This report is complete by Shubham Soni under the guidance of the DGM of BHEL TRM BLOCK which is beneficial for the our juniors for as a hint to complete there report .Enjoy the bhel vocational training as much as possible in the BHEL Thank You

1. 1
VOCATIONAL TRAINING
REPORT
UNDER THE GUIDENCE OF
SHRI. RAJESH K. SINGH (DGM)
(BLOCK 3 TRE BHEL BHOPAL)
(UMA NATH SINGH INSTITUTE OF ENGINEERING & TECHNOLOGY)
VEER BAHADUR SINGH PURVANCHAL
UNIVERSITY, JAUNPUR
SUBMITTED BY
SHUBHAM SONI
Token no.VT-2019/636

2. 2
CERTIFICATE
I am Shubham Soni, students of 3rd
year semester 6th
of Bachelor of
Technology,
Department of Electrical Engineering, Veer Bahadur Singh Purvanchal
Jaunpur
University Jaunpur.
I here certify that this vocational training work carried out by me at Bharat
Heavy Electrical Limited, Bhopal and report submitted in partial fulfilment of
the requirement of the programmer is an original work of mine under the
guidance of the experienced mentor Shri.Rajesh k.Singh (DGM) is not
based on or reproduced from any existing work of any other person or any
earlier work undertaken at any other time or for any other purpose, and has
not been submitted anywhere else at any time. And it is also based upon
my individual observation and work experience.
SHUBHAM SONI SHRI. RAJESH K. SINGH
V.B.S.P.U JAUNPUR (DGM) TRANSFORMER BLOCK
Token no: VT-119/2019 TRE Assembly section Block-3
BHEL BHOPAL

3. 3
ACKNOWLEDGENT
I would like to express my gratitude for the people who were part of my
project report, directly or indirectly the people who gave unending support
right from the stage the idea was conceived.
An engineer with only theoretical knowledge is not a complete engineer.
Practical knowledge is very important to develop and apply engineering
skills. It give me a great pleasure to have an opportunity to acknowledge
and to express gratitude those who were associated with me during my
training at BHEL, Bhopal.
I take this opportunity to express my sincere gratitude to the people who
have beenhelpful in the successfulcompletion of my Industrial training and
this project. I would like to show my greatest appreciationto SHRI RAJESH
K. SINGH, DGM TRE block no 3 who granted me the permission of
Industrial training in the BHEL, Bhopal.
I would like to thanks to all those people who directly or indirectly helped
and guided us to complete my training and this project including the
following instructor, technical staff and supervisor of various section.
Thinking you
SHUBHAM SONI
V.B.S.P.U JAUNPUR

4. 4
INDEX
Chapter: 1 Introduction
 Index……………………………………………………...……..…04
 BHEL-An overview……………………………………………..…05
 BHEL- Bhopal……………………………………………………..06
Chapter: 2 Product of BHEL
A) Transformer………………………………………………….08
a) TransformerIntroduction……………………………………..08
b) Principle of Transformer……………………………………...09
c) Transformercore……………………………………………...10
d) Winding………………………………………………………...11
e) Coil Assembly…………………………………………………12
f) Power Assembly……………………………………………...13
g) Case Fitting……………………………………………………15
h) Testing…………………………………………………………16
i) Dispatching……………………………………………………17
j) Assembling…………………………………………………….18
B) Motor/Generator……………………………………………..
a) Motor/Generator Introduction………………………………..19
b) Principle of motor……………………………………………...19
c) Principle of Generator…………………………………………19
d) Type of motor…………………………………………………..20
e) Type of Generator……………………………………………..21
Chapter:3 TractionMotor……………………………………………….
a) Traction Motor Introduction…………………………………….22
b) Principle of Traction motor……………………………………..22
c) Application of Traction…………………………………………..23
Chapter:4Reference:…………………………………………………………24

