BHARAT HEAVY ELECTRICALS LIMITED

BHOPAL

Industrial Training Report

B.TECH ELECTRICAL ENGINEERING SIXTH SEMESTER

Duration: 16th June to 13th July, 2016

Under the guidance of: Mr. Narendra Kumar

(Designation: Sr. Production Engineer, T.M.X Division)
Prepared By:

Utkarsh Sharma (13BEE028)

Token Number: VT 449/16
Career Point University, Kota (Raj.)

CERTIFICATE
This is to certify that training project at BHEL in Bhopal is successfully completed
by Mr. UTKARSH SHARMA and the brief report about the industrial training at
BHEL; Bhopal is the bonafide work and is original. This work is submitted in
partial fulfillment for the award of B.Tech degree in electrical engineering from
CAREER POINT UNIVERSITY, Kota in year 2016-2017.

Date:

Signature of Guide

ACKNOWLEDGEMENT
I would like to express my gratitude and regards to all those who gave me the
possibility to complete the training. A special thanks to my training guide Mr.
Narendra Kumar, with whom reference I was able to complete this training project.
I would also like to acknowledge and thank with much appreciation Mr. Shishu
Pal, Sr. Engineer (design) and Mr. Ravi Kumar Choudhary, Sr. Engineer (TXM) for
the same cause. I would also like to thank Mr. C.S Joshi for accepting my CV and
giving me an opportunity to learn.

TABLE OF CONTENT

SR.NO

TOPICPAGE NO.

1.

PREFACE

2.

ACKNOWLEDGEMENT

3.

CERTIFICATE

4.

LIST OF ABBREVIATIONS

5.

BRIEF ABOUT HINDUSTAN ZINC LTD.

6.

BRIEF ABOUT CAPTIVE POWER PLANT

7.

THERMAL POWER PLANT WORKING PRINCIPLE

8.

COAL PROCESSING

9.

BOILER SECTION

10.

TURBINE

11.

CONDENSING SYSTEM

12.

EXHAUST SYSTEM

13.

WATER PATH

14.

FLUE GASES PATH

15.

AIR PATH

16.

MRS AND SWITCH YARD

CHAPTER 1: ELECTRIC TRACTION SYSTEM

Electric traction means a locomotion in which the driving force is obtained from electric motors.
There are various types of traction system:
1) Steam Locomotive: This consists of a steam boiler which produces superheated steam at a
pressure of 10 to 15 kg/cm2. This steam drives steam engines which provide the motive power
for the train. The speed is controlled by regulating the flow of steam to the engine. These engines
have now become obsolete and are being gradually withdrawn from services.
2) Diesel Engines: In these engines a diesel engine is coupled to a dc generator which supplies
power to the dc traction motors . These engines can be easily started from cold conditions and are
more efficient than steam engines.
3) Electric Locomotive: Power is taken from overhead lines which drives the motors of the
locomotive. Electric traction systems may be broadly categorized based on type of supply:

Alternating current supply

Direct current supply

In general following electric traction systems exist:

1. AC 3 phase 3.7 kV system
2. AC single phase 15/16 kV -161/25 Hz
3. AC single phase 20/25 kV - 50/60 Hz
4. DC 600 V
5. DC 1200 V
6. DC 1.5 kV
7. DC 3 kV.

If operating supply is D.C. then A.C. power obtained from overhead transmission line (using
pantograph) and steel track is return conductor. AC is rectified to DC and then supplied to the dc
series motors for providing tractive force. These substations receive power from 3- 11 kV or 3 33 kV or 3- 66 kV transmission lines. Operating voltage is about 1500V - 3000V.
If operating supply is A.C. then it can be single phase or three phase. Generally 3 induction
motors are used for driving the locomotive. 25 kV A.C. system has several advantages over D.C.
system thats why it is mostly adopted.

1.

Catenary

2.

Pantograph

3.

Circuit breakers

4. On

load tap changer

5.

Transformer

6.

Rectifier

7.

Smoothing reactor

8.

D.C. motor used for traction

Fig. A.C. Locomotive

TRACTION SYSTEM IN INDIA:

1) A.C. system: As discussed above this system is employed for Indian Railway. Forced
ventilation system is there, in which fan is externally connected. Free running period is large as
the distance between the stops is large. Speed time curve is shown in the figure.

2) MRTS (Mass Rapid Transit System): Mass

transit system refers to public shared transportation, such as trains, buses, ferries etc that can
commute a larger number of passengers from origin to destination on a no-reserved basis and in
lesser time. Distance between the stops is very less thus it requires frequent acceleration and
deceleration. Rate of acceleration and deceleration is very high. It has multiple unit system where
no separate locomotive is required as electric traction motors are incorporated within one or
more of carriages. Self-ventilated system is there. Multiple unit system can be categorized as:

DEMU Diesel Electric Multiple Unit

EMU Electric Multiple Unit

Speed time curve for MRTS is as follows:

CHAPTER

2:

TRACTION

MOTOR

MANUFACTURING

DIVISION (BLOCK 9)
Major three machines are manufactured in this division of BHEL for traction application as well
for oil rig application.

3- asynchronous motor
D.C. series motor
Oil rig alternator

2.1 D.C. MOTOR (SERIES) MANUFACTURING

A motor is a machine that converts electrical energy to mechanical energy. Its operation is based
on principle that when a current carrying conductor is placed in magnetic field, it experiences a
mechanical force whose direction is given by Flemings left hand rule and whose magnitude is
given by:
F=BIl Newtons

Major parts of any D.C. machine are:

1.
2.
3.
4.
5.
6.
7.

Magnetic frame or yoke

Pole core and pole-shoe
Field coils
Armature core
Armature windings
Commutator
Brushes and bearings

Fig. DC machine parts

D.C. motors are of three types:

1. Shunt motor field windings and armature windings are connected in parallel
2. Series motor - field windings and armature windings are connected in series
3. Compound motor field windings are connected in both parallel and series with
armature windings.
D.C. series motors are used in traction applications because it provides high starting torque
which is required so that locomotive can drive the heavy load in traction systems.

2.2 TRACTION MOTOR MANUFACTURING BLOCK 9: OVERVIEW

Major sections:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Commutator and core

Winding area
Stator frame
Fielding area
Machine assembly
Light run test
Final testing
Dispatch
TAG (customer final inspection)

2.2.1 COMMUTATOR AND CORE

The function of Commutator is to facilitate collection of current from armature conductors. It is
an electromechanical device which converts the alternating current induced in the armature to the
unidirectional current in the external load circuit. It is a cylindrical structure and is buildup of
wedge shape segments of high conductivity hard drawn copper. Each copper segment is insulated
from each other by a thin layer of mica. Number of segments is equal to number of armature
coils. Process followed for manufacturing of Commutator is described as follows:

Slitting of copper bars slitting is done in copper bars so that armature winding ends

can be fitted in these slits.

Arrangement of copper and mica circular structure using curved rings is used for
arranging copper and mica segments in circular manner according to the number of slots.

