Bhel Jhansi Report

BHARAT HEAVY
ELECTRICALS
LIMITED, JHANSI (U.P.)
ROTATION REPORT
&
SUMMER TRAINING PROJECT REPORT ON
LOCOMOTIVE MANUFACTURING
FOR A PERIOD OF FOUR WEEKS
UNDER THE GUIDANCE OF

Mr. K.D MANJHI (DGM, LMM)
And Mr Y R TRIPATHI(ENGINEER LMM)
LOCOMOTIVE MANUFACTURING DEPT.
SUBMITTED BY:
SAURABH AGARWAL
VIPUL AGARWAL
NIT-ALLAHABAD
NIT-K SURATKAL
nd
2 yr Mechanical Engg.
1
ACKNOWLEDGEMENT
We am extremely thankful & indebted to the numerous BHEL Engineers
and technical staffs who provided vital information about the functioning of
their respective departments thus helping me to gain an overall idea about the
working of organization. We are highly thankful for the support & guidance of
each of them.
We are extremely thankful to Mrs. Seema S. Rawal (Manager-HRD) for
providing me the opportunity to undergo this training and to work on my
project. We also express my thanks to Mr. Ravinder and all the members of
HRD for their help & cooperation.
We am highly indebted and thankful to my project guide, Mr. K.D
MANJHI (DGM, LMM) and Mr. Y R TRIPATHI and Mr. Rishav Kumar for
giving me their valuable time and helping me to grasp the various concepts of
locomotive manufacturing and their various parts and assembly processes and
testing. We would also like to thank Mr. Rahul, Mr. Ashish and all other
members of LME Dept. and Ishwar Chandra of Testing Dept. for providing
enough support and cooperation.
Last but not the least, We would like to thank my parents & all my fellow
trainees who have been a constant source of encouragement & inspiration
during my studies & have always provided me support in every walk of life.
SAURABH AGARWAL VIPUL AGARWAL

NIT-ALLAHABAD
NIT-K SURATKAL
2nd yr Mechanical Engg.
1. BHEL AN OVERVIEW
BHEL is the largest engineering and manufacturing enterprise in India in the energy related
infrastructure sector today. BHEL was established more than 40 years ago when its first plant
was setup in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India
a dream which has been more than realized with a well recognized track record of
performance it has been earning profits continuously since 1971-72.
BHEL caters to core sectors of the Indian Economy viz., Power Generation's &
Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defence, etc.
The wide network of BHEL's 14 manufacturing division, four power Sector regional centres,
over 150 project sites, eight service centres 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, and ISO 14001 certification for environment management.
1.1 POWER GENERATION

Power generation sector comprises thermal, gas, hydro and nuclear power plant
business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the
total installed capacity of 99,146 MW in the country, as against nil till 1969-70.
BHEL has proven turnkey capabilities for executing power projects from
concept to commissioning; it possesses the technology and capability to produce thermal sets
with super critical parameters up to 1000 MW unit rating and gas turbine generator sets of up
to 240 MW units rating. Co-generation and combined-cycle plants have been introduced to
achieve higher plant efficiencies to make efficient use of the high-ash-content coal available
in India, BHEL supplies circulating fluidized bed combustion boilers to both thermal and
combined cycle power plants.
The company manufactures 235 MW nuclear turbine generator sets and has commenced
production of 500 MW nuclear turbine generator sets.
Custom made hydro sets of Francis; Pelton and Kapian types for different head discharge
combination are also engineering and manufactured by BHEL.
In all, orders for more than 700 utility sets of thermal, hydro, gas and nuclear have been
3
placed on the Company as on date. The power plant equipment manufactured by BHEL is
based on contemporary technology comparable to the best in the world and is also
internationally competitive.
The Company has proven expertise in Plant Performance Improvement through renovation
modernisation and updating of a variety of power plant equipment besides specialised know
how of residual life assessment, health diagnostics and life extension of plants.
1.2 TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production,
installation, and maintenance and after-sales service of Rolling Stock and traction propulsion
systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000 HP,
diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting duly
applications. BHEL is also producing rolling stock for special applications viz., overhead
equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides traction propulsion
systems for in-house use, BHEL manufactures traction propulsion systems for other rolling
stock producers of electric locomotives, diesel-electric locomotives, electrical multiple units
and metro cars. The electric and diesel traction equipment on India Railways are largely
powered by electrical propulsion systems produced by BHEL. The company also undertakes
retooling and overhauling of rolling stock in the area of urban transportation systems. BHEL
is geared up to turnkey execution of electric trolley bus systems, light rail systems etc. BHEL
is also diversifying in the area of port handing equipment and pipelines transportation system.
1.3 INTERNATIONAL OPERATIONS

BHEL has, over the years, established its references in around 60 countries of the world,
ranging for the United States in the West to New Zealand in the Far East. These references
encompass almost the entire product range of BHEL, covering turnkey power projects of
thermal, hydro and gas-based types, substation projects, rehabilitation projects, besides a
wide variety of products, like transformers, insulators, switchgears, heat exchangers, castings
and forgings, valves, well-head equipment, centrifugal compressors, photo-voltaic equipment
etc. Apart from over 1110MW of boiler capacity contributed in Malaysia, and execution of
four prestigious power projects in Oman, Some of the other major successes achieved by the
Company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt,
Bangladesh, Azerbaijan, Sri Lanka, Iraq etc.
1.4 VISION, MISSION AND VALUES OF BHEL

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1.4.1 VISION
A WORLD-CLASS ENGINEERING ENTERPRISE COMMITTED TO ENHANCING
STAKEHOLDER VALUE.
1.4.2 MISSION
TO BE AN INDIAN MULTINATIONAL ENGINEERING ENTERPRISE
PROVIDING
TOTAL
BUSINESS
SOLUTIONS
THROUGH
QUALITY
PRODUCTS, SYSTEMS AND SERVICES IN THE FIELDS OF ENERGY,

INDUSTRY,
TRANSPORTATION,
INFRASTRUCTURE
AND
OTHER
POTENTIAL AREAS.
1.4.3 VALUES
ZEAL TO EXCEL AND ZEST FOR CHANGE.
INTEGRITY AND FAIRNESS IN ALL MATTERS.
RESPECT FOR DIGNITY AND POTENTIAL OF INDIVIDUALS.
STRICT ADHERENCE TO COMMITMENTS.
ENSURE SPEED OF RESPONSE.
FOSTER LEARNING, CREATIVITY AND TEAMWORK.
LOYALTY AND PRIDE IN THE COMPANY
1.5 VARIOUS UNITS OF BHEL ACROSS THE COUNTRY

1.5.1 FIRST GENERATION UNITS
Bhopal
Haridwar
: Heavy Electrical Plant.

: Heavy Electrical Equipment Plant.
Hyderabad: Heavy Electrical Power Equipment Plant.
1.5.2 SECOND GENERATION UNITS

Tiruchy
: High Pressure Boiler Plant.
Jhansi
: Transformer and Locomotive Plant.
Haridwar
Tiruchy
: Seamless Steel Tube Plant.
Central Foundry and Forge Plant.
1.5.3 UNITS THROUGH ACQUISTION & MERGER

Bangalore :
Electronics Division
Electro Porcelain Division.
1.5.4 NEW MANUFACTURING UNITS

Ranipet
Boiler Auxiliaries Plant.
Jagdish
Insulator Plant.
Govindwal : Industrial Valve Plant.

Rudrapur
Component and Fabrication Plant.
Bangalore
Energy Systems Division
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. Its 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.
1.6 ACTIVITY PROFILE OF BHEL

1.6.1. POWER SECTOR PROJECTS
Thermal sets and Auxiliaries.
Steam generators and Auxiliaries.
Industrial fans.
Electrostatic precipitators.
Air pre heaters.
Nuclear power equipments.
Hydro sets and Auxiliaries.
Motors.
Transformers.
Rectifiers.
Pumps.
Heat Exchangers.
Capacitors.
Porcelain/Ceramics insulators.
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Seamless steel tubes.
Casting and forging.
1.6.2. SYSTEMS/SERVICES
Turnkey power station.
Data acquisition Systems.
Power systems.
HVDC Commissioning systems.
Modernization and Rehabilitation.
1.6.3. TRASPORTATION SECTOR
Diesel Electric generators.
AC/DC locomotives.
DC locomotives and loco shunters.
Traction system for railways.
Electric trolley buses.
1.6.4. INDUSTRY SECTOR
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.
BHARAT HEAVY ELECTRICALS LIMITED JHANSI (UNIT)

2. BHEL JHANSI
2.1 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
countrys 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 KVA, 132 KV class and other
77transformers like Instrument Transformers, 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 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.
2.2 MODERN MACHINARY IN BHEL JHANSI: CNC CROPPING LINE MACHINE

VAPOR PHASE DRYING SYSTEM
COMPUTER ICM 6040 AND 6080 AND IRISII 40/20 WITH GRAPHIC
FACILITIES
BOGIE FRAME MACHINE CENTER
CNC AXLE TURNING LATHE
FACING AND CENTERING MACHINE
WHEEL FORCING PRESS
CNC PIPE BENDING MACHINE
2.3 THE PRODUCT PROFILE OF BHEL JHANSI UNIT
PRODUCTS
RATINGS
1.
Power transformer
up to 220 KV class 250 MVA
2.
Special transformer
up to 132 KV.
3.
ESP transformer.
100 KV, 1400 MA
4.
Freight Loco transformer
3900 to 5400 KVA & 7475.

KVA for 3 phase.
9
5.
ACEMU transformer
upto 1000 KVA 2(1-phase).

1385 KVA (3 phase).
6.
Bus-Duct transformer
upto 5000 KVA.
7.
Instrument transformer
VT & CT up to 220 KV class.
8.
Diesel electric locomotives
up to 2600 HP.
9.
AC/DC locomotives
5000 HP.
10.
Over Head Equipment cum Test

Car
11.
Well wagon
200 tone.
2.4 GROWTH OF PRODUCTIONS AND MILESTONES
YEAR
OUTPUT
MILESTONES
Rs. (crores)
1976-77
0.53
Start of Instrument Transformer
1977-78
3.49
Start of traction transformer and

power transformer (up to 132 KV).
1978-79
7.56
Start of HFTT type freight loco

transformer .
1979-80
7.02
commissioning of 2,500 KV DG
set (due to server power cuts).
1980-81
15.74
Start of ESP transformer.
1981-82
19.78
Start of 220 KV power transformer.
1982-83
28.54
ACHIEVED BREAK EVEN.
1983-84
37.42
Start of Bus-Duct.
1984-85
38.61
Start of dry type transformer.

