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Mr. Dalpat
VT-698\2015
Engineer (Design)
Sr.
T.I.T - E
DIVISION
H.T.E
DECLARATION
We hereby submit the training report entitled
TRANSFORMER MANUFACTUREING AND
TESTING, ELECTRICALS MACHINES is in the partial
fulfilment of the degree of BACHELOR OF
ENGINEERING in ELECTRICAL & ELECTRONICS
ENGINEERING. The work has been carried out at
B.H.E.L Bhopal and is an authentic record of own work
under the guidance of Mr. Dalpat Borana, H.T.E
Department, B.H.E.L, Bhopal (M.P)
MAYANK KUMAR
SINGH
VT-698/15
CERTIFICATE
This is to certify that the work embodied in this project
work entitled TRANSFORMER MANUFACTURING
AND TESTING, ELECTRICAL MACHINES has been
satisfactorily completed by MAYANK KUMAR SINGH
(Electrical & Electronics engineering) of T.I.T - E
Bhopal (M.P.) during the period of 2nd July, 2015 to
15th July, 2015 under the guidance of the under
signed. It further certifies that the work in this report
fulfils the requirements of the ordinance related to the
degree of B.E. in ELECTRICAL & ELECTRONICS
ENGINEERING from T.I.T - E, Anand Nagar, Bhopal
(M.P.)
UNDER THE
GUIDANCE OF:Mr. Dalpat Borana
Sr. Engineer
(Design),
H.T.E Department,
B.H.E.L., Bhopal
(M.P.)
PREFACE
A student gets theoretical knowledge from classroom
and gets practical knowledge from industrial training.
When these two aspects of theoretical knowledge and
practical experience together than a student is fully
equipped to secure his best. In conducting the project
study in an industry, students get expose knowledge of
real situation in the work field and gains experience
from them. The object of the summer training cum
project is to provide an opportunity to experience the
practical aspect of technology in any organization. It
provides a chance to get the feel of organization and its
function.
CONTENT
S.NO
TOPIC
PAGE NO.
1.
INTRODUCTION TO BHEL
6
2.
TRANSFORMER
12
3.
TRANSFORMERS IN BHEL
15
4.
BHEL
POWER TRANSFORMERS IN
16
5.
ULTRA HIGH VOLTAGE
LABORATORY 18
6.
27
ELECTRICAL MACHINES
7.
28
TRACTION MOTOR
8.
M/C
9.
M/C
10.
37
RECENT DEVELOPMENT IN AC
36
CONCLUSION
INTRODUCTION TO
B.H.E.L.
ABOUT THE COMPANY
LABORATORIES
BHEL, Bhopal has its own laboratories for material
testing and instrument calibration which are accredited
with ISO 17025 by NABL. The hydro laboratory and
center for electric transportation are the only
laboratories of it are in this part of the world.
PRODUCTS
BHEL, Bhopal with state-of-the-art facilities,
manufactures wide range of electrical equipment. Its
product range includes hydro, steam, marine and
nuclear turbines ,heat exchanger hydro and turbo
generator, transformer and switch gears, control gears ,
transportation equipment, capacitors, bushings,
electrical motor, rectifiers, oil drilling, rig equipment
and diesel generating sets
EMPLOYEES
BHEL Bhopals strength is its employees. The company
continuously invests in Human resources and pays
utmost attention to their needs. The plants township
well known for its greenery is spread over an area of
around 20 sq. km and provides all facilities to residents
like, parks community halls, library shopping centers,
banks, post offices etc. 0besides, free health services
are extended to all the employees through 350 bedded
(inclusive of 50 floating beds) Kasturba hospital and
chain of dispensaries.
SHUNT REACTOR
BUSHING
420 kv, 1800 A,O/P Bushing
800 kv, 1250 A,O/P Bushing
CAPACITORS
450kvAr, 10 kv Capacitor unit
HVDC EQUIPMENTS
HVDC CONVERTER TRANSFORMER
500 kv/ 800kv 600 MVA, 1- Phase
CURRENT TRANSFORMER
400 kv, 4000 Amp SF6 CT
800kv, 3000Amp SF6 CT
BLOCKS IN BHEL
BLOCK NAME
OPERATIONS
BLOCK 1(A)
FPM
BLOCK 1(B)
SFM
BLOCK 1
BLOCK 2
BLOCK 3
TCB
BLOCK 4
SCR
BLOCK 5
FYM
BLOCK 6
SDM
BLOCK 7
MOD
BLOCK 8
CIM
BLOCK 9
TXM
BLOCK 10
PRM
BLOCK 11
TGM
BLOCK 12
TRANSFORMER
NEW
BLOCK 13
BLOCK
NEW HYDRO
BLOCK 14
LABS
BLOCK 15
UHB
HLX LAB
TRANSFORMER
A transformer is an electrical device that transfers
energy between two or more circuits through
electromagnetic induction.