The whole structure is surrounded by a ring which is tightened using a belt. Copper and
mica segments are arranged alternately to provide insulation between each copper

segment.
Oven for absorbing moisture structure formed is heated in oven at high temperature

so that all moisture get absorbed from the commutator.

Commutator V turning area - then it goes to commutator V turning area where the
machine forms the V shaped grooves in the commutator and all its machining is done.
These V shape grooves are made so that commutator hub easily gets fixed with the

commutator and later shaft is fixed inside the com. hub.

Fitting of Commutator hub commutator hub is fixed in the V shaped grooves.

Fig. Commutator

Oven for tightening heating of whole structure is done in oven at the temperature of
150 C and then let it cool to 60 or 70 C. After that bolts in the hub are tightened 4 times.

Ring surrounding the commutator is also removed by pressing using machines.

Dynamic Seasoning This is also done for tightening of Commutator.
Placing of Steel bearing- steel bearings, steel ring, band etc are fitted to the Commutator
and according to the standards CSD and CRD (Commutator rising distance) distances are
maintained.

HV test and bar to bar testing after formation of commutator, HV test and bar to bar
testing is done.
Bar to bar testing is done to check whether the mica insulation between the two copper
bars is proper or not and to check whether bars are shorted to each other or not. For AG
3101, this test is done at 250 V AC.

HV test is done to check the proper insulation of the body and commutator (mica). HV
test voltage is according to the rating of the machine. Here for AG 3101, HV test is done

at 3.5 kV.
Fitting of armature core and Commutator armature core and commutator are fixed

the same shaft using machines.

Dynamic balancing Transfer to winding section - armature fitted with commutator is transferred to the
winding assembly section.

Armature core houses armature coils and causes them to rotate and hence cut the magnetic flux.
It provides a very low reluctance path to flux through armature from N-pole to S-pole. It is
cylindrical in shape and is formed of thin sheet of steel in which slots are cut on outer periphery.
Each sheet is known as punching and usually these sheets are perforated for air ducts which
permit axial flow of air through armature for cooling purposes. Each sheet is laminated and
purpose of these laminations is to reduce the eddy current losses.
Initially fixture is there, each laminated sheet (punching) is placed on one another forming the
complete armature core. Then laminations are placed on each end of the core and finally shaft is
fitted inside the core. Armature core used for electrical machines is made up material known as
CRNGO. This is cold roll non grain oriented.

Fig. Armature core structure

2.2.2 ARMATURE WINDINGS

Armature coils are fitted in the slots present in the armature core. These coils are wound in the
form of flat rectangular coils and then pulled into their proper shape in the coil puller. The length
of wire lying in magnetic field and in which e.m.f is induced is known as conductor. Coil may be
single turn coil or multi-turn coil as shown in figure. Single turn coil contains only two
conductors and multi-turn coil may contain more number of conductors per coil side. Each
conductor is insulated from each other. Coils are placed in armature slots and lined up with tough
insulating material. Coils are manufactured and turned into proper shape in CIM block. In DC
machines, winding can be of two types i.e. Lap and Wave. Coils are placed in slots according to
the applications and design.

Fig. coil conductors

1) Lap winding End of one coil is connected to beginning of next coil. Number of parallel
paths is equal to the number of poles. Lap windings are used in high current and low voltage
applications as the number of parallel paths are more thus the current will be high as compared to
wave windings.
2) Wave windings - Two ends of coils are connected to a commutator segments that are
approximately 360 apart. This way all the coils carrying current in the same direction are
connected in series. Number of parallel paths is always equal to two. Wave windings are used in
low current and high voltage applications.

Fig. lap and wave windings

Pole pitch is defined as the distance between two adjacent poles. It is equal to the number of
slots per pole.

pole pitch=

total number of slots

number of slots

Coil span or coil pitch is the distance measured in terms of armature slots between two sides of
the coil. If pole pitch is equal to coil pitch then it is called full pitch. It means coil span is 180
electrical degrees. Coil sides lie under opposite poles and hence induced e.m.f in them is
additive. Maximum e.m.f is induced in the coil as a whole, it being the sum of induced e.m.f in
the two coil sides. If the coil span is less than the pole pitch, then the windings is fractionalpitched or short-pitched. In this case, there is a phase difference between the e.m.f's in the two
sides of the coils. Hence, the total e.m.f round the coil is the vector sum of e.m.f in the two coil
sides. This e.m.f in this case is less than that in full pitched coil. Short pitched coils are purposely
used because of following advantages:
1. It reduces the harmonic content in induced e.m.f voltage. Waveform becomes more
refines and nearer to perfect sine wave.
2. It saves the amount the copper conductor used for coils;
3. It improves commutation.
For example, in the D.C. motor AG3101, there are 46 slots and 4 poles and pitch = 9,
Thus,
Pole pitch = 48/4 =12

Coil pitch = 9
Hence, it uses short pitched coils.
Single layer winding it is that winding in which one conductor or one coil side is placed in
each armature slot. Such winding is not much used.
Two layer winding there are two conductors or coil sides per slot arranged in two layers.
Usually, one side of every coil lies in upper half of one slot and other side lies in the lower half
of some other slot at a distance of approximately one pitch away. Number of slots for two layer
windings is equal to the number of coils i.e. half of the number of coil sides.
Commutator segments number of commutator slots are also equal to the number of coils in
double layer winding. Numbers are given to the coil not individual turns. The top side of the coil
will be shown by continuous lines and bottom side will be shown by dashed lines. The
numbering of the coils will be consecutive i.e. 1,2,3,4etc and such that odd numbers are
assigned to the top conductors and even numbers are assigned to bottom side of two layer
winding.
Equalizer windings No of conductors z =

2.2.3 ARMATURE WINDING ASSEMBLY

Armature fitted with commutator comes from comm. and core section and coils for armature
comes from CIM section. Once the windings (lap or wave) are fitted in armature slots, further
processes are carried out as follows:

Temporary banding after windings are fitted, HV test is done and then it is placed in
oven for about 5-6 hours at 160-165 C. Temporary banding is done around them using
insulating materials like glass tape etc, so that winding does not come out when armature
is rotated. HV test is again done after temporary banding.

Wedging and packing - sometimes wedges are used to cover the slots. This is mainly
done in A.C. machines.

First turningwhen coil ends are placed in slits on commutatorthen extra copper
material is removed i.e. the conductor ends coming out of commutator slits. After first
turning impulse testing is done.

TIG weldingTIG welding is done so that armature windings gets fixed. Put the machine
in oven for 5-6 hours at 160-165 C.

Permanent bandingafter that permanent banding is done. Bands are fitted to both ends
of the whole structure. Then again oven for 5-6 hours at 160-165 C. Do impulse and HV
test after this.

