BHEL OVERVIEW

BHEL was established more than 50 years ago when its first plant was setup
in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India.

BHEL is largest engineering and manufacturing enterprise in India in the

energy related/infrastructure sector. BHEL was established more than four decades
ago ushering in the indigenous Heavy Electrical Equipment industry in India. BHEL
has built over the years, a robust domestic market position by becoming the largest
supplier of power plant equipment in India, and by developing strong market
presence in select segment of the industry sector and the Railway. Currently, 80% of
the Nuclear power generation in the country is through BHEL sets.

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 and
achieved a turnover of Rs 2,658 crore for the year 2007-08, showing a growth of 17
per cent . Bharat Heavy Electricals Limited is country’s ‘Navratna’ company and has
earned its place among very prestigious national and international companies. It
finds place among the top class companies of the world for manufacture of electrical
equipments.

BHEL caters to core sectors of the Indian Economy viz., Power Generation's
& Transmission, Industry, Transportation, Telecommunication, Renewable Energy,
Defense, etc. BHEL has already attained ISO 9000 certification for quality
management, and ISO 14001 certification for environment management and OHSAS
– 18001 certification for Occupational Health and Safety Management Systems. The
Company today enjoys national and international presence featuring in the “Fortune
International -500” and is ranked among the top 10 companies in the world,
manufacturing power generation equipment. BHEL is the only PSU among the 12
Indian companies to figure in “Forbes Asia Fabulous 50” list.

Probably the most significant aspect of BHEL’s growth has been its
diversification .The constant reorientation of the organization to meet the varied
needs in time with a philosophy that has led to total development of a total capability
from concepts to commissioning not only in the field of energy but also in industry
and transportation.

In the world power scene BHEL ranks among the top ten manufacturers of
power plant equipments not only in spectrum of products and services offered, it is
right on top. BHEL‘s technological excellence and turnkey capabilities have won it
worldwide recognition. Over 40 countries in world over have placed orders with
BHEL covering individual equipment to complete power stations on turnkey basis
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BHEL has
 Installed equipment for over 90000MW of power generation-for
utilities, captive and industrial users.
 Supplied over 225000MW a transformer capacity and other
equipment operating in transmission and distribution network up to
400Kv (AC& DC).

 Supplied over 25000 motors with drive control system to power

projects, petro chemicals, refineries, steel, aluminum, fertilizers, cement
plants etc.
 Supplied traction electrics and AC/DC locos to power over 12000kms
railway network.
 Supplied over one million valves to power plants and other industries.

BHEL manufactures over 180 products under 30 major product groups and
caters to core sectors of the Indian Economy viz., Power Generation &
Transmission, Industry, Transportation, Telecommunication, Renewable Energy, etc.
The wide network of BHEL's 14 manufacturing divisions, four Power Sector
regional centers, over 100 project sites, eight service centers 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. The high level
of quality & reliability of its products is due to the emphasis on design, engineering
and manufacturing to international standards by acquiring and adapting some of the
best technologies from leading companies in the world, together with technologies
developed in its own R&D centers.

 BHEL has acquired certifications to Quality Management Systems

(ISO 9001), Environmental Management Systems (ISO 14001) and
Occupational Health & Safety Management Systems (OHSAS 18001)
and is also well on its journey towards Total Quality Management.

 BHEL vision is to become a world class engineering enterprise,

committed to enhancing stakeholder value. The company is striving to
give shape to its aspiration and fulfill the expectations of the country to
become a global presence:-

Vision:

“A world class engineering enterprise committed to enhance stakeholder

values.”
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Mission:

“To be an Indian multinational engineering providing total business solution

through quality product system and services in the field of energy, transportation,
industry, infrastructure and other potential area.

Values:

 Ensure speed of response.

 Foster learning, creativity and team work.

 Respect for dignity and potential of individuals

 Loyalty and pride in company

 Zeal for the change.

 Zeal to excel.

 Integrity and fairness in all matters.

 Strict adherence to commitments.

BUSINESS MISSION

To maintain a leading position as supplier of quality equipments, system and

services in the field of conversion, transmission, utilization, and conversation of
energy for application in the area of electric power, transportation oil and gas
exploration and industries. To utilize company’s capability and resources to expand
busyness in to allied area an priority sector of economy like defense, communication
and electronics.

BHEL OBJECTIVES

A dynamic organization is one which keeps its aim high, adopts itself quickly
to changing environment, so we are in BHEL. The objectives of the company have
been redefined in the corporate plane for 90’s.

Growth

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 To ensure a steady growth by enhancing the competitive edge of BHEL in
existing busyness, new area and international market so as to fulfill national
expectation from BHEL.

Profitability

To ensure a reasonable and adequate return on capital employed, primarily

through improvements in operation, efficiency, capacity utilization & productivity
and to generate adequate internal resources to finance the company’s growth.

Focus

To built a high degree of customer confidence by providing increased value of

his money through international standards of product quality performance and
superior customer service.

People Orientation

To enable each employee to achieve his potential, improve his capabilities,

understand is role and responsibilities and participate and contribute to the growth
and success of the company.

Technology

To achieve technological excellence in operation of indigenous technologies

and efficient absorption and adoption of imparted technologies to suit business.

Image
To fulfill the expectations, which stack holders like government as owner
employee, customer and the country at large have from BHEL.

BHEL BHOPAL PROFILE

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 Heavy Electrical Plant , Bhopal is the mother plant of Bharat Heavy
Electricals Limited, the largest engineering and manufacturing enterprise inIndia in
the energy-related and infrastructure sector, today. It is located at about 7 kms. from
Bhopal Railway station, about 5 kms. from Habibganj Railway station and about 18
kms. From Raja Bhoj Airport. With technical assistance from Associated Electricals
(India) Ltd., a UK based company, it came into existence on 29th of August, 1956.
Pt. Jawaharlal Nehru, first Prime minister of India dedicated this plant to the nation
on 6th of November, 1960.

BHEL, Bhopal with state-of-the-art facilities, manufactures wide range of

electrical equipments. It’s product range includes Hydro, Steam, Marine & Nuclear
Turbines, Heat Exchangers, Hydro & Turbo Generators, Transformers, Switchgears,
Control gears, Transportation Equipment, Capacitors, Bushings, Electrical Motors,
Rectifiers, Oil Drilling Rig Equipments and Diesel Generating sets.

BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is
moving towards excellence by adopting TQM as per EFQM / CII model of Business
Excellence. Heat Exchanger Division is accredited with ASME ‘U’ Stamp. With the
slogan of “ Kadam kadam milana hai, grahak safal banana hai”, it is committed to
the customers.

BHEL Bhopal has its own Laboratories for material testing and instrument
calibration which are accredited with ISO 17025 by NABL. The Hydro Laboratory,
Ultra High Voltage laboratory and Centre for Electric Transportation are the only
laboratories of its in this part of
theworld.

BHEL Bhopal's strength is it's employees. The company continuously

invests in Human Resources and pays utmost attention to their needs. The plant's
Township, well known for its greenery is spread over an area of around 20 sq kms.
and provides all facilities to the residents like, parks, community halls, library,
shopping centers, banks, post offices etc. Besides, free health services is extended to
all the employees through 350 bedded (inclusive of 50 floating beds) Kasturba
Hospital and chain of dispensaries.
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 BHEL – BUSINESS AREAS

BHEL today is the largest Engineering Enterprise of its kind in India with
excellent track record of performance, making profits continuously since 1971-72.

