This document discusses a minor training report submitted by Ayushi Pandey to Bharat Heavy Electricals Limited (BHEL) in Bhopal, India. It provides certificates signed by her project guide acknowledging her work. It also includes acknowledgements, preface, table of contents, and begins discussing BHEL and its manufacturing units in Bhopal, as well as some of its major product lines including turbines, generators, transformers and control equipment.

1. BHARAT HEAVY ELECTRICALS LIMITED,
BHOPAL
Academic session
2015-2016
A Minor Training Report on
Control Equipment Engineering
Under the Guidance of : Submitted By:
MR AJAY DHOTE AYUSHI PANDEY
Sr. DGM (Design) ELECT. & COMM. ENGINEERING
C.E.E., BHEL Bhopal MANIPAL UNIVERSITY JAIPUR

2. CERTIFICATE
This is to certify that the project report entitled “Control Equipment Engineering
” is a piece of project work done by AYUSHI PANDEY student of Electronics
& Communication Department, Manipal University Jaipur under my guidance
and supervision for partial fulfillment of the requirement for the award of the
degree of B.Tech in Electronics & Communication Engineering at Manipal
University Jaipur.
To the best of my Knowledge and belief, the project report:
1) Embodies the work of candidate herself;
2) Has duly been completed;
3) Fulfills the requirement of the ordinance relating to the B.TECH. degree
of the University;
4) Is up to the standard both in respect of content and language for being
referred to the examiner.
PROJECT GUIDE:
Mr. AJAY DHOTE
Sr. DGM (Design) DATE: 4TH JULY’15
C.E.E., BHEL Bhopal

3. ACKNOWLEDGEMENT
I would like to thank the project co-coordinator Mr. AJAY DHOTE for providing
all the material possible and encouraging throughout the course. It is great pleasure
for me to acknowledge the assistance and contributions of all the engineers of
various departments of BHEL BHOPAL for their prompt and timely help in the
official clearances and valuable suggestions during the time of this training. I am
also thankful to numerous BHEL engineers especially Mr. PRAMOD KUMAR
MEHER, who helped me in understanding the products of their respective
product groups.
Secondly, I am thankful to Mr. Pramod Kumar, for his support, cooperation, and
blessings.
Thirdly, I would like to express sincere gratitude to Mr. Dinesh Dubey, for and to
Mr. Ankur Saxena, under whose guidance I completed my training, for their
constant support, cooperationand guidance during the course of my training.
I also extend my sincere appreciation to all staff members of C.E.E Division
BHEL, Bhopal who provided there valuable suggestions and precious time in
accomplishing my project report.
I would also like to express my profound gratitude to Control Equipment
Engineering for constant and valuable suggestions while doing the training work.
Last but not least, I express my heartiest gratitude to Almighty god, our Parents for
their love and blessings to complete the training successfully
Submitted By:
AYUSHI PANDEY

4. PREFACE
In this growing age of technology, the extent of correctness is a major point. This
correctness and pin pointed guess is achieved only through hard work, experience
and well guided practice. As a new comer to this field we required to have
professional knowledge that will help in improving our skills and efficiency.
Having a training work on the same topic increased our interest and made the work
simpler.
The most vital part is the presence of a guide whose knowledge and practical
experience built our self-confidence and helping hand by which we finished this
project successfully. So we all are indebted to Mr. AJAY DHOTE who
acted as a burning candle and enlightened us about this training.

5. TABLE OF CONTENT
Introductionof BHEL Bhopal
o Manufacturing Units of BHEL Bhopal
o ProductProfile
o BHEL objective
Introductionto C.E.E
Oil Rig Control
o System Description
o Drilling
o SCR
o DC/AC Module
Plant Control
o Automatic voltage regulator
o Electro Hydrolic Governor
o Large Current Rectifier
o Electronic Controller
Transportationcontrol
o Electric traction system
Bibliography
Conclusion

6. BHARAT HEAVY ELECTRICALS
LIMITED
Bharat Heavy Electricals Limited (BHEL) is one of the oldest and
largest state owned engineering and manufacturing enterprise in India in
the energy-related and infrastructure sector which
includes Power, Railways, Transmission and Distribution, Oil and
Gas sectors and many more. It is the 12th largest power equipment
manufacturer in the world. In the year 2011, it ranked ninth most
innovative company in the world by US business magazine Forbes.
BHEL is the only Indian Engineering company on the list, which
contains online retail firm Amazon at the second position with Apple
and Google at fifth and seventh positions, respectively. It is also placed
at 4th place in Forbes Asia's Fabulous 50 List of 2010. BHEL was
established more than 50 years ago, 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-
77.74% of the total power generated in India is produced by equipment
manufactured by BHEL.
It is one of India's nine largest Public Sector Undertakings or PSUs,
known as the Navratnas or 'the nine jewels'. In June 2012, BHEL
commissioned a 250 MW power generating unit at Harduaganj in Uttar
Pradesh.This would add six millin units of electricity on a daily basis.