A varying current in the transformer's primary winding
creates a varying magnetic flux in the core and a
varying magnetic field impinging on the secondary
winding. This varying magnetic field at the secondary
induces a varying electromotive force (EMF) or voltage
in the secondary winding. Making use of Faraday's Law
in conjunction with high magnetic permeability core
properties, transformers can thus be designed to
efficiently change AC voltages from one voltage level to
another within power networks
Transformers range in size from RF transformers less
than a cubic centimeter in volume to units
interconnecting the power grid weighing hundreds of
tons. A wide range of transformer designs is
encountered in electronic and electric power
applications. Since the invention in 1885 of the first
constant potential transformer, transformers have
TYPES OF TRANSFORMERS
Various specific electrical application designs require a
variety of transformer types. Although they all share
the basic characteristic transformer principles, they are
customizing in construction or electrical properties for
certain installation requirements or circuit conditions.
Autotransformer: - Transformer in which part of the
winding is common to both primary and secondary
circuits.
Capacitor voltage transformer: - Transformer in
which capacitor divider is used to reduce high voltage
before application to the primary winding.
Distribution transformer, power transformer: International standards make a distinction in terms of
distribution transformers being used to distribute
energy from transmission lines and networks for local
consumption and power transformers being used to
transfer electric energy between the generator and
distribution primary circuits.
Phase angle regulating transformer: - A specialized
transformer used to control the flow of real power on
three-phase electricity transmission networks.
Scott-T transformer: - Transformer used for phase
transformation from three-phase to two-phase and vice
versa.
APPLICATIONS
Transformers are used to increase voltage before
transmitting electrical energy over long distances
through wires. Wires have resistance which loses
energy through joule heating at a rate corresponding to
square of the current. By transforming power to a
higher voltage transformers enable economical
transmission of power and distribution. Consequently,
transformers have shaped the electricity supply
industry, permitting generation to be located remotely
TRANSFORMERS IN BHEL
HVAC Power Transformer for voltage up
to 1200kV
Phase Shifting
Transformer
SALIENT FEATURES
Offers very low background level during PD and RIV
measurements.
Major test equipment are mobile on air-cushion
transport system, thus provides flexibility of
Impulse Voltage
4.0 Million-volt, 400 kWs Impulse generator
500 Kilo-volt, 15 kWs impulse generator
3.6 Million-volt, 400 pF Impulse voltage divider
3.0 Million-volt Multiple chopping gap
AC Voltage
1.5 Million-volt, 1A Cascade test transformer
1.5 Million-volt, 200 pF AC voltage divider
Million-volt, 1000 pF Coupling capacitor
DC Voltage
Power Sources
40 MVA, 0-11 kV, 50Hz, 3-phase MG set
9 MVA, 0-11 kV, 50-200 Hz, 3-phase MG set
7 MVA, 0-11 kV, 50 Hz, 3-phase MG set
2 MVA, 0-11 kV, 30-180 Hz, 3-phase MG set
2000 amps, 1200 volts DC power source.
Other Equipment
Oil tank for dielectric and thermal stability test on
bushing upto 800 kV class
Artifical rain-spray (Wet test) equipment
Salt-fog spray (Pollution test ) equipment
Calibration Equipment
200kV AC/DC voltage measuring system
Reference impulse calibrator
500 kV reference voltage divider
Function generator / unit step generator
Rod-rod gap assembly
1 m and 12.5 cm dia sphere gap assemblies
All HV test systems are calibrated as per the
calibration procedures in accordance with IEC.
INSTRUMENTATION
The testing equipment are supported by latest
state-of-the-art instrumentation for controlling the
ELECTRICAL MACHINES
LABORATORY
The laboratory is engaged in the development of
special electrical machines, like Brushless Exciters,
Permanent Magnet Machines, and High Frequency
Motors and Generators. The laboratory also carries out
studies to predict machine performances under normal
and abnormal operating conditions.
