VOCATIONAL TRAINING AT BHEL

BHOPAL, (M.P)

PROJECT REPORT
Submitted In the Partial Fulfillment Of the Requirement

For the Award of the Degree of Bachelor of Engineering

IN ELECTRICAL ENGINEERING

RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALA, BHOPAL

(M.P)

SESSSION 2009-2013
 PROJECT REPORT
BHABHA ENGINEERING RESEARCH INSTITUTE, BHOPAL

14 JUNE 2012 – 11 JULY 2012

PREPARED FOR

HUMAN RESOURCE DEVELOPMENT CENTRE (H.R.D.C.)

B.H.E.L., BHOPAL

GUIDED BY :- SUBMITTED BY :-
MR.PANKAJ E KUJUR SHREYANSHU

BHEL,(BHOPAL) ROLL NO - 0129EE91028

Acknowledgement
Many lives & destinies are destroyed due to the lack of proper
guidance, direction& opportunities. It is in this respect I feel I
am in a much better condition today due to continuous process
of motivation & focus provided by my parents and teachers. The
process of completion of this training was a tedious job &
required care & support at all stages. I would like to highlight
the role played by individuals towards this. I am eternally
grateful to BHEL, BHOPAL for providing me the opportunity &
infrastructure to complete the training as a partial fulfilment of B
.Tech degree. I would like to express my sincere thanks, with
deep sense of gratitude to my training officer and project guide,
Mr PANKAJ E. KUJUR, SENIOR ENGINEER of TSE
Department for his keen interest in my project. I also thankful to
all visible & invisible hands which helped me to complete this
training with a feeling of success.

SHREYANSHU
BERI,(BHOPAL)
ROLL-NO- 0129EE091028
 PREFACE
At very outset of the prologue it becomes
imperative to insist that vocational training is
an integral part of engineering curriculum.
Training allows us to gain an insight into the
practical aspects of the various topics, with
which we come across while pursuing our B.E
i.e. vocational training gives us practical
implementation of various topics we already
have learned and will learn in near
future. Vocational training always emphasizes
on logic and common sense instead of
theoretical aspects of subject. On my part, I
pursued four weeks training at B.H.E.L.
BHOPAL. The training involved a study of
various departments of the organization as per
the time logically scheduled and well planned
given to us. The rotation in various departments
 was necessary in order to get an overall idea
about the working of the organization.

BHARAT HEAVY ELECTRICAL LIMITED

BHOPAL (M.P)

SESSION-2009-2013

CERTIFICATE
This is to certify that SHREYANSHU Student of final year ELECTRICAL
ENGINEERING branch has successfully completed the Vocational training in
BHEL BHOPAL.
This Technical Project Report is hereby approved for submission towards partial
fulfillment for the Bachelor degree in ELECTRICAL ENGINEERING.

From RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA,

Signature of the Training Officer

 Seal

Focus
To build a high degree of customer confidence
by providing increased value for his money
through international standards of product
performance superior customer service. To
enable each employee to achieve his potential,
improve his capabilities, perceive his role and
responsibilities and participate and contribute to
the growth and success of the company, to invest
inhuman resources continuously and be alive to
their needs.

People Orientation
To achieve technological excellence in operations
by development of indigenous technologies and
efficient absorption and provide competitive
advantage to the company.

Technology
 To fulfill the expectations which stakeholders
like government as owner, employees, customers
and the country at large have from B.H.E.L.

VISION, MISSION AND VALUES OF B.H.E.L.

VISION:
A world class engineering enterprise committed to
enhancing stakeholder value.

Mission:
To be an Indian Multinational Engineering Enterprise
providing total business solution through quality
products, system and services in the fields of energy,
industry, transportation, infrastructure and other
potential areas.
VALUES:
1. Zeal to Excel Zest for change.

2. Integrity and fairness in all matters.

3. Respect for dignity and potential

every individual.