7. MANUFACTURING UNIT OF BHEL
First GenerationUnits:-
BHOPAL Heavy Electrical Plant
HYDERABAD Heavy Electrical Equipment Plant
HYDERABAD Heavy Electrical Power Equipment Plant
TIRUCHY High Pressure Boiler Plant
Second GenerationUnits:-
JHANSI Transformer and Locomotive Plant
HARIDWAR Central Foundry and Forge Plant
TIRUCHY Seamless Steel Tube Plant
New Manufacturingunits:-
RANIPAT Boiler Auxiliaries Plant
JAGDISHPUR Insulator Plant
RUDRAPUR Component and Fabrication Plant
BANGALORE Industrial System Group

8. BHARAT HEAVY ELECTRICALS LIMITED,
BHOPAL
Heavy Electrical Plant, Bhopal is the mother plant of Bharat Heavy Electricals
Limited, the largest engineering and manufacturing enterprise in India in the
energy-related and infrastructure sector, today. It is located at about 7 kms. From
Bhopal Railway station, about 5 kms . From Habibganj Railway station and about
18 kms. From Raja Bhoj Airport. With technical assistance from Associated
Electricals (India) Ltd., a UK based company; it came into existence on 29th of
August, 1956. Pt. Jawaharlal Nehru, first Prime minister of India dedicated this
plant to the nation on 6th of November, 1960.
BHEL, Bhopal with state-of-the-art facilities, manufactures wide range of
electrical equipments. Its product range includes Hydro, Steam, Marine & Nuclear
Turbines, Heat Exchangers, Hydro & Turbo Generators, Transformers,
Switchgears, Control gears, Transportation Equipment, Capacitors, Bushings,
Electrical Motors, Rectifiers, Oil Drilling Rig Equipments and Diesel Generating
sets.
BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving
towards excellence by adopting 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.

9. BHEL Bhopal has its own Laboratories for material testing and instrument
calibration which are accredited with ISO 17025 by NABL. The Hydro
Laboratory, Ultra High Voltage laboratory and Centre for Electric Transportation
are the only laboratories of it’s in this part of
Theworld. .
BHEL Bhopal's strength is its employees. The company continuously invests in
Human Resources and pays utmost attention to their needs. The plant's Township,
well known for its greenery is spread over an area of around 20 sq kms. And
provides all facilities to the residents like, parks, community halls, library,
shopping centers, banks, post offices etc. Besides, free health services is extended
to all the employees through 350 bedded (inclusive of 50 floating beds) Kasturba
Hospital and chain of dispensaries
BHEL caters to core sector of Indian economy viz. Power Generation
and Transmission, Industry, Transportation, Telecommunication, Renewal energy
defense etc. The wide network of BHEL 's, 14 manufacturing divisions, 4 Power
sector regional centers, 8service centers ,18 regional office and a large numbers of
project sites spread all over India and abroad enable the company to promptly
serve its customer and provide them with suitable products, system and services at
competitive prices. BHEL has already attained ISO 9000 and all the major
units/divisions of BHEL have been upgraded to the latest ISO-9001: 2000 version
quality standard certification for quality management. All the major units/divisions
of BHEL have been awardedISO-14001certification for environmental
management systems and OHSAS 18001 certification for occupational health and
safety management systems.

10. POWERSECTOR:
Generation:
Power sector comprises of thermal, nuclear and hydropower plant business. Today
BHEL supplied sets account for nearly 6473 MW or 68% of the total installed
capacity of 99146
MW in company as against nil in 1969-70.
Transmission:
BHEL also provides a wide range of transmission products and systems of up to
400 KV class.
These include high voltage power and distributed transformer, capacitor, insulator
etc. For economic transmission of bulk power over long distances High voltage
Direct Current (HVDC) systems are supplied.
INDUSTRYSECTOR:
BHEL is a major contributor of equipment and systems to industries like cement,
fertilizers,
Refinery, petrochemicals, etc.
TRANSPORTATION:
Most of the trains operated by the India Railways including Metro in Kolkata are
equipped
With BHEL’s traction controlequipment.
TELECOMMUNICATION:
BHEL also caters to the telecommunication sector by way of small, medium and
large switching systems.
RENEWABLEENERGY:
Technologies that can be offered by BHEL for its exploiting non-conventional and
renewable
Sources of energy include: wind-electric generator, solar power based water pumps,
lighting
And heating systems
.
INTERNATIONALOPERATIONS:
BHEL has over the years, established its reference in over 60 countries worldwide,
ranging from USA to New Zealand in the Far East.

11. NATIONAL CUSTOMERS OF BHEL:
 Punjab state electricity board(PSEB)
 Uttar Pradesh state electricity board(UPSEB)
 National thermal power corporation(NTPC)
 Appolo tyres
 Bakco
 Sail
 Birla tyres and birla cement
 Grasim industries
 IOC
 Essar oil
 ONGC
 Larsen and turbo
 Jk cement
 Kirloskar
 Siemens etc.
INTERNATIONALCUSTOMERS OF BHEL:
M/S ESBARA CORPORATION,JAPAN
M/S ZEECO IN CORPORATION,USA
SIMMCO INTERNATIONAL
SIEMENS, GERMANY
SIEMENS, SINGAPORE
BIEJI PROJECT, IRAQ
LMZ, RUSSIA, etc
.
TECHNOLOGICALUPGRADATIONAND RESEARCH&DEVELOPMENT:
Toremain competitive and meet customers' expectations, BHEL lays great emphasis on
the continuous up gradation of products and related technologies, and development
of new products. BHEL's commitment to advancement of technology is reflected
in its involvement in the development of futuristic technologies like fuel cells and
superconducting generators. BHEL's investment in R&Dis amongst the largest in the
corporatesectorin India. During the year 2010-11, BHEL invested Rs.10,050 Million on
R&D efforts- 21% higher than the previous year.

12. PRODUCT PROFILE OF BHEL BHOPAL
1. Ac motors and alternators
2. Hydro turbines
3. Hydro generators
4. Heat exchangers
5. Excitation control equipment
6. Steam turbines
7. Transformer
8. Switch gear
9. OLTC
10. Large current rectifiers
11. Control and relay panels
1. AC MOTORS & ALTERNATORS
Figure 1 Alternator
BHEL is a leading AC Machines manufacturer and in the last four decades have supplied more
than 20000 HT & LT A.C. Machines for various applications to Indian as well as Export market.