10
1985-86
43.67
Repowering of DESL loco started.
1986-87
51.87
Start of new DESL loco

manufacturing.
1987-88
65.29
manufacturing facilities of AC
loco.
1988-89
109.41
Crossed 100 crore target.
1990-91
128.10
Successful
design
and
manufacturing 450 HP 3 axel

DESL CCL.
1991-92
155.82
Manufacturing of first 2600 HP

DESL for NTPC.
1992-93
215.61
Successful
Design
and
development of 5000HP Thirstier

control locomotive.
1993-94
225.05
Unit has been awarded ISO

9001 certificate fir quality Schemes
1994-95
215.0
240 MVA power

transformer produced first time.
1995-96
238.0
AC/DC locomotive first time in

India
1996-97
328.43
100th loco manufactured.
1997-98
435.60
250 MVA transformer

produced first time.
1998-99
287.0
Developed over head equipment

cum test car. Exported one
DESL loco to Malaysia.
1999-00
218.96
Diesel hydraulic shunting.
2.5 SECTIONS OF BHEL JHANSI UNIT

BHEL has many departments, while production and administrative departments are separate.
Broadly speaking BHEL has two-production categories11
1. Transformer section.
2. Loco section.
3. Bus Duct section
2.6 TRANSFORMER SECTION

2.6.1 TRANSFORMER COMMERCIAL (TRC)
The objective of the department is interaction with the customers. It brings out tenders
and notices and also responds to them. It is this department that bags contracts of building
transformers. After delivery regarding faults, this department does failures and
maintenance. All such snags are reported to them and they forward the information to the
concerning department.
The main work of the TRC is classified as: 1. Tenders and notices.
2. Interaction with design department.
3. Place of the work.
4. Approximate cost of the work.
5. Earnest money.
6. The place and time where contract documents can be seen.
7. The place and time where tender documents can be obtained.
8. The time up to which the tender documents will be sold.
2.6.2 TRANSFORMER ENGINEERING (TRE)
The transformer manufactured in BHEL Jhansi range from 10 MVA to 240 MVA and up to
220 KV. The various transformer manufactured in this unit are:-
Figure 2.1 POWER TRANSFORMER
Power transformer
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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.
All above types are oil cooled except dry type, which are air-cooled.
The generated voltages at the power station are 6.9 KV, 11 KV and 13.8 KV but due
to certain advantages like economical generation 11 KV is the most widely used. For
this voltage needs to be stepped up. Transmission at high voltage is desirable because
it results in lesser losses, needs thinner wire and hence is economical. If the current is
kept high the copper losses become very high but iron losses are practically constant.
In certain cases the required voltage may be less than the output voltage, so in order to
obtain it we require a tapping circuit. The output voltage may have a certain
percentage variation, which may be tapped in 4 or 6 equal steps.
The type of tap changer depends on the application of the transformer, where a
continuous power supply is not required an Off Circuit Tap Changer (OCTC) may be
used and where a continuous power supply is a must e.g. at a substation in cities etc.
on Load Tap Changer (OLTC) is used.
2.6.3TRANSFORMER MANUFACTURING (TRM):

The manufacturing of transformer is carried out in a systematic manner with work
assigned to the following sections to smoothly carry out the job within the promised
period.
2.6.3.1FABRICATION:
Fabrication is nothing but production. It comprises of 3 bays i.e., Bay0, Bay1 &Bay 2.
2.6.3.1.1BAY-0
It is the preparation shop while the other two bays form the
assembly shop.
13
This section has the following machines:

1.
Planner machine To reduce thickness
2.
Shearing machine
3.
CNC / ANC Flame Cutting machine To cut complicated shaft items using
Oxy-Acetylene flame
4.
Bending machine
5.
Rolling machine
6.
Flattening machine
7.
Drilling machine
8.
Nibbling machine
9. Pantograph flame cutting machine
2.6.3.1.2 BAY-1
It is an assembly shop where different parts of tank come from bay 0.Here welding
processes are used for assembly, after which a rough surface is obtained Grinder
operating at 1200 rpm is used to eliminate the roughness.
2.6.3.1.3 BAY-2
It is an assembly shop dealing with making different objects mentioned below:1-Tank assembly
5-cross feed assembly
2-Tank cover assembly
6-core clamp assembly
3-End Frame assembly
7-pin and pad assembly
4-foot assembly
Before assembly, short blasting (firing of small materials i.e., acid pickting) is done
on different parts of jobs to clean the surface before painting.
After assembly some tests are done known as NON DESTRUCTIVE TEST
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 put. 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.
14
2.6.3.2 BAY-3
Here are basically three sections in the bay:
1.
Machine section
2.
Copper section
3.
Tooling section
2.6.3.2.1 MACHINE SECTION:

The operations to form small components of power and traction transformer are
done in this section. The shop consist of following machines:
CENTRAL LATHE: it consist one tailstock, headstock, lower part of tailstock is
fixed and tail stock spindle is moving. On this machine facing, turning and
threading is done
TURRET LATHE: its function is same as central lathe but it is used for mass
production. Here turret head is used in presence of tailstock because turret head
contains many tailstocks around six.
CAPSTAN LATHE: It is belt drive.
RADIAL ARM DRILLING MACHINE: It is used for drilling and boring.
HORIZONTAL BORING MACHINE: It is computerized and used for making
bore, facing etc.
MILLING MACHINE:a) Horizontal milling machine: It is used for making gear and cutting operations.
b) Vertical milling machine: By the machine facing cutting, and T-slot cutting is
done
2.6.3.2.2 COPPER SECTION:
All the processes related to copper are done here.
TUBE SLITTING MACHINE: This machine is developed here and is used for
cutting the tube along its length and across its diameter. Its blade thickness is 3mm.
SHEARING MACHINE: It is operated hydraulically and its blade has V-shape and
a thickness of 15mm
DIE AND PUNCHING MACHINE: It is also hydraulically operated and has a die
and punch for making holes.
HYDRAULIC BENDING MACHINE: It is used for bending the job upto 90.
15
SHEARING MACHINE: It is fully mechanical and is used to cut the job along its
width.
FLY PRESS MACHINE: It is used to press the job. It is operated mechanically by
a wheel, which is on the top of the machine.
BEND SAW MACHINE: This machine is used for cutting job having small
thickness. It has a circularly operated blade, around 5.1 mtr long.
WATER COOLED BRAZING MACHINE: It contains two carbon brushes. The
sheet is put along with a sulfas sheet and the carbon brushes are heated. A Lap Joint
is formed between the sheets as the sulfas sheet melts.
LINCING BELT MACHINE: It creates a smooth surface.
HYDRAULIC PRESS MACHINE: To press the job.
SOLDER POT MACHINE: It has a pot that contains solder. Solder has a
composition of 60% Zn and 40% Pb.
2.6.3.2.3 TOOLING SECTION:
In this section the servicing of tools is done.
BLADE SHARP MACHINE: It sharpens the blade using a circular diamond
cutter. Blade of CNC cropping line machine is sharpened here.
MINI SURFACE GRINDER MACHINE: It serves grinding purposes. It has a
grinding wheel made of Aluminum Oxide.
TOOL & SURFACE GRINDING MACHINE: This is specially used to grind the
tools used in Bay 7.
DRILL GRINDING MACHINE: To grind the drills.
2.6.3.3 BAY 4:
This is the winding section.
TYPES OF WINDING : 1. Reverse section winding.
2. Helical winding
3. Spiral winding
4. Interleaved winding
5. Half sectional winding
There are four TYPES OF COIL fixed in a transformer, they are :
1. Low voltage coil (LV)
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2. High voltage coil (HV)

3. Tertiary coil
4. Tap coil
The type of winding depends upon job requirement. Also, the width and thickness of
the conductors are designed particulars and are decided by design department.
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.
The moulds are of following types.1. Belly types
2.
Link types
3.
Cone type
2.6.3.4BAY-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
1. SLITTING MACHINE: It is used to cut CRGO sheets in different width. It has
a circular cutter whose position can be changed as per the requirement.
2. CNC CROPPING LINE PNEUMATIC: It contains only one blade, which can
rotate 90 about the sheet .It is operated pneumatically.
3. CNC CROPPING LINE HYDRAULIC: It is also used to cut the CRGO sheet.
It contains two blades, one is fixed and the other rotates 90 above the sheet. It is
operated hydraulically .M4 quality sheet 0.23-0.33 mm thickness is used
17
2.6.3.5BAY-6
Single-phase traction transformer for AC locomotives is assembled in this section.
These 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.
Three-phase transformers for ACEMU are also manufactured in this section. The
supply lines for this transformer is of 25 KV and power of the transformer is6500
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).
2.6.3.6 BAY-7:
This is the insulation shop. Various types of insulations are
1- AWWW: All Wood Water Washed press paper.
The paper is 0.2-0.5mm thick cellulose paper and is wound on the
conductors for insulation.
2-PRE-COMPRESSED BOARD: This is widely used for general insulation
&
separation of conductors in the forms of blocks.

3-PRESS BOARD: This is used for separation of coils e.g. L.V. from H.V. It is
up to 38 mm thick.
4-UDEL: UnDemnified Electrical Laminated wood or Permawood
This is special type of plywood made for insulation purposes.
5-FIBRE GLASS: This is a resin material and is used in fire pron areas.
6-BAKELLITE
7-GASKET-It is used for protection against leakage.
8-SILICON RUBBER SHEET-It is used for dry type transformer.
The machines used for shaping the insulation material are
1-Cylindrical machines
2-Circle cutting machine
3 Scarping machines
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4-Punching press machine

5-Drilling machine
6-Guilletin machines
7-Bench saw (spl for OD)
8-Jig saw (spl for ID)
9-Circular saw
10-Linesin machines
2.6.3.7 BAY 8
It is the instrument transformer and ESP transformer manufacturing section.
2.6.3.7.1 INSTRUMENT TRANSFORMER These are used for measurement. Actual measurement is done by measuring
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 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.
They are of two types.
1-Current transformer (CT)
2-Voltage transformer (VT)
2.6.3.7.1.1 CURENT TRANSFORMERIt is a step down transformer. High current is not directly measured by the CT but is
stepped down to lower measurable voltages.
BODY:
The main body is a bushing, which houses the winding and also acts as an insulator.
The CT has a bottom and top chamber.
The top chamber is a cylindrical tank of mild steel. It has
terminals for connection of HV coils. It also has a glass window to

indicate the oil level.
19
Below the top chamber is the bushing made of porcelain. It
has several folds or rain sheds to provide a specific electric field

distribution and long leakage path. Some bushings are cylindrical
while modern ones are conical as amount of oil porcelain used is
reduced without any undesirable defect.
Bottom chamber houses the secondary winding. There is also
connection box to which the connection of the low voltage (LV) coil
is made.
WINDINGS:
The primary winding consists of hollow copper/aluminum pipe bent in form of a U.
Aluminum is used for low rating. For higher rating a set of wires is passed through the
pipe. For still higher ratings, a copper pipe is used and for highest rating copper pipe
with copper wires passing through it is used. This arrangement depends on the current
carrying capacity. The bent portion of primary as in the bottom chamber where as the
free end is the top chamber. The straight portion lies inside the bushing.
The primary is wound with crepe paper insulation. The thickness of the insulation
goes in increasing as we go downwards in the bottom chamber. The free ends are
provided with ferrules, which are, small hollow cylinders through which wires can
pass connection to the primary are made through these ferrules.
The secondary is divided in a number of coils for different set of tapings. Connections
are different tapings are made in connection box. Each coil has an annular core of
CRGO (silicon steel). The wire use is insulated copper wire. The winding may be
done both manually and by machine. After winding the coils are covered with paper
tape insulation. The coils are then slipped into both the legs of the primary winding
and connections are made in connection box for different tapping.
2.6.3.7.1.2 VOLTAGE TRANSFORMERS:
This is also a stepped down transformer. The outer construction is same as that of the
CT that is this also has a top chamber, bushing and a bottom chamber. The difference
is only in the winding.
WINDINGS:
The primary winding is of the thick wire having a few turns. The winding is heavily
insulated with paper insulation. It has a hollow cylinder passing centrally through it,
which houses the secondary winding. The clean and painted with either enamel or
20
epoxy paint. The customer gives the choice of paint. Epoxy paint is generally used in
chemical plants and seashore installation. Terminals are then mark and ratings and
diagram plate is fixed.
The job is then sent to the shipping department, which takes care of its dispatch by
packing it in the wooden boxes.
2.6.3.7.1.3 ESP TRANSFORMER:
The Electrostatic Precipitator transformer is used for environmental application. It is
used to filter in a suspended charge particle in the waste gases of an industry. They are
of particular use in thermal power stations and cement industry.
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 that
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 a marshalling box which is the control box of the transformer.
2.6.3.8 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 substations. There are various ratings 11KV, 22KV, manufactured, they are
Generator transformer.
System &
Auto transformer.
21
A transformer in a process of assemblage is called a job. The design of the transformer is