BHEL's operations are organised around three business sectors, namely

Power, Industry - including Transmission, Transportation, Telecommunication &
Renewable Energy - and Overseas Business. This enables BHEL to have a strong
customer orientation, to be sensitive to his needs and respond quickly to the changes
in the market.

 Power

 Industry

 Transportation

 Transmission

 Defenses etc.

The greatest strength of BHEL is its highly skilled and committed 42,600
employees. Every employee is given an equal opportunity to develop himself and
grow in his career. Continuous training and retraining, career planning, a positive
work culture and participative style of management all these have engendered
development of a committed and motivated workforce setting new benchmarks in
terms of productivity, quality and responsiveness.

POWER SECTOR

Power is the core sector of BHEL and comprises of thermal, nuclear gas,
diesel and hydro business. Today BHEL supplied sets, accounts for nearly 66 % of
the total installed capacity in the country as against nil till 1969-70.

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 BHEL manufactures boilers auxiliaries, TG sets and associate controls,
piping and station C & I up to 500 MW rating with technology and capability to go
up to 1000 MW range. The auxiliary products high value capital equipment like
bowl and tube mills, pumps and heaters, electrostatic precipitators, gravimetric
feeders, fans, valves etc.

BHEL has contracted so far around 240 thermal sets of various ratings, which
includes 14 power plants set up on turnkey basis. Nearly 85 % of World Bank
tenders for thermal sets floated in India have been won by the company against
international competition.
BHEL has adopted the technology to the needs of the country and local conditions.
This has led to the development of several technologies in house. The fluidized bed
boiler that uses low graded high-ash abrasive Indian coal is an outcome of such an
effort. With large-scale availability of natural gas and the sudden increase in demand,
BHEL began to manufacture gas turbines and now possesses two streams of gas
turbine technology.

It has the capability to manufacture gas turbines up to 200 MW rating and

custom built combined cycle power plants. Nuclear steams generators, turbine
generators, sets and related equipment of 235 MW rating have been supplied to
most of the nuclear power plants in India. Production of 500 MW nuclear sets, for
which orders have been received.

BHEL has developed expertise in renovation and maintenance of power plant

equipment besides specialized know how of residual life assessment, health
diagnostic and life extensions of plants. The four power sectors regional centers at
New Delhi, Chennai, Kolkata and Nagpur will play a major role in giving a thrust to
this business and focus BHEL's efforts in this area.

As part of India’s largest Solar Power-based Island Electrification Project in

India, Bharat Heavy Electricals Limited (BHEL) has successfully commissioned two
Grid-Interactive Solar Power Plants of 100 KW each in Lakshadweep.

With this, the company has commissioned a total of eleven Solar Power
Plants in the Lakshadweep islands, adding over 1 MW of Solar Power to the power
generating capacity of the coral islands in the Arabian Sea.

 BHEL has proven turnkey capabilities for executing power projects

from concept to commissioning and manufactures boilers, thermal turbine
generator sets and auxiliaries up to 500MW.

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  It possesses the technology and capability to procure thermal power
generation up to 1000MW.

 Co- generation and combined cycle plants have also been introduced.

 For the efficient use of high ash content coal BHEL supplies
circulating fluidized boiler.

 BHEL manufacturers 235MW nuclear sets and has also commenced

production of 500MW nuclear turbine generator sets.

Custom made hydro sets of Francis, pelton and kepian types for different
head discharge combination are also engineering and manufactured by BHEL.

In, all 700 utility sets of thermal, hydro, gas and nuclear have been 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 modernization and up rating of variety of power plant equipment
besides specialized know how of residual life assessment, health diagnostics and life
extension of plants.

POWER TRANSMISSION AND DISTRIBUTION (T&D)

BHEL offer wide-ranging products and systems for T & D applications

Products.
manufactured include power transformers, instrument transformers, dry type
transformers, series – and shunt reactor, capacitor tanks, vacuum – and SF circuit
breakers gas insulated switch gears and insulators.

A strong engineering base enables the Company to undertake turnkey

delivery of electric substances up to 400 kV level series compensation systems (for
increasing power transfer capacity of transmission lines and improving system
stability and voltage regulation), shunt compensation systems (for power factor and
voltage improvement) and HVDC systems (for economic transfer of bulk power).
BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for
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reactive power management on long transmission lines). Presently a 400 kV Facts
(Flexible AC Transmission System) project under execution.

A wide range of transmission products and systems are produced by BHEL to

meet the needs of power transmission and distribution sector. These include:

 Dry Type Transformers

 SF6 Switch Gears
 400 KW Transmission Equipment
 High Voltage Direct Current System
 Series and Shunt Compensation Systems

In anticipation of the need for improved substations, a 33 KV gas insulated

sub station with micro processors base control and protection system has been done.

INDUSTRY SECTOR

BHEL is a major contributor of equipment and system to important industries

like

 Cement
 Petrochemicals
 Fertilizers
 Steel papers
 Refineries
 Mining and telecommunication

BHEL has indigenously developed the state-of-the-art controlled shunt

reactor (for reactive power management on long transmission lines). Presently a 400
kV FACTS (Flexible AC Transmission System) projects is under execution.

The range of system and equipment supplied includes:-

 Captive power plants

 High speed industrial drive turbines
 Industrial boilers and auxiliaries
 Waste heat recovery boilers
 Gas turbine pump, valves, seamless steel tubes
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 Heat exchangers
 Process control etc.

The Company is a major producer of large-size thruster devices. It also

supplies digital distributed control systems for process industries, and control &
instrumentation systems for power plant and industrial applications. BHEL is the
only company in India with the capability to make simulators for power plants,
defense and other applications.

The Company has commenced manufacture of large desalination plants to

help augment the supply of drinking water to people.

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 systems.

 65 % of trains in Indian Railways are equipped with BHEL's traction

and traction control equipment. These include:
 Broad Gauge 3900 HP AC / DC locomotives
 Diesel Shunting Locomotives up to 2600 HP
 5000 HP AC Loco with thyristor control
 Battery Powered Road Vehicles and Locomotives

TELECOMMUNICATION

BHEL also caters to telecommunication sector by way of small, medium and

large switching system.

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Renewable energy
Technologies that can be offered by BHEL for exploiting non-conventional
and renewable resources of energy includes: wind electric generators, solar power
based water pumps, lighting and heating systems.

The company manufactures wind electric generators of unit size up to 250 KW for
wind farms, to meet the growing demand for harnessing wind energy.

International operations
BHEL has, over the years established its references in over 50 countries of
the world, ranging from 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 type sub-station projects,
rehabilitation projects, besides a wide variety of products, like switch gear,
transformer, heat exchangers, insulators, castings and forgings. Apart from over
1100MW of boiler capacity contributed in Malaysia, some of the other major
successes achieved by the company have been in Oman, Saudi Arabia, Libya,
Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan, Sri lanka, Iraq etc. execution
of overseas projects has also provided BHEL the experience of working with world
renowned consulting organizations and inspection agencies.

RESEARCH AND DEVELOPMENT(R&D)

To remain competitive and meet customers’ expectations, BHEL lays great

emphasis on the continuous up gradation of products and related technologies, and
development of new products. The company has upgraded its products to
contemporary levels through continuous in house efforts as well as through
acquisitions of new technologies from leading engineering organizations of the
world.