13. The applications include Power Plants, Nuclear Energy, Petrochemicals, Fertilizers, Refineries,
Cement & Steel Industries, Irrigation Projects, Pipelines, etc.
The manufacturing plant in Bhopal was established in technical collaboration with AEI UK.
Commercial production of A.C. Machines commenced in the year 1963. Technology was
upgraded by collaborating with Siemens AG, Germany from 1980-1990 and subsequently from
1996-2006. Motors are offered both in standard as well as tailor made designs to meet customer's
specific needs. High performance is achieved through optimum utilization of the active materials
and components. BHEL A.C. Machines offer high efficiency, exceptional reliability, quick
installation and minimal maintenance costs.
Our engineers combine their extensive experience with state-of-the-art analytical design tools,
latest machine tools, Six Sigma methodology and advanced material development to deliver the
best product.
Installed Capacity: 1500 machines per annum.
2. HYDRO TURBINES
Figure 2 Hydro Turbine
 A leading turbine manufacturer offering a wide range of Hydro Turbine, Valves,
Governors, Turbine and Station Auxiliary systems, balance of plants for Hydro Power
Station and related Services.
 Installed manufacturing capacity:2500 MW/annum.
 Two units manufacturing hydro turbines.
 In the market for more than three decades.
 Dedicated shop area of over 100000 sq. meters.
 Ultramodern model development and testing facilities.
 Sophisticated CAD/CAM facilities.
 ISO 9001 Certification.
 ASME "Q" stamp for fabrication facilities.

14. 3. HYDRO GENERATORS
Figure 3 Hydro Generator
Hydro generator is a synchronous alternator driven by a hydraulic turbine. Motor is synchronous
motor to drive pump. BHEL Bhopal is a leading supplier of large, medium& small hydro
generators, motors, bulb generators and related services.
 Installed manufacturing capacity : 2500 MW
 Sophisticated CAD facilities
 ISO-9001 certification
4. HEAT EXCHANGERS
Thermal group of BHEL-Bhopal was formulated in year 1968 (Initial collaboration with M/s
AEI -U.K. took place in year 1970) and started its production from year 1971
onwards. Subsequently, new collaboration agreement with M/s BALCKE DURR- Germany for
Moisture Separator Re-Heater (MSR) took place in 1987. MSR to this new design were
manufactured and supplied for 236 MW RAPP 3, 4 & KAIGA 1, 2 and 500 MW TAPP 3&4
Nuclear plants.
BHEL-Bhopal Thermal group products manufactured and supplied all over India to different
State Electricity Boards and exported to countries like LIBYA, Malaysia, Azerbaizan,
Bangladesh, OMAN etc. major customers of thermal equipment’s are State Electricity Boards
and NTPC. Similarly Industrial Heat Exchangers have been supplied to IFFCO, FEDO,
RELIANCE, GAIL, ONGC, IOCL, etc. Production of some of the other products like Rubber
Expansion Joints, Flash Tanks, Miscellaneous storage tanks and Butterfly valves added in
subsequent years.
All the Thermal products are tailor made and customer specific product and Customer
requirements are continuously captured through pre-tender and post tender discussions, contract
review etc. Perception is collected through customer surveys.

15. Thermal group products are Technology intensive and therefore Technology development is of
strategic importance. Product technology is continuously upgraded through in house
development projects/ or Technical Collaboration.
AUXILIARY HEAT EXCHANGERS
Different types of auxiliary heat exchangers are being manufactured at BHEL. Depending upon
application these auxiliary Heat Exchangers are named as
 Air Coolers (CACW)
 Oil Coolers (Shell & tube type / Frame and tube type (Single tube &Concentric double
tube construction) / OFAF), Plug in type
 Water Cooler (Shell & Tube type)
 Hydrogen Cooler etc. (Frame and tube type).
 Air Cooler CACA ( Duct and tube type)
These coolers are accessories to main equipment’s such as Generator, Turbine, Transformer,
Motors, etc. hence special attention is given to make these coolers compact in design and for
trouble free service.
To ensure long life of these coolers materials for different components is decided carefully
considering its application and water chemistry. Constructionally these coolers are very easy to
maintain.
5. EXCITATION CONTROLEQUIPMENT
Excitation control equipment (automatic voltage regulator (AVR) and static excitation
equipment-(SEE) for semi-static, static and brushless type of excitation system.
Complete range of Digital AVR and SEE available to suit all types of systems and generators
added to product profile in the year 2003. More than 35 years of field experience.
More than 600 AVRs are operating satisfactorily at various Hydro, Thermal and Industrial Power
Plants. A number of captive power plant installed in Sugar, Chemicals, Paper and other
industries are also equipped with BHEL make AVRs. Total system solutions on offer
retrofitting of old excitation control system with latest state of art digital systems.
There is a dedicated shop area with modern manufacturing and testing facilities