4. Strict adherence to commitments.

 5. Ensure speed of response.

6. Faster learning, team work and creativity

STUDY REPORT ON :-
TRANSFORMER,CAPACITOR & BUSHING
 SR. NO. SECTION PAGE

01. INTRODUCTION
CHAPTER 1
02. CORE PUNCH
TRM
03. INSULATION

TABLE OF CONTENTS
 04. WINDING

05. COIL AND POWER ASSLY

06. TECHNICAL DIVISION

07. INSTRUMENT

CHAPTER 2 08. BCM

CHAPTER 3 09. CPM

TRM
 TCB

Transformer Capacitor Bushing

TRANSFORMERS
 Power Transformers upto 420kV class, 50/60 Hz 930 MVA, 3-phase Bank.
 Power Transformers upto 420kV class, 50/60 Hz 400 MVA, 3-phase Unit.
 HVDC Converter Transformers and Smoothing Reactors.
 500 MVA, ± 500kVDC, 3 winding, 1- Phase. Convertor Transformer.
 254 MVAR, 360mH, 1568A, ±500 kVDC 1 –Phase Smoothing Reactor.

INSTRUMENTS TRANSFORMERS
 Current transformers up to 400 kV.
 Capacitor voltage Transformer up to 420 kV.

REACTORS
 Gapped core Shunt Reactors up to 420 kV class, 125 MVAR 3 Phase Unit.
 Series and Neutral Grounding Reactors.
 Controlled Shunt Reactor up to 420 kV class, 80 MVAR 3 Phase Unit.

Major Consumers of BHEL:

National International

NTPC TNB, Malaysia

PGCIL PPC, Greece

NJPC MEW, Oman

NHPC OCC, Oman

NLC GECOL, Libya

NPCIL Trinidad & Tobago

NEEPCO New Zealand

APTRANSCO Tanzania etc

APGENCO

JPPCL
ALL State Electricity Boards
 CORE PUNCH

Ferrous M/C Assembled

Material Comp Core

CRGO Lamination Core To Next Process

Preparation Building

B.O. Insulation
Component

In House
Insul. Comp.

Fabrication
Component
Core Manufacturing Process:
CRGO Imported

Slitting Machine

Cropping Machine

Stacking / Arranging

Setting (Job)

Core Building

Clamping

Lifting

Tapping

Curing

Test (2KV / 10KV)

Shift to Assembly / Tank
 Types of CRGO Silicon Steel Used
CRGO Type Lamination Size Losses (Watts per Kg)

M4 0.27 mm 1.00 W/Kg

MOH 0.27 mm 1.00 W/Kg

ZDKH 90 0.27 mm 0.90 W/Kg

ZDKH 85 0.23 mm 0.85 W/Kg

CRGO Imported from:

1) Nippon Steel Corporation, Yawata Works (Japan)
2) VIZ-Stal Ltd., Etakerinburg (Russia)
3) POSCO

Slitting Machine (Sequence of operation):

- Drawing / Q plan
- Size / Grade CRGO
- Burr Level 20 micron
- Steel width within tolerance
- Every 500m width check Burr Gauge
- Scrap and Buckling

Cropping Machine (Sequence of operation):

- Revised drawing / QA Plan checked
- Every 100 sheet parameter check

After completion of assembly of core including curing of resin glass tape,

10 KV AC test between
- Core and End-Frame
- Core and Yoke-Bolts
- End-Frame and Yoke-Bolts

Current CRGO grades used in various projects:

Core Building Project CRGO Grade Used

BINA Power ZDKH - 85

TATA Mundra MOH

PG Sujalpur MOH
 INSULATION SHOP

Materials Used:
i. Press Board (1mm – 50mm)
ii. Perma Wood
iii. Bakelite (2mm – 25mm)
iv. Fiber Glass (0.5mm – 4mm)
v. Card Sheet / Gasket (for tanking) (3mm – 12.5mm)
vi. GUM –Fevicol & Dendroid