Research and product development centers at each of the manufacturing divisions

play a complementary role.

BHEL’s investment in R&D is amongst the largest in the corporate sector

in India.
BHEL's vision is to become a world-class engineering enterprise, committed to
enhancing stakeholder value. The company is striving to give shape to its aspirations
and fulfill the expectations of the country to become a global player.

The greatest strength of BHEL is its highly skilled and committed 42,600
employees. Every employee is given an equal opportunity to develop himself and
11
grow in his career. Continuous training and retraining, career planning, a positive
work culture and participative style of management – all these have engendered
development of a committed and motivated workforce setting new benchmarks in
terms of productivity, quality and responsiveness.

BHEL has a corporate R & D center supported by R & D groups at each of

the manufacturing divisions. The dedicated effort of BHEL's R & D engineers have
produced several new products like automated storage retrieval system automated
guide vehicles for material transportation etc. Establishment of Asia's largest fuel
evaluation test facility at Tiruchi was high light of the year. This facility will enable
evaluation of combustion, heat transfer and pollution parameters in boilers.

Major R & D achievement include:

 Design manufacture and supply of countries first 17.2 MW industrial steam
turbines.
 Development of 4700 HP AC / DC loco for Indian Railways.
 Development of largest capacitor voltage transformers of 8800 PF 400 KV
rating.
 Development and application low cost ROBOTS for job loading/unloading.

According to ex- CMD Mr. R.K.D. Shah, "BHEL is spending Rs. 60 Crores
on Research and Development. Earning from product which has been
commercialized has gone up 26 % to Rs. 760 Crores."
PRODUCTS

Thermal Power Plants

 Steam turbines, boilers and generators of up to 800 MW capacity for
utility and combined-cycle applications ; Capacity to manufacture boilers and
steam turbines with supercritical system cycle parameter and matching
generator up to 1000 MW unit size.

 Steam turbines, boilers and generators of CPP applications; capacity

to manufacture condensing, extraction, back pressure, injection or any
combination of these types of steam turbines.

Nuclear Power Plants

 Steam generator & Turbine generator up to 700 MW capacity.

Gas-Based Power Plants

 Gas turbines of up to 280 MW (ISO) advance class rating.
 Gas turbine-based co-generation and combined-cycle systems of
industry and utility applications.

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There are other products given as follows

Hydro Power Plants, DG Power Plants, Industrial Sets, Boiler, Boiler Auxiliaries,
Piping System, Heat Exchangers and Pressure Vessels Pumps, Power Station Control
Equipment, Switchgear, Bus Ducts, Transformers, Insulators, Industrial and Special
Ceramics, Capacitors, Electrical Machines, Compressors, Control Gear, Silicon
Rectifiers, Thyristor GTO/IGBT Equipment , Power Devices, Transportation
Equipment

Oil Field Equipment, Casting and Forgings, Seamless Steel Tubes, Distributed
Power Generation and Small Hydro Plants.

TECHNICAL COLLABORATIONS

PRODUCT COLLABORATIONS

# Thermal Sets, Hydro Sets, Motors & Prommashexport

Control Gears. RUSSIA

# Bypass & Pressure Reducing Systems Sulzer Brother Ltd.

SWITZERLAND

# Electronic Automation System for Siemens AG.

Steam Turbine & Generators GERMANY

# Francis Type Hydro Turbines General Electric

CANADA

# Moisture Separator Reheaters Baloke Duerr

GERMANY

# Christmas Trees & Conventional Well National Oil Well

Head Assemblies, USA

# Steam Turbines , Generators and Axial Siemens AG.

Condensers GERMANY

# Cam Shaft Controllers and Tractions Siemens AG.

Current Control Units GERMANY
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 MAJOR CUSTOMERS OF B.H.E.L

 Supplied to all major utilities in India :

National Thermal Power Corporation (NTPC)

PGCIL
NJPC
NHPC
NLC
NPCIL
NEEPCO
APTRANSCO
APGENCO
JPPCL
ALL State Electricity Boards (SEBs)

 Abroad:
TNB,Malaysia
PPC,Greece
MEW,Oman
OCC,Oman
GECOL,Libya
Trinidad & Tobago
New Zealand
Tanzania etc

MAJOR COMPETITORS OF BHEL

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 1. Ansaldo Italy
2. Asea Brown Boueri Switzerland
3. Beehtel USA
4. Block & Neatch USA
5. CNMI & EC China
6. Costain U.K.
7. Electrim Poland
8. Energostio Russia
9. Electro Consult Italy
10. Franco Tosi France
11. Fuji Japan
12. GEC Alsthom U.K.
13. General Electric USA
14. Hitachi Japan
15. LMZ Russia
16. Mitsubishi Japan
17. Mitsui Japan
18. NEI U.K.
19. Raytheon USA
20. Rolls Royce Germany
21. Sanghai Electric Co. China

DIVISIONS OF BHEL

There are 20 Divisions of BHEL, they are as follows:

 HEEP, Haridwar
 HPEP, Hyderabad
 HPBP, Tiruchi
 SSTP & MHD, Tiruchi
 CFFP, Haridwar
 BHEL, Jhansi
 BHEL, Bhopal
 EPD, Bangalore
 ISG, Bangalore
 ED, Bangalore
 BAP, Ranipet
 IP, Jagdishpur
 IOD, New Delhi
 COTT, Hyderabad
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 IS, New Delhi
 CFP, Rudrapur
 HERP, Varanasi
 Regional Operations Division ARP, New Delhi
 TPG, Bhopal
 Power Group (Four Regions and PEM)

MANUFACTURING UNIT OF BHEL

First Generation Units

BHOPAL Heavy Electrical Plant

HARDWAR Heavy Electrical Equipment Plant

HYDERABAD Heavy Electrical Power Equipment Plant

TIRUCHY High Pressure Boiler Plant

Second Generation Units

JHANSI Transformer and Locomotive Plant

HARDWAR Central Foundry and Forge Plant

TIRUCHY Seamless Steel Tube Plant

Unit Through Acquisition and Merger

BANGALORE Electronic Division

Electro Porcelain Division

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 New Manufacturing Units

RANIPAT Boiler Auxiliaries Plant

JAGDISHPUR Insulator Plant

RUDRAPUR Component and Fabrication Plant

BANGALORE Industrial System Group

TRANSFORMERS

A transformer is a device that transfers electrical energyfrom one circuit to

another through inductively coupled conductors—the transformer's coils. A
varying current in the first or primary winding creates a varying magnetic flux in the
transformer's core and thus a varying magnetic field through the secondary winding.
This varying magnetic field induces a varying electromotive force (EMF), or
"voltage", in the secondary winding. This effect is called inductive coupling.
If a load is connected to the secondary, current will flow in the secondary
winding, and electrical energy will be transferred from the primary circuit through
the transformer to the load. In an ideal transformer, the induced voltage in the
secondary winding (Vs) is in proportion to the primary voltage (Vp) and is given by
the ratio of the number of turns in the secondary (Ns) to the number of turns in the
primary (Np) as follows:

By appropriate selection of the ratio of turns, a transformer thus enables

an alternating current (AC) voltage to be "stepped up" by making Ns greater than Np,
or "stepped down" by making Ns less than Np. The windings are coils wound around
a ferromagnetic core, air-core transformers being a notable exception.
Transformers range in size from a thumbnail-sized coupling transformer
hidden inside a stage microphone to huge units weighing hundreds of tons used to
interconnect portions ofpower grids. All operate on the same basic principles,
although the range of designs is wide. While new technologies have eliminated the
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need for transformers in some electronic circuits, transformers are still found in
nearly all electronic devices designed for household ("mains") voltage. Transformers
are essential for high-voltage electric power transmission, which makes long-
distance transmission economically practical.