done by the design department & is unique of each job; depends on the requirement of
customer. The design department provides drawing to the assembly shop, which assembles
it accordingly.
The steps involved in assembly are:
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.
2.6.3.8.1Core Building:
It is made of cold rolled grain oriented steel CRGO. The punched core is sent to
this shop from core punching shop. Here it is assembled with the help of drawing a set of 4
laminations is called a packet. The vertical portion of the core is called a leg the
horizontal one is called as yoke. Packets of both are interlinked. It is undesirable to keep
the X section of core circular to provide low reluctance part without air space. A perfect
circle cannot be made so the core is stepped to achieve a near circle. The rest of the spaces
left are filled with thin wooden rod.
After core building the end frames are bolted. The bolts are insulated from the cores.
2.6.3.8.2 Core Lifting:
The core is lifted by a crane and is placed vertical. The rest of assembly is done
on the core in this position.
2.6.3.8.3 Unlacing & Core Coil Assembly:
The yoke of the core is removed using crane. Bottom insulation in form of 50MM
thick UDEL sheets is placed PCB and press board are also used for filling the gap and to
provide a good base for the coil to rest. The coil are then lowered primary, secondary,
tertiary and tap in that sequences.
2.6.3.8.4 Relacing & End-frame Mounting:
22
After lowering a coil the top insulation similar to the bottom one is provided. The
removed yoke is placed end-frame bolted back into its position.
The connections are then made as per drawings. All the conductors are insulated using
crepe paper. Brazing copper makes the connections. For brazing silphos is used.
The following tests are done during re lacing:
1.
Megger Test.
2.
Ratio test.
3.
Meg current / High Volt test.
Testing at this stage is called pre testing. This is essential because if false are seen
at a later stage; whole of the transformer will have to be dissembled.
2.6.3.8.5 H.V.T.G & L.V.T.G.:
Terminals gears are accessories provided at high voltage and low voltage terminals. Main
device used is tap changer. Tap changer can be on load or offload. In offload type the
supply has to be tripped, then the tapings changes but in on load type the tapings can be
changed while the supply is on. On load tap changer (OLTC) are used where the supply is
desired to be continuous.
The upper portion of the OLTC contains mechanism by which tapping is changed. There is
switch which changes tap in very small type (Micro-seconds). But there is a possibility of
sparking. To get rid of it, OLTC IS filled with oil. The bottom part houses the terminals and
the mechanism, which makes automatic connections.
The terminals are made of thick aluminum strips.
2.6.3.8.6 Vapour Phasing & Oil Soaking:

It is well known fact that water (impure) conducts electricity. Therefore, moisture
presence in transformer will effect insulation; the process of moisture removal from
transformer is called vapour phasing.
The job is put in dummy type and place in a vacuum vessel. It is an airtight chamber
with heating facilities. A solvent vessel is released is the chamber which enters all
transformer parts and insulations. It absorbs water rapidly. The job is heated in
vacuum. All the solvent vapours are sucked out with moisture. Metals contain no
moisture but a lot of insulations is provided which contains this moisture and if not
taken care of, may burst the job
23
After moisture removal tank is filled with transformer oil and soaked for at least three
hours, so that every gets wet with oil.
The job remains in vessel for three days during phasing. It is then taken out of the
vessel and also out of the dummy time.
2.6.3.8.7 Final Servicing & Tanking:
After taking the job out of dummy time all the parts retightened any other defects are
rectified and job is retimed in mild steel tank. After tanking oil is filled.
2.6.3.8.8 Case Fitting:
The accessories are fixed and final touches given to job. The accessories include tank
cover, fixing bushing, fixing valves etc. The terminals are marked and R and D.
(Rating and Diagram) plate is fixed. Bolting and not riveting because it may require
maintenance and hence opening close the tank.
Bushings are hollow to provide a passage for conductor; oil is filled inside the
hollow spaces for better insulation. Bushing is built on a mild steel base, which is
bolted to bottom chamber with a cork gasket in vacuum.
The bottom chamber is mild steel tank with a steel frame attached to its base for earthling.
This chamber houses the secondary winding.
2.7.1 WORK ENGINEERING & SERVICES (WE&S)

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.
The department has 03 different divisions:
Electrical Engg
Electronics Engg
Mechanical Engg
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 department by the concerning department. WE&S takes prompt action to rectify it.
The factory has a feeder of 11KV .The total load sanctioned for the factory is
24
2500MVA but the maximum demand reaches the range of 1700-2000 MVA.
There are various sub-stations (SS) inside the factory, for distribution of power to different
sections.
SS -1
Supplies
Bay-6 to Bay 9
SS -3
Supplies
Bay 1to Bay-4
SS -4
Supplies
Boiler and loco plant
SS -5
Supplies
Bay -5
SS -6
Supplies
Administrative building
2.7.2 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.
FUNCTIONS:
Technology functions can be classified as:
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 reconsidered.
Productivity projects compilation: It includes the initial analysis of the problem and
25
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.
2.7.3 QUALITY CONTROL

CENTRAL QUALITY SERVICE
First we get acquainted with a few terms concerning this department.
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.
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 is termed
quality inspection.
3. ELECTRIC TRACTION
3.1 INTRODUCTION
We the human beings are known to continuously improve our surroundings and in endeavour
to do so we curiously keep reinventing with the technologies and one of such greatest
26
inventions of man is known to be electricity which has completely made our lifestyle
complacent. Be it about facing the scorching heat or resisting a chilly December night we are
dependent on electricity. Our day to day life has become inaccessible without electricity. One
such example is of our day to day to travelling to our workplaces for which we our dependent
on metros, local emu trains, etc. This is all possible because of electricity only and electric
traction has basically helped to redefine our complacent lifestyle. As an engineer what often
fascinate me are what this traction is and how this all technology works and today after my
training at BHEL Jhansi I would like to share how all this stuff works with the advent of my
knowledge gathered here.
What is traction? This is the question that arises first in everybodys mind and
here is what the oxford dictionary has to say about it. It describes traction as an act of hauling
or pulling a thing over a surface and electric traction means doing it with the aid of electricity.
It means to transport men and material from one place to another as described in the book
Fundamentals of Electrical Drives by Gopal K. Dubey. Electric traction according to the
same author can be broadly classified as:
1) Electric Trains
2) Electric buses, trams and trolleys
3) Battery driven and solar powered vehicles
3.2 OTHER TRACTION DEVICES MANUFACTURED AT BHEL

BHEL is not only into manufacturing electric locomotives but also some various other
devices required to cater the need of transportation sector. We would be discussing these
devices in brief here as the next section would be dedicated to electric locomotives technical
know-how completely.
3.2.1 OHE Inspection Car (Tower Wagon)

This is the recording cum test car for the overhead equipment used for maintenance of OHE
and for attending to break downs. It carries necessary tools for maintenance and break
downs such as tackles, straining screws, clamps, ropes, ladders, adequate stock of insulators,
length of contact and catenary wires and other OHE fittings.
These are of two types:
Four Wheeler (speed potential upto 75 KMPH)
Eight Wheeler (speed potential upto 110 KMPH)
27
Figure3.5 OHE INSPECTION CAR
3.2.2 RRV
RRV stands for Rail cum Road Vehicle. It is a type of track equipment which can be run both
on rail and the road.
Figure 3.6 RAIL CUM ROAD VEHICLE
3.2.3 BALLAST CLEANING MACHINE

This is used for cleaning of the tracks after some accident or incident has occurred on the
railway tracks.
28
Figure 3.7 BALLAST CLEANING MACHINE
3.2.4 DYNAMIC TRACK STABILIZER

This is used for track stabilization after ballast cleaning.
Figure 3.8 DYNAMIC TRACK STABILIZER
3.2.5 OTHER USEFUL EQUIPMENTS

The various other useful equipments are shown below with their descriptions just below them
a) UTILITY VEHICLE
29
Figure 3.9 UTILITY VEHICLE CAN BE USED FOR A HUGE NUMBER OF TASKS
b) WELL WAGON
Well wagon are manufactured at BHEL Jhansi for BHEL Haridwar for the transportation of
turbines manufactured there. Presently, two types of well wagons have been manufactured
and they are:
Figure 3.10 200T; 18 axle Well Wagon
Figure 3.11 280T; 24 AXLE WAGON
30
PROJECT REPORT ON
31
1 Loco Section.
1.1 Loco Commercial

The main objective of this department is interaction with customer. It brings out tender and
notices and also responds to them. It bags the contracts to manufacture locos.
After delivery it further takes care and interrogates of faults and failures as well and takes the
appropriate action to solve the problem.
Its function can be broadly classified as:
1.1.1 Tendering
1. Tender:
Requirement of customer comprises of the following:
a) Technical specification / requirement
b) Estimated cost of project / equipment
c) Estimated time of completion of project
d) Other information
2. Type of tenders:
Broadly classified as:
a) Open tender-published in news dailies, open for all
b) Limited tender issued to limited parties
c) Single party tender-issued to single party on propriety basis
32
3. Enquiry:
On receipt of tender forms formal enquiries are issued to:
a) Engineering department-for technical acceptance
b) Production planning and control-for delivery period
c) Central dispatch cell-for mode of transportation and transportation charge
4. Offer:
If tender is feasible as obtained from reports of other departments offer is submitted to
customer.
5. P.O /Contract Agreement:

On the opening of technical bid the commercial bid of technically qualified tender is
opened and order is placed on lowest value tender followed by negotiations if
required.
1.1.2 Contract Execution:
1) Issue of work orders: on receipt of purchase order internal work orders are
issued by commercial department for execution of work.
2) Type of work orders: 1) Technical, 2) Financial, 3) Shipping
3) Monitoring: To maintain the key dates of the contract internal meetings with the
concerned departments are held on regular basis to monitor the progress.
4) Payment collection: To collect the payment from the customer.
5) Contract closing: After the dispatch and completion of all the aforesaid tasks the
contract is formally closed by commercial department.
1.1.3 After sales service:

1) Within warranty period free of cost service and replacement of material if
required
2) Beyond warranty period on chargeable basis
33
1.2 Locomotive manufacturing

A locomotive can be broadly classified as:
a) Superstructure
b) Under frame
c) Bogie
1.2.1 FABRICATION
This shop does not come under Loco Unit but manufactures all the basis parts
necessary fore locomotive manufacturing like Shell, Traction Transformer etc.
PARTS MADE IN THE SHOP
STRUCTURE
SHELL
BOGIE FRAME
UNDERFRAME
SUPERSTRUCTURE
CABIN
SIDEWALL
ROOF
To manufacture the structure following Machines are used in fabrication shop.
BUTLER Milling Machine: It is a PLANO Milling machine with multiple cutting

tools. It is used for milling operation. Its milling head is universal which does angular
movement for chamfering.
Bending Machine: It performs bending operation on thick metallic sheets of

thickness up to 32mm and of length up to 3200mm approx. tonnage of capacity is 500
tones
stroke of machine (height up to which tool is lifted) is 15mm. shut height
from top is 250. max pressure which can be applied is 140kg/cm2
Rolling Machine: It contains one power generating roller, below two are driving
rollers. This is used to roll the sheet.
Roller arm drilling machine: it has a fixed bed. If job cannot be fixed on the bed
it can be rotated to work directly on the job. Its movement is controlled hydraulically
in vertical direction.
34
Hydraulic press Machine or flattening Machine : It flattens the thick metal

sheets in the shop. It has a max. capacity of 100 tones.
CNC Flame Cutting Machine: It is used to cut various shapes on thick sheets of
metal. This is done by suitable program feed in machine.
Sample program: For creating the following shape
G91
G21
M04 Y-15
X15 Y15
X1422
X15 Y-15
Y-275
X-15 Y-15
X-1422
X-15 Y15
Y275
M30
G91
G21
M04 X75
G02 I-75
M03 X-75
X172
Y229.5
M04 X-60
G02 X50 Y-50 J-50
Y-359
G02
X-50 Y-50 I-50
X-244
G02
X-50 Y50 J50
Y359
G02
X50 Y50 I50
X244
M03
M30
Welding Process in Fabrication Shop

Welding is a process of joining together of two metal pieces to
produce essentially a single piece of metal.
35
Basic Arc welding Process

1.
2.
3.
4.
5.
Shielded Metal Arc Welding(SMAW)

Gas Tungsten Arc Welding(GTAW)
Gas Metal Arc Welding(GMAW)
Flux Cored Arc Welding(FCAW)
Submerged Arc Welding(SAW)
Two types of Welding used in BHEL Jhansi.