List of machines used in Insulation Shop:

i. Power Press (T-Block)
ii. Crepe Paper Cutting
iii. Embossing m/c
iv. Plate Bending m/c
v. Cylinder Gumming m/c
vi. Scraffing m/c
vii. Press Board Impregnation Equipment
viii. Shield Ring Milling m/c
ix. Guillitone m/c
x. RM62 / Drill m/c
xi. Lissing m/c
xii. Weighing Drill m/c
xiii. Bend Saw –Cutting m/c
xiv. Angle Hot Press
xv. Circular Saw
xvi. Hydraulic Press m/c (300T / 500T)
xvii. Pneumatic Platform - 4
xviii. Structural Platform – 8
xix. Steam Oven – 2
xx. Vacuum Drying Vessel – 2
xxi. EOT Cranes (50/10 T, 25/5 T)
 COIL WINDING

PICC / CTC Wound Coil

Moulded Comp. Coil To Process

Winding

B.O. Insul.
Component

In House
Insul. Comp.
Copper imported from:

Sr. No. M/S From Dimension

01. Precision Wires Ltd. Silvassa 7.00 x 2.05 mm

02. Bhandari Power Lines Pvt. Ltd. Manipal 10.05 x 1.40 mm

03. BPCL Conductors Pvt. Ltd. Mandideep 1.90 x 7.50 mm

04. Sam Dong Co. Ltd. Japan 2.05 x 9.60 mm

05. Chandra Proteco (CP Transco) 2.00 x 4.15 mm

Coil Pre-Heating:
- 100 oC (min 95 oC oven temperature)
- Duration 3 Hours

Types of Winding:
- Disc and Interleaved
- Helical, Spiral and Inter-Wound Helical

Copper Conductors:
- PICC - Bunched
- Glued

- CTC - Glued
 COIL ASSEMBLY AND POWER ASSEMBLY

Wound Coil

Coil Assembled Coil

Moulded Comp. Assembly

To Process 4
B.O. Insul
Comonent.

In House
Insul. Comp.

General Winding Arrangement:

TAP LV HV

LV TAP HV

LV HV TAP

Transformer Oil Properties – (Ascoryl / OM 16 / Pyroclor)

- High insulating
- Low Viscosity
- Low Surface Tension
- Optimum Cooling Point
- Low Decomposition

Material used : SRBP – Synthetic Resin Best Paper

 TECHNICAL DIVISION
(VAPOR PHASE DYING PLANT)

Capacity : 430 KW
Autoclave Size : 12500 x 6000 x 6000
Max Loading : 450 Ton
Transformer Rating : 750 MVA, 765 KV

Process:
It is a process of proper drying of insulation of transformer by a perfectly
controlled automatic process, with lowest possible paper de-polymerization and
energy consumption.

Basic Equipment of Vapor Phase Drying (VPD) plant:

a. Evaporator system.
b. Condensation system.
c. Autoclave.
d. Vacuum system.
e. Solvent Pumping system.
f. Heating system for evaporator and autoclave.
g. Heat recovery system.
h. Distillation equipment.
i. Special water extraction measuring equipment.
j. Computer aided process.

The whole process is carried out in % stages, which is as explained below:

R1: Preparation:
In this first stage, the oven is prepared for the process. The job is let
inside the chamber by means of crane. All the instruments and devices are
checked for correct operation. The oil filling pipe is placed in position.
Thermocouple is attached to the core of the transformer for temperature
monitoring; drain plug is connected by steel pipe, etc... Finally, the door is
closed and clamped by hydraulic pump.
H1: Heating Up:
The heating process is started after initial preparation. Pressure of
7mBar is maintained within the autoclave. The capacity of solvent tank is
12,000 L and a minimum of 5,000-6,000L is maintained during the process.
The heating cycle is of 48-60 Hrs and 2-3 intermediate pressure lowering (IPL)
of 1.5-2 Hrs is applied in between.

The job temperature is maintained between 105oC – 125oC.

P1: Fine Pressure Reduction:

V1: Fine Vacuum:

When water is obtained at 50mL/hour is obtained for three hours in
three simultaneous reading at 105oC – 125oC temperature and 0.2 Torr pressure,
the solvent is closed down through valves.