BASIC PRINCIPLES

An ideal transformer. The secondary current arises from the action of the
secondary EMF on the (not shown) load impedance.
The transformer is based on two principles: first, that an electric current can
produce a magnetic field(electromagnetism) and second that a changing magnetic
field within a coil of wire induces a voltage across the ends of the coil
(electromagnetic induction). Changing the current in the primary coil changes the
magnetic flux that is developed. The changing magnetic flux induces a voltage in the
secondary coil.
An ideal transformer is shown in the adjacent figure. Current passing through
the primary coil creates amagnetic field. The primary and secondary coils are
wrapped around a core of very high magnetic permeability, such as iron, so that most
of the magnetic flux passes through both the primary and secondary coils. If a load is
connected to the secondary winding, the load current and voltage will be in the
directions indicated, given the primary current and voltage in the directions indicated
(each will be alternating current in practice).

Induction law
The voltage induced across the secondary coil may be calculated
from Faraday's law of induction, which states that:

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 where Vs is the instantaneous voltage, Ns is the number of turns in the
secondary coil and Φ is the magnetic flux through one turn of the coil. If the turns of
the coil are oriented perpendicularly to the magnetic field lines, the flux is the
product of the magnetic flux density B and the area A through which it cuts. The area
is constant, being equal to the cross-sectional area of the transformer core, whereas
the magnetic field varies with time according to the excitation of the primary. Since
the same magnetic flux passes through both the primary and secondary coils in an
ideal transformer, the instantaneous voltage across the primary winding equals

Taking the ratio of the two equations for Vs and Vp gives the basic
equation for stepping up or stepping down the voltage

Np/Ns is known as the turns ratio, and is the primary functional characteristic
of any transformer. In the case of step-up transformers, this may sometimes be stated
as the reciprocal, Ns/Np.
Turns ratio is commonly expressed as an irreducible fraction or ratio: for
example, a transformer with primary and secondary windings of, respectively, 100
and 150 turns is said to have a turns ratio of 2:3 rather than 0.667 or 100:150.

Ideal power equation

The ideal transformer as a circuit element

If the secondary coil is attached to a load that allows current to flow,
electrical power is transmitted from the primary circuit to the secondary circuit.
Ideally, the transformer is perfectly efficient. All the incoming energy is transformed
from the primary circuit to the magnetic field and into the secondary circuit. If this
condition is met, the input electric power must equal the output power:

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 giving the ideal transformer equation

This formula is a reasonable approximation for most commercial built

transformers today.
If the voltage is increased, then the current is decreased by the same factor.
The impedance in one circuit is transformed by the square of the turns ratio.For
example, if an impedance Zs is attached across the terminals of the secondary coil, it
appears to the primary circuit to have an impedance of (Np/Ns)2Zs. This relationship is
reciprocal, so that the impedance Zp of the primary circuit appears to the secondary
to be (Ns/Np)2Zp.

Detailed operation
The simplified description above neglects several practical factors, in
particular, the primary current required to establish a magnetic field in the core, and
the contribution to the field due to current in the secondary circuit.
Models of an ideal transformer typically assume a core of
negligible reluctance with two windings of zero resistance. When a voltage is
applied to the primary winding, a small current flows, driving flux around
the magnetic circuit of the core.: The current required to create the flux is termed
the magnetizing current. Since the ideal core has been assumed to have near-zero
reluctance, the magnetizing current is negligible, although still required, to create the
magnetic field.
The changing magnetic field induces an electromotive force (EMF) across
each winding. Since the ideal windings have no impedance, they have no associated
voltage drop, and so the voltages VP and VSmeasured at the terminals of the
transformer, are equal to the corresponding EMFs. The primary EMF, acting as it
does in opposition to the primary voltage, is sometimes termed the "back
EMF". This is in accordance with Lenz's law, which states that induction of EMF
always opposes development of any such change in magnetic field.

PRACTICAL CONSIDERATIONS:
Leakage flux

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 Leakage flux of a transformer
The ideal transformer model assumes that all flux generated by the primary
winding links all the turns of every winding, including itself. In practice, some flux
traverses paths that take it outside the windings. Such flux is termedleakage flux, and
results in leakage inductance in series with the mutually coupled transformer
windings. Leakage results in energy being alternately stored in and discharged from
the magnetic fields with each cycle of the power supply. It is not directly a power
loss (see "Stray losses" below), but results in inferior voltage regulation, causing the
secondary voltage to not be directly proportional to the primary voltage, particularly
under heavy load. Transformers are therefore normally designed to have very
low leakage inductance. Nevertheless, it is impossible to eliminate all leakage flux
because it plays an essential part in the operation of the transformer. The combined
effect of the leakage flux and the electric field around the windings is what transfers
energy from the primary to the secondary.
In some applications increased leakage is desired, and long magnetic paths,
air gaps, or magnetic bypass shunts may deliberately be introduced in a transformer
design to limit the short-circuit current it will supply.Leaky transformers may be
used to supply loads that exhibit negative resistance, such as electric arcs, mercury
vapor lamps, and neon signs or for safely handling loads that become periodically
short-circuited such as electric arc welders.
Air gaps are also used to keep a transformer from saturating, especially
audio-frequency transformers in circuits that have a direct current component
flowing through the windings.
Leakage inductance is also helpful when transformers are operated in
parallel. It can be shown that if the "per-unit" inductance of two transformers is the
same (a typical value is 5%), they will automatically split power "correctly" (e.g.
500 kVA unit in parallel with 1,000 kVA unit, the larger one will carry twice the
current)

21
 Effect of frequency
The time-derivative term in Faraday's Lawshows that the flux in the core is
the integral with respect to time of the applied voltage. Hypothetically an ideal
transformer would work with direct-current excitation, with the core flux increasing
linearly with time. In practice, the flux rises to the point where magnetic saturationof
the core occurs, causing a large increase in the magnetizing current and overheating
the transformer. All practical transformers must therefore operate with alternating (or
pulsed direct) current.
The EMF of a transformer at a given flux density increases with
frequency. By operating at higher frequencies, transformers can be physically more
compact because a given core is able to transfer more power without reaching
saturation and fewer turns are needed to achieve the same impedance. However,
properties such as core loss and conductor skin effect also increase with frequency.
Aircraft and military equipment employ 400 Hz power supplies which reduce core
and winding weight. Conversely, frequencies used for some railway electrification
systems were much lower (e.g. 16.7 Hz and 25 Hz) than normal utility frequencies
(50 – 60 Hz) for historical reasons concerned mainly with the limitations of
early electric traction motors. As such, the transformers used to step down the high
over-head line voltages (e.g. 15 kV) were much heavier for the same power rating
than those designed only for the higher frequencies.
Operation of a transformer at its designed voltage but at a higher frequency
than intended will lead to reduced magnetizing current. At a lower frequency, the
magnetizing current will increase. Operation of a transformer at other than its design
frequency may require assessment of voltages, losses, and cooling to establish if safe
operation is practical. For example, transformers may need to be equipped with
"volts per hertz" over-excitation relays to protect the transformer from overvoltage at
higher than rated frequency.
One example of state-of-the-art design is transformers used for electric
multiple unit high speed trains, particularly those required to operate across the
borders of countries using different electrical standards. The position of such
transformers is restricted to being hung below the passenger compartment. They
have to function at different frequencies (down to 16.7 Hz) and voltages (up to 25
kV) whilst handling the enhanced power requirements needed for operating the
trains at high speed.
Knowledge of natural frequencies of transformer windings is necessary for
the determination of winding transient response and switching surge voltages.
Transformer universal EMF equation
If the flux in the core is purely sinusoidal, the relationship for either winding
between its rms voltage Erms of the winding, and the supply frequencyf, number of

