Bharat

heavy
electrical
limited
bhopal

Vocational training report

Submitted by: submitted to:

AKASH BHARDWAJ(VTN202401812) Mr.Piklal Mahto
Electrical & Electronics Engineering Sr. Manager (TRM)
3rd year Block-3, BHEL, Bhopal
Lakshmi Narain college of Technology ,Bhopal

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 Acknowledgement
Industrial training has an important role in exposing the
real-life situation in an industry. It was a great
experience for me to do training under this prestigious
and one of them Maharatnas of India “Bharat heavy
electrical limited” Bhopal.

Now, I would like to thank the people who guided me

and have been a constant source of inspiration
throughout the tenure of my training.
I wish my deep sense of gratitude to my project guide
Mr. Piklal Mahto (Sr.Manager Winding Division).
Whose affectionate guidance has enabled me to
complete this training successfully I also wish my deep
sense of gratitude to different workers and engineers
who gave me time to make me understand the scenario
and whose guidance and encouragement made my
training successful.

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 Certificate
This is to certify that Akash Bhardwaj (B.tech Electrical
& Electronics Engineering of VI Semester) Student
from Lakshmi Narain College of Technology , Bhopal
has vocational training in Bharat heavy electrical
limited Bhopal from 16-July- 2024 to 30 July 2024.
It is further certified that the work report in the project
fulfils the requirement of the information related to the
degree of B.tech in mechanical engineering.
His discipline and performance during the training
Excellent. We wish him a very prosperous and bright
career in future.

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 Content
 Introduction
 BHEL (overview)
 BHEL Bhopal - (Overview)
 Block 3 (TRM BLOCK)

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 Introduction
Bharat heavy electrical limited (BHEL) owned and founded
by government of India, is an engineering and manufacturing
company based in New Delhi, established in 1964, BHEL is
India’s largest power generation equipment manufacturer.

Government of India (Ministry of heavy electrical and public

enterprises) has granted the status of Maharatna to Bharat
Heavy Electrical Limited on 1st feb 2013.

BHEL is engaged in the design, engineering, manufacturing,

construction, testing, commissioning and servicing of a wide
range of product system and services for the core sector of the
economy viz, power, transmission, industry, transportation,
renewable energy, oil and gas and defence.

It has a network of 17 manufacturing unit, 2 repair unit, 4

regional office, 8 service centre, 8 overseas office, 15 regional
centre, 7 joint venture and infrastructure allowing it to execute
more than 150 project at site across India and abroad. The
company has established the capacity to deliver 20,000 MW
p.a. of power equipment to address the growing demand for
power generation equipment.

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 Bhel overview
BHEL was established more than 50 years ago when its first plant was
set up in Bhopal ushering in the indigenous heavy electrical
equipment industry in India.
BHEL is largest engineering and manufacturing enterprises in India in
the energy related sector. BHEL was established more than 4 decades
ago in the indigenous heavy electrical equipment industry in India.
BHEL has built over the years a robust domestic market position by
up becoming the largest supplier of power plant equipment in India
and by developing strong market presence in select segment of the
industry sector and the railway. Currently, 80% of the nuclear power
generation in the country is through BHEL sets.
BHEL has been a reliable designer, manufacturer and supplier of
world class power generation, transmission, transportation, defence,
aerospace and industrial equipment for infrastructure sector to
customers across the globe. Our international footprints span 89
countries across all the six inhabited continents. BHEL’s in-house
design team is well-versed with international design standards and our
solutions are adaptable to the customer requirements. The company
undertakes projects and contracts in all modes including EPC, Supply,
Supply & Supervision, Consortium partner, Contract Manufacturer,
etc., as per customer requirement. Our spectrum of offerings includes
one-stop solution for hydro, nuclear, solar, gas, thermal, railways,
transmission as well as standalone products such as compressors,
transformers, shunt-reactors, motors, pumps, heat exchangers, valves,
oil-field equipment, after sales support etc. Besides 195+ GW
installed power capacity in India, we have so far supplied and
installed 12 GW of power-plant equipment internationally and another
5 GW is under installation.

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 BHEL BHOPAL – OVERVIEW
Bharat Heavy Electricals Limited (BHEL) is a central public sector
undertaking and the largest government-owned power generation
equipment manufacturer in India . BHEL was established in 1964 and
is headquartered in New Delhi, India . BHEL is a leading power
equipment manufacturer globally and has contributed significantly
towards building an Aatmanirbhar Bharat .