The job is flooded with oil and it is soaked for a minimum of 12Hrs.

A1: Aeration:
The vacuum inside the clave is broken down and air is let inside. Oil
is drained from the job and it is sent to the assembly unit for servicing.

Post servicing, the job is let in for P2 process. This is generally carried out by
conventional process only. The ob is heated to 100 +/- 5oC 0.2 torr vacuum
pressure. When simultaneous 3 reading of 50mL/hour of water is obtained for 3
hours, the job is sent to Testing department for further process in oil-filled
condition.

Transformer Oil Properties – (Ascoryl / OM 16 / Pyroclor)

- High insulating
- Low Viscosity
- Low Surface Tension
- Optimum Cooling Point
- Low Decomposition
Advantages of VPD:

01.Fast, uniform heating up of the material to be dried.

02.Substantial reduction in the drying cycle of the transformer compared to
conventional process.

Sr. Conventional Process VPD Process

1st Process 12 to 15 days 5 days

2nd Process 07 to 08 days 3 days

03.Little de-polymerization of insulating material.

04.Optimum and homogeneous dring quality, since the heating process takes
place in practically air free atmosphere, i.e. NO2.
BCM
Following are the products of Bushing Manufacturing Division:

 52KV TO 525 KV OIP condenser Bushings up to 3150 amps. Rating

 25 kV, up to 300 amps. Bushing for Indian Railways.
 Bushing for miscellaneous applications such as bushings, roof
bushings, T.G. bushings etc. To suit customer requirements.
 SRBP cylinders for transformer application up to 1400 mm I/D, up to
2400 mm long.

Bushing Core Winding

Assembly

Processing

Leakage Test

Testing

Pinking
Bushing Core Winding:
The Core of bushing is hollow copper conductor. It is wrapped up with a
layer of insulation and aluminum foil, alternatively, to form parallel capacitors.
This is done so as to reduce the electrical field stress, which would otherwise occur
and cause breakdown.

A center terminal is then taken out from aluminum foil for testing purposes
(2KV test). This ready core is then treated in oven to remove moisture content for
48 hours at around 100oC. It is then delivered to the Assembly Line for further
process.

Assembly:
Following materials are generally installed in a complete assembly of
bushing, in order from bottom to top:

Bottom End Nut

Bottom Sealing Plate

Bottom Porcelain
O - Ring
Flange
O - Ring
Top Porcelain
O - Ring
Top Cap

Top Cover

The top cover consists of pack assembly which accommodated washer /

stud. Force is applied by compressor and nut is tightened to hold the complete
bushing.
Entire assembly is carried out in five stages, which are explained
below:
Stage 01: Assembly of bushing in horizontal position

- Top Porcelain.
- Core condenser bushing.
- Top cap.
- Bottom porcelain.
- Sealing item.

Stage 02: Assembly of bushing in Vertical position

- Spring pack.
- Top cap setting / adjustment.

Stage 03: Vacuum & Impregnation processing

- Quality of oil according to specified parameters.

- Impregnation of bushing for specified time / temperature / vacuum.
- Moisture in bushing according to specified vacuum / temperature.
- Correct filling of oil.
- Minimum 12hrs of soaking in plant.
- Top-up of oil in case of low oil level.
- Minimum 5 days of soaking.
- Protection from dust.

Stage 04: Post-Processing Checks

- Mounting in upright position in fixture.

- Gauge mounting.
- N2 pressure
- Stabilization of pressure at specified oil level.
- Rectification of oil, if any.

Stage 05: Assembly of extra items according to design for dispatch

- Check Lead / Lead length.

- Cable thumble.
 - Terminal stand.
- Painting
- Checking of oil in bushing in vertical position.

In N2 pressure test, the bushing is filled up with N2 gas at 1.5 Kg/cm2 and kept
under observation for 12 hours. If any leakage exists, there’s a fall in the inside
pressure, it is then identified and rectified. The bushing is then sent to the
processing plant for moisture removal and oil filling.