VPI (vacuum pressure impregnation)there are two tanks, in tank 1 armature is placed
and vacuum is created so that all the air, moisture gets removed from pores. Vacuum is
created at the pressure of 10-20 torr for 15 minutes. In tank 2 varnish is filled. Varnish is
poured from tank 2 to tank 1 after vacuum is created. Nitrogen pressure is given in tank
1at a particular temperature so that varnish gets deeply absorbed. Varnish gets absorbed
in the pores of the machines and it gets covered with the varnish. After this, windings
become harder and non-flexible. Now moisture and contaminants and external
environment will not have any effect on machine. After VPI oven for 10-12 hours at 190195 C for drying of varnish.

Second and final turning first turn the commutator as per drawing and check, then
turn the mica V ring and wiper as per drawing and check critical dimension with two
identical instruments. Final polish turn commutator as per drawing and check as per
reference.
For AG3101, final turning is done according to the following drawing.

Mica under cutting (GDP) grooving, deburring and polishing of commutator is done
here. Mica segments in commutator are cut inside so that carbon brushes can smoothly

run over the commutator copper bars without any friction. After this final impulse test,
HV test and IR test is done.

Shipment assembly

Insulations used in here in machines are

Glass mica, glass tape, glass cloth, molded mica, captan tape, captan glass mica, elastomer tape,
nomex paper, finger cut molded mica )for equalizer winding), wedge slot made up of fiber glass,
nomex liner (for slots), U-piece (nomex), feld (for A.C. motors), glass card, horse strip.

Process chart for winding assembly:

Core from comm.
and core section

Coil from CIM

HV test
Equalizer winding

Equalizer
coil

Armature winding

Armature
coil

Shipment assembly

HV, Impulse and IR

testing

HV test

Mica under cutting

and P.T.F.E. fitment

Temporary banding
HV test

Second and final

turning

Oven for 5-6 hrs at

160 to 165 C
Oven for 5-6 hrs at
160 165 C

Wedging & packing

Vacuum pressure
impregnation (VPI)

HV test
First turning

OvenImpulse
for 5-6 testing
hrs at
160 toTIG
165welding
C

HV test
Oven for 10-12 hrs
at 190 to 195 C

Impulse
Oven
for 5-6testing
hrs at
Permanent banding
160 to 165 C

HV testing: HV test is done to check whether or not coil is short to its body. HV test is done
after permanent banding at 3kV A.C. voltage for 15seconds in AG 3101. For different machine
test voltage depends on the rating of machine. HV test after main winding is done at 3.5 kV. HV
test on final machine is done at 3kV. Neutral is connected to body (shaft) and phase is connected
to commutator.
Impulse testing: Impulse test is done to check the inter-turn short between the winding
conductors. Coils has its own R, L,C , if there is a short between the conductors then, R,L,C
parameters of coils will be affected. In this test, high voltage is provided through probe, if
voltage appears cross proper R,L, C values then proper sinusoidal graph will be shown in the
screen given and if the R, L, C values are disturbed (due to short circuit) then, nature of graph
will be changed.
2.2.4 STATOR FRAME
Stator frame is also called yoke, which carries the flux produced. It provides the mechanical
support for poles and acts as a protecting cover for whole machine. Stator frame for D.C.
machine is made up of cast iron. All the machining and finishing of stator is done in this block.
Carbon brush holders are also there on the stator frame for holding the carbon brushes which
makes the contact with commutator. Carbon is used because it provides smooth running with
commutator. It does not oxidize easily and has high resistance. It gets torn out after two or three
years and needs to be replaced, thus external window is always provided for replacement of
carbon brushes.

Stepwise process is as follows:

Pinion end (PE) semi finish boring

Commutator end (CE) semi finish boring center line marking is done so as to distribute

the material equally in 360 .

PE, CE drilling, taping for end shield
Pole pad machining
All round machining
All round drilling, taping, counter boring
PE, CE final boring
Block building for carbon brush-mode
Deburring
Offer to quality control BHEL
Offer to quality control railway
Painting and dispatch

2.2.5 FIELDING AREA

Filed magnets consist of pole core and pole shoes. In the modern design of pole structure, the
complete pole cores and pole shoes are built of thin laminations of annealed steel which are
riveted together under hydraulic pressure. Thickness of laminations varies from 1mm to 0.25
mm. Field coils or pole coils which consist of copper wire or strip are former wound for the
correct dimensions. Then, the former is removed and wound coil is put into place over the core.
When the current is passed through these coils, due to electromagnetic effect in the poles
necessary flux is produced that is cut by revolving armature conductors.
2.2.6 MACHINE ASSEMBLING
Stator and rotor are assembled here, stator is held vertically and rotor is placed inside it. Bearings
and end seals are then fixed here. Carbon brushes, pinion etc. are attached in this section.
Stepwise procedure is as follows:

Dynamic balancing of armature: Dynamic balancing is once again done in this section
before assembling. If rotor is not properly balanced, then rubbing of machine will occur
and heating will be more. Balancing is generally done by dividing it in 4 angles i.e. 0

-180 and 90 -270 . Tolerance allowed is about 6 grams and if there is misbalance in rotor
then either weight (metal) is deposited or welding is done. There is weight sensor and
rpm sensor present to measure the weight of rotor in all four directions and to measure
the speed of rotor.

Bearing assembly: There is two ends of D.C. machine used in traction i.e. pinion end
(PE) and commutator end (CE). Bearings are fitted in both the sides for smooth and
frictionless running of armature on the shaft.

Armature dropping: Stator is held vertically and armature is dropped inside it.

Light run test: Light run test is done to check whether heat produced during operation of
machine is proper or not. It is also done the measure the vibrations which should be
within certain limits. Noise level is also measured in dB using dB-meter which shows the
sound level. Sound level for motor should be less than < 95 dB. Vibrations at different
speeds are also measured during light run. Procedure for light run test of motor TM4907
is as follows:
1. Run the motor at speed 1 of 1100 rpm for 30 min.
2. Run the motor at speed 2 of 1500 rpm for 15 min.
3. Run the motor at over speed of 230 rpm for 2 min.
4. Run the motor at speed1 for 15 min and check the bearing temperature. It should
be < (35 + ambient) deg. Centigrade.
5. Check vibrations also. It should be less than the limit decided for it.
6. Grade and beeding of carbon brush is checked up to 80%.

Final testing: Final testing is done to measure the temperature rise of machine which
should be under the limit of insulation class decided for that machine. Losses, efficiency,
power output etc. are calculated from the observations taken during different tests
performed during final testing.

Pinion fitting area: Pinion is a small gear which is coupled with large gear (which is
connected to locomotive wheels) to transfer the tractive force to locomotive wheels. It is
fitted on the PE end of the motor using hydraulic pressure.

2.2.7FINAL TESTING
TM 4907 TESTING
1. Cold resistance is measured by giving 75 amps to 1 and 38th mica and measuring the
voltage drop across it.
2. Then machine is run for 1 hour at 305 volts, 1060 amperes, and reading is taken after
every 15 minutes. Rpm, field voltage drop, inter-pole drop, armature drop, bearing
temperature, yoke temperature, air inlet temp., air outlet temp, ambient temperature of
air is measured. After running for 1 hr. same readings are taken at hot condition.
3. Then hot resistance is measured by giving 75 A to 1 and 38 th mica and measuring
voltage drop. Armature voltage reading is taken after every 10 sec (5 readings are
taken). Then temperature of armature, field, inter-pole, bearing (PE), bearing (CE) is
measured so as to check the heating of machine during its operation.
4. Over-speed test is done by running the motor at over-speed of 2940 rpm for 2 min.
this is done so as to check whether machine is able to withstand higher speed or not.
5. Speed load characteristic is taken. At first 100% field is given and rpm (speed) is
measured at different loading conditions.