16. Figure 5 Excitation Control equipment for Hydro, Thermal Nuclear, Naval and Industrial
applications.
6. STEAM TURBINES
1) Design, Manufacturing, Erection, Commissioning and Services of :
 30 MW, 120 MW Steam Turbines
 236 MW Nuclear Turbines.
 15000 SHP Marine Turbines
 210 MW Steam Turbines.
2) Supply of Spares and Repairs of above Steam Turbines.
3) R & M and Life assessment studies of BHEL & Non BHEL TG sets.
4) Repair and Supply of Spares of 210 MW and 500 MW KWU Turbines.
5) Repair and supply of Spares for Non BHEL TG Sets.
7. TRANSFORMER
 A Leading Engineering Enterprise which Supplies wide Spectrum of Power Transmission
Systems/ Solutions from a single entity
 A Leading Transformer Manufacturer Offering wide range of Transformers
 Installed manufacturing capacity: 18000 MVA/Annum with dustproof facility in critical
areas.
 The capacity is being augmented by another 12000 MVA/Annum with totally dust proof
facility
 Having nearly 4 decades or over 30,000 man-years of experience
 Dedicated shop area of over 80000 sq. meters and unique Ultra High Voltage testing
facility

17. 8. SWITCHGEAR
 Leading Switchgear Group involved in Design, manufacturing, installation,
commissioning and services of Switchgear.
 A wide spectrum of switchgear catering to various applications like power station
auxiliaries, power distribution, process industries, rural electrification, open cast mines,
electric traction and other special applications.
 Market leaders in India.
 Experience of 5 decades
 Thousands of various types of breakers working satisfactorily in India and abroad.
 Unique distinction of widest range of medium voltage Switchgear meeting every
requirement of the customer in stringent Indian conditions.
 Strong R & D infrastructure.
 Dedicated shop and design area of over 50,000 sq meters.
 Regular facilities updating with new capital investment.
 Clear room facility for GIS
 Strengths:
- Reliable and problem free product
- Proven product in service
- Repeated successful type testing and special testing
- Largest range to suit various application requirements viz Power Stations,
 Distribution, Industrial & Railways.
- 100% routine testing as per IS & IEC.
 Switchgear design fully type tested as per IEC:62271
9. ON LOAD TAP CHANGER
 A leading On Load Tap Changer (OLTC) group involved in Design, manufacturing,
commissioning and services of Tap Changers.
 Latest Technology incorporating high speed resistor switching of OLTC
 Complete system for parallel operation of transformers and remote Tap changer control
panel.
 Market leaders in India
 Capacity to supply 500 nos. OLTC
 Experience of more than 4 decades.
 Dedicated shop area of over 10,000 sq meters

18. A
TRAINING
REPORT ON
CONTROL EQUIPMENT
ENGINEERING
(CEE)

19. INTRODUCTION OF CEE
The Control Equipment Engineering (CEE) group is engaged in serving all the
Industries i.e. Industry sector, Power sector, Transportation sector, Oil Rig sector
and Defence sector.
There are more than 30 main products each having 4/5 variety w.r.t. rating,
specification, features, etc. are being engineered and pioneered in SCR division.
Besides, more than 100 variety of sub-assemblies / apparatus are also being catered
to meet customer's need.
The different controls are:
1. Transportation controls
2. Plant and Industrial Controls
3. Oil Rig Controls
4. Defence Controls

20. OIL RIGS CONTROL
System description
The system consist of six 670 KW , 12.5 KVA, 3 phase, 50 Hz diesel generator
feeding a common 600V collecting bus. The system can be operated with any
number of generators running on the line and control of each generated frequency
and volume is set individually on the respective switch gear cubicle.
Six SCR plant power cubicles are connected to the common bus and draw AC
power from which ever generator running, converting it to DC power for driving
various DC motors.
The SCR drive automatically selects the correct speed control function suitable for
the motor to which it is assigned, as soon as the main DC contactors are energized.
There are two 600 V feeder breaker which supply the 500 KVA transformer to
feed the 380V distribution.
DRILLING ASSIGNMENT
a. Single Assignment switch
The main control centre for the drilling operation is the drillers console usually
fixed on or close to the draw works. The main drilling assignment switch allows
the driller to assign each of the SCR bridges he has for drilling to anyone of the
pre-arrange programs shown on the console engraving.
b. Multiple assignmentswitch
A separate switch is provided for each function allowing assignment of each
function to one of several SCR

21. DRILLING INSTALLATIONS
Types of oil rigs:
• OFF SHORE RIGS
• ON SHORE RIGS (LAND RIGS)
MAIN DRILLINGEQUIPMENTS
1. TYPE-I RIG : E760 RIG-Up to 3600 mtrs
2. TYPE-II RIG : E1400 RIG-Up to 4900 mtrs
3. TYPE-III RIG : E2000 RIG- Up to 6100 mtrs
4. TYPE-IV RIG : E3000 RIG- Up to 9000 mtrs

22. DeepDrilling
 E 760 RIG
SALIENT SPECIFICATIONS OF THE RIG EQUIPMENT ARE:
- BHEL E760 AC SCR RIGS ARE SUITABLE FOR DRILLING UPTO 3600 MTRS.
- MAST CLEAR HEIGHT 142 FEET
- FLOOR HEIGHT 25 OR 18 FEET
- CASING LOAD CAPACITY IS 500,000 LBS
- E760 DW (1000HP) SUITABLE FOR DRIVE WITH TWO MOTORS & ECB.
- ROTARY IS EITHER CHAIN DRIVEN THROUGH DW OR INDEPENDENT
ROTARY DRIVE.
- RIG EQUIPPED WITH 3 AC POWER PACKS 1215/1430 KVA RATED
- DCPCR WITH 3 GEN AND 3/4 SCR PANELS ( 4 IN CASE OF IRD RIG)
- 2 NOS 850PT MUD PUMPS WITH RATED INPUT HP 850. MAX WORKING
PRESSURE 5000PSI
- 5 TANK MUD SYSTEM
DeepDrilling
 E1400 RIG
SALIENT SPECIFICATIONS OF THE RIG EQUIPMENT ARE :
- BHEL E1400 AC SCR RIGS ARE SUITABLE FOR DRILLING UPTO 4900 MTRS.
- MAST CLEAR HEIGHT 142 FEET
- FLOOR HEIGHT 25 FEET
- CASING LOAD CAPACITY IS 800,000 LBS
- E1400 DW (1400 HP) SUITABLE FOR DRIVE WITH TWO MOTORS & ECB.
- ROTARY IS EITHER CHAIN DRIVEN THROUGH DW OR INDEPENDENT
ROTARY DRIVE.
- RIG EQUIPPED WITH 4 AC POWER PACKS 1215/1430 KVA RATED