GMAW
Submerged Arc Welding(SAW)

Submerged Arc Welding is a arc welding process where weld is produced by
heating with an electric arc between a bare metal electrode and the work.
The welding zone is shielded by a blanket of granular fusible material on the
work.
Pressure is not used .
Filler metal is obtained from the electrode wire.
ELECTRODES
Electrodes classification as per
1. The prefix E refers to Arc welding
2. The first two digit indicate
strength in psi,
Ex: E60XX indicate minimum
60,000 psi.
3. Second last digit indicates the
1- All position.
2- Flat position and horizontal fillets.
AWS A 5.1.
electrodes.
minimum tensile
tensile strength
welding position.
36
4. The last two digit together indicate the welding position giving coating type current and
polarity.
POLARITY
When the power source is DC the work is connected with positive pole of the
machine, it is called Straight Polarity or DCEN(DC Electrode Negative).
When the work is connected with negative pole of machine it is called Reverse
Polarity or DCEP(DC Electrode Positive)
The Positive Pole generates two third of heat produce.
Common Electrode used in BHEL, Jhansi
E6013 suitable for all welding position can be used with AC and DC negative.
E7018 low hydrogen electrode suitable for all welding position can be used with AC
and DC(+)
E7024 iron powder electrode suitable for flat position can be used DC and AC both.
E309 for welding mild steel and stainless steel.
E308 for welding stainless steel.
WELDING CHECKS & TESTS
LPT/DPT ( Liquid/dye penetrant test)

MCD / MPI ( Magnetic Crack Detection/ Magnetic particle detection)
UT ( Ultrasound Testing)
RT ( Radiographic test )
Colour Wave length(m)
frequency(Hz)
Red
6.22-7.8 x 107
4.82- 3.84 x 104
Orange5.97-6.22 x
5.03-4.82
Yellow 5.77-5.99
5.20-5.03
Green 4.92-5.77
6.10-5.20
Blue 4.55-4.92
6.59-6.10
Violet 3.90-4.55
7.69-6.59
LIGHT OF VISIBLE SPECTRUM

Wavelength 7.8 x 107 m down to 3.8 x 107 m and frequency 4x 104 Hz upto 8 x 104Hz
X-ray
Wavelength 109 m down to 6x 1012 m and frequency between 3 x 104 Hz and 5x 109
Hz
1.2.2 Locomotive Manufacturing Unit

Here is the locomotive manufacturing unit .It has been divided in two shops:
1)
Bogie shop
Step by step process carried out in Bogie shop
A.
37
1. Machining of axle
Axle is prepared in bogie shop out of thick cylindrical raw material.
Facing and drilling operation is done on the axle.
Turning operation is done on the axle to get the required
diameter, by CNC machine.
Grinding operation is done on the axle to make the surface
smooth.
2.
3.
4.
5.
6.
Preparation of collar and wheel

The collar and wheel are machined to get the desired accuracy.
Collar contains a small hole inside which helps in releasing of oil.
It is provided across the gears so that it doesnt move on axle and
forms a firm grip.
After machining these parts are assembled on pressing machine.
The collar, gear, wheel are pressed on the axle via pressing
machine.
Tube is fitted on the axle and traction motor is assembled on it.
Tube supports the traction motor and keeps it stationary while axle
is rotating. The gear and pinion (gear of traction motor) are meshed
together (the teeths are in ratio 64:16 respectively).
Axle box is assembled. It has tapered bearing system.
After the assembly is complete following test is performed as per
the specification:
Wheel Testing: In this process the testing of the assembly of
traction motor and wheel (with gears and axle box) on axle is
done. This test is called traction motor run test. In this test
servo-57 or ENCLO-68 oil is used. It ensures clean
commutater.
Specification:
In axle caps of TM-4906 and
TM-4605 AZ
Traction motor supplyVoltage 30-40 V DC
Current 70-90 Amps
Duration 2hrs
Backlash test: Any backlash if occurred is recorded and any
abnormality like bearing noise is also noted. Backlash limits
0.3-0.8mm.
B.
1. Bogie frame is prepared by achieving desired accuracy. Accuracy
is achieved by machining it through CNC machine (COOPER
machine).
38
2. After final machining bogie fitting is done. Bogie fitting includes

following steps:
Liner mounting is done. It is done so that the shell of the bogie
can be mounted at this place. The shell structure is pivoted at
this place, and liner provides a smooth joint.
Pneumatic brake system is installed.
a) Bush brake system is assembled.
b) Brake rigging is done.
Wheel axle system is mounted.
Suspension arrangement is done which includes mounting of
springs and linkages.
Beam mounting is carried out by mounting two equalizer
beams. These beams maintain the alignment of the train by
transmitting the suspension motion equally.
Bogie trail load is applied for coupling of Axle with Bogie by
tightening of Horn Stay to the Bogie. By applying load the
vertical gap between the axle box and padstle reduces and thus
the gap can also be maintained. Horn stay provides a support
to the axle mounted in the padestle, so that if frame assembly
is lifted the Wheel Axle arrangement does not run out.
Rubber is mounted on the frame which is connected to the
Traction motors for giving a vibration absorbing support
caused due to the suspension of Wheel and Axle system.
After bogie frame is ready it is send to the assembly shop.
2. Assembly shop:
The shell is received from fabrication shop.

Dismantling of roof
Transformer marking drilling
Main reservoir &Aux. reservoir mtg.
Battery box mtg.
After cooler mtg.
SL-30 1st,2nd mtg.
Cattle guard mounting at both end.
Pivot mtg.
AC-2 panel mtg.
39
MVMT 1st mtg.

Roof sub. Assy.
a)
Roof line & Panto insulater mtg.
b)
Lightening Arrester
c)
Earthing on roof.
Compressor (MCP)-1,2,3 mounting.

Baby Compressor mtg. with its oil tray.
AC transformer mtg
Power cable termination
Painting
Chequred plate in cabin-1&2
Cable laying
General Inspection
Testing
1.2.3 TESTING
Testing is carried out after all the assembly is complete. Following steps are
performed in testing:
1. HV & IR (High Voltage and Insulation Resistance) Test: In this testing the
insulation of the cabling is tested. Whether there is any leakage of current and its
resistance fits the required limit.
2. Sequence Test: This is to check whether the wiring is done accordance with the drawing
or not and supply circuit is working properly.
3. Under Catenary Test: 100V supply is provided through battery to baby compressor (8
kg/cm2) then Pantograph is lifted. VCB (Vacuum Circuit Breaker) is closed so that the
supply gets transferred. Supply goes to the Rectifier, SL etc. and the circuit is thus
tested completely.
4. Auxillary Run Test: MVMT (for cooling of motors), MVRH (cooling of circulated oil),
MVSL (cooling of smoothening reactor), MVSI (cooling of rectifier), MVMP
(cooling of motors) run test.
5. Pneumatic Test: This is to check the working of brake system.
6. Traction Motor Test: To check the direction of rotation of traction motor.
7. Rain Test.
8 Long Run Test: Final Bogie is tested by running 4-5 km in nearby station and DBR test
is performed during the run.
40
1.2.4 Various machines employed in the shop:

HOESC pressing machine wheel, axle, collar, and gears are pressed
together
on
this machine. Pressing limit (95 132 tones)
1)
Cooper machine: wheel turning CNC machine.
2)
Specification
Travel along x-axis 1000mm
Travel along z-axis 3000mm
Swing over bead 760mm
Spindle nose 5mm
Spindle power 20 kw
3) Asquith CNC machine (bogie machining centre): Bogie after being prepared
from fabrication shop comes to bogie shop for machining. In machining of bogie,
various processes like boring drilling, milling, facing etc is done through ASQUITH
CNC MACHINE
Specification of this machine are :1.
travel in x axis 8000 mm
2.
travel in y- axis 4000 mm
3.
travel in z- axis 800 mm
4.
spindle dia. - 180 mm
5.
spindle power 40kw
6.
auto tool changer 40 tools
4) Hydraulic arm drilling machine

5)
Radial arm drilling machine
6)
Turret lathe:
Specification:
Swing over saddle- 596mm (max)
Swing over cross
Slide-317mm
Flange to turret
41
Face 1500mm
7) Axle drilling machine

8)
Centre drilling and facing machine:

Specification:
Work holder 160*3000 HID
Stock removal 5.5mm
Gang drilling 3no UNC 98mm PCD/100mm PCD
Motor power 10.5 5.5 HP
9) Axle turning machine

10)
Churchill machine tool: CNC vertical milling m/c

Specification:
1.
Travel in x-axis 1200mm
2.
Travel in y-axis 600mm
3.
Travel in z-axis 400mm
4.
Spindle dia 180mm
5.
Spindle nose ISO 50
6.
Spindle power - 30 kw
7.
System SINUMARIL 80Omm
11) Hydraulic Pipe Bending Machine: This machine is in Assembly Sop and it is
used to bend pipe of various diameter at various angles.
Specification:
Max. capacity 65mm OD*6mm thick ferrous tube
Max. bend radius - 300mm
Length over mandrel - 6mtr
42
Hyd. Tank capacity - 200 ltr
Total H.P- 100
1.2.5 Types and product ranges:

a) Electric Locomotives :WAG-9,WAG-7,WAG-5,WCAM-2,WCAM-3,WCAG-1
b) Diesel Electric Shunting Locomotives :350 hp,450 hp,700 hp(TPP),1150
hp(SPP),1350 hp(SPP),1400 hp(SPP),2600 hp(SPP)
c) New Products :
1. OHE (Recording and Testing car)
2. UTV (Utility vehicle)
3. RRV (Rail cum Road vehicle)
4. DETV (Diesel Electric Tower car)
5. BPRV (Battery powered road vehicle)
6. BCM (Ballast cleaning machine)
7. Metro Rake-Kolkata Metro Railways
8.200 T Well wagon for BHEL Haridwar
This section deals with manufacturing of locomotives.
The main parts of the locomotive are
Under frame: The frame on which a locomotive is built
Super structure: The body of locomotive is called superstructure
or Shell and
is
made of sheet of Mild steel
DC motor
Alternator
Compressor
Flower
Static Rectifier-MSR
Static Converter-SC
Exchanger
43
Bogie-The wheel arrangement of a loco is called a bogie. A bogie essentially contains

1-wheel axle arrangement
2-Suspension
3-Brake rigging
Traction transformer: It is fixed on under frame and gets supply from an
overhead line by equipment called pantograph. The type of pantograph depends on

supply. This transformer steps down voltage and is fitted with a tap changer. Different
taps are taken from it for operating different equipment. One tap is taken and is rectified
into DC using MSR and is fed to the DC motor.
Railways has two types of power supplies 25 KV, 1 Phase, 50 Hz AC

-1500 V DC
An AC/DC loco is able to work on both of these supplies. For e.g. WCAM-3.
1.3 LOCOMOTIVE PRODUCTION (LMP)

There are two products
Alternating Current Locomotive (ac Loco)
WAG-7
AC./D.C. Loco
o WCAM-2P
o WCAM-3
W-broad gauge
A-running in AC mode
C-running in DC mode
G-hauling goods train
P-hauling passenger train
M-hauling passenger& goods train
Diesel Electric Locomotive Shunting (DESL)
350 HP
700 HP
o Single Power Pack (SPP): One 700 HP m/c is made as a single