22
turns N, core cross-sectional area a and peak magnetic flux density B is given by the
universal EMF equation:

If the flux does not contain even harmonics the following equation can be
used for half-cycle average voltage Eavg of any waveshape:

ENERGY LOSSES
An ideal transformer would have no energy losses, and would be 100%
efficient. In practical transformers, energy is dissipated in the windings, core, and
surrounding structures. Larger transformers are generally more efficient, and those
rated for electricity distribution usually perform better than 98%.
Experimental transformers using superconducting windings achieve
efficiencies of 99.85%. The increase in efficiency can save considerable energy, and
hence money, in a large heavily loaded transformer; the trade-off is in the additional
initial and running cost of the superconducting design.
Losses in transformers (excluding associated circuitry) vary with load
current, and may be expressed as "no-load" or "full-load" loss.
Winding resistance dominates load losses, whereas hysteresis and eddy
currents losses contribute to over 99% of the no-load loss. The no-load loss can be
significant, so that even an idle transformer constitutes a drain on the electrical
supply and a running cost. Designing transformers for lower loss requires a larger
core, good-quality silicon steel, or even amorphous steel for the core and thicker
wire, increasing initial cost so that there is a trade-off between initial cost and
running cost (also see energy efficient transformer).
Transformer losses are divided into losses in the windings, termed copper
loss, and those in the magnetic circuit, termed iron loss. Losses in the transformer
arise from:
Winding resistance
Current flowing through the windings causes resistive heating of the
conductors. At higher frequencies,skin effect and proximity effect create additional
winding resistance and losses.

Hysteresis losses

23
 Each time the magnetic field is reversed, a small amount of energy is lost due
to hysteresis within the core. For a given core material, the loss is proportional to the
frequency, and is a function of the peak flux density to which it is subjected.

Eddy currents

Ferromagnetic materials are also good conductors and a core made from such
a material also constitutes a single short-circuited turn throughout its entire
length. Eddy currents therefore circulate within the core in a plane normal to the
flux, and are responsible for resistive heating of the core material. The eddy current
loss is a complex function of the square of supply frequency and inverse square of
the material thickness. Eddy current losses can be reduced by making the core of a
stack of plates electrically insulated from each other, rather than a solid block; all
transformers operating at low frequencies use laminated or similar cores.

Magnetostriction

Magnetic flux in a ferromagnetic material, such as the core, causes it to

physically expand and contract slightly with each cycle of the magnetic field, an
effect known as magnetostriction. This produces the buzzing sound commonly
associated with transformers that can cause losses due to frictional heating. This
buzzing is particularly familiar from low-frequency (50 Hz or 60 Hz) mains hum,
and high-frequency (15,734 Hz (NTSC) or 15,625 Hz (PAL)) CRT noise.

Mechanical losses

In addition to magnetostriction, the alternating magnetic field causes

fluctuating forces between the primary and secondary windings. These incite
vibrations within nearby metalwork, adding to the buzzing noise and consuming a
small amount of power.

Stray losses

Leakage inductance is by itself largely lossless, since energy supplied to its

magnetic fields is returned to the supply with the next half-cycle. However, any
leakage flux that intercepts nearby conductive materials such as the transformer's
support structure will give rise to eddy currents and be converted to heat. There are
also radiative losses due to the oscillating magnetic field but these are usually small.

Core form and shell form transformers

24
 Core form = core type; shell form = shell type

As first mentioned in regard to earliest ZBD closed-core transformers,

transformers are generally considered to be either core form or shell form in design
depending on the type of magnetic circuit used in winding construction (see image).
That is, when winding coils are wound around the core, transformers are termed as
being of core form design; when winding coils are surrounded by the core,
transformers are termed as being of shell form design. Shell form design may be
more prevalent than core form design for distribution transformer applications due to
the relative ease in stacking the core around winding coils Core form design tends to,
as a general rule, be more economical, and therefore more prevalent, than shell form
design for high voltage power transformer applications at the lower end of their
voltage and power rating ranges (less than or equal to, nominally, 230 kV or 75
MVA). At higher voltage and power ratings, shell form transformers tend to be more
prevalent. Shell form design tends to be preferred for extra high voltage and higher
MVA applications because, though more labor intensive to manufacture, shell form
transformers are characterized as having inherently better kVA-to-weight ratio, better
short-circuit strength characteristics and higher immunity to transit damage.

EQUIVALENT CIRCUIT

25
 Transformer equivalent circuit, with secondary impedances referred to the primary
side

The parameters of equivalent circuit of a transformer can be calculated from

the results of two transformer tests: open-circuit test and short-circuit test.

TRANSFORMER RATINGS
Transformers are rated at their kilovolt-ampere (kVA) outputs. If the load to
be supplied by a transformer is at 100 percent power factor (pf), the kilowatt (kW)
output will be the same as the kilovolt-ampere (kVA) output. If the load has a lesser
power factor, the kW output will be less than the kVA output proportionally as the
load power factor is less than 100 percent.

CLASSIFICATION OF TRANSFORMERS

1. According to method of cooling

a. Self-air–cooled (dry type)

b. Air-blast–cooled (dry type)
c. Liquid-immersed, self-cooled
d. Oil-immersed, combination self-cooled and air-blast

e. Oil-immersed, water-cooled
f. Oil-immersed, forced-oil–cooled
g. Oil-immersed, combination self-cooled and water-cooled

2. According to insulation between windings

a. Windings insulated from each other

b. Autotransformers

3. According to number of phases

26
 a. Single-phase
b. Polyphase

4. According to method of mounting

a. Pole and platform

b. Subway
c. Vault
d. Special

5. According to purpose

a. Constant-voltage
b. Variable-voltage
c. Current
d. Constant-current

6. According to service

a. Large power
b. Distribution
c. Small power
d. Sign lighting
e. Control and signaling

TRANSFORMER CORES
Until recently, all transformer cores were made up of stacks of sheet-steel
punchings firmly clamped together.Sometimes the laminations are coated with a thin
varnish to reduce eddy-current losses. When the laminations are not coated with
varnish, a sheet of insulating paper is inserted between laminations at regular
intervals.

A new type of core construction consists of a continuous strip of silicon steel

which is wound in a tight spiral around the insulated coils and firmly held by spot
welding at the end. This type of construction reduces the cost of manufacture and
reduces the power loss in the core due to eddy currents.