23. - DCPCR WITH 4 GEN AND 4 SCR PANELS
- 2 NOS 1100PT MUD PUMPS WITH RATED INPUT HP 1100. MAX WORKING
PRESSURE 5000PSI
- 6 TANK MUD SYSTEM.
- AC TOP DRIVE CAN BE FITTED.
DeepDrilling
 E2000 RIG
SALIENT SPECIFICATIONS OF THE RIG EQUIPMENT ARE :
- BHEL E2000 AC SCR RIGS ARE SUITABLE FOR DRILLING UPTO 6100 MTRS.
- MAST CLEAR HEIGHT 142 FEET
- FLOOR HEIGHT 25 FEET
- CASING LOAD CAPACITY IS 800,000 LBS
- E2000 DW (2000 HP) SUITABLE FOR DRIVE WITH TWO MOTORS & ECB.
- ROTARY IS EITHER CHAIN DRIVEN THROUGH DW OR INDEPENDENT
ROTARY DRIVE.
- RIG EQUIPPED WITH 4 AC POWER PACKS 1215/1430 KVA RATED
- DCPCR WITH 4 GEN AND 4 SCR PANELS
- 2 NOS 1400PT MUD PUMPS WITH RATED INPUT HP 1400. MAX WORKING
PRESSURE 5000PSI
- (ALTERNTIVELY 1700PT MUD PUMPS WITH INPUT OF 1700HP CAN BE USED)
- 8 TANK MUD SYSTEM.
- AC TOP DRIVE CAN BE FITTED
Super Deep Drilling
 E3000 RIG
SALIENT SPECIFICATIONS OF THE RIG EQUIPMENT ARE :
- BHEL E3000 AC SCR RIGS ARE SUITABLE FOR DRILLING UPTO 9000 MTRS.
- MAST CLEAR HEIGHT 152 FEET
- FLOOR HEIGHT 35 FEET
- CASING LOAD CAPACITY IS 1500,000 LBS
- E3000 DW (3000 HP) SUITABLE FOR DRIVE WITH THREE MOTORS & ECB.
- ROTARY IS EITHER CHAIN DRIVEN THROUGH DW OR INDEPENDENT
ROTARY DRIVE.
- RIG EQUIPPED WITH 6 AC POWER PACKS 1215/1430 KVA RATED

24. - DCPCR WITH 6 GEN AND 6 SCR PANELS
- 3 NOS 1700PT MUD PUMPS WITH RATED INPUT HP 1700. MAX WORKING
PRESSURE 5000PSI
- 6 TANK MUD SYSTEM WITH HIGHER CAPACITY OF EACH TANK.
Main drives of oil rigs:
1. DRAW WORKS-A
2. DRAW WORKS-B
3. MUD PUMP-1
4. MUD PUMP-2
5. ROTARY
AC PCR SYSTEM
PRIME MOVER:
• ENGINE D399/ KTA 3067 : 1000rpm
• KTA-50-G/KTA 3067-G : 1500 rpm
ALTERNATOR:
• ALTERNATOR KATO:1000 rpm1215 KVA
• BHEL OA7001: 1000 rpm1215 KVA
• BHEL OA6301: 1500 rpm,1430 KVA

25. DC CONTROLMODULE
SCR
Silicon controlled rectifier is a solid state switching device that is used to rectify
on AC to produceDC. It provides controlled rectification, this enable a fixed
voltage AC supply to be converted into a variable voltage DC supply. By applying
this variable voltage to a DC motor armature, can control both its speed and current
hence maintaining complete and accurate controlof any equipment to which motor
is coupled.
Operating an Engine
i) Starting an engine
 Check the over speed device is reset
 The engine may hunt for a period of time until the actuator warms up.
 The engine will automatically ramp up to full speed and voltage
ii) Stopping an engine
 Check that another engine is running on line and can take the load.
 Open the AC circuit breaker
 Select the governor controlswitch to ‘Idle’
 Allow the engine to cool
Energizing an SCR cubicle
 Reset the SCR AC circuit breaker
 Check that the fuse and over temperature indicator on the logic display
panel mounted on the cubicle doorare lit.
 Charge and close the AC circuit breaker
 Ensure that :
i) SCR blower are running
ii) SCR ON lamp is lit
iii) Circuit breaker closed indicator on the logic display panel is lit.

26. Running the motors
A. Electricianstep up Procedure
i) Turn field supply controls is ‘Auto’
ii) Turn blower started control to ‘Auto’
iii) Check that motor lock out switch is in the ‘run positions’
iv) Check that AC controlsupply is on
B. Running the draw works
i) Check that SCR are on
ii) Select assignment position
iii) Turn switch to ‘forward ‘ or ‘reverse’
iv) When regenerative breaking is provided the motors will slow down
rapidly (10 sec) to catch hold speed
v) Use footthrottle to give rapid acceleration up to top speed.
C. Running the Mud pumps
i) Check that SCR are on
ii) Select assignment positions
iii) Turn driller’s consolelockout switch on ‘On’
iv) The blower auxiliary motors and filed supply will start
automatically when the console lockout switch is turned on.
v) Wait until the “MP READY’’ lamp is on.
vi) ‘Turn MP hand throttle to give desired strokes/ press.
ELECTRICAL EQUIPMENTS
1. POWER PACKS
 Diesel engines.
 Alternators.
 Housing with oil field skid.