44
unit. It is a meter gauge locomotive.

o Twin Power Pack (TPP): 2 350HP m/cs are combined in 1 engine
& can be operated individually or in combination depending on 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.
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
1.4 Locomotive Engineering (LME)

It forms a link between locomotive commercial department and manufacturing unit. It take
the technical specification of the job from commercial department and prepare the drawing of
the job required taking all the constraints into consideration. Various softwares such as
AutoCAD, Catia, Ansys are used, however manual drawings is also required sometimes.
Presently they are working on the designing of WAG-9. WAG-9 is upgraded model of WAG45
7. It has additional features such as Air Conditioned driver cabin etc.
1.5 Locomotive Planning (LMP)

It looks after that how a certain project is to be executed so that it turns out smoothly. The
various functions performed by it includes customer enquiry, receipt of order, issue of work
order from commercial department, issue of manufacturing information from Engineering,
product specification and routing sheet, indenting of items etc.
1.6 STORES:
There are three sections in store:
Control Receiving Section
Custody Section
Scrap Disposal Section
2. ELECTRIC LOCOMOTIVE WAG-7

2.1 INTRODUCTION
The BHEL Jhansi performs its own tests to check the quality of the job undertaken besides
that railway takes utmost care to keep the quality check in control by establishing its own
RDSO (Research Designs & Standards Organisation) unit in the BHEL compound to
regularly monitor the proceedings of the order. The RDSO is headquartered at Lucknow. Now
let us have a look on the work undertaken by the locomotive section:
SL. NO.
TYPE
OF
PRODUCTS
PRODUCTION
YEAR
1.
350 HP DIESEL ELECTRIC SHUNTING 1985-86

LOCOMOTIVE
700 HP T.P.P.
DIESEL
ELECTRIC 1986-87
2.
3.
SHUNTING LOCOMOTIVE
700 HP S.P.P. DIESEL
ELECTRIC 1987-88
4.
SHUNTING LOCOMOTIVE
A.C. ELECTRIC LOCOMOTIVE WAG-5 1988-89
5.
HB
6.
LOCOMOTIVE
46
7.
LOCOMOTIVE
8.
LOCOMOTIVE
9.
LOCOMOTIVE
10.
LOCOMOTIVE
A.C./D.C. ELECTRIC
LOCOMOTIVE 1994-95
11.
WCAM-2
A.C./D.C.
ELECTRIC
LOCOMOTIVE 1995-96
12.
WCAM-3
A.C./D.C.
ELECTRIC
LOCOMOTIVE 1998-99
13.
14.
15.
WCAG-1
200MT WELL WAGON
1998-99
O.H.E. RECORDING TEST CAR
1998-99
800 HP DIESEL HYDRAULIC SHUNTING 1999-2000
LOCOMOTIVE
16.
KOLKATA METRO
2000-01
17.
UTILITY VEHICLE (UTV)
2002-03
18.
RAIL CUM ROAD VEHICLE
2002-03
19.
DIESEL ELECTRIC TOWER CAR
2003-04
20.
B.P.R.V.
2003-04
21.
BATTERY LOCOMOTIVE
2004-05
22.
SYNCHROLIFT HOIST ASSEMBLY
2004-05
23.
D.T.S.
2005-06
24.
B.C.M.
2008-09
25.
WELL WAGON-280T
2008-09
26.
ACEMV RAKE
2008-09
27.
WAG-7
2008-09-10
There was no order from the Indian Railways during the period 1999-2007. New orders were
received of WAG-7 for 50 locomotives in December 2007 and tender for 150 numbers WAG7 is still under negotiation. The designs are provided by the CLW (Chittranjan Locomotive
Works) and specifications provided by the RDSO are implemented by the BHEL.
47
2.2 TECHNICAL PARAMETERS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Power Supply
Continuous rated power
Max. Service Speed
Axle Load
No. Of Axles
Gauge
Stating Tractive Effort
Haulage Capacity
Balancing speed on level
Gear Ratio
Control System
22.5 KVA AX, 50 Hz

5000 Hp at rail
100 km/hr
20.5 t
6
1676 mm
44.0 t
4830 t@ 86 km/hr
86 km/hr
16/65
Tap
changer
with
microprocessor
based
fault diagnostic system
48
2.3 EQUIPMENTS AT A GLANCE
Figure 2.1 BLOCK DIAGRAM OF ENGINE ROOM LAYOUT
Cab 1
COMPRESSOR
MVMT BLOWER: Cooling of traction motors.
BA-1 PANEL: Speeding control through shunt resistance.
TRIPLATE PNEUMATIC CONSOLE
RSI-1 {RECTIFIER}
DYNAMIC BRAKE RESISTANCE (DBR)
49
SL-30 {SMOOTHING REACTOR}: Removes pulses from DC signal.

TRANSFORMER
SMGR (TAP CHANGER)
SL-30{SECOND}:
ATFEX TRANSFORMER
BA-3 PANEL
BA-2 PANEL
RSI-2
RC-DAMPING
STATIC CONVERTER: Converts single phase current to 3 phase.
MVMT BLOWER-2
BABY COMPRESSOR
CAB 2
The above flowchart clearly gives us a handy look at the equipments used in the
locomotive WAG-7. The coding of the locomotives has been already discussed in the
second chapter of this report but even then I am breaking code for the present locomotive.
W- BROAD GAUGE A- RUNNING IN AC MODE G- HAULING GOODS TRAIN
So, this locomotive is basically made for hauling goods train or we can say its freight
carrier.
In this part, we had a glimpse of all the major equipments used in WAG-7 but being an
Electrical & Electronics student in the coming sections my main emphasis would be on the
electrical equipments being used in the locomotive WAG-7.
2.4 WAG-7 TENDER SPECIFICATION

50
The electrical equipment should generally include:

1) Components for collection of power from the overhead system
2) Converter set comprising of main transformer, rectifier, smoothening reactors and
voltage control device.
3) Auxiliary machine i.e. various rotary and static machines required for offered traction
equipments.
4) Traction motor, reverser, main line contactor and field weakening devices, etc.
5) Rheostat braking equipment
6) Low voltage control equipment, protective devices/relays, etc.
7) Sanding control apparatus
8) Signaling and indicating lamp and lighting equipment
Now in the sections to follow we would be seeing that what the electrical equipments
that are mounted are, what is the purpose of that equipment, and its advantages.
2.5 PANTOGRAPH
The pantograph is the collector used to slide along the contact wire as has been explained in
section 3.6.3.1. It has a conducting strip which is pressed against the contact wire by springs.
The collector strips are usually of steel with grease lubrication, or of carbon, in which case no
lubrication is needed. Function of the pantograph is to maintain as constant a pressure as
possible between the collector strip and contact wire and to prevent any vertical oscillation of
the collector strip; as these will produce arcing due to braking of electric contact. When the
pantograph is not in use, it is maintained in lower position with the help of stiff springs. The
collector strip is raised by compressed air when it is to be used.
Figure 4.2 PANTOGRAPH
51
As per the specifications, the WAG-7 locomotive shall be equipped with two pantographs
having the metallised carbon strips. Normally, the trailing end pantograph will be used but a
selector switch should be provided on the drivers desk so that either or both of the
pantographs can be raised. The raising up or down of the pantograph while in motion should
not cause any disturbance in the OHE.
2.6 MAIN CIRCUIT BREAKER

An electro pneumatically operated single bottle vacuum circuit breaker is mounted on the
roof of the locomotive to connect the transformer to 25 KV AC overhead line through the
pantograph and to clear any fault in traction power circuit. The breaker should be operational
via a switch located in the drivers cab. The circuit breaker should have a rupturing capacity
of 400MVA and a continuous rating of 1000Amps at 25 KV. The suitable interlocks are
provided for tripping the circuit breaker in case the air pressure becomes low to a value at
which the raised pantograph leaves the contact wire.
2.7 LIGHTENING ARRESTOR

A gapless lightening arrestor of proven design similar to those working in three phase locos is
provided for protection against the line voltage transients caused by lightening or system
switching.
2.8 MAIN TRANSFORMER

As supply lines are to be laid all along the track, with adequate spacing, the economy dictates
use of minimum number of such lines. Therefore, single phase supply is used. The current
enters locomotive through the collector. This is where the use of transformer arises. The
current from the collector flows through the primary of a step down transformer and returns
to supply earth through locomotive wheels and one of the rails on which the locomotive
travels, thus avoiding need for a second conductor. Main secondary windings of the
transformer feed the power modulator, which in turn powers the driving motors. The
auxiliary secondary windings of the transformer feed power for other needs of the train such
as lighting, fans, air conditioning etc.
Now, in WAG-7 the main transformer is of oil immersed type. The oil is forced
circulated through the windings by an electric pump and cooled in a radiator by a blower set.
The transformer has a variable auto transformer winding incorporating various taps
connected to the tap changer, the nominal voltage being 22.5 kV and maximum 27.5 kV. The
transformer also has a fixed ratio transformer, the primary winding of which is connected to
the auto transformer tap changer having a variable voltage from 0 to 22 kV. This transformer
has two separate secondary windings. The continuous rating of rectified current is
2x2700Amps and apparent power for traction on primary and the designed power of
secondary are same that is 5400kVA.
52
2.9 TAP CHANGER

A transformer tap is a connection point along a transformer winding that allows a certain
number of turns to be selected. By this means, a transformer with a variable turn ratio is
produced, enabling voltage regulation of the output. The tap selection is made via a tap
changer mechanism.
If only one tap changer is required, tap points are usually made on the high voltage,
or low current, side of the winding in order to minimize the current handling requirements of
the contacts. However, a transformer may include a tap changer on each winding if there are
advantages to doing so. For example, in power distribution networks, a large transformer may
have an off-load tap changer on the primary winding and an on-load tap changer on the
secondary winding. To minimize the number of windings and thus reduce the physical size of
a transformer, a 'reversing' winding may be used, which is a portion of the main winding able
to be connected in its opposite direction and thus oppose the voltage. Insulation requirements
place the tap points at the low voltage end of the winding. This is near the star point in a star
connected winding. In delta connected windings, the tapping is usually at the center of the
winding. In an autotransformer, the taps are usually made between the series and common
windings, or as a series 'buck-boost' section of the common winding.
With an on load tap-changer the transformer voltage can be varied in steps by adding
or subtracting turns. For this purpose a transformer is furnished with a tapped winding and
these taps are connected to terminals on the tap-changer. The tap-changer provides two basic
functions, first to select a transformer tapping connection in an open-circuit condition, the
second is to divert or transfer power to that selected tapping without interrupting the
through current.
In WAG-7 the tap changer is on load type oil immersed with oil circulating pump and
filter. It has 32 running taps controlled by an electro pneumatic servo motor.
2.10 RECTIFIER
The locomotive is provided with two sets of air-cooled silicon rectifier connected in Graetz
Bridge. Each of these rectifiers are supplied by a separate secondary of the main transformer.
2.11 TRACTION MOTOR

Traction motor refers to an electric motor providing the primary rotational torque of a
machine, usually for conversion into linear motion i.e. traction.
Traction motors are used in electrically powered rail vehicles such as Electric multiple units
and Electric locomotives, other electric vehicles such as electric milk floats, elevators and
53
conveyors as well as vehicles with electrical transmission systems such as diesel-electric and
electric hybrid vehicles. Additionally the electric motors in other products such as the main
motor in washing machines are described as traction motors.
Figure 4.3 TRACTION MOTOR
Before the mid-20th century, a single large motor was often used to drive multiple driving
wheels through connecting rods that were very similar to those used on steam locomotives. It
is now standard practice to provide one traction motor driving each axle through a gear drive.
Usually, the traction motor is simply suspended between the truck (bogie) frame and the
driven axle; this is referred to as a "nose-suspended traction motor". The problem with such
an arrangement is that a portion of the motor's weight is unsprung, increasing forces on the
track.
In WAG-7 the traction motor used is of series DC pulsating current type. The armature is
vacuum pressure impregnated solvent less resin. The motor fulfils the following parameters
broadly:
Mounting: Axle hung nose suspended
Rating: One hour: 750V, 960A, 870RPM, 670 kW
Continuous: 750V, 900A, 895RPM, 630kW
Weak field: 40%
Maximum permissible Ripple
28%
at continuous current of 900A