5. 5
BHEL – An Overview
BHEL – AN OVERVIEW Bharat Heavy Electrical Limited (BHEL) owned by the
Government of India, is a power plant equipment manufacturer and operates as
engineering and manufacturing company based in New Delhi, India. Established in
1964, BHEL is India’s largest engineering and manufacturing company of its kind.
The company has been earning profit continuously since 1971-72 and paying
dividends uninterruptedly since 1976-77. It has been granted the prestigious
Maharatna (big gem) status in 2013 by Govt of India for its outstanding performance.
The elite list of Maharatna contains another 6 behemoth PSU companies of India.
BHEL was established in 1964 Heavy Electricals (India) Limited was merged with
BHEL in 1974. In 1982, it entered into power equipment, to reduce its dependence
on the power sector. It developed the capability to produce a variety of electrical,
electronic and mechanical equipment for all sectors, including transmission,
transportation, oil and gas and other allied industries. In 1991, it was converted into
a public limited company. By the end of 1996, the company had handed over 100
Electric Locomotives to Indian Railway and installed 250 Hydro-sets across India.
IT’S OPERATION: BHEL is engaged in the design, engineering, manufacturing,
construction, testing, commissioning and servicing of a wide range of products,
systems and services for the core sectors of the economy, viz. power, transmission,
industry, transportation, renewable energy, oil & gas and defense.
It has a network of 17 manufacturing units, 2 repair units, 4 regional offices, 8
service Centre’s, 8 overseas offices, 15 regional Centre’s, 7 joint ventures, and
infrastructure allowing it to execute more than 150 projects at sites across India and
abroad. The company has established the capability to deliver 20,000 MW p.a. of
power equipment to address the growing demand for power generation equipment.
BHEL has retained its market leadership position during 2015-16 with 74% market
share in the Power Sector. An improved focus on project execution enabled BHEL
record its highest ever commissioning/synchronization of 15059 MW of power plants
in domestic and international markets in 2015-16, marking a 59% increase over
2014-15. With the all-time high commissioning of 15000 MW in a single year
FY2015-16, BHEL has exceeded 170 GW installed base of power generating
equipment’s.
It also has been exporting its power and industry segment products and services for
over 40 years. BHEL's global references are spread across over 76 countries across
all the six continents of the world. The cumulative overseas installed capacity of
BHEL manufactured power plants exceeds 9,000 MW across 21 countries
6 including Malaysia, Oman, Iraq, UAE, Bhutan, Egypt and New Zealand.
Their physical exports range from turnkey projects to after sales services.

6. 6
MANUFACTURINGUNIT IN INDIA
 Centralized Stamping Unit & Fabrication Plant (CSU & FP), Jagdishpur
 Insulator Plant (IP), Jagdishpur
 Electronics Division (EDN), Bangalore
 Industrial Systems Group (ISG), Bangalore
 Electro-Porcelains Division (EPD), Bangalore
 Heavy Electrical Plant (HEP), Bhopal
 Industrial Valves Plant (IVP), Goindwal
 Heavy Electrical Equipment Plant (HEEP), Ranipur (Haridwar)
 Central Foundry Forge Plant (CFFP), Ranipur (Haridwar)
 Heavy Power Equipment Plant (HPEP), Hyderabad
 Transformer Plant (TP), Jhansi
 Boiler Auxiliaries Plant (BAP), Ranipet
 Component Fabrication Plant (CFP), Rudrapur
 High Pressure Boiler Plant (HPBP), Tiruchirappalli
 Seamless Steel Tube Plant (SSTP), Tiruchirappalli
 Power Plant Piping Unit (PPPU), Thirumayam
 Heavy Plates & Vessels Plant (HPVP), Visakhapatnam
PRODUCTS OF BHEL:
 Thermal power Plants
 Nuclear power Plants
 Gas based power Plants
 Hydro power Plants
 DG power Plants
 Boilers (steam generator)
 Boiler Auxiliaries
 Gas generator
 Hydro generator
 Steam turbine
 Gas turbine
 Hydro turbine
 Transformer
 Switchgear
 Oil field equipment
 Boiler drum
 Piping System
 Soot Blowers
 Valves
 Seamless Steel Tubes
 Condenser s and Heat exchangers
 Pumps

7. 7
 Desalination and Water treatment plants
 Automation and Control systems
 Power electronics
 Transmission system control
 Semiconductor devices
 Solar photo voltaic
 Software system solutions
 Bus ducts
 Insulators
 Control panels
 Capacitors
 Bushings
 Electrical machines
 DC, AC heavy duty Motors
 Compressors
 Control gears
 Traction motors
 Research and development products
BHEL BHOPAL
Vision:
A Global Engineering Enterprise providing Solutions for better tomorrow
Mission:
Providing sustainable business solutions in the fields of Energy, Industry &
Infrastructure
Values:
Governance, Respect, Excellence, Loyalty, Integrity, Commitment, Innovation, Team
Work BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving
towards superiority by acquiring TQM as per EFQM/CII model of Business Excellence.
Heat Exchanger Division is accredited with ASME “U” Stamp. With the slogan of
“Kadam Kadam milana hai, grahak safal banana hai”, it is committed to the customers.
BHEL Bhopal has its own Laboratories for material testing and instrument calibration
which are accredited with ISO 17025 by NABL. The hydro Laboratory and Centre for
Electric Transportation are the only laboratories of it are in this part of world. Awards
and Recognition National e-Governance Award: Bharat Heavy Electricals Limited
(BHEL), has been conferred upon the prestigious National e-Governance Gold Award of
Government of India for 2012-13, in the category L