Field
100%
100%
100%
49%
49%
49%

Voltage
325 V
325 V
325 V
300 V
300 V
300 V

Current
1260 A
1060 A
160 A
990 A
705 A
405 A

RPM in CW
-

RPM in CCW
-

6. Commutation test is performed to check the sparking at the brush.

Field
100%
100%
100%
49%
49%

Voltage
100 V
305 V
1100 V
285 V
770 V

Current
1467 A
1060 A
15-16 A
980 A
-

RPM
-

7. HV test is done at 3.2 kV for 1 min. IR is measured after and before the HV test.
Using ovality meter, ovality is checked before and after the HV test.

OA 7002 AZ TESTING
1. Measure cold resistance of main stator winding, exciter armature winding, exciter
field resistance, main rotor winding. IR is also measured. There are 6 RTDs and
resistance of RTDs is also measured.
2. Vibration test is done (in microns). Vibrations at DE and NDE ends in horizontal,
vertical, axle direction are measured at 1000 rpm.
3. Over-speed test at 1200 rpm is done for 2 min.
4. Heat run test is done by running the alternator at 1000 rpm, 1515 A for 1 hour.
Readings are taken at every 15 minutes and exciter voltage, exciter current and short
circuit current are measured. Temperature of air outlet, air inlet, yoke etc. is also
measured.
5. After shut down, hot resistance is measured for all four windings.
6. O.C.C test 1000 rpm up-to 720 V A.C. is performed. Exciter field current, exciter
voltage and open circuit voltage (between RY, YB, BR) is measured.
7. S.C.C test is performed at 1000 rpm up-to 1650 A at 720 V. Exciter field current,
exciter voltage and current transformer amperes is measured.
8. HV test is done for 1 minute at 2.5 kV for main stator, 1.5 kV for main rotor, 1.5 kV
for exciter armature and 1.5 kV for exciter field.
9. IR is measured before and after the HV test.

10. Bearing temperature stabilization test is performed for 2 hours at 1000 rpm,
temperature is noted after every hour and bearing temperature rise is then
calculated.

CHAPTER 3: CENTRE FOR ELECTRICAL MACHINE

TRANSPORTATION (CET)
25 kV Single Phase is the most preferred and universally accepted voltage standard for overhead
traction system. The system has a single overhead wire supplied at 25 kV 50 Hz which is the
standard industrial frequency. A transformer is mounted on locomotive and it steps down the
voltage which is further rectified and supplied to the traction motors. The substations are
supplied at a high voltage of up-to 132 kV which is stepped down to 25 kV by transformer
installed at each substation. All modern electric traction work is being done by this system. The
driving force is obtained from D.C. series motors or A.C. traction motors (3).
This block is mainly for testing purpose of the traction motors. 25 kV A.C. as well as 600 kV
D.C. testing facility is provided here. 11 kV supply is converted to 25 kV A.C. using step up, 1-
transformer. Another loco-transformer is present which would be generally present on the
locomotive, it steps down the voltage of 25 kV (1-) to 928 V. 3 A.C. induction motors are
used for providing tractive force.

Fig.3.1 Electric traction system

Fig.3.2 Electric traction system

VFD drive is set up for smooth speed control of 3- induction motors. Hence, IGBT based 3
traction propulsion system for AC EMU is present. This whole set up is being tested as it is
going to be established in Mumbai local trains.

Block diagram for IGBT based 3 traction propulsion system for AC EMU:
25 kV 1- line

AIRCO convertor
110 V
1 AC

110 V
1 AC
Load
Traction transformer of
IGBT AC EMU
25kV/928
VVVF
AC to DC
M V DC)
(1800

Motor
under test

Down chopper

Auxiliary
converter

415 V
3 AC

120 V
DC

Load
motor

DC to 3 AC

110 V
1 AC

415 V
3 AC

LOAD

CHAPTER 4: TRACTION ALTERNATOR MANUFACTURING

DIVISION (BLOCK 2)
4.1 TAM DIVISION
Diesel engine alternators are manufactured in this division. They are used in diesel electric
locomotive. Actually the engine of this locomotive is nothing but an alternator driven by diesel
engine. The alternating current produced by this generator is converted to DC by integrated
silicon diode rectifiers to feed all the dc traction motors. And these dc traction motors drive the
wheel of the locomotive. Some of the alternators manufactured here in this division are:

GM 9901 (diesel engine)

TA 10102 (traction alternator)

Ta 10106 (traction alternator)

TA 9901 (traction alternator)

TM 4907 (traction DC motor)

TM 4605 (traction DC motor)

HS-6FRA (traction AC motor)

A.C. generators or alternators operate on the same fundamental principles of electromagnetic

induction as D.C. generators. But there is one important difference between the two, in DC
generator the armature rotates and field system is stationary whereas in AC generator, the
arrangement is reverse of it. Armature winding are present on stationary element called stator
and field windings are present on rotating part called rotor.
The rotor has N and S pole fixed to its outer rim. The magnetic poles are excited from D.C.
currrent supplied by a D.C source. In most cases, necesssary excitation is is obtained from a
small d.c. shunt generator which is mounted on the shaft of rotor.because the field magnets are
rotating, this current is supplied through two sliprings. When the rotor rotates, the stator
conductors are cut by the magnetic flux, hence they have induced e.m.f. produced in them.
Because the magnetic poles are alternately N and S, they induce an e.m.f. and hence the armature
conductor. Thus voltage is produced in the stator conductors whose frequency depends upon the
number of N and S poles moving past a conductor in 1 second.

Fig.4.1 A.C. AlternatorFig.4.2 Stationary stator windings

There are two types of rotor used in alternators

Salient pole rotor- It is used in low and medium speed alternators. It has a large number
of projecting poles. Such generators are characterized by their large diameters and short
axial length.

Cylindrical rotor- It is used for steam turbine driven alternators which run at very high
speed. Such rotor is designed mostly for 2-pole or 4-pole generators. In this case, poles

are non salient i.e. they do not project out from the surface of the rotor. Hence, they are
characterised by small diameters and very long axial length.