Starting current: 1350A for 2 minutes
Short time rating: 1200A for 10 minutes
2.12 RHEOSTATIC BRAKING

54
Dynamic braking is the use of the electric traction motors of a railroad vehicle as generators
when slowing the vehicle. It is termed rheostatic if the generated electrical power is
dissipated as heat in brake grid resistors and regenerative if the power is returned to the
supply line. Dynamic braking lowers the wear of friction braking components and
additionally regeneration can also lower energy consumption.
During braking the motor fields are connected across either the main traction
generator (Diesel-electric loco) or the supply (Electric locomotive) and the motor armatures
are connected across either the brake grids or supply line. The rolling locomotive wheels turn
the motor armatures, and if the motor fields are now excited, the motors will act as
generators. For a given direction of travel, current flow through the motor armatures during
braking will be opposite to that during motoring. Therefore, the motor exerts torque in a
direction that is opposite from the rolling direction. Braking effort is proportional to the
product of the magnetic strength of the field windings, times that of the armature windings.
The locomotive WAG-7 is equipped with rheostatic braking arrangement capable
of braking effort of around 20T over a speed range of 25 to 50 km/h. In the event of failure of
the electric brake brakes on the train the air brake on the locomotive will be applied
automatically. Braking effort regulation are obtained by adjustments of the traction motor
excitation. The field of all the motors are connected in series and fed by one of the two silicon
rectifier bridge connected by means of an intermediate transformer to one of the two
secondary windings of the transformer. The control of the excitation is provided by the tap
changer. The dynamic braking resistance is forced cool by AC motor blower set (AC MVRF).
In case of emergency brake application by the driver, the electric brake, if applied will be
automatically cut off.
2.13 BATTERY
Batteries of adequate capacity are provided on the locomotive to feed the equipment for three
hours starting with a half charged battery when the locomotives are coupled in multiple. The
battery can be of lead acid type or latest with PPCP containers.
2.14 CONTROL EQUIPMENT & SAFETY DEVICES

The LED flashers light are provided in the locomotive. The microprocessor based control and
fault diagnostic systems are there which can even indicate the availability of OHE power
supply through capacitive coupling.
The safety devices include a new feature in the locomotives manufacturing. The
Vigilance Control Device (VCD) has been installed on WAG-7. The driver has to
55
acknowledge to periodic vigilance check by pressing a push button. In case the driver is not
vigilant with the first step then the device will flash an indication. If even now, the driver
does not respond then an audio-visual warning will be played and in case of no response
automatically the emergency brakes will be applied and the whole loco has to be started all
again.
2.15 POWERING OF SINGLE PHASE LOAD

This part is not associated with the manufacturing but is an important part of traction system
and I believe this report would be incomplete without discussing this part. The locomotive
power ratings can be as high as 6000 HP. The WAG-7 has a power rating of 5000 HP and
powering such a large single phase load can lead to large unbalance in the supply system
which is always three phase. Due to this the track supply is divided into sections which are
electrically isolated from each other, and substations supplying these sections are connected
to different phases of the three phase supply. Though the unbalance is reduced, its magnitude
still remains large. If the three phase supply system capacity is much larger than the power
drawn by the locomotive, then this unbalance will not significantly affect the three phase
supply system. Therefore, it is essential that the main source of traction supply should be
sufficiently large.
Figure4.4 SCHEMATIC DIAGRAM OF TRACTION SUBSTATION
2.16 PNEUMATIC BRAKING SYSTEM

In the air brake's simplest form, called the straight air system, compressed air pushes on a
piston in a cylinder. The piston is connected through mechanical linkage to brake shoes that
can rub on the train wheels, using the resulting friction to slow the train. The mechanical
linkage can become quite elaborate, as it evenly distributes force from one pressurized air
cylinder to 8 or 12 wheels.
The pressurized air comes from an air compressor in the locomotive and is sent from car to
car by a train line made up of pipes beneath each car and hoses between cars. The principal
problem with the straight air braking system is that any separation between hoses and pipes
causes loss of air pressure and hence the loss of the force applying the brakes.
56
Ballast Cleaning Machine

INTRODUCTION
The Ballast Cleaning Machines offered by BHEL is based on proven on Track Ballast
Cleaning system of M/s. MTH PRAHA a.s., Czech Republic with all major components of
working unit imported from MTH. The Power unit made by BHEL as per basic design and
specification of foreign MTH PRAHA as. The fabricated frame work (steel structure) for
working unit (SCV 602 IN) is manufactured at BHEL works and the assembly of the entire
unit is done under technical supervision of the experts from MTH PRAHA.
The machines offered will not only provide trouble free service and durability but will also
pave the way for reliable Track maintenance for Indian Railways.
BCM being manufactured by BHEL Jhansi, Comprises mainly of two parts:

a.) Power Car
b.) Working Unit
Ballast Cleaning
Machine
(Power Car)
Power car comprises of one no. KTA 38L Cummins make diesel engine.(1120 hp).
Traction Alternator TA 6301AZ
Twin Impeller Blower 10000cfm
Aux. generator AG2513
IR make Compressor model 15T.
Screw Coupler with hook.
Roof mounted radiator with fan hydraulically driven.
Dynavane filter.
57
58
TECHNICAL DESCRIPTION OF THE WORKING UNIT SCV 602 IN

1.0. GENERAL
The SCV 602 IN is a specially designed track maintenance machine with two double axle
bogies - one is driving bogie & other is trailing bogie. During the work mode the driving
bogie is powered from the power unit and works in tandem with the power unit. During
transport mode-driving bogie is not powered and allow free running for towing purpose.
The SCV 602 IN has no power source of its own and will operate only if connected to the
Power Unit PA 801 IN which is the source of energy, supplies the compressed air and
tractive force to the SCV 602 IN.
During the work mode, total control of the work unit SCV 602 IN and the Power Unit 801
IN are controlled using the control panels in the working cabin of the SCV 602 IN.
The machine is capable of working under electrified overhead catenary without a power
block. The machine is equipped with a physical protection barrier fitted to prevent access
to the roof area whilst the machine is in operation.
The purpose of the SCV 602 IN is to clean the ballast of the entire width of Ballast section
for plain track & turnouts, separating the gravel larger than 25 mm and smaller than 70
mm from the spoil down to the sub grade.
The minimum cutting depth is 300 mm. and the maximum depth of cut is 650 mm.
underneath the bottom of the sleeper.
The cross fall of the cutting chain can be adjusted to suit the cant required and doesnt
have to be parallel to the rail track at all times. This is to allow for drainage if required.
The SCV 602 IN is able to fully excavate the ballast down to the sub grade and lay the
track directly on to the cut level.
The SCV 602 IN requires only 3 operators. One in the cabin as the main operator and the
other two for connections and disconnections at start up and close down. In turnouts 5
workers are required.
Whilst the machine is in work mode the two operators are used as observers either side of
the machine to ensure safe and accurate work procedures. All three operators can alternate
their work position during operation.
1.1. CLIMATIC AND GEOGRAPHIC CONDITION
The SCV 602 IN is capable of continuously operating in ambient temperatures of 0 C to
55C, up to an altitude of 700 m above sea level, at up to 100% relative humidity and
maximum rail temperature of 70C. Transportation of the machine can be carried out at
below zero temperatures but not operation.
2.0. DETAILED DESCRIPTION OF THE MACHINE COMPONENTS

59
All the components of the SCV 602 IN are arranged in sequence on the special frame of
the machine.
2.1. MAIN FRAME
The frame is of welded plate construction and designed to allow the correct placement of
groups of components of the machine.
On each side of the frame close to the bogies, special allowance has been made to
accommodate special compartments for tools, batteries and spare parts.
In calculation for the strength of the frame such forces have been taken into consideration
as, weight of the groups of components, dynamic effects, all outside forces appearing
during operation, compression and pulling forces due to transportation.
2.2. EXCAVATING SYSTEM
The ballast is excavated by the undercutting chain, which is then transported to the
receiving hopper and then to the conveyor belt. The undercutting chain has scoops with
replaceable grappling teeth, which excavate the ballast and then passes through chutes and
the undercutting bar. During the transport mode the undercutting chain and bar is attached
to the transport console and hung by the electric hoist.
The undercutting bar is lowered by the electric hoist at the center of the track and
appropriately placed into the correct working position.
At both ends of the chutes adjustable wings are provided that allow the extension or
retraction of the width of cut.
For safety purposes on the lower edge of the chute a safety bar is attached which allows
for automatic stoppage of the chain if anything impedes the space covered by the safety
bar. The positions of the chutes, which are attached to the undercutting bar, are continually
adjusted by the hydraulic cylinders.
For undercutting the turnouts the undercutting chain and undercutting bar is extended in
steps. This extension is carried out by insertion of extensions to the chain and bar in 500
mm lengths. The connection between the inserted extensions and the chain are rigid to
ensure accuracy of the cut. The undercutting chain, which comprises of pins and scoops
with replaceable teeth, is made of non - abrasive high tensile cast steel thus giving a
longer life span.
The undercutting chain is driven by electric motors with an epicyclic gearbox with bevel
gear. The tension of the undercutting chain can be controlled either by movement of the
gearbox or the telescopic extension of one of the chutes. The transmission allows
reversing of the chain for a short period.
2.3 BOGIES
The machine is fitted with two bogies, 1 of locomotive type, 1 of wagon type. Only
locomotive type bogie is equipped with two traction motors type TM4501AZ of BHEL
make, one for each axle.
60
Each bogie has its own braking system controlled by pneumatic cylinders, in addition to
this, one of these bogies (FRONT) has mechanical brakes on the wheels of the leading
axle and the control mechanism is located in driving cabin.
The bogies fulfill the requirement for speed limits, axle load and quality ride index.
2.4. SCREENING UNIT
The screening unit comprises of a 2,5 level screen system of reliable and proven design.
The selection of screen unit has been done based on experience of similar machines
supplied by our supplier of equipments M/s MTH Praha a.s. with adequate margin for
higher spoil content. The total area of screen (including two decks) is minimum 22 Sq.M.
The Screen mesh is made of Steel wire and the shape of the aperture is square.
Recommended mesh size for top and bottom decks of the screen:
a)
Bottom Deck
25 x 25 mm.
b) Middle Deck
1/4th
3/4 th of the deck 50 x 50 mm. and the last
c)
of the deck 65 x 65 mm.