27. 2. DC PCR
 Generator panel
 SCR panel
 Feeder panel
 Field supply panel
SCR DRIVE SPECIFICATION:
 Three phase AC input.
 Voltage: 600VAC
 frequency: 50 HZ
 DC output per SCR unit: 0-750VDC
 Zero to current limit value AMPS continuous throughout maximum
voltage.
 Different limits are selected to allow maximum horsepower and torque to
be obtained from the rig equipment without exceeding the manufacturer’s
ratings.
 The over temperature switch, associated with each SCR is set for 165°F
(74°C).
3. AC PCR
 Incomer panel
 MCC
 Baylor controls
 Transformers incomer panel.
3. DRILLER’S CONSOLE
 Indication panel
 metering
 drive selection
 drive control.
4. DC MOTORS
- Shunt motor
- Separately excited
- 1000HP

28. 5. RIG LIGHTING PACKAGE
• Flame proof
• Explosion proof
• Weather proof
• Heavy Duty
• Hazardous AreaClass-1 Zone-1, Division-1, Gas group-IIA & IIB
6. INTERCONNETIONPACKAGE
- Plug and sockets
- Power and controlcable
- Cable trays/cable boxes.
7. ELECTRICALCREW ROOM
- Elect. office
- workshop
- Store room.

29. TRANSPORTATION
CONTROL

30. ELECTRIC TRACTION SYSTEM
DEFINITION:
• Traction means to moveforward a vehicle ... and so a systemwhen move
forward by means by electric is known is electric traction system. In electric
traction mainly we have to run a motor by means of electricity and for
running a motor we need some power circuit and controlcircuit.
REQUIREMENTS OF AN IDEAL TRACTION SYSTEM:
• High starting pulling effort in order to have rapid acceleration.
• Itshould be self-contained and able to run on any route.
• Capability of withstanding voltage fluctuations and temporary interruption
of supply.
• Parallel running usually morethan one motor (two or four motors) should
be possible.
CLASSIFICATION OF ELECTRIC TRACTION SYSTEMS:
Electric - receive electricity externally
- Self-contained locomotives

31. NOMENCLATUREIN INDIANRAILWAYS:
Name consists of four parts
e.g. WDP2: Diesel-Electric Passenger train running on broad gauge
W/Y/Z
(Gaugetype)
A/C/D/CA
(Mode of traction)
P/G/M/S/U
2/4/6/2C
(Model No.)
W  B.G.
Y  M.G.
Z  N.G.
A  ACTraction
C  DCTraction
D  Diesel-Electric
CA  DualPower
AC-DCTraction
P  Passenger
G  Goods
MMixed(Passenger and
Goods)
S  Shunting
U  EMU
TYPES OF GAUGES USED:
SL No. Type of Gauge Gauge Width
1 Broad Gauge (B.G) 1.676 m
2 Meter Gauge (M.G) 1.0 m
3 Narrow Gauge(N.G) 0.762 m
4 Narrow Gauge(N.G) 1.48 m

32. TYPES OF RAILWAY SERVICES:
 Main line service : LOCO
 City service or urban service: EMU
 Sub-urban service: EMU
EMU:
 An electric multiple unit or EMU is a multiple unit train consisting of self-
propelled carriages, using electricity as the motive power. An EMU requires
no separate locomotive, as electric traction motors are incorporated within
one or a number of the carriages. EMUs are popular on commuter and
suburban rail networks around the world due to their fast acceleration and
pollution-free operation.
ADVANTAGES OF EMU:
• Multiple units have cabs at both ends , the train may be reversed without
uncoupling/re-coupling the locomotive, giving quicker turnaround times,
reducing crew costs, and enhancing safety
• As multiple unit trains have multiple engines, the failure of one engine does
not prevent the train from continuing its journey. A locomotive drawn
passenger train typically only has one power unit, meaning the failure of this
causes the train to be disabled
ADVANTAGES OF LOCO:
Maintenance- It may be easier to maintain one locomotive than many self-
propelled cars.
• Large locomotives can be substituted for small locomotives when more
power is needed. Also, different types of passenger cars (such as reclining-
seats, compartment cars, couchettes, sleepers, restaurant cars, buffet cars,
etc.) can be easily added to or removed from a locomotive-hauled train

33. • The passenger environment of a multiple unit is often noticeably noisier than
that of a locomotive-hauled train, due to the presence of underfloor
machinery. The same applies to vibration
SYSTEMS OF TRACK ELECTRI-FICATION:
 Direct current system : 550V DC,750V DC,1500V DC
550V DC used in Kolkata Trams
750V DC used in Kolkata Metro trains, Bangalore Metro trains
1500V DC used in some area of Mumbai region, presently they are switching
over to 25KV AC
Single phase 25KV AC, 50Hz used in Main lines, Delhi Metro and all other
remaining regions of EMU’s
100kVAAUXULIARY CONVERTOR:

34. Auxiliary convertor is used to providepower to locomotives. Itis called auxiliary
because it feeds power to the auxiliary of main converter. Itdoesn’tprovide
variable power. Itgives constantpower. 300 kvA auxiliary converter, so 100 kvA
auxiliary converter is used and we give three 100 kvA auxiliary converter.
If one of the auxiliary converter fails then the resttwo auxiliary converter will take
the load of the failed one. This is known as redundancy.
Itconverts 1 phase AC to 3 phaseAC.
WORKING-
1 phaseAC is given to switching device(rectifier) which then converts to DC which
is then passed through 3 phaseinverter and then it becomes 3 phaseAC. The
input is not stable (700kv-1000kv) so for stability weuse controlled rectifier
25 KVA STATIC INVERTER (ON BOARD TYPE) FOR ROOF MOUNTED
AC PACKAGE UNITS OF SELF GENERATING AC COACHES OF
INDIAN RAILWAYS:
Equipment description:
The static inverter is designed to feed 415 V, 3 phase, 50 Hz power to the roof
mounted AC package units for AC coaches of Indian railways. This is achieved by
locating the +110 VDC input voltage to establish a DC line voltage and
subsequently inverting this link voltage to producepulse width modulated 3 phase
output voltage.
Constructionalfeatures:
The equipment is housed in a cubicle. The cubicle structure is of welded
construction made up of situational steel angles. Sheet steel covers on sides, near
and top and two hinged doors onfront are provided side top and bottomcovers are
provided with necessary louvers and holes for ventilation. The various assemblies
are firmly fixed to the frame using suitable hardware so as to meet the traction duty
requirement.

35. Electronic controls are modular type housed in a control rack with plug in type of
cards. Booster circuit consisting of IGBT and link capacitor is also of modular
construction. The inverter portion is a self-sufficient modular limit.
Indications and metering are provided on front LHS door. The unit is forced cooled
with air duct at rear top cover and covered with a canopy.
Applications:
The booster /static inverter is specially designed to power the roof mounted AC
package units of AC coaches of Indian Railways.
Principle of Operation:
Inverter consists of step up chopper which converts the input 100V DC supply
(from battery plus alternator) to 550 V DC link voltage. Subsequently this DC link
voltage is inverted 415V/50Hz/3phase AC by the static inverter.
Operating sequence:
Switch on the control MCB and fan MCB located behind RHS cubicle door.
Switch on 110V DC input to the cubicle and check that input power ON.
LED indication starts growing. Booster voltage starts building up (through soft
start) and when it reaches approx. 500V booster output OK indication appears.
Once the booster voltage has reached to 550+/- 25V “inverter fault” LED goes off
and ‘inverter ON’ LED starts glowing within 2 to 5 sec. Booster cooling fan also
starts working as soon as inverter voltage appears. Direct measurement meters for
input DC voltage and DC current are provided on front door AC voltage and AC
current meters are provided with selector switches for different phases.
3 Phase (AC/DC) EMU
These are small trains. EMU basically stands for electrical manufactures units.
Each unit in an EMU has three bogies.

36. 1) motor car
2) trailer car
3) driver car
The motor car is basically the driving unit here unlike in normal trains where the
engine is either at start or at end. These units can be connected in series for adding
more bogies to the train multiple units is connected. These machines are run by
electricity so these are called electrical multiple units. These emu’s are basically
used in metro cities like Bombay and Delhi where power supply is both AC and
DC. The switching of power from AC to DC is still going. So, these emu’s are AC
/ DC. Now 3 Phase supply is needed for the motors which drive the wheel.
FIGURE 
This is a simple circuit diagram for an EMU system.
The separate components for a DC system are:
i) High voltage distribution
ii) Four quadrant controller
iii) Inverter
iv) Low power module
v) Low voltage system
DRIVERTRAILER CAR TRAILER CARMOTOR CAR

37. Circuit component description
A. Pantograph(25 KV AC/1500 V DC) (211 W1)
The pantograph is mounted on the roof of the motor coach and feeds the
power from the overhead line either 25 KV AC or 1500 V DC operation.
Operation is by a pneumatic control valve. Since pantograph is connected to
only one line, we get only one phase in case of AC. This single phase is first
converted to DC by rectifier and then 3 Phase AC by inverter.
B. Surge Arresters (25 KV AC) (211F2,211F6)
The 25 KV AC surge arrester protects the traction system against overhead line
voltage surges. These are two types:
One is directly connected to the pantograph and protects the supply voltage
sensing unit.
Other protects the main transformer and the 4 Q controllers, in case of opening
the VCB.
Both surge arresters are mounted on the vehicle roof.
C. DC Surge Arrester (211F3)
A surge arrester for 1500 VDC is mounted on the pantograph side of the system
selector switch in this way train is always protected against over voltage
coming from a 1500 VDC supply.
D. Primary current transformer (211T1)
The primary current transformer is a part of the roof bushings. With this
transformer any over current is detected, in which case a protection system
opens the VCB.
E. High voltage detectionunit
The supply voltage sensing circuit senses the overhead line supply i.e. 25 KV AC
or 1500 V DC and communicates the type of overhead supply to relay logic a well
also the traction converter controls, to ensure activation of the proper mode of
operation.

38. F. Vacuum Circuit breaker(211Q2)
In the AC mode of operator the VCB supplies 25 KV AC to the primary of the
main traction transformer. The VCB is operated by pneumatic pressure through an
electric solenoid valve. The VCB is mounted on the roof.
G. AC Earthing Switch(211Q12)
This earthing switch ensues proper supply of roof mounted power equipment as
well as HT room and under frame mounted power equipment i.e. pantograph, main
transformer, traction converters etc. The AC earthing switch is double pole double
throw type switch, connected across the VCB.
H. DC circuit breaker(211Q6)
When operating from 1500 VDC the traction converter is protected by a DC
circuit breaker. The circuit breaker has a built in over current and provides short
circuit protection. This DC circuit breaker is located in the switch gear rack in
the HT roof.