Fig. 4.3 Salient and cylindrical rotor

4.1.1 ALTERNATOR STATOR AND SHAFT MACHINING

Rotor shaft is finished and given proper shape and diameter. Process and machines used here are:

Facing and centric machine

Coping machine
Semi-finish CNC (computer numerical control)
Grinding parallel grinding or taper grinding (pinion end)
Final finish removing extra material and then final finish

Basically all machines can be classified into two broader categories:

Milling machine spindle is rotated and job is kept stationary

Lathe machine job is rotated

4.1.2 ALTERNATOR WINDING

4.1.3 ALTERNATOR TESTING
TA 9901 traction alternator 4000 HP

1. IR test 1kV megger is used, IR should be greater than 50 M.

2. Winding resistance cold resistance is measured (phase to phase)
3. Heat run test this is temperature rise test which is performed for 1 hour at 2400A, 900
rpm and readings (temperature) are recorded after every 15 minutes and finally
4.
5.
6.
7.

temperature rise is calculated.

S.C.C field is applied and graph between field and load is plotted.
O.C.C graph is plotted between field v/s open circuit voltages.
Over speed test machine is run at over-speed for 2 minutes.
HV test of windings HV test is performed for 1 min. For main stator winding it is
carried out at 5.8 kV and for field windings it is carried out at 1.5 kV. This test is done to
check the puncture and insulation strength. IR test is measured before and after the HV
test.

Testing of companion alternator is also done in parallel.

4.2 IMM AND LEM DIVISION
Mostly two types of motors are used in industries i.e. 3- induction motors and 3- synchronous
motors.
4.2.1 MANUFACTURING
4.2.2 ASSEMBLY
4.2.3 TESITNG
Induction motor routine/type testing
Initially measurement of cold resistance of stator, rotor, RTD, BTD and space heater using milli
ohm meter is done. Then IR value of stator and rotor windings is measured using 5 kV megger
for 1minute and 10 minutes. PI value is calculated using these values. IR values of RTD, BTD
and space heaters are measured using either 1 kV or 500 V megger. To calculate the temperature
of RTD and BTD, then a multiplying factor of 2.58 is multiplied to the resistance.
Routine tests for squirrel cage I.M.:
1. Torque test (type test)/ S.C. test/ lock rotor test
Voltage

Current

Power

KVA

PF

Freq.

100%

150%

200%

2. 12 PT100, simplex RTDs, 3W

3. 1 PT 100, duplex BTDs per side, 3W
4. 2 Space heater 600 W, 240 V (total 1200 W)
5. Measurement of shaft voltage
6. Measurement of vibration test
Routine tests for slip ring I.M.:
1. O.C.C test (machine run at no load)
2. Over voltage test at 125% of rated voltage for 2 minutes.
3. No load rpm
4. Rpm at 1/1.73 voltage
5. Vibrations are measured
6. No load saturation curve/ no load characteristics
7. Noise level
8. Shaft voltage
9. Temperature rise test (efficiency is also calculated)
10. HV test (measure IR before and after HV test)
Special tests:

1. Tan test (capacitance measurement)

2. IP55 test on demand of customer this test is done. Machine is packed and then water
pressure is supplied to whole surface of machine for 15 minutes. Then open the machine
and check whether moisture is present on terminals and other parts or not. IR is measured
and light run the machine for 15 minutes. HV test is then done at [rated voltage + 1.25
kV].

Routine test synchronous motor

Rating 4600 kW, 11 kV, 261 A, CW from DE, 600 rpm
1. Cold resistance of stator windings (R, Y, and B phases), exciter rotor, exciter field and
main rotor is measured.
2. RTD resistance () resistance is measured between red-white and white-white.
BDT resistance () is measured from DE and NDE ends.
Space heater resistance () is measured in ohms (mains and exciter).
3. IR, PI and HV test
IR of stator winding by 5 kV mains megger is measured for every phase for 1min, 10 min
and PI = IR(10)/IR(1). AC HV at (2E + 1) volts is done for 1min. Then IR is measured
after HV test 1 min. IR of main rotor, exciter rotor, exciter field, RTD/BTD, space heater
is measured by 500 V hand megger for 1 min. AC HV test is then performed for 1 min.
IR is measured after HV test.
4. Unity PF characteristics

RY

YB

BR

R (line

B (line

Power

Ex.

PF

(line

(line

(line

current

current

i/p (kW)

Amp

volt.)
-

volt.)
-

volt.)
-

)
-

)
-

PF

5. Zero PF characteristics
Freq.

RY

YB

BR

R (line

B (line

Power

Ex.

(line

(line

(line

current

current

i/p (kW)

Amp

volt.)

volt.)

volt.)

6. Vibrations measured at rated speed/ voltage in UPF condition. Bearings vibrations are
measured from DE and NDE ends in m, mm.
7. Synchronous impedance characteristics
Freq.

RY

YB

BR

R (line

B (line

Power

Ex.

(line

(line

(line

current

current

i/p (kW)

Amp

volt.)
-

volt.)
-

volt.)
-

)
-

)
-

PF

Momentary overloading is performed at 160 % current for 15 sec.

8. Mechanical run (in UPF condition)
Time

Dial C

(min)
-

BTD

Oil

Dial C

BTD
-

Oil

Wdg. RTD

Amb

()
-

. ( C)
-

9. Phase sequence UVW of machine connected to RYB of supply system for CW from
DE end.
10. Machine over-speed machine is overloaded at 120% rated done, abnormalities
observed during and after test.
11. Shaft voltage (UPF condition) between DE-NDE, DE-earth and NDE-earth.

Type test:

ZPF heat run test: loading parameters

Freq. (Hz)

Line voltage

Line voltage Line voltage

RY

YB

BR

Exciter amps.

time

ZPF heat run: temperature records

RTD

DE

DE

NDE

NDE

()

(bearing)

(bearing)
BTD

(bearing)
Dial C

(bearing)
BTD

Dial C

Air/water
RTD
Hot

Air/water
RTD
Cold

Amb.
( C)

UPF heat run test: loading parameters

Freq. (Hz)

Line voltage

Line voltage Line voltage

RY

YB

BR

Exciter amps.

time

UPF heat run test: temperature parameters

RTD

DE

DE

NDE

NDE

()

(bearing)

(bearing)
Dial C

(bearing)
BTD

Dial C
-

(bearing)
BTD
-

Air/water
RTD
Hot

Air/water
RTD
Cold

Amb.
( C)

CHAPTER 5: TRANSFORMER, CAPACITOR AND BUSHING

MANUFACTURING DIVISION (BLOCK 3)
Based on the construction mainly there are two types of transformers: Shell type and Core type.
In B.H.E.L. most of the transformers manufactured are shell type. They can be 1- or 3-, for 1 it is 3 limbs transformer and for 3- it is 5 limbs transformer. For making the construction
easier and to reduce the size of transformer nowadays, LV and HV windings are wound on same
limb. At inner side firstly LV is placed then insulation layers and then HV windings are placed
and then insulation layers, then lastly tap windings are placed.

