punching the core three machines are installed in shop
BAY-6
Single-phase traction transformer for AC locomotives is assembled in this section. This
Freight locomotive transformers are used where there is frequent change in speed. In
this bay core winding and all the assembly and testing of traction transformer is done.
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Three-phase transformers for ACEMU are also manufactured in this section. The
supply lines for this transformer are of 25 KV and 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).
BAY-7
BAY 8
It is the instrument transformer and ESP transformer manufacturing section.
INSTRUMENT TRANSFORMER
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
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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.
ESP TRANSFORMER
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 the 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 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 an ‘marshalling box’
which is the control box of the transformer.
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BAY-9
In this bay power transformer are assembled. After taking different input from different
bays 0-9 assembly is done Power transformer is used to step and step down voltages at
generating and sub-stations. There are various ratings –11KV, 22KV, manufactured,
they are
1. Generator transformer.
2. System
3. Autotransformer.
1. Core building
2. Core Lifting.
3. Unlacing.
4. Delacing and end-frame mounting.
5. High voltage terminal gear and low volt terminal gear mounting
6. Vapour phasing and oil soaking
7. Final servicing and tanking.
8. Case fitting.
STORE
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2. Custody Section
3. Scrap Disposal Section
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.
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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
This section deals with manufacturing of locomotives. The main parts of the
locomotive are
DC motor
Alternator
Compressor
Flower
Static Rectifier-MSR
Static Converter-SC
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Exchanger
2-Suspension
3-Brake rigging
-1500 V DC
An AC/DC loco is able to work on both of these supplies. For e.g. WCAM-3.
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.
Electrical Engg
Electronics Engg
Mechanical Engg
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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 -5 Supplies Bay -5
TECHNOLOGY
This department analyses the changes taking place in the world. and suggest
changes accordingly. This is very important because the products must not get
obsolete in the market otherwise they will be rejected by the customer.
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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 welding
Special tools requirement - Special tools are allotted, if possible, when
required else the design has to be reconsider.
Productivity projects compilation - It includes the initial analysis of the
problem and their appropriate solution to enhance productivity.
The principle of working is that
“IF YOU DO NOT MAKE THE CHANGES IN YOUR COMPANY, THE
CUSTOMER WILL CHANGE YOU”.
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 technique and activities that are used to fulfill requirement for quality are
quality control.
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QUALITY INSPECTION
Activities such as measuring, testing, gauging one or more characteristics of a product
or service and comparing these with specified requirement to determine conformity are
termed quality inspection.
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PHYSICAL
DESL NOS 15 10
AC LOCOMOTIVE NOS 53 62
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Environment, Occupational Health and Safety, is committed to protecting Environment in
and around its own establishment, and providing safe and healthy working environment
to all its employees. For fulfilling these obligations, Corporate Policies have been
formulated as:
ENVIRONMENTAL POLICY
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PROJECT
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