Bushing Processing Plant:

The processing of bushings is carried out in two forms: Full process and
Short process. The Full process is carried out over bushings which come for
processing for the first time, and the short process takes place for those bushings
which have been already treated once.
For a 420 KV bushing, the typical Full process is:

Oven 100oC /
96 hours minimum
Start vacuum 0.005 mBar pressure /
48 hours
Temperature 60oC
24 hours
Start oil filling
Drop by Drop
18 – 20 hours
Stop Heating

Soaking 24 hours

For a 420 KV bushing, the typical short process is:

Start vacuum 0.005 mBar pressure /

24 hours
Temperature 60oC
24 hours
Start oil filling
Drop by Drop
18 – 20 hours
Stop Heating

Soaking 24 hours
For 245 KV / 145 KV / 72 KV / 52.5 KV bushing, the typical full
process is:

Oven 100oC /
72 hours minimum
Start vacuum 0.005 mBar pressure /
48 hours
Temperature 60oC
24 hours
Start oil filling
Drop by Drop
18 – 20 hours
Stop Heating

Soaking 24 hours

For 245 KV / 145 KV / 72 KV / 52.5 KV bushing, the typical short

process is:

Temperature 60oC - 65oC

12 hours
Vacuum
48 hours
Start oil filling
Drop by Drop
18 – 20 hours
Stop Heating

Soaking 24 hours
Soaking Duration:

Rating Duration

420 KV Bushing 16 Hours minimum

245 KV Bushing 12 Hours minimum

145 KV Bushing 08 Hours minimum

72.5 KV Bushing 04 Hours minimum

52 KV Bushing 04 Hours minimum

Bushing Testing:

Routine and type tests are carried out on bushing according to the
requirement and customers demand. A typical routine test observation on 420 KV
bushing is shown below. The basic device for testing is Schering Bridge, and the
parameters C3 and R3 are measured:

Parameter KV 10 122 255 364 420 364 255 122 10

Capacitance C3
Tan delta
Partial Discharge (internal)

The applied voltage on bushing is increased from 0-420 KV and reduced to

zero again, and readings are taken as shown above. Upon reaching 420 KV, an
overvoltage of 630 KV is maintained for a period of one minute and the same
parameter readings are taken.
CPM
Following Products are manufactured at the CPM Division:

Sr. No. Product Rating Purpose

01. Shunt Capacitors 6.6 KV - 500 KV improvement of power
factor
02. Series Capacitors 33 KV - 400 KV reactive compensation
and voltage regulation
03. Filter Capacitors up - 500 KV different types of
harmonics filtering
(HVDC)
04. Surge Capacitors up - 40 KV protection of generator &
transformers
05. CVTs 33 KV - 1200 KV measuring line metering
& power line carrier
communication
06. Motor Capacitors 3.3 KV - 11 KV improving power factor
07. Roof Capacitors 2000 volts dc traction locomotive

 Shunt Capacitor banks with all film dielectric impregnated with non PCB
Impregnate of desired ratings from 6.6 to 400 kV complete with manual /
automatic control equipment for Industrial and power system application.
 Pole mounted Capacitors for mounting in line with Rural Electrification scheme
up to 11 KV
 Roof Capacitor in Traction Motor application: 4 microfarad, 2 KV DC
 Series capacitors for Reactive compensation and voltage regulation in power
system from 33kV to 400 KV
 Capacitor to improve power factor of traction substations suitable for Railway
Electrification.
 Surge Capacitor for protection of Rotating Machine and Generator transformers
winding 15 kV and 40 kV, 0.125 micro farad.
 AC filter Capacitor for Harmonic filtering suitable for HVDC application up to
500 kV.
 Coupling capacitors / CVT up to 800 kV class for Power line carrier
communication application, meeting and protection.
Manufacturing Process of Power Capacitor:

Element Winding

Testing 4.5 KV
Element Stack Assembly

Pack Testing Testing at 4 KV

Soldering and Wiring

Boxing

VP Plant

Rack / Dispatch
Major raw materials:

Sr. No. Material Purpose / Dimension

01. Polypropylene film as a dielectric- 9 to 18 microns

02. Aluminum Foil 5 microns

03. PXE (Phenyl Xylyl Ethane) oil as liquid dielectric

04. Bushing -

Capacitor consists of electrode made of 5 microns Aluminum Foil. The

dielectric used is of Polypropylene film having thickness 9 microns to 18 microns.
Three layer dielectrics are used between two electrodes of 5 microns Al Foil.