Major Achievements:
A range of Brushless Exciters for Synchronous
Machines up to 10 MW rating
3 kVA, 1500 RPM, Permanent Magnet Generators for
TGs up to 25 MVA rating
5 kVA, 3000 RPM, Permanent Magnet Generators for
TGs up to 50 MVA rating
8 HP DC Servo Motor with Permanent Magnet Field
Excitation
600 VA, 32 V, 12000 RPM PMG for special application
Major Ongoing Projects:
Development of 40 kVA, 400 Hz, 12000 RPM Compact
Generator
TRACTION MOTORS
PRODUCT RANGE
TRACTION ALTERNATORS
Application
Traction
Alternators
Remarks
3100 HP DE
Loco
TA10102CW/DW
3300 HP DE
Loco
TA10102EV
4000 HP DE
Loco
TA9901AZ
For GM Loco
4000 HP DE
Loco
AA9201AZ
Companion of TA9901AZ
1350 HP DE
Loco
TA10106CY
3300 HP DE
Loco
TA10103AZ
3300 HP DE
Loco
CA10104AZ
Companion Alternator of
TA10103AZ
TRACTION GENERATORS
Application
Traction
Generators
Remarks
TG10931AZ
Broad gauge DE
loco (Not in
regular
Production)
1350HP DE Loco
TG10919AZ
Meter gauge DE
loco (Not in
regular
Production)
350HP shunters
TG4302AZ
For Shunters at
Jhansi
2600HP DE Loco
350HP MG-DEMU
TG4302BY
DC MOTORS
Application
Traction Motors
Remarks
TM4907AZ/BZ
Regular traction
motor for WDM2
etc.
3100 HP
BGDE Loco
TM5002AZ/BY/BX
Light weight
compared to
TM4907AZ
3100 HP
BGDE Loco
TM5002BW
Dog-Link
Arrangement
TM4701AZ
New development
of light weight
traction motor
3100 HP
BGDE Loco
3100 HP
BGDE Loco
25 kV AC EMU TM4303BY
with Hitachi
insulation
1400 HP HHPTM4303DY
DEMU
25 KV AC EMU TM4601AZ/BZ/BX
Also used in
700HP DEMU
2300 HP DE
LOCO
TM4501AV
With roller
suspension
bearing
350 HP MG-
TM3801AZ
DEMU
DEMU
For BPRV
TM1701AZ
Battery powered
Road Vehicle
For NSTL
M3001AZ
High power to
weight ratio
HS15250A
for 4000 HP
locomotive type
WAG5.
25 KV AC
locomotive
AC MOTORS
Application
6000HP AC
Loco
AC Motors
Remarks
6FRA6068
6000HP AC
Loco
IM4801AZ/HT
6000HP AC
Loco
6FXA7059
Passenger Loco
WAP5
4000HP Loco
IM4507AZ
For GM Alternator
25 kV AC-DC
EMU
DMKT 53/42
Dual Voltage
EMUs for Mumbai
Suburban Area
1600 HP
IM3401AZ
Delta connected
stator
DEMU
AUXILIARY MACHINES
Application
Aux Machines
Remarks
For TA10102DW
& TA10102EV
AG / Exciter
2300 HP Loco
Foot Mounted AG
for Malasian Loco
AG3102AZ
For TG10931AZ
1350 HP DE
Loco
AG2513AZ
For TG10919AY
1350 HP DE
Loco
AG2501AZ
For TG10919AY
1350 HP /2300
HP DE Loco
AG2702AX/BX/BY
For TA10106CY
350 HP DEMU
AG1702AZ
Offer Submitted
to M/s ICF ( New
Development)
25 kV AC Loco
BM2101AZ
2300 HP Loco
DY3423BY/M
Foot Mounted AG
for Malasian Loco
BRUSHLESS EXCITERS
For 700HP
DEMU, 1400HP
OE2501AZ DEMU & 1215
kVA Oil Rig
Alternator
For 700HP
Shunters &
OE2501BZ
1430 kVA Oil
Rig Alternator
OE2901AZ
Brushless Exciter
forOA7002AZ
EX2904AZ
For Ballast
EX2904BZ Cleaning
Machine
For 700HP
DEMU
RECENT DEVELOPMENT in AC
MACHINES
2500 kw, 11kv, 4 P SCIM for BFP application for M/s
Raichur power corporation Ltd. For 2 X 800 MW
Yeramarus TPS
17500 kw, 11 kv, 4 P vertical SCIM for primary
coolant pump application for M/s NPCIL
5200kw, 11kv, 22P vertical SCIM for CWP
application for M/s KBL for Mundra
3600kw, 3.15 kv,10 P variable speed vertical
induction motor for SSp application for fast breeder
reactor for M/s NPCIL
12.5 MW, 11kv, 4p synchronous motor in Line F
construction with on line brush changing facility
CONCLUSION
BHEL BHOPAL is continuously improving its test plan in
order to bring it in competition with the best product
available in the world. Its aim in this regard is to meet
with maximum satisfaction of its esteemed consumers.
So that they have got the best product available
internationally.
BHEL has already proved its existence in national and
international market. Its turnover, commitment and
dedication of its employees which give it the tittle of
Maharatna can speak a lot in its appreciation.
BHEL BHOPAL is dealing with a lot of progress in the
field of traction system and transformer and has
created a global reputation. Its main aim is to provide
best with the latest updated technology to the market.