Fig. shell and core type transformers

5.1 CAPCACITOR BANK MANUFACTUIRNG

Capacitor banks are also manufactured in B.H.E.L. They can be used as line filters, power factor
improvement devices, and CVD (capacitive voltage devices).
As capacitors are source of reactive power, they can be used as power factor improvement
device. They are generally used where inductive loads are connected. If the power factor is poor
the ampere burden of transmission, distribution network, transformers, alternators and other
equipments connected to the system, becomes high for required active power. And hence reactive
power compensation becomes so important. This is done by capacitor banks.
Capacitor voltage devices are manufactured which can be used in manufacturing capacitor
voltage transformers (CVT). A capacitor voltage transformer is a transformer used in power
system to step down the extra high voltage signals and provide a low voltage signal for
measurement or to operate a protective relay.
Shunt capacitor banks are used for power factor improvement. Series capacitors are used as
filters. Here, one rack may consists of 20 units, 12 unit etc. as required by customers. During
manufacturing of element for CVT, there is no folding done in aluminum foil. But in

manufacturing of element for other uses, folding of 5mm is done in aluminum foil for blocking
the voltage.
5.1.1 MANUFACTURING PROCESS OF CAPACITOR BANKS
Aluminum foil is used as conductors and polypropylene (pp film) is used as insulator.
Mathematically, capacitance is dependent on area of plates and distance between the two plates,
formula is given as
C=

A
Farad
d

Here area is equal to width * length of conductor (i.e. aluminum foil), and length is variable here.
By varying the length of aluminum foil, capacity of condenser can be changed according to the
applications. Andd is kept equal to 32 m. stepwise process for capacitor bank manufacturing is
as follows:

Element is formed which is called condenser.

Winding of aluminum foil and pp film is done using the machine. In the similar manner,
packets of condenser are formed.

Each packet is tested at 4.5 kV for 5 sec.

Then packets are assembled. Here, there are six packets inside one condenser and
connections are such that two packets are in parallel and three such condensers are
connected in series. This connection is known as 3 parallel and 2 series.

Connections are made as indicated above and soldering is done. Fuse wire and discharge
resistance (DR) of 1.5 M is connected. Number of DR will be equal to the number of
series connected condensers (here it is 3). DR are generally connected for providing the
discharge path when short circuit occurs and hence for safety of humans.

Each packet is tested at 4.5 kV for 5 seconds.

Then terminals (positive and negative) are taken out and whole assembly is placed inside
the box and covered.

Terminals are welded to the box and then oil is filled in these capacitor boxes by whole
processing as done in case of bushings.
Then these capacitor banks go to final testing in which they are tested on high voltage.
5.1.2 CAPACITOR BANK TESTING
If capacitor bank is of rating 11 kV, then final testing is done at 44 kV. This test is basically done
for following purposes

Measuring of capacitance of capacitor banks

Tan is measured and checked.

AC, DC voltages given to check the DR value (DR value may get effected during any of
the process).

To check over voltage withstand capacity.

5.2BUSHING MANUFACTURING DIVISION

Bushing is an important part of transformer that insulates the body of transformer and supply. It
provides the terminals for input and output supply of transformer. Another important function of
bushing is that it reduces the flux producing area due to high voltages carried by supply terminals
and output terminals. Types of bushings are:
1. OIP bushing
2. SRBP bushing
3. RIP bushing
Bushings manufactured in B.H.E.L are:
1. 52 kV

2.
3.
4.
5.
6.

72.5 kV
145 kV
245 kV
420 kV
800 kV

Major parts of any bushing are:

OIP core
Bottom porcelain
Mounting flange
Top porcelain
Conservator
Oil indicator
Pack assembly
Mineral oil (as coolant)
Stress shield
Compressor nut
Sealing plate
Bottom end nut

OIP (Oil Impregnated Paper) core has main function in the bushing and other parts are just for
protection of this core. OIP core has many superconductor wires made up of either copper or
aluminum, and there are layers of insulation (OIP paper) between each conductor. They are
arranged such that there is distance of about 2mm between starting and ending of each conductor.
In this way, last conductor will lie in the middle portion of the core only and hence the middle
area will be thicker than the ends of the core. There is a shaft passing through the center of the
core which will carry the same current which is applied to transformer primary and the current
obtained at transformer secondary. But due to mutual inductive effect, voltage induced in every
superconductor present in the core will reduce due to its arrangement. Hence due to reduced
voltage, its flux will be produced in lesser area hence protecting the transformer.
For example: in B.H.E.L there are
18 superconductors for 52 kV bushing
20 superconductors for 72.5 kV bushing

30 superconductors for 145 kV bushing

47 superconductors for 245 kV bushing
78 superconductors for 420 kV bushing
100 superconductors for 800 kV bushing
Last number of conductor in each bushing is taken out and marked externally on the body of
bushing, for example in 420 kV bushing, 78th conductor is taken outside. This point is known as
2 kV point or testing point. This point is attached to the body of transformer which is grounded
thus this point is also grounded. This is for protection of any person which goes near the body of
transformer even near bushings. Oil is filled between the core and outer body of bushing for
proper insulation of each section. Conservator tank is there which maintains the level of oil in the
bushing, when heating occurs than oil expands so there is space provided for expansion of oil in
the conservator tank. Oil indicator is there to show the level of transformer oil in the bushings.

5.2.1 BUSHING PROCESSING:

Loading

Pre heat at 105 C for 72 hours

Oil
(processed),
BDV = 70
kV, tan at
90 C =
0.005, water
content
volume = 10
ppm

Evacuation cycle temperature

is 105 C and vacuum of 0.005
mm of Hg. This is done for
100 hrs.

Impregnation cycle
temperature = 65 C and
vacuum of 0.005 mm Hg

Vacuum breaking

Unloading

After the complete assembly of the bushing, bushing is brought to the processing plant where
processed oil is filled inside it. Firstly, moisture is removed from the bushing by heating at 10-12
hours. Then it is allowed to cool down at 65 C and then at 65 C and vacuum of 0.005 mm of
Hg, oil is filled in it. All the moisture, dust and contaminants get removed in this whole process.
Time taken for oil filling is according to the standards, for example in 52 kV bushing, time taken
for oil filling his about 4 hours. Similarly for 145 kV, it is 6 hours, for 245 kV, it is 12 hours, for
420 kV, it is 16 hours. This much time is given for oil filling so that oil completely gets absorbed
in insulation paper and air properly gets removed.

5.2.2 BUSHING TESTING

Major testing done on bushings are:

1. Capacitance and tan test (before HV test): Tan , also called loss angle or dissipation
factor testing, is used to determine the integrity of insulation. By measuring the electrical
properties such as capacitance and tan regularly it is possible to ensure the operational
reliability of HV insulating system and to avoid costly insulation breakdown. This test is
important for high voltage bushings. Capacitance and tan measurement set is available
which can be directly used to determine its value. Tan should be in range of0.001 to
0.004.
2. Impulse test with lightening, switching and chopped impulse voltage: Lighting is a
common phenomenon in bushings because of their tall height. This lightning stroke on
the line conductor causes impulse voltage. Power transformers and bushings then
experiences these lightning impulse voltages. Again during all kind of online switching
operation in the system, there will be switching impulses occur in the network. Insulation
is one of the most important constituents of bushings. Any weakness in the insulation
may cause failure of bushings. That is why impulse test is performed on it.