90 x90 mm
Auxiliary Deck
The vibration of the screens is caused by two electric motors with eccentric wheels. The
vibrating units are attached to the machine in a longitudinal slope of 25 and the screens
are attached to the tilted auxiliary frame via spring coils and this frame is attached to the
main frame. This arrangement enables the screens to remain in the lateral horizontal
position even in a super elevation situation.
The screen is fixed to the machine by means of an auxiliary tiltable frame which enables
the tilting of the screen to the required extent which is 200 mm. This is achieved by 2
Nos. hydraulic cylinders, which are controlled from the working table. The screen is be
fitted with an automatic tilting device.
2.5. LIFTING UNIT
The lifting units can lift the track and move the track laterally in the work mode.
The lifting unit comprises of two lifting beams, two lifting rollers and two directional
rollers. Both lifting beams can be controlled separately for the required cant and the
change, if necessary, to the track, which has influence on distribution of Ballast.
The purpose of lifting unit is for complete lifting and freeing from rail bed while enables
easier excavation of ballast material and keeping the track in correct geometric position
until the first required amount of cleaned ballast is put into place.
The design of the lifting unit allows continuous movement even at the joints and welded
portion of rails. During the transport mode the lifting unit is mechanically locked in the
raised position.
2.6. CONVEYOR BELT FOR EXCAVATED MATERIALS
The conveyor belt transports the ballast from the receiving hoppers to the screening units.
The conveyor belt is a standard conveyor belt, channeled and made from rubber driven by
electrically operated drums. The whole conveyor belt is fixed to the frame as a sliding
61
unit, which enables flexibility of the conveyor belt so that even in the full excavation
mode the ballast can be transferred either to the storage wagons or to the side of the track.
2.7. CONVEYOR BELT FOR BALLAST
The conveyor belt transports screened ballast from the screening unit to the equipment for
returning the ballast to the ballast bed.
The conveyor belt is a standard flat conveyor belt made of rubber, driven by electrically
operated drums and fixed rigidly to the frame.
2.8. CONVEYOR BELT FOR SPOIL
The conveyor belt transports the spoil from underneath the screening unit to the swiveling
conveyor and is able to transport the spoil along with the over sized ballast when the
machine is in the full excavation mode.
The conveyor belt is a standard conveyor belt, which is channeled, made from rubber and
driven by electrically operated drums. This conveyor is fixed rigidly to the frame and at
the upper end of the conveyor is a receiving hopper that feeds the swiveling conveyor in
any position.
2.9. SWIVELING CONVEYOR BELT
The conveyor belt transports the spoil to either into muck wagons at the front of the
machine or to the side of the track. The conveyor belt is a standard conveyor belt, which is
channeled, made from rubber and driven by electrically operated drums.
The swivel unit comprises of a large bearing and an exterior toothed rim which allows the
conveyor to be swiveled to 100 the track center line. A hydraulic motor does the swivel
action. .
When the swiveling conveyor is in the machine centerline of the axis of the track and so
as not to overstep the length of the machine, the conveyor is cranked into the travel
position and locked mechanically. At the end of the swiveling conveyor a searchlight is
attached to illuminate the discharge area during poor light conditions.
The swiveling conveyor belt is equipped with safety mechanism to prevent the
infringement of parallel tracks and or to prevent collision with exterior obstacles eg.
Masts, posts, trees etc. To achieve this sensors are provided which can detect the obstacles
and enables to conveyor to swing away from the obstacles. We are enclosing herewith
Sketch No. (7) showing the arrangement of infrared sensor of spoil discharge conveyor.
2.10. BALLAST PLACEMENT UNIT
This unit is designed for the optimal placement of cleaned ballast back to the rail bed
under the rails in both plain track and points crossing.
This unit consists of front and rear Ballast divider, satellite conveyor and lateral conveyor.
This equipment is placed on a satellite, which is wheeled and towed during work mode
and is located between the bogies of the machine.
62
In addition on one side of the machine there are side conveyors, which enable the
placement of ballast in turnouts.
FRONT DIVIDER
The front divider receives the ballast from the conveyor and places the ballast under the
rails via outside of the rails. This is the first pouring. The volume of the pouring is
controllable by the side flap of the front divider. In the event that there is an excess of
ballast at this pouring, it is placed on the satellite conveyor.
SATELLITE CONVEYOR
The satellite conveyor transports the excess ballast to the rear divider. This is a standard
flat rubber conveyor belt driven by electrically operated drums.
REAR DIVIDER
The rear divider receives the ballast from the conveyor and places the ballast at the center
of the track. In the event there is an excess of ballast at this pouring, it is placed on the
shoulders of the track. To enable the control of volume of ballast to either left or right,
there is a moveable flap. The rear wall of the rear divider acts as a plough, which moves
and levels the excess ballast from the top of the sleepers. The width of the rear plough can
be extended manually by moving the side wings. In the event of a large volume of ballast
the excess is put on the lateral conveyor.
LATERAL CONVEYORS
The lateral conveyors enable the movement of the excess ballast to the shoulders either
left or right and are a standard flat rubber conveyor driven by electrically operated drums.
The conveyors are fixed to the satellite.
BROOM
At the rear of the satellite there is a broom, which cleans the upper surface of the sleepers.
The cleaning of the fasteners is not necessary as they are protected during the pouring
process.
SATELLITE
The satellite is hydraulically lifted and mechanically locked in the transport position
during travel mode. During the cleaning of the ballast in points and crossings the function
of the described system doesnt change except that the flap in between the front divider
and the conveyor diverts the ballast to the upper side conveyor.
SIDE CONVEYORS
There are two standard flat rubber conveyors driven by electrically operated drums and
are located under the arched frame one above the other.
The lower conveyor, fixed to the frame, can slide laterally and is able to be extended to
double its length.
The ballast is transferred from the upper conveyor to the lower conveyor and the lower
conveyor is positioned and extended step by step according to the position of the crossing.
63
Manipulation of the lower conveyor and the diverter flap is done manually by means of
remote control from the position of optimal view of the work site.
2.10.1. Ballast Distribution System
The Ballast Cleaning Machines offered are provided with MTH Praha a.s patented ballast
distribution system developed and perfected over large number of machines installed
worldwide by MTH Praha.
At the initial set up, the following parameters of the machines are set by the operator
depending on volume and quality of ballast to achieve continuous feed of ballast on the
track within the tolerance allowing a speed of 40 KMPH.
a) Lift of Track
b) Position of side Flap of Front Divider.
The volume of the ballast is controlled by (i) Angle of Feed, (ii) variable width of Feed,
(iii) the distance between the bottom of the sleeper and the level of the cut, which can be
changed by the lifting device.
All cleaned ballast first goes to the Front Divider, which is always kept full. The ballast is
fed gravitationally under the sleeper to area A (please refer Sketch No. 2). When the
Front Divider is overfilled the excess ballast is transferred to the Rear Divider via the
conveyor and this ballast is fed to the center of the Track up to the top of ties i.e. area B
(please refer Sketch No. 2). In the event there is more ballast it is then transferred to area
C i.e. shoulder of ties. When the Rear Divider is overfilled with ballast the excess
ballast is transferred to the Lateral Conveyor, which transferred the ballast to area D i.e.
beyond the shoulder. This situation rarely happens or may only offer when there is
lowering of the Track. The rear wall of the Rear Divider is designed as a Plough, which
regulates the profile of ballast. In both Front and Rear Dividers covers are provided for
Rails & Fasteners as a protection system. At the time of the routine stoppage or otherwise
of the machines, feeding also stops automatically due to the angle of the feed which
avoids overfeeding or heaping of ballast in one area. As soon as the Machine is started, the
feeding also starts automatically. As an added the feature of the Machine a Blocking
device is provided which stops all working components when the Machine is stopped. The
Machine has been designed in such a manner that the ballast is accumulated at all the
distribution points of the machine and the moment the Front Divider is at the position of
the excavated Track the feeding begins and on the reverse, the accumulated ballast is
enough to be returned to the free areas.
For feeding the ballast internals, only the Front Divider is used. In the Front Divider, there
is a flap, which regulates the amount of ballast required for the track on which the
machine is standing, and then transferring ballast to the side conveyor belt to feed the
ballast to the parallel Track. This control is exercised by the operator who is located
outside the cabin with the help of cable connected remote control device.
The ballast is compacted by the down pressure of the rear bogie of the Machine that
means there is no necessity for ballast distribution under the entire length of the sleepers.
2.11. WORKING CABIN
The main operating position during work mode of the SCV 602 IN enables full operation
of all functions for the operation of the SCV 602 IN during work mode and the control of
the driving speed of the power unit PA 801 IN.
64
The cabin is so designed that the operator can operate in seated position. In the cabin there
are two suspension chairs, control panels with all control elements, a panel with
measuring gauges and the main switchboard.
The placement and lighting of the panels have been done in relation to ergonomic
standards. The cabin is dust proof and air-conditioned.
All this ensures a comfortable and ergonomic environment for the operators.
The cabin is a self contained unit made of welded square profile tubular steel, which is
covered on the outside by sheet metal and is decorated on inside by special sheets
The spaces between the inside and outside walls are filled with sound and thermal
insulation class C1. The floor is covered with PVC Vinyl.
Entrance on both sides of the cabin is provided with sliding doors. Because of the special
design, access to the cabin is easily possible from ground level. The cabin is equipped
with large windows at front, sides and rear to enable full sight of the work area. What is
not visible can be viewed through the optional T.V. monitor e.g. screening, conveyors,
swiveling conveyor etc.
During poor lighting conditions, the cabin is equipped with lighting for proper visibility,
with the focus being the control panels and measurement system.
The cabin is equipped with an internal communication system between the cabin and the
power unit PA 801 IN. On the wall behind the operator is the main switchboard with
circuit breakers sensors etc. These circuit breakers etc. are easily accessible without
opening the whole switchboard.
The cabin unit is located under the arched frame and suspended on silent blocks, which
eliminate vibration from the main frame to the cabin.
2.12. DRIVING CABIN
The cabin is of welded square steel tube covered on the outside by thin sheet metal and on
the inside by decorative materials.
The spaces between the inside and outside walls are filled with sound and thermal
insulation class C1. The floor is covered with PVC Vinyl. The cabin is dust proof and
ventilated.
Windows are of safety glass with rubber sealing. Side windows can be opened
The doors are glazed and the lights of the cabin for cabin illumination are installed in the
roof.
At the front of cabin is a control panel equipped with all necessary controls and group of
indicating lights.
With the control panel is the communication system to the PA 801 IN. The brake control
levers are located on the left side of the control panel.
65
Above the windscreen is a space for the windscreen wiper motors, headlights and the
speakers of the communication system. Below this space is attached the sun visor. There
are two suspension chairs for operators. Vibration from the main frame to the cabin is
eliminated through the mounting of the cabin on the four silencing rubber steel blocks. At
the front of the machine on the outside is a double headlight in one mounting, handrails
for easy access to the windscreen for cleaning.
2.13.
HYDRAULIC EQUIPMENT
The hydraulic equipment is specifically designed for all direct action movement of the
machine components, i.e. flaps, positioning of working units etc. The source of
pressurized oil is the hydraulic power pack located on a platform at the rear of the
machine.
For the protection of the hydraulic power pack against the dust or foreign elements, it is
housed in its own small cabin which also contains, a work bench with vice, hand tools
and an area for the location of small materials.
The hydraulic power pack comprises of an oil tank, a pump driven by an electric motor,
radiator with cooling fan and all other necessary components including safety devices. As
the hydraulic functions are not required at all times, the power pack is activated by a
switch in the work cabin as & when required and this activation is indicated by the light
on the control panel. In the work-mode the hydraulic pressure is ON constantly during
the wind-up and wind-down period and at other times the work mode is ON on a need
basis. During work mode the hydraulic working units are locked in position by means of
hydraulic lockers or by means of the closed position of hydraulic terminals. In the event of
an emergency due to the failure of hydraulic power pack, a small emergency hydraulic
power unit is provided in the small cabin.
The emergency hydraulic power unit has a small hydraulic pump driven by a petrol
engine, which produces 5 kW of power. Connection of the emergency hydraulic power
unit to the main hydraulic circuit is provided in the small cabin.
The control elements of the hydraulic power pack are located in accessible and suitable
positions on the frame of the machine.
The hoses and seamless pipes for the hydraulic circuit are located within the profile of the
frame.
2.14.
ELECTRIC EQUIPMENT
The electric motors installed on the machine are required for all rotational movements of
the machine components. There are three separate electric circuits:
a) Technology Power CIRCUIT -3 x 415 / 230 V. 50 Hz
The source being the PA 801 IN by means of interconnecting cables.
b) CONTROL CIRCUIT - 24 V. DC. Its source being a battery located within the frame
of the machine and charged by the tractive circuit.
c) TRACTION CIRCUIT its source being the traction control rectifier located
on the power unit PA 801 IN which supplies energy to the two traction motors by means
of two interconnecting cables.
66
The TRACTION CIRCUIT supplies energy to all electric motors of all working
components of the machine, most contactors and part of the lighting system of the
machine.
The CONTROL CIRCUIT supplies energy to all control elements and signaling, part of
the contactors and the lighting during poor visibility.
The TRACTION CIRCUIT is only for the supply of energy to the traction motors.
All electrical connections are of wire and cables suitable for outdoor use and vibration.
All these wirings are located either within the profile of the frame or in metal conduit
fitted on the frame.
All these circuits are terminated in the switchboard located in the work cabin. The
switchboard houses all necessary contactors, circuit breakers, sensors etc.
The machine is equipped with the required signal lights on both ends of the machine.
For protection against electric shock an earthing system is provided and all the electric
motors & components are properly earthed. For the protection of the electric circuit,
circuit breakers are used.
2.15.
PNEUMATIC EQUIPMENT
The pneumatic system is used for two purposes, for the braking system and for some of
the working units.The source is the PA 801 IN and is fed to the SCV 602 IN via four
connected hoses (brake, straight air brake, main tank, vacuum brake
At each end of SCV 602 IN the main pipe is split to give two connections, one each side
of the end of the machine.
The pneumatic brake system comprises of the compressed air tank and one direct acting
and one self-acting unit.
The pressure gauges of the main tank, brake pipe and brake cylinder are located on the
measurement panel in the work cabin.
The valve for the emergency brake and the release valve for the brakes are located in the
work cabin.
The pneumatic working units are fed with compressed air from the air tanks through
reduction valves.
This system feeds the units via electro pneumatic valves.
The supply is fed through metal tubes and hoses that are located on the outside of the
machine frame.
2.16.
MEASUREMENT SYSTEM
The SCV 602 IN is equipped with a measurement system, as an optional, which