BHEL’s Bhopal unit is one of the company’s major manufacturing

facilities. It was established in 1956 and is located in Bhopal, Madhya
Pradesh . The Bhopal unit has a wide range of capabilities and
facilities, including engineering and technology, research and
development, testing and calibration facilities, and pollution control
research institutes . BHEL Bhopal has centers of excellence and offers
a range of products and services to meet the ever-growing needs of
the core sectors of the economy .

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Transformer Block distribution of BHEL Bhopal
 Block-3:- TRM Block (Transformer Capacitor &
Bushing)
The Bushing of power transformer is a type of porcelain or ebonite post
insulator put on the top or side of the transformer tank through which
connections are made to the external circuit.

The types of bushing are as follows:-

1. Porcelain insulator bushing used upto 11 KV.

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2. Oil filled bushings consisting of a hollow porcelain cylinder of special
shape with a hollow tube shaped conductor through its centre used for the
voltage above 33 KV.

CAPACITIVE VOLTAGE TRANFORMER

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The capacitive voltage transformer step-down the high voltage input signals and
provide the low voltage signals which can easily measure through the
measuring instrument. The Capacitive voltage transformer (CVT) is also called
capacitive potential transformer
For measuring high voltage (above 100kV) the high insulated transformer is
required. The highly insulated transformer is quite expensive as compared
to the normal transformer. For reducing the cost, the capacitive potential
transformer is used in the system. The CVT is cheap, and their performance is
not much inferior to the highly insulated transformer.

INSULATION

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Insulation of transformers is important to protect the internal components of the
transformer from damage due to electrical currents, voltage surges, and other
factors that can degrade the transformer's performance.

Insulation materials, such as paper, oil, and resin, are used to insulate the core
and coils of the transformer. This is to ensure that electricity is transmitted
correctly while minimizing the risk of arcing and electrical faults that can lead
to serious damage to the transformer or even catastrophic failure.

One of the main benefits of a well-insulated transformer is its longevity.

Properly insulated transformers can last for decades without experiencing
significant degradation in performance or reliability. This leads to a reduction in
downtime and maintenance costs for the transformer.

Apart from longevity, insulation ensures the safety of the transformer. Reliable
insulation prevents electrical faults and reduces the risk of harm to personnel
and equipment. Electrical faults can cause short-circuits, fires, and serious
damage to the transformer. Hence, installing proper insulation helps protect the
transformer from such accidents

TRANSFORMER WINDING

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 High-voltage winding (many turns of small gauge wire, thicker
insulation)

The high-voltage winding is made up of many turns of relatively thin, insulated

wire wound around the core. This winding is thinner than the low-voltage
winding because it is designed to handle lower currents. The insulation on this
winding must be able to withstand the stress of the higher voltage applied across
it.

Low-voltage winding (fewer turns of larger gauge wire, thinner insulation)

The low-voltage winding has fewer turns of thicker, insulated wire around the
core. This thicker winding is designed to handle higher currents. However, the
insulation on this winding does not have to withstand the same high stress as the
high-voltage winding.

LAMINATION & CORE MANUFACTURING

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Core is an essential component of the transformer. It has a direct impact on the
performance and life of the transformer. The key factors that make CRGO so
special are its high electrical resistivity and low thermal conductivity. This
combination ensures excellent performance in terms of voltage regulation,
current rating, and insulation. Because of these benefits, CRGO has become the
preferred core material for transformers used in demanding applications such as
renewable energy systems and data centers..

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Laminated Core
A transformer comprises a primary and a secondary coil that are
electromagnetically linked. This means that alternating current passed through
the primary creates a varying magnetic field around it, which in turn induces an
alternating current in the secondary. This implementation of Faraday’s law of
induction is valuable because the ratio of input to output voltages – and currents
– can be set by adjusting the ratio of primary turns to secondary turns.
Transformers are according widely used as step-up or step-down devices in
alternating-current circuits. They are also useful for safety isolation.
Within practical transformers, primary and secondary coils are wound around a
common iron core to maximise energy transfer efficiency between them.
However, electric currents flow in the core as well, as it is also a conducting
medium experiencing a varying magnetic field. These currents, known as eddy
currents, are an unwanted source of inefficiency and waste heat generation in
the transformer.