Switching impulse test is not performed on bushings because switching impulse is given
only when switchgears are used and when step up and step down of voltages occur like in
transformers. Here lightening impulse and chopped impulse voltage test is performed.
For bushings of rating lower than 145 kV, impulse voltage test is not performed.

Fig. impulse generator

Impulse test for 420 kV bushing is done at 625 kV for 60 seconds. Impulse generator
circuit is present in testing lab for generating impulse voltages. Ideally, lightening
impulse voltage waveform should have front time between 0.86 to 1.2 s and tail time
between 40 to 60 s. Chopped impulse voltage waveform should have front time
between 2 to 4 s and tail time between 200 to 300 s.

Fig. Lightrning impulse voltage waveform

Fig. Chopped impulse waveform

3. High voltage test and partial discharge test: High voltage test and partial discharge test
is done for 60 seconds. Partial should be < 10 pC (Pico coulombs). High voltage test
for420 kV bushing is done at 695 kV. Then voltage level is reduced and partial discharge
is measured at 364 kV, 255 kV, 122 kV, and 10 kV. For high voltage generation, there is
800 kV series resonant equipment in which input given is about 11 kV and high voltage
obtained is equal 800 kV. There are voltage dividers so as to lower the voltage and
current value such that they can be measured easily.

Fig. Voltage dividers in Bushing HV testing lab

4. Capacitance and tan test (after HV test): Capacitance and tan are measured again
after HV test and this value should be equal to or nearer to the previously measured
value.

5. Isolation test at 2 kV: Voltage of 2 kV is applied at testing point and capacitance and tan
is measured. Then voltage is stepped down to 1kV and again capacitance and tan is
measured.

5.3 TRANSFORMER MANUFACTURING PROCESS

Insulation

Windings

CRGO

Lamination sheets

Pre coil assembly

Put in oven at 110-120 for 36 hrs.

Core build-up

Pressing and
CD

If CD not
achieved

Power assembly

Bottom tank

Pack, dispatch

Core assembly

Mech. testing

Un-lacing

HV testing

Coil assembly

Core fitting

Re- lacing

VPD (P2)

T.G. mounting

Servicing

Top tank

VPD (P1)

If CD
achieved

Stabilization

5.3.1 CORE BUILDING SECTION

In transformers, CRGO is used as core material. CRGO rolls are imported from Korea and they
are available in rolls of standard width. CRGO is used because it has uniform direction of
alignment of its domains. This makes the direction of flow of flux uniform and reduces
hysteresis and eddy current losses. Machines used in core building section are:

CNC cropping machine sheets are cut according to width, shape. Punching is done.
Piece cutting is done using this machine.

George cropping line

Slitting machine it is used to cut the CRGO sheets in sheets of required widths.

Core lifting platform

EOT cranes

Cheese cores are used in reactors. Cheese core manufacturing:

1. Cleaning of mould Ensure all the old cast slush is removed including those on bottom
base. 0 grade sand paper or cotton can be used for cleaning. Adjust any level
differences between bottom of mould and center part.
2. Applying releasing agent on mould surface - All cast surfaces of the mould should be
covered on even layer of silicon releasing agent.
3. Reinforcement with fiber glass chopped strand mat - Place fiberglass chopped strand mat
in mould according to drawing.
4. Stacking of cheese lamination Cheese laminations shall be well wedged. Knife test to
be done at four different places. Ensure complete section assembly have a smooth
surface. Maximum deviation between different laminations or rings shall be less than 0.6
mm.

5.3.2 COIL SECTION

Two types of transformers are manufactured on the large basis: Generating transformers and
Auto transformers. Generating transformer uses HV (high voltage), LV (low voltage) and tap
coils. An auto transformers use 4 coils i.e. HV, LV, tap and common coils. The windings consist
of the current-carrying conductors wound around the sections of the core, and these must be
properly insulated, supported and cooled to withstand operational and test conditions. Types of
windings:

Helical /spiral winding(LV)

Disc winding (HV)

Types of copper used for windings in a transformer:

PICC (Paper Insulation Covered Conductor)

CTC (Continuously Transposed Cable)

LV winding
In low voltage winding of a transformer, voltage level is low and current carried is more. Thus
more number of conductors is required in LV windings. For windings of low voltage (20 kV or
below) and large current, a helical coil is used. It consists of large number of parallel conductors
wound in radial direction. Adequate transposition is necessary to equalize the share of current
among parallel conductors. Helical winding is thus used for LV windings of a transformer. Each
conductor is transposed at interval of fixed number of turns. Conductors used in power
transformers are stranded with rectangular cross section. Technique involving many rectangular
conductor strands combined into a cable is called continuously transposed (CTC).Thus in LV,
about 15 to 200 conductors are used of CTC/PICC type. There are about 4-6 leads in LV
windings. It can be single layer or double layer for example; it can be have 2 in LD, 8 in CD.

Fig. CTC

Fig. Horizontal winding machine

Some insulating materials are also used while winding are wound such as T block, T spacer,
DOF (direction of oil flow), fiber insulator or paper belt at ends of coil for support of
windings, OGR, heat sinking tape, crap paper, polyester film tape, solid block and washer
etc. Oil ducts are provided between coils for proper flow of oil between coils.
There are moulds available on which windings are wound. Moulds are generally adjustable and
are set according to the inner diameter of coil. Two types of machines are available for coil
wounding either vertical or horizontal. Either of them can be used for LV or HV but, generally
vertical machine is used for HV windings and horizontal machine is used for LV windings.
5.3.3 POWER ASSEMBLY
Core comes from core building section and coil from winding section; they are assembled
together in this section. Initially, core is placed in bottom tank and fitted tightly. Tie rod are used
for mechanical support of core with the tank. Shunts are placed so as reduce the flux leakage,
then leveling is done using insulation material so that coil can be placed easily. Then unlacing is
done, it means the upper portion of core is removes so that coil can be placed between limbs.
Coil is placed inside the core and then re-lacing is done, which means upper portion of core
which was removed is fitted again to complete the assembling of coil and core. Then all the
terminals of LV, HV, tap etc are taken outside and connected such that they can reach to

bushings. Tap coils are connected to tap changer. Hence, terminals are connected to terminal
gear box. Detailed connections of winding with the bushings are discussed below:

GT (Generating Transformer) -

Auto transformer-

Vapor phase drying (VPD): Process P1

VPD is done to remove the moisture, dust particles from the transformer. This process is carried
out by drying of paper insulation of transformer by a perfectly controlled automatic process with
lowest possible paper de-polymerization and energy consumption.
Thermocouple or RTD is used for temperature measurement. Oil pipe is arranged for filing the
oil then door of oven is closed after placing the job inside it. Heating of job is done using solvent
and steam (vapors). Stepwise process is discussed below:

Preparation is done for job for heating. Vacuum is created in a chamber where solvent has
to be filled, till 7 to 5 mbar pressure is achieved. Now solvent is ready to be filled.

Heating: Solvent is heated till 130 C temperature is achieved. Vapors of solvent go to

the job in the oven. Vapors of solvent are used for heating of job and drying of moisture.
This is done until 110-120 C of job is achieved.