continuously provides information to the operator about the position of the working units
and other data about the working of the machine.
This data is
distance from the beginning work.

actual speed
middle depth of the ballast excavation
lateral position (super elevation or cant) of the rails
that are held by the lifting unit.
67
super elevation behind the machine

cutting level
These data are continuously fed to the operator and can also be observed on the monitor
located on the measurement panel.
Some of these data can be continuously recorded as evidence of the distance worked.
2.17.
INDUSTRIAL T.V.
As an option, it is possible to have mounted at strategic positions cameras with the screen
located in the work cabin within easy view of the operator for the purpose of viewing
work areas of the machine not visible from the work cabin, e.g. screening unit, ballast
separators, spoil discharge by swiveling conveyor, transport of clean ballast to the
conveyor, ballast distribution for both front and rare Divider, ballast distribution in
turnout, etc. Operator can choose which he wishes to view.
3 BASIC TECHNICAL DATA
3.1WEIGHT AND MAIN DIMENSIONS OF SCV 602 IN
Total weight
Axle load
Weight difference between wheels on one axle
Weight difference between axles on one bogie
Length over buffers
Width in transport mode
Height
Distance between bogie pins
Bogie wheel base
Diameter of wheel
Weight per meter
Max.
max.
max
max.
80 tonne
20 tonne
4%
2%
24,75 m
3.1 m
3.9 m
18 m
2,2 m
1000 mm
3.5 tonne
PART B -TECHNICAL DESCRIPTION OF THE POWER UNIT PA 801 IN

1.
GENERAL
1.1. This specification covers the Technical Particulars of Single Power Pack 1100 h.p.,
Broad Gauge, Bo-Bo, Diesel Electric Power Car. This shall have two 2-axle
bogies with all 4 axles independently motored. The power car shall have one
diesel engine of 940h.p. Gross (continuous) and 1120HP (intermittent) rating
driving a traction alternator. The alternator ac output is controlled by Electronic
Governor and fed to the DC Series Traction motors.
1.2. The design incorporates the features and equipments well proven in traction
service and conforms to the extent possible to Indian Railways Standards.
2.
Power Car Particulars:

The principal dimensions and the data of the power Car shall be as under :
Wheel arrangement
BO-BO
68
Gauge
1676 mm
Power car G.A. Drawing
27180005103
Weight Per Axle (Max.)
20Tonnes
Fuel Tank Capacity
4000 Litres (approx)
Wheel Diameter New
1000mm
Gear Ratio
19/92
No. of Seats in the Cabin
4Nos. (Including Driver)
Bogie Pivot Centres
6500mm
Length Over headstock
12500mm
Maximum Width
(Over Cab)
3040 mm
Maximum Height
4051 mm
Height of buffers & coupler

Over rail level
1090 mm +15 mm
-10 mm
Rail Clearance with

New Wheel
140 mm (below motor gear case)
Rail clearance with full

Worn wheel
102 mm (below motor gear case )
Maximum Gross Weight
80 + 0 %
-3%
45 Meters
Negotiability on Curve
Diesel Engine
38L
One no. Cummins India make KTA
Max. Starting TE on Wheel Tread.
19200 kg. @ 24% adhesion
69
POWER CAR DESCRIPTION

The power car shall be fitted with electrical equipment manufactured by BHEL
and shall be powered by CUMMINS engine. The vehicle will operate in two
modes namely "Traveling mode" (TM) and "Working Mode" (WM). In Traveling
Mode, the alternator shall run at 1800rpm receiving 920HP Input to traction from
Diesel engine and deliver full output of 840KW to the Uncontrolled rectifier
mounted on alternator shaft. This power shall be used to haul the Ballast Cleaning
Machine (BCM) at 75KPH to the working site. The operation shall be switched to
Working mode whence the engine rpm shall be 1500RPM and alternator shall be
used to deliver power at 415VAC from phase to phase to the trailing Ballast
cleaning machine (BCM). There will be a tapping on the winding of the Traction
alternator, which will be used to deliver a small part of power, around 20%, to a
controlled rectifiers (SCR) to the traction motors. Since the speed requirement of
the Power Car in Working Mode is very small i.e.0.5Kph (min.), the traction
Motors shall be connected in series.
For above-mentioned operations to be performed by Power Car, a 72Volts DC
Control system is designed for controlling the speed of the Diesel engine as well
as excitation current for Traction Alternator in the both Mode.
70
5. CONCLUSION
This report clearly replicates the tremendous growth of a company which continuously
renovated its technology to contribute not only in the infrastructure building in India but also
of the world. It is an asset for our country to have such a public sector industry which has
fulfilled the dream of our first Prime Minister Sh. Jawahar Lal Nehru by operating in 65
countries and making it go global.
The vision and mission of this company are successful can be adjudged with the faith of the
stake holders in this company. BHEL Jhansi although a smaller unit in comparison to other
units of BHEL, is a very productive one with the manufacturing of the electric locomotives,
power transformers, etc. The work load here can be accessed from the fact that the order of
the locomotives has forced the company to shift its Bus duct section to the other unit of
BHEL. Presently company is about to finish its project on BCM machine, it clearly shows
that company has good working hands on the coming technology and has rapid pace of
working.
In future also the company is having orders of metro coaches and this clearly shows why this
company is still recession proof. And the designing department has started to work on the
technology of WAG-9 so that it can take fresh orders of WAG-9 from Indian Railways.
71
6. REFERENCES
Gopal K. Dubey, Fundamentals of Electrical Devices, Second Edition,
Fifteenth Reprint, Narosa Publishing House Pvt. Ltd.,2008
Ashfaq Hussain, Electric Machines, Second Edition, Dhanpat Rai & Co.,2008
Y.P.Singh, Presentation on Standards and Practices Overhead Electric
Equipments.
Presentation on Locomotive Manufacturing by BHEL.
Presentation on Locomotive Planning by BHEL.
WAG-7 Tender Specification by RDSO Lucknow.
Presentation on BCM by BHEL.
Presentation on Basic Welding Process by BHEL.
General drawings by LME Dept.
Presentation on WE & S by BHEL.
Websites
www.wikipedia.com
www.sayaedsaad.com
www.bhel.com
www.bheljhs.co.in
www.scribd.com
72
TECHANICAL DESCRIPATION OF DIESEL ENGINE

FUNCTION:Diesel engines acts as the prime mover for the
Diesel locomotives. In a Diesel-electric locomotive, Diesel engine
drives an electrical generator/ alternator whose output provides
power to the traction motors .
Technical Details for Diesel Engine

TYPE
CAT 3406
GROSS POWER OF ENGINE
350 h.p.
AT SITE CONDITION
POWER OF ENGINE TO TRACTION
300 h.p.
AT SITE CONDITION
RATED SPEED AT 8TH NOTCH
2100 rpm
IDLE SPEED
600 rpm
NO. OF CYLINDERS
CYLINDER ARRANGEMENT
6
IN - LINE
CYLINDER BORE
137mm
STROKE LENGTH
152mm
ASPIRATION
NET DRY WEIGHT
TURBO CHARGED
AFTER COOLED
1340 k.g.
73

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BHARAT HEAVY

UNDER THE GUIDANCE OF

SAURABH AGARWAL VIPUL AGARWAL

2nd yr Mechanical Engg.

1.1 POWER GENERATION

1.3 INTERNATIONAL OPERATIONS

1.4 VISION, MISSION AND VALUES OF BHEL

PRODUCTS, SYSTEMS AND SERVICES IN THE FIELDS OF ENERGY,

ZEAL TO EXCEL AND ZEST FOR CHANGE.

INTEGRITY AND FAIRNESS IN ALL MATTERS.

RESPECT FOR DIGNITY AND POTENTIAL OF INDIVIDUALS.

STRICT ADHERENCE TO COMMITMENTS.

ENSURE SPEED OF RESPONSE.

FOSTER LEARNING, CREATIVITY AND TEAMWORK.

LOYALTY AND PRIDE IN THE COMPANY

1.5 VARIOUS UNITS OF BHEL ACROSS THE COUNTRY

: Heavy Electrical Plant.

Hyderabad: Heavy Electrical Power Equipment Plant.

1.5.2 SECOND GENERATION UNITS

: High Pressure Boiler Plant.

: Transformer and Locomotive Plant.

: Seamless Steel Tube Plant.

Central Foundry and Forge Plant.

1.5.3 UNITS THROUGH ACQUISTION & MERGER

1.5.4 NEW MANUFACTURING UNITS

Boiler Auxiliaries Plant.

Govindwal : Industrial Valve Plant.

Component and Fabrication Plant.

Energy Systems Division

1.6 ACTIVITY PROFILE OF BHEL

Thermal sets and Auxiliaries.

Steam generators and Auxiliaries.

Air pre heaters.

Nuclear power equipments.

Hydro sets and Auxiliaries.

Seamless steel tubes.

Casting and forging.

Turnkey power station.

Data acquisition Systems.

HVDC Commissioning systems.

Modernization and Rehabilitation.

1.6.3. TRASPORTATION SECTOR

Diesel Electric generators.

DC locomotives and loco shunters.

Traction system for railways.

Electric trolley buses.

1.6.4. INDUSTRY SECTOR

Photo Voltaic cells.

Blow out preventers.

Control systems for electric devices.

BHARAT HEAVY ELECTRICALS LIMITED JHANSI (UNIT)

2.2 MODERN MACHINARY IN BHEL JHANSI: CNC CROPPING LINE MACHINE

2.3 THE PRODUCT PROFILE OF BHEL JHANSI UNIT

up to 220 KV class 250 MVA

100 KV, 1400 MA

Freight Loco transformer

3900 to 5400 KVA & 7475.

upto 1000 KVA 2(1-phase).

upto 5000 KVA.

VT & CT up to 220 KV class.

Diesel electric locomotives

Over Head Equipment cum Test

2.4 GROWTH OF PRODUCTIONS AND MILESTONES