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 PRE COIL ASSEMBLY

The core coil assembly is a vital component in the transformer that plays a
crucial role in efficiently converting electrical energy. A core coil assembly is
the heart of a transformer, which transforms voltage levels to facilitate the
smooth transmission and distribution of electricity across power grids.
Understanding the significance of core coil assemblies unveils the essence of
their role in ensuring the seamless functioning of transformers, which are
indispensable in modern power systems. Delving deeper into their construction,
operation, and importance unveils a fascinating journey into electrical
engineering and power distribution.

A core coil assembly (CCA) is the winding assembly on the core of a

transformer, often referred to as the active part. This crucial component plays a
vital role in the transformer’s functionality, as it is responsible for the magnetic
flux that induces the electromotive force (EMF) in the transformer’s coils.

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 POWER ASSEMBLY

A power transformer assembly is made up of several components, including:

Magnetic core: A crucial part of the transformer assembly process, the core's
flux is sent through a low reluctance channel to complete the magnetic circuit
and then to the secondary cables
Primary and secondary windings: Made from high conductivity copper and
aluminum materials, the windings are manufactured in various sizes and shapes
Cooling system: Transformers generate heat during operation, so cooling
methods are necessary, such as air cooling, oil cooling, or a combination of both
Bushings: Connect the transformer windings to the external electrical system
Protective devices: Safeguard the unit against faults, overloads, and excessive
temperatures, and include devices such as fuses, circuit breakers, and
temperature monitoring systems
Insulating materials: An important part of the transformer
Transformer oil: An important part of the transformer

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 CASE FITTING
1. Understand the Transformer Specifications:

 Type and Size: Determine the type of transformer (e.g., step-up, step-
down, isolation) and its physical dimensions.
 Cooling Requirements: Assess whether the transformer needs air or oil
cooling and ensure the case accommodates these requirements.
 Electrical Ratings: Know the voltage, current, and power ratings to
ensure that the case does not interfere with transformer operation.

2. Design the Case:

 Material: Choose materials that can withstand electrical, thermal, and

mechanical stresses. Common materials include steel, aluminum, or high-
grade plastic.
 Ventilation: Ensure proper ventilation or cooling provisions if the
transformer generates significant heat. This might involve perforations,
fans, or heat sinks.
 Protection: The case should provide adequate protection from
environmental factors like dust, moisture, and mechanical impacts.

3. Prepare for Installation:

 Mounting: Design the case to allow for secure mounting of the

transformer. This may involve brackets, slots, or custom fittings.
 Access Points: Include access points for wiring and maintenance. Ensure
these points are easily reachable and can be sealed properly to maintain
safety.
 Insulation: Ensure that the case includes appropriate insulation to
prevent electrical hazards.

4. Fit the Transformer into the Case:

 Align and Secure: Carefully align the transformer within the case,
ensuring it fits snugly without undue stress on any components.
 Fixation: Use appropriate mounting hardware to secure the transformer
in place. This could include screws, bolts, or other fasteners.
 Connect Wires: Connect any necessary wiring, ensuring that all
connections are properly insulated and secured.

5. Testing and Verification:

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  Safety Checks: Verify that all safety protocols are followed. Check for
proper grounding and insulation.
 Operational Testing: Test the transformer in its case to ensure it operates
correctly and that the case does not obstruct its function or cooling.

6. Compliance and Documentation:

 Standards: Ensure the case complies with relevant electrical standards

and regulations.
 Documentation: Document the installation process, including any
modifications made to the case or transform

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 OIL & DEVELOPMENT

Transformer oil is refined electrical insulating oil, which is extremely stable at

high temperatures and possesses excellent electrical insulating properties. These
special types of oils are widely used in high voltage apparatus such as power
transformers, high voltage capacitors and circuit breakers. Traditionally, mineral
oils have been most commonly used as a coolant or as electrical insulation
medium. However, the main concern related to mineral oil is overheating,
overloading, short circuits that reduce the shelf life of the transformer unit and
restrict its function as a reliable coolant

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 TRANSFORMER TESTING
UHV transformers are tested to ensure they are installed correctly and are in
good working condition. These tests are performed before connecting the
transformer to the electrical system and include:
AC withstand voltage test: Provides a reference for future UHV electric
equipment tests
During testing, the test object's voltage can reach 765 kV, which is many times
its operating voltage. The test can also run for a long time and accurately
measure the amount of PD. When the voltage is 1.5U /, less than 50pC PD can
be distinguished, which means that it's possible to measure the UHV power
transformer

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