OIL USED IN TRANSFORMERS

It performs two important functions. It serves to insulate the various coils

27
from each other and from the core, and it conducts the heat from the coils and core to
some cooler surfaces, where it is either dissipated in the surrounding air or
transferred to some cooling medium. It is evident that the oil should be free from any
conducting material, it should be suffi-ciently thin to circulate rapidly when
subjected to differences of temperatures at different places, and it should not be
ignitable until its temperature has been raised to a very high value. Although
numerous kinds of oils have been tried in transformers, at the present time mineral
oil is used almost exclusively. This oil is obtained by fractional distillation of
petroleum unmixed with any other substances and without subsequent chemical
treat-ment. A good grade of transformer oil should show very little evaporation at
100oC, and it should not give off gases at such a rate as to produce an explosive
mixture with the surrounding air at a temperature below 180 oC. It should not contain
moisture, acid, alkali, or sulfur compounds.

It has been shown that the deteriorating effect of moisture on the insu-lating
qualities of an oil is very marked; moisture to the extent of 0.06 percent reduces the
dielectric strength of the oil to about 50 percent of the value when it is free from
moisture, but there is very little further decrease in the dielectric strength with an
increase in the amount of moisture in the oil.

Dry oil will stand an emf of 25,000 V between two 0.5-in (12.7-mm) knobs
separated by 0.15 in (3.8 mm). The presence of moisture can be detected by thrusting
a red-hot nail in the oil; if the oil “crackles,” water is present. Moisture can be
removed by raising the temperature slightly above the boiling point of water, but the
time consumed (several days) is excessive. The oil is subsequently passed through a
dry-sand filter to remove any traces of lime or other foreign materials.

OIL PRESERVATION SYSTEM

We use a conservator oil preservation system as a standard. Many publications have
stated the technical advantages of this system over both sealed tank and automatic
positive pressure oil preservation systems, these being:

1. high dielectric integrity,

2. positive static pressure on unit at all times,
3. reduced maintenance,
4. possibility to use a buchholz relay & to collect gasses

The conservator oil preservation system uses an expansion tank to and from which
the transformer oil may flow freely as it expands or contracts due to oil temperature
changes. This system always provides a head of oil above the main tank and keeps it
completely filled. An oil level gauge is mounted on the conservator and indicates the
change in liquid level.
Due to the heating of the oil in the transformer, oil expands and flows freely towards
28
the conservator. The oil expansion of the On-Load Tap Changer diverter is
completely separate from the transformer oil. A separate compartment is mounted to
the main conservator. Both conservator compartments are equipped with an oil level
gauge with a minimum alarm contact, pipes for oil draining, air inlet from the
breather and connection to the transformer or OLTC. The oil level gauge is tilted
downwards for the ease of reading when standing at the base of the transformer. The
breather is filled with silica gel (Caldigel Orange) that removes all moisture and dust
particles from the air that is inhaled by the conservator. To reduce maintenance and
to save the environment, the standard silica gel breather can be replaced by an
automatic breather with repetitive heating cycle on request.

Atmoseal

The main conservator can be fitted with a nitrile membrane to avoid all
contact of ambient air with the transformer oil. This eliminates the possibility of
moisture entering the transformer oil and oxidation of the oil in the conservator. On
request, a leakage detector can be mounted on the conservator to signal a rupture of
the membrane. A nitrile membrane in the load tap changer compartment is not
possible due to the gasses produced at each tap change operation. For the same
reason, a buchholz relay cannot be fitted on the load tap changer compartment; a
special protective relay is designed for this purpose with an oil-surge sensitive
damper system that cannot be tested with gas pressure or a spring operated pressure
relay

29
 COOLING OF TRANSFORMER

The oil-filled tank often has radiators through which the oil circulates by natural
convection. Some large transformers employ electric-operated fans or pumps for
forced-air or forced-oil cooling or heat exchanger-based water-cooling. Oil-filled
transformers undergo prolonged drying processes to ensure that the transformer is
completely free of water vapor before the cooling oil is introduced. This helps
30
prevent electrical breakdown under load. Oil-filled transformers may be equipped
with Buchholz relays, which detect gas evolved during internal arcing and rapidly
de-energize the transformer to avert catastrophic failure. Oil-filled transformers may
fail, rupture, and burn, causing power outages and losses. Installations of oil-filled
transformers usually includes fire protection measures such as walls, oil
containment, and fire-suppression sprinkler systems.
Polychlorinated biphenyls have properties that once favored their use as a dielectic
coolant, though concerns over their environmental persistence led to a widespread
ban on their use. Today, non-toxic, stable silicone-based oils, or fluorinated
hydrocarbons may be used where the expense of a fire-resistant liquid offsets
additional building cost for a transformer vault.Before 1977, even transformers that
were nominally filled only with mineral oils may also have been contaminated with
polychlorinated biphenyls at 10-20 ppm. Since mineral oil and PCB fluid mix,
maintenance equipment used for both PCB and oil-filled transformers could carry
over small amounts of PCB, contaminating oil-filled transformers.
Some "dry" transformers (containing no liquid) are enclosed in sealed, pressurized
tanks and cooled by nitrogen or sulfur hexafluoride gas.
Experimental power transformers in the 2 MVA range have been built
with superconducting windings which eliminates the copper losses, but not the core
steel loss. These are cooled by liquid nitrogen orhelium
Though it is not uncommon for oil-filled transformers to have today been in
operation for over fifty years high temperature damages winding insulation, the
accepted rule of thumb being that transformer life expectancy is halved for every 8
degree C increase in operating temperature. At the lower end of the power rating
range, dry and liquid-immersed transformers are often self-cooled by natural
convection and radiation heat dissipation. As power ratings increase, transformers
are often cooled by such other means as forced-air cooling, force-oil cooling, water-
cooling, or a combinations of these. The dielectic coolant used in many outdoor
utility and industrial service transformers is transformer oil that both cools and
insulates the windings. Transformer oil is a highly refined mineral oil that inherently
helps thermally stabilize winding conductor insulation, typically paper, within
acceptable insulation temperature rating limitations. However, the heat removal
problem is central to all electrical apparatus such that in the case of high value
transfomer assets, this often translates in a need to monitor, model, forecast and
manage oil and winding conductor insulation temperature conditions under varying,
possibly difficult, power loading conditions. Indoor liquid-filled transformers are
required by building regulations in many jurisdictions to either use a non-flammable
liquid or to be located in fire-resistant rooms. Air-cooled dry transformers are
preferred for indoor applications even at capacity ratings where oil-cooled
construction would be more economical, because their cost is offset by the reduced
building construction cost.

31
 INSULATION DRYING

Construction of oil-filled transformers requires that the insulation covering

the windings be thoroughly dried before the oil is introduced. There are several
different methods of drying. Common for all is that they are carried out in vacuum
environment. The vacuum makes it difficult to transfer energy (heat) to the
insulation. For this there are several different methods. The traditional drying is done
by circulating hot air over the active part and cycle this with periods of hot-air
vacuum (HAV) drying. More common for larger transformers is to use evaporated
solvent which condenses on the colder active part. The benefit is that the entire
process can be carried out at lower pressure and without influence of added oxygen.
This process is commonly called vapour-phase drying (VPD).
For distribution transformers, which are smaller and have a smaller insulation
weight, resistance heating can be used. This is a method where current is injected in
the windings to heat the insulation. The benefit is that the heating can be controlled
very well and it is energy efficient. The method is called low-frequency heating
(LFH) since the current is injected at a much lower frequency than the nominal of
the grid, which is normally 50 or 60 Hz. A lower frequency reduces the effect of the
inductance in the transformer, so the voltage needed to induce the current can be
reduced. The LFH drying method is also used for service of older transformers.