IPL (Intermediate Pressure Lowering): After some time a level is reached where the
pressure solvent and oven becomes equal and then no vapors will flow to job for heating.
Thus for removing this stage, we lower the pressure of job.

PR (Pressure reduction): vapors of solvent and moisture go to the condenser and cools
down. Vapor is thus converted into liquid form.

Fine vacuum: In this process temperature of transformer is maintained constant. Vacuum

is created may be up-to 36-72 hours till 0.2 torr pressure and 30ml/hr rate after 3 readings
is achieved. If this as fulfilled we can say that the process is complete.

Oil filling: under vacuum transformer oil is filled. Oil is allowed to be absorbed
completely and then job is released for assembling. Before oil is filled following
properties of oil is checked: Viscosity, BDV (> 60 kV), dielectric strength, tan , ppm
(impurities < 100 ppm), resistance (> 10 G), DGA etc.

Basic equipments of VPD plants:

1. Evaporator system
2. Condensation system
3. Autoclave
4. Vacuum system
5. Solvent pumping system
6. Heating system for evaporator and auto cycle
7. Heat recovery system
8. Distillation equipment
9. Special water extraction measuring equipment
10. Computer aided process

Servicing:
After process P1, joint inspection is done presence of engineers, quality control, production
engineers etc. During this process, some moisture again gets entered in the body of transformer,
thats why process P2 is performed which is known as conventional process.

Conventional process: process P2

After case fitting, heating is done at 100-110 C. Vacuum is created till 0.2 torr pressure and
water rate = 3ml after 3 readings is achieved. This may take up-to 24 hours. Oil is filled after
vacuum is created. Case and press fitting is done.

Case fitting:
Other accessories and important parts of transformer are connected after VPD process (P1 and P2)
is completed. Otherparts of a transformer are:
The following are the basic components of a transformer.
1. Tap changer - The output voltage may vary according to the input voltage and the load.
During loaded conditions the voltage on the output terminal fall and during off load
conditions the output voltage increases. In order to balance the voltage variations tap
changers are used. Tap changers can be either on load tap changer or off load tap changer.
In on load tap changers the tapping can be changed without isolating the transformer
from the supply and in off load tap changers it is done after disconnecting the
transformer. Automatic tap changers are also available.
2. Conservator- Conservator conserves the transformer oil. It is an airtight metallic
cylindrical drum which is fitted above the transformer. The conservator tank is vented to
the atmosphere at the top and the normal oil level is approximately in the middle of the
conservator to allow expansion and contraction of oil during the temperature variations. It
is connected to the main tank inside the transformer which is completely filled with
transformer oil through a pipeline.
3. Breather - The insulating oil of transformer is provided for cooling and insulating
purpose. Expansion and contraction of oil during the temperature variations cause
pressure change inside the conservator. Transformer breather is a cylindrical container
which is filled with silica gel. Insulating oil reacts with moisture can affect the paper
insulation or may even lead to some internal faults. So it is necessary that the air entering
the tank is moisture free. For this purpose breather is used. Breather consists of silica gel

contained in a chamber. When the atmospheric air passes through the silica gel breather
the moisture contents are absorbed by the silica crystals.

4. Cooling tubes - Cooling tubes are used to cool the transformer oil. The transformer oil is
circulated through the cooling tubes. The circulation of the oil may either be natural or
forced circulation. In natural circulation, when the temperature of the oil raises the hot oil
naturally moves to the top and the cold oil moves downwards. Thus the oil keeps on
circulating through the tubes. In forced circulation, an external pump is used for
circulating the oil.
5. Buchholz Relay - It is a protective device container housed over the connecting pipe
from main tank to conservator tank. It is used to sense the faults occurring inside the
transformer. It is a simple relay which is operated by the gases emitted due to the
decomposition of transformer oil during internal faults. It helps in sensing and protecting
the transformer from internal faults.
6. Explosion vent - Explosion vent is used to expel the boiling oil in the transformer during
heavy internal faults in order to avoid the explosion of the transformer. During heavy
faults the oil rushes out of the vent. The level of the explosion vent is normally
maintained above the level of the conservatory tank.

5.4 ULTRA HIGH VOLTAGE LABORATORY AND TRANSFORMER TESTING

B.H.E.L has the capacity of testing equipments of up-to 1200 kVA class. UHV lab has
electromagnetically shielded halls of all sizes 67*35*35 M and 50*27*30 M, with double walled
GI construction with electrical continuity. It possesses acoustic attenuation with a reverberation
time of 3 to 3.5 seconds. It is provided with a low impedance grounding system.
Test resources of UHV lab:
Impulse voltage

4 MV, 400 kJ impulse generator

0.5 MV, 15 kJ impulse generator

3.6 MV, 400 pF impulse voltage divider

3 MV, multiple chopping gap

AC voltage

1.5 MV, 1 A cascade test transformer

1,5 MV, 200 pF impulse voltage divider

1 MV, 1250 pF, 2400 M DC voltage divider

Power frequency test station

160 MVA, 66/650 kV, 3 transformer

3*13.33 MVA, 11/90 kV, 1 transformer

3*3.33 kVAr, 11 kV, 1 reactor

Static capacitors

100 (60 + 40) MVAr, 13-156 kV, 3 capacitor bank

Standard capacitors

800 kV, 71.5 pF SF6 filled standard capacitor

600 kV, 50.9 pF SF6 filled standard capacitor

Measuring and recording instrument

High resolution impulse analyzing system

Loss measurement system for shunt reactors

Digital power analyzers

Partial discharge detector

RIV meters according to CISPR

High frequency impedance analyzer

Power sources

40 MVA, 0-11 kV, 50 Hz, 3 MG set

9 MVA, 0-11 kV, 50-200 Hz, 3 MG set

7 MVA, 0-11 kV, 50 Hz, 3 MG set

2 MVA, 0-11 kV, 30-180 Hz, 3 MG set

2000 amps, 1200 volts, DC power source

Major equipments tested in UHV lab:

315 MVA, 3, 400/220/33 kV auto transformer

200 MVA, 1, 21/420/sq. root 3 kV generating transformer

315 MVA, 1, 400/ 1.73/

254 MVAr, 1, 500 kV HVDC smoothing reactor

315 MVA, 3, 16.5/235 kV generator transformer

213
( 1.73
)

/ 213 kV HVDC convertor transformer

80 MVAr, 3, 420 kV shunt reactor

280 MVA, 3, 400/157.5/30 kV auto transformer for PPC, Greece

160 MVA, 3, 66 /650 kV testing transformer

800 kV OIP bushing

800 kV capacitive voltage transformer

All power systems equipment up-to 420 kV class

Safe clearance for HV testing (AC/DC)

Distance from HV source (in mm)

kV

1.5

10 -100

2.5

100-200

3.5

200-300

4.5

300-400

400-700

Safe clearance for HV testing (impulse)

Distance from HV source (in mm)

kV

50-200

200-500

500-1100

1100-1450

10

1450-2000