8. 8
Introduction To Transformer
a) Power Transformers:
The term 'Power Transformers'is refer to the transformers used
between the generator and the distribution circuits, and these are
usually rated at 500 kVA and above. Power systems typically consist
of a large number of generation locations, distribution points, and
interconnections within the system or with nearby systems,such as a
neighboring utility. The complexity of the system leads to a variety of
transmission and distribution voltages. Power transformers must be
used at each of these points where there is a transition between
voltage levels. Power transformers are selected based onthe
application, with the emphasis toward custom designbeing more
apparent than larger the unit. Power transformers are available for
step-up operation, primarily used at the generator and referred to as
generator step-up (GSU) transformers;step-downoperation, mainly
used end to feed distribution circuits and to connect grids operating at
differentvoltage levels through in terconnecting transformers.Power
transformers are available as single-phase or three-phase apparatus.
Power transformers have been looselygrouped into three market
segments based on size ranges. These three segments are:
1. Small power transformers 500 to 7500 kVA
2. Medium power transformers 7500 to 100 MVA
3. Large power transformers 100 MVA and above

9. 9
b) Principles of Transformers:
A transformeris a static piece of apparatus used for transferring
power from one circuit to another without change in frequency.It can
raise or lower the voltage with a corresponding decreaseor increase
in current. In its simplestform,a transformer consists of two
conducting coils having a mutual inductance. The primary is the
winding which receives electric power, and the secondary is the one
which may deliver it. The coils are wound on a laminated core of
magnetic material. The physical basis of a transformer is mutual
inductance betweentwo circuits linked by a commonmagnetic flux
through a path of low reluctance as shown in fig.
1 The two coils possesshigh mutual inductance. If one coil is
connected to a source of alternating voltage, an alternating flux is set
up in the laminated core, mostof which is linked up with the other coil
in which it produces mutually induced emf (electromotive force)
according to Faraday's laws electromagnetic induction, i.e.
e = M di
dt
Where,e = induced emf
M = mutual inductance
If the second circuit is closed,a current flows in it and so electric
energy is transferred (entirely magnetically) from the first coil (primary
winding) to the second coil(secondary winding).

10. 10
TRANSFORMER CORE BUILDING:
Following steps are involved in power transformercore construction:
 Cutting & punching of CRGO
 Stacking of CRGO
 Fiber Glass End Frame insulation
 Insulated Bolting of End Frame.

11. 11
WINDING:
TYPE OF WINDING MACHINE
Winding machine are of two type;
1) Horizontal Winding Machine
2) Vertical Winding Machine
Horizontal Winding Machine Vertical Winding Machine

12. 12
TYPE OF WINDING CONDUCTOR:
The various type of conductoruse in coil winding are
1) CTC (Continuously Transposed Conductor)
2) PICC (Paper Insulated CopperConductor)
3) BPICC (Bunch Paper Insulated CopperConductor)
COIL ASSEMBLY:
The coils are specified in the designmay be of following types on the basis
of operating voltage:
1) L.V. Coil Winding
2) COMMON Winding
3) H.V. Coil Winding
4) Tap Coil Winding
Coil Sequence:
L.V. Coil is placed adjacent to the CRGO steelcore and H.V coil
outside, in order to minimize the amount of insulation required.
while assembling the differentcoils (i.e. Tap coil, L.V. Coil & H.V.
Coil) tap coil can be placed in either of three positions depending upon the
length of tap coil i.e. if tap coil is small it is placed inside of LV coil, if it is
medium then between LV & HV coil, and if large then outside of HV coil.

13. 13
POWER ASSEMBLEY:
- Coil Assembly1
a) Unlatching of core
b) Fitting of bottom insulation
c) Core coil assemblyas per drawing/electrical specification
- Coil Assembly2
a) Fitting of top insulation
b) Relacing of core

14. 14
a) Crimping & Brazing
b) Insulation Wrapping
c) OLTC Connection
d) Electrical Circuit manufacturing
a) Vapour Phase Drying
b) Servicing.