TERMINALS
Very small transformers will have wire leads connected directly to the ends
of the coils, and brought out to the base of the unit for circuit connections. Larger
transformers may have heavy bolted terminals, bus bars or high-voltage
insulated bushings made of polymers or porcelain. A large bushing can be a complex
structure since it must provide careful control of the electric field gradient without
letting the transformer leak oil.
BUSHINGS

32
 A bushing is a hollow electrical insulator through which a conductor may
pass. Bushings are used where high voltage lines must pass through a wall or other
surface, on switchgear, transformers, circuit breakers and other high voltage
equipment.
DISCRIPTION
The bushing is a hollow insulating liner that fits through a hole in a wall or
metal case, allowing a conductor to pass along its centre and connect at both ends to
other equipment. The purpose of the bushing is to keep the conductor insulated from
the surface it is passing through. Bushings are often made of wet-process fired
porcelain, and may be coated with a semi-conducting glaze to assist in equalizing the
electrical stress along the length of the bushing.
The inside of the bushing may contain paper insulation and the bushing is
often filled with oil to provide additional insulation. Bushings for medium-voltage
and low-voltage apparatus may be made of resins reinforced with paper. The use
of polymer bushings for high voltage applications is becoming more common. The
largest high-voltage bushings made are usually associated with high-voltage direct-
current converters.

Capacitor types
Some of the higher voltage types (layers of conductive paper, film, ink or
aluminum foil are used with an insulating medium) are called capacitor bushings
because they form a low value capacitor between the conductor and the wall. This is
done to disperse the electrical field stress and thus reduce the peak stress that could
cause breakdown.

BUSHING FAILURE

33
 Bushings sometimes fail due to partial discharge degradation in the
insulation. There is at present great interest in the electricity supply industry in
monitoring the condition of high voltage bushings.

METHODS OF MOUNTING

Transformers are constructed with different types of metal enclosing

structures to meet the requirements of different conditions of installation. One type
of enclosure is designed for mounting on poles, either directly or with hanger irons,
for use in overhead distribution work. Another type of enclosure, called the platform
type, is suitable for installations in which the transformer stands upon its own base. It
can be mounted on any flat horizontal surface having sufficient mechanical strength,
such as a floor or a platform between poles. Subway transformers have watertight
tanks which are designed primarily for underground installa-tions when the
transformer may be completely submerged in water. Vault transformers also have
watertight enclosures so that they will not be injured by total submersion, but they
are not designed to operate satisfactorily under such conditions. The vault
transformers are intended for operation in underground vaults in which the
transformer would not be required to operate for any considerable length of time
while submerged. Small transform-ers for power and special application are
designed with special types of mounting to meet the requirements of installation for
these types of service.

APPLICATIONS

34
 electrical substation showing 220kV/66kV transformers, each with a capacity of 185MVA

A major application of transformers is to increase voltage before transmitting

electrical energy over long distances through wires. Wires have resistance and so
dissipate electrical energy at a rate proportional to the square of the current through
the wire. By transforming electrical power to a high-voltage (and therefore low-
current) form for transmission and back again afterward, transformers enable
economical transmission of power over long distances. Consequently, transformers
have shaped the electricity supply industry, permitting generation to be located
remotely from points of demand. All but a tiny fraction of the world's electrical
power has passed through a series of transformers by the time it reaches the
consumer.
Transformers are also used extensively in electronic products to step down the
supply voltage to a level suitable for the low voltage circuits they contain. The
transformer also electrically isolates the end user from contact with the supply
voltage.
Signal and audio transformers are used to couple stages of amplifiers and to match
devices such as microphones and record players to the input of amplifiers. Audio
transformers allowed telephone circuits to carry on a two-way conversation over a
single pair of wires. A balun transformer converts a signal that is referenced to
ground to a signal that has balanced voltages to ground, such as between external
cables and internal circuits.
The principle of open-circuit (unloaded) transformer is widely used for
characterisation of soft magnetic materials, for example in the internationally
standardized Epstein frame method.

MANUFACTURING SECTIONS

35
INVENTORY

It is the section of storage of raw material.

FABRICATION

Fabrication is nothing but production.It is basically a machine / preparation shop.

This section has following machines:

 Pacific Hydraulic Shear & pressure: Hydraulically operated

machine to cut to sheet of different thickness. It contain pressure
holder which is used to flatten the sheet.
 CNC (Computerized Numerical control) Flame cutting
machine: Used to cut complicated shaft item using OXY-
ACETYLENE flame. Maximum 6 torches are used in it. Cutting is
done on the basis of computer programming.
 Rolling Machine: used for making cylindrical shape from a
sheet.
 Bending Machine: Hydraulically operated machine used to
bend the job.
 Hydraulic power press: Has the capacity of 100 tons used to
flatten the object.
 Nibbling Machine: used to do various tasks like straight
cutting, circle cutting, nibbling, slot cutting, circular and square
punching.
 Hydraulic Guillotine Shear: It is to cut the sheet which has
maximum cross section area of (3200*13 sq.mm).
 Butler machine: used for facing, tapering, & slot cutting.
 Plasma Cutting Machine: used for non ferrous metal.

ASSEMBLY SHOP:

It is an assembly shop where different part of tank comes . Hear welding

processes are used for assembly, after which a rough surface is obtained and is
eliminated by grinding. Grinding operates at 1200 RPM.
It is assembly shop dealing with making different objects like.

 Tank Assembly
 Tank cover assembly
 End frame assembly
 Cross feed assembly
 Core Clamp assembly
36
 Pin & pad assembly

Before assembly, short blasting is done on different part of jobs to clean the surface
before painting.
After assembly some tests are done as non-destructive tests like.

1. Ultrasonic Test: To detect the winding fault on CRO. At the

fault place high amplitude waves are obtain.
2. Die Penetration Test: Red solution is put at the welding and
then cleaned. After some time white solution is put. Appearance of
red spot indicates a fault at the welding.
3. Magnetic crack detection: magnetic field is created and then
iron powder is put on the welding. Sticking of the iron powder in the
welding indicates the fault.
4. X-Ray Test: It is same as human testing and a fault is seen in
X-ray.
5. Air / Vacuum Test: the air is filled inside the body of
transformer, than soap solution is produced outside the body. If the
holes appear, it is indicate the fault.

MACHINE SECTION:

To operation to form small components of power and traction transformer are

done is this section. The shop consists of following machines.

 CENTRAL LATHE: It consist one tail stock, head stock.

Lower part of tail stock is fixed and tail stock spindle is moving. On
this machine is facing, turning and threading is done.

 TURRET LATHE: Its function is same as central lathe

machine but it is used for mass production. Here turret head is used in
presence of tail stock because turret head contains many tailstocks
around six.

 CAPSTAN LATHE: It is belt driven.

 RADIAL ARM DRILLING MACHINE: Used for drilling

and boring.

 HORIZONTAL BORING MACHINE: It is computerized

and used for making bore, facing etc.

 MILLING MACHINE:

37
 a. HORIZONTAL MILLING MACHINE: Used for
making gear and cutting operations.

b. VERTICAL MILLING MACHINE: The machine

does facing, slot cutting and T-slot cutting.