39. PLANT &
INDUSTRIAL
CONTROL

40. AUTOMATIC VOLTAGE REGULATOR
TYPE VXB32M
Principal of Operation:-
The automatic voltage regulator ensures stable operation of the synchronous
generators in the entire load range. It ensures very fast recovery of generator
voltage following changes in load demand. The protective features ensure safe
operation of the generator.
The equipment automatically regulates the output voltage of a synchronous
generator by providing it with a controlled field supply via an exciter generator.
The equipment is active over the entire load range with negligible dead band.
The basic system consist of two completely independent channel the ‘AUTO
CHANNEL’ with closed loop current regulation. Both the auto and manual
channel separate signal phase fully controlled Thyristor as their element. The auto
control loop compares the generator voltage with a fixed voltage to produce the
auto control signal, which calls for an increase or decrease in excitation, as and
when necessary. Potentiometer 90A sets the required generator output voltage
when the excitation is being controlled manually field connections are switched
over from the AUTO thyristor bridge to the MANUAL thyristor bridge and the
AVR output is determined by the position of the motorized pot 90M. Both the
AUTO AND MANUAL control alp stages are normally fed from a 415 VAC, 1
phase 50 Hz unit supply through a suitable step down generator terminals the
converter alp controls the exciter field current, which is determined by the firing
control signal to the thyristor bridges for auto and manual channels.
ConstructionalFeatures
The equipment is housed in a signal cubicle is complete with ventilated top cover.
It is provided with full height front and rear hinged doors. The doors have been
provided with louvers for ventilation and rubber sealing strips vermin protection.
The cubicle is fitted with anti-condensation heater and illuminating lamps. Cable
entries are through a removable palate mounted on the cubicle bottom. Terminal
blocks for external connections are accessible from the rear door. The regulator
circuit makes use of solid state electronic components. The voltage regulation and
other control and protection circuits are contained in separate control racks. The
circuits within the racks are mounted on plug in printed circuit cards. The racks are
provided with card guides and wire wrapping type female connectors for the cards.

41. Potentiometer for various controls is fitted on the front of racks. Distribution of the
circuits in the racks is on functional basic. Distribution of components on sub
panels is also on functional basis.
SILICON POWER RECTIFIER
LARGE CURRENT RECTIFIER FEATURES
The large current rectifier equipment provides dc power for
electrolytic/process chemical and aluminum industry.
The rectifier unit basically consists of a regulating transformer having
configuration of double star with IPT or 30 bridge connections, transducers having
variable voltage characteristics and one or two rectifier cubicle.
The voltage range required for starting and controlling the output of the process is
obtained with help of transduction in conjunction with an on load top changer
mounted on regulating transformer.
The large current is achieved by high power silicon diodes connected in parallel on
a heat sink for each phase. The heat sink are either forced air cooled or forced de-
mineralized water cooled depending upon rating and application.
The water cooled rectifier are compact and the compactness of equipment is
achieved by mounted the silicon diodes on hollow heat sink cooled by circulating
water. The thermal impedance of the heat sinks is improved about 20 times as
compared to air cooling.
Applications
i) Electroplating
ii) Aluminum smelting
iii) Caustic sodaplant
iv) Graphite Furnace
v) Potassium chlorate production
vi) Manganese diode plant
vii) Hydrogen production
Description

42. Rectifier equipment comprises an assembly of silicon diodes on heat sink together
with fuse and surge voltage protection components, al suitably enclose and a
separately mounted transformer for large current applications above 25 KVA
important advantages are gained by mounted the rectifier assembly in close
association with the transformer known as rectiformer.
ELECTRONIC CONTROLLER-HVR
The EC-HVR is high voltage DC power supply equipment for electrostatic
precipitator used for extracting fly ash from exhaust gases. The equipment is supplied
in two parts:
1. The high voltage transformer rectifier (HVR)
2. The electronic controller (EC)
The transformer rectifier unit (HVR) consists of oil immersed step up transformer, ac
reactor, high voltage rectifier, high frequency chock, and measuring and protection
components.
The electronic controller (EC) contains the antiparallel connected thyristor pair for
controlling the input voltage to the rectifier unit along with, a microprocessor based
control module BAPCON.
The complete equipment is designed to provide continuously adjustable rate peak DC
output voltage across the precipitator electrodes. The controller operates as constant
current source adjustable up to rated DC output average current. Occurrence of spark at
the electrodes is sensed and made to block the output voltage for fixed duration of 20
ms and voltage is build up again in a specified manner to provide optimum operational
efficiency of the precipitator.
A simplified block scheme of electronic controller and HVR set is shown below:

43. CONCLUSION
“An Engineer with theoretical knowledge is not a complete engineer. Practical knowledge is
very important for an engineer to develop and apply engineering skills”.
BHEL Bhopal is a vast service center. The headquarters of the services of BHEL is in Bhopal. It
was a great experience for me to interact with the engineers and learn about the working of
such a huge organization of the stature of BHEL. I learned about the manufacturing of various
products used in almost all sectors of the economy and numerous industries. It is one of India's
nine largest Public Sector Undertakings or PSUs, known as the “Navratnas” or 'the nine jewels'.
The Switchgear department is one of the largest of its kind in India today.
This is the only place in India to manufacture Gas Insulated Switch Gear with a clean room
facility. BHEL Bhopal houses Asia’s largest Ultra High Voltage Lab (UHV Lab) operating at
voltages as high as 3 million volts!!!!

44. BIBLIOGRAPHY