15. 15
CASE FITTING:
Case Fitting involves connecting accessories of transformer,these
accessories include following:
a) CT connections & Feed positions
b) Conservator
c) Bushing Connections
d) Magnetic Oil Gauge
e) Oil Temperature Indicator
f) Buchholz Relay
g) Radiator
h) Breather
i) Control panel

16. 16
TESTING TO THE STANDARDS
Routine tests:
1) Voltage ratio and polarity.
2) Winding resistance.
3) Short-circuit impedance and load loss.
4) Dielectric test.
5) No-load losses and current.
6) On-load tap-changer.
Type tests:
1) Temperature rise test.
2) Lightning impulse test

17. 17
ROUTINE TEST FOR TRANSFORMER AS PER IS 2026:
1) Dimensional Check
2) Winding Resistance Test
3) Short Circuit Test
4) Open Circuit Test
5) Induced Over Voltage Test
6) Separate Source Voltage
7) Insulation Resistance Test
8) B.D.V of Oil
9) Turns Ratio Test
DISPATCH
After successfulcompletionof testing, transformeris handed over to
dispatch sections.At this stage after checking oil leakage, dismantling of all
bushings, turrets etc. and covered with the blanking plates and the tank is
fitted with nitrogen gas and then the transformer is dispatched to the
concerned site. The power factor terminal is the terminal of the earth foil of
primary insulation and it is brought either on transformer tank separately or
inside secondaryterminal box.
As a quality control measure the power factor of the primary
insulation is monitored constantly during processing to determine dryness
of insulation before impregnationwith oil. The system has been designed
with menu driven prompts so that an user without any knowledge of 3-D
modelling software or database packages can use the system.The only
need is that the user know how to use Auto CAD, which is a commonCAD
software.
There are generally three separate shipments made:
1) The main tank c/w core and coils,
2) The accessories that have been removed and packaged,and
3) The insulating oil.

18. 18
Assembly

19. 19
MOTOR / GENERATOR:
Motor:
An electric motor is an electrical machine that converts electrical
energy into mechanical energy. Most electric motors operate through the
interaction between the motor's magnetic field and electric current in a wire
winding to generate force in the form of rotation of a shaft.
Generator:
In electricity generation, a generator is a device that converts motive
power (mechanical energy) into electrical power for use in an
external circuit. Sources of mechanical energy include steam turbines, gas
turbines, water turbines, internal combustionengines and even
hand cranks. The first electromagnetic generator,the Faraday disk, was
invented in 1831 by British scientist Michael Faraday.
Principle of motor:
The basic working principle of a DC motor is: "whenevera current
carrying conductoris placed in a magnetic field,it experiencesa
mechanical force". The directionof this force is given by Fleming's left-hand
rule and its magnitude is given by
F = BIL.Where,
B = magnetic flux density,
I = current and
L = length of the conductorwithin the magnetic field.
Principle of Generator:
Generators produce electrical power based on the principle of Faraday’s
law of electromagnetic induction. The magnitude of this induced EMF
depends upon the rate of change of flux (magnetic line force) linkage with

20. 20
the conductor. This EMF will cause a current to flow if the conductor
circuit is closed.
Motor Type:

21. 21
Type of Machine
1) DC Machine
2) AC Machine

22. 22
TRACTION MOTOR:
Traction motor refers to a type of electric motor. A traction motor is used
to make rotation torque on a machine. It is usually changed into a straight
line motion.
Traction motors are used in electrically powered rail vehicles such
as electric multiple units and electric locomotives.They are also used in
electric vehicles, such as electric milk floats, elevators,
and conveyors. Vehicles with electrical transmission systems such
as Diesel-electric locomotives,electric hybrid vehicles and battery power.
.
As the DC motor starts to turn, the magnetic fields inside start to join
together. They create an internal voltage. This electromagnetic force (EMF)
works against the voltage sent to the motor. The EMF controls the current

23. 23
flow in the motor. As the motor speeds up, the EMF falls. Less current
flows into the motor, and it makes less torque. The motor will stop
increasing its speed when the torque matches (is the same as) the drag on
the train. To accelerate the train, more voltage must be sent to the motor.
One or more resistors are removed to increase the voltage. This will
increase the current. The torque will increase, and so will the speed of the
train. When no resistors are left in the circuit, full line voltage is applied
directly to the motor

24. 24
REFERENCES
[1] Dr. P. S. Bhimbra, “Electrical Machines”, Khanna Publications, New
Delhi.
[2] D. P. Kothari and I. J. Nagrath, “Electrical Machines”, 3rd Edition, TMH,
New Delhi.
[3] BHEL, “Transformers” 2nd Edition, Tata McGraw Hill Education Private
Limited.