All these layers of Polypropylene film and Aluminum Foil are wound on a
Semi Automatic winding machine. And then it is pressed to get the capacitor
element. This complete process is done in a dust proof air-conditioned winding
room.

All the elements are then tested using element-testing machine. If faulty
elements are detected then they are at once rejected and are separated from the
manufacturing process.

For Power Capacitors, the elements are arranged in an appropriate series or

parallel combination, so as to get desired capacitor rating. The arrangement of the
elements is called a stack. The stacks are again tested in a pack-testing machine.
These stacks are boxed in a steel container of suitable dimensions. This box can be
referred as a Capacitor can. The Can is welded and the appropriate terminals are
taken out through the bushings.

The box is then impregnated by PXE (Phenyl Xylyl Ethane) oil under fine
vacuum and temperature.
 Each unit is then routine tested as per relevant IS/IEC. Once the unit passes
in the entire test it is then painted and assembled into a rack. The rack when
completed is then dispatched to the customer.
 Testing:

Well Equipped Capacitor test & ultra high voltage laboratory to cope up
with routine & type test requirements as per latest Indian & International for Power
capacitor & coupling capacitor.

ROUTINE TEST as per IS 13925 (1998)

Sr. TEST PROCEDURE

1. Measurement of Capacitance is measured at rated voltage.

Capacitance.

2. Capacitor Loss tangent Capacitor Loss tangent is measured after 48 hrs of stabilization
measurement at rated or at the end of Thermal Stability Test.
voltage.

3. Voltage test between 4 times the rated voltage in DC is applied between the terminal
terminals. for 10 sec.

4. Ac test terminals and An Ac Voltage depending on the BIL level of the unit is
container. applied between shorted terminals and container for 10 sec.
this is applied only for units having all terminals insulated.

5. Test of Discharge Discharge resistance shall be measured. The DR shall be

device. suitable discharge to less than 50 volts from an initial peak
voltage of sqrt of 2 times the rated voltage after disconnecting
from supply. The maximum discharge time shall be 10 min.

6. Sealing test A sealing test shall be carried out to demonstrate that the
impregnate does not leak from the capacitor. The test shall be
carried out at 80`c for a period of 4 hours after attaining
container temperature of 80`c.
 TYPE TESTS as per IS 13925(1998)
Sr. TEST PROCEDURE

1. Thermal Stability Test
2. Capacitor loss tangent
measurement at elevated
temperature
a. Capacitor units are placed inside the oven
having 55+- 2`c.
b. An AC voltage equal to 1.2 Un is applied
for 48 hrs.
c. Te value of tan delta measured during last
10 hrs shall not increase by 1x 10-4
Capacitance is measured at rated voltage.
Capacitor Loss tangent is measured after 48 hrs
of stabilization or at the end of thermal stability
test.

3. Ac test terminals and An Ac Voltage depending on the BIL level of

container. the unit is applied between shorted terminals
and container for 1 min. this is applied only for
units having all terminals insulated.

4. Lighting impulse voltage test An Impulse Voltage depending on the BIL

between shorted terminals and level of the unit is applied between shorted
container. terminals and container. this test is applicable
only for units having all terminals insulated.

5. Shorted Circuit Discharge a. 2.5 times the rated voltage in DC is applied

Test. between the terminals & then discharged
through a gap situated as close as possible to
the capacitor. The unit shall be subjected to
give 5 such discharge within 10 min.

b. Within 5 min after this test, the unit shall be

subjected to 4.3 times the rated voltage
between terminals for 10 sec.