COPPER SECTION:

o Tube slitting Machine: used for cutting the tube along its
length and across the diameter.
o HYDRAULIC SHEARING MACHINE: It is hydraulically
operated and its blade has V-shape and a thickness 15 mm.
o WATER COOLED BRAZING MACHINE: It contains two
carbon brushes. The sheet is put along with sulfas sheet and the
carbon brushes are heated. A lap joint is formed between the sheets as
the sulfas sheets melts.
o LINCING BELT MACHINE: It creates a smooth surface.
o SOLDER POT MACHINE: It has a pot that contains solder.
Solder has composition of 60 % Zn and 40 % Pb.

TOOLING MACHING:

In this section the servicing of tools is done.

 Blade sharp machine

 Mini surface grinding Machine(used for grinding purpose)
 Tool and surface grinding Machine(used to grind the tool)
 Drill grinding Machine (to grid the drills)

WINDING , COIL AND MOULDS SECTION

TYPES OF WINDING
 Reverse section winding
 Helical winding
 Spiral winding
 Interleaved winding
 Half section winding

The type of winding depends upon the job requirement. Also, the width and
thickness of conductors designed and decided by design department.

TYPES OF COIL

38
1. Low voltage coil
2. High voltage coil
3. Tertiary coil
4. Tap coil

THE MOULDS ARE OF FOLLING TYPES

1. Belly type
2. Link type
3. Cone type

LAMINATION AND PUNCHING SHOP

The lamination used in power, dry and 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 and Germany. It is available
in 0.27&0.28 mm.
For the purpose of cutting and punching the core three machines are installed
in the shop.
 Slitting machine (used to cut CRGO sheets in different width)
 CNC cropping line pneumatic
 CNC cropping line hydraulic

INSULATION SHOP

Various type of insulation are:

 AWWW: all wood water washed press paper. The paper is 0.2-0.5
mm thick cellulose paper is bound on conductor for insulation.
 Pre-Compressed Board: this is widely used for general
insulation and separation of conductors in the form of blocks.
 Press Board: this is used for separation of coil e.g. LV from HV. It is
up to 38 mm thick.
 Fiber Glass: this is resin material and is used in fire prone area.
 Bakelite
 Gasket: used for protection against leakage.
 Silicon Rubber Sheet: It is used for dry type transformer.

Insulation between windings

The great majority of transformers are constructed with two or more

39
windings which are electrically insulated from each other. In some cases a single
winding is employed, parts of the winding functioning as both primary and
secondary. These transformers are called autotransformers. They are frequently used
when the voltage ratio is small. Autotransformers should never be used for high
voltage ratios, as the low-voltage winding is not insulated from the high-voltage one,
so that in case of trouble it would be dangerous to both life and equipment.

Machine used for shaping the insulation material are:

1. Cylindrical machine
2. Circular cutting machine
3. Bending machine
4. Punching press machine
5. Drilling machine
6. Guillotine machine
7. Bench saw
8. Jig saw
9. Circular saw
10. Lansing machine

MANUFACTURING PROCESS

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 CORE ASSEMBLY

 Power Systems transformers are of the “Core Form” design. All cores are
stacked, using high-quality grain-oriented silicon steel laminations, purchased
slit-to-width and coated with carlite to increase the interlamination resistance and
to reduce eddy current losses. Where loss evaluations justify its use, laser or
mechanically scribed or plasma treated silicon steel will be used.

 All cores utilize the step lap principle in the corner joints to reduce losses,
magnetizing current and sound level. The cores are fully-mitered on all joints in
order to improve the flux distribution.

 Ultra modern computerized core shears supply fully-mitered, high-efficiency

cores. These machines are able to shear the maximum width of core steel
currently available.

 Some machines automatically stack the legs and yokes to minimize steel
handling and mechanical stresses, helping to guarantee the designed loss level.

 The laminations are stacked in steps, resulting in a circular core shape which
gives the windings optimum radial support, especially during short-circuit
conditions.

 The exposed edges of all finished cores are bonded with low viscosity, high-
strength epoxy resin on the legs and bottom yoke to help lower the sound level.
The temperature rise of the core is designed to be low and is controlled, if neces-
sary, by careful placement of vertical oil ducts within the core packets.

 The core is clamped using structural steel clamps which provide high
strength under both static (lifting and clamping) and dynamic (short-circuit)
mechanical loads. The clamps are very lightweight for their strength and provide
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 a smooth surface facing the winding ends, eliminating regions of high local
electrical stress.

Under this process bonded core design is used to eliminate hold notching clamp and
to minimize fixed losses and magnetizing current. The clamping frames for top and
bottom yokes are incorporated into the still age but this must also provide support
rigidity for the limbs until the core has been lifted in the vertical positions for
assembling of the winding.

 COIL WINDINGS AND INSULATION ASSEMBLE

Coil windings is of two Types:

The precise details of the winding arrangements will be varied according to the
rating of the transformers. The general principles remain the same throughout most
the range of transformer. The copper or Alluminium strips/wires used in winding are
meticulously selected for its quality to give the best output.

1. L.V.Coil
2. H. V. Coil

1. L. V. COIL WINDING:

The Low Voltage coil is designed to approximately match the current rating of the
available low-voltage (LV). The L.V. coil is normally wound on robust tube of
insulation material and this is almost invariably of synthetic resin-bonded paper. This
material has high mechanical strength and is capable of withstanding the high
loading. Electrically it will probably have sufficient dielectric strength to withstand
the relatively modest test voltage applied to the L.V. winding during the repairing
without any additional insulation.

2. H. V. COIL COIL WINDING:

The second process is H.V. Coil Winding, which are wound with strip conductor and
it usually consists of continuous disc type. The coils are usually created in layers and
ideally all the joints are extremely well brazen and insulated in order to withstand
difficult service conditions and tests.

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 The LV windings are made from Paper covered Copper Strip and placed
nearest to the core. The HV winding are wound with Super Enamelled Copper Wire
or Alluminium wire or Paper covered Round wire or paper covered Strip depending
upon the reting of the transformers. The cross section of the conductor is also chosen
to keep the thermal gradiet in the winding to a minium and thus increase the life of
transformer.

The coils are assembled with the best insulating material avail and they are
adequately clamped by the use of permawood rings where necessary to give required
mechanical strength.

The tappings are provided o the external HV windings. The off circuit tapping swich
is gang operated type and good contact is maintained by means of floating spring
pressure. Teh tapping swich can be looked in ay desired position. The transformer
preferably off capacity 2000 KVA and above can be supplied with on load tap
changer alongwith the desired controls as per the requirement.

 CORE AND COIL ASSEMBLY

A part of the transformer manufacturing process, the core and coil assembly aspect
plays a significant role where the core assembly is vertically placed where the foot
plate touches the ground and the top yoke is removed. The limbs of the core are
tightly wrapped with cotton tape and then varnished during the manufacturing and
even repairing process.

 First, the individual windings are assembled one over the other to form the
entire phase assembly.
 The radial gaps between the windings are subdivided by means of
solid transformer board barriers.
 Stress rings and angle rings are placed on top and bottom of the
windings to achieve a contoured end insulation design for optimal control of the
oil gaps and creepage stresses.
 The complete phase assemblies are then carefully lowered over the
separate core legs and solidly packed towards the core to assure optimal short
circuit capability.
 The top core yoke is then repacked and the complete core and coil
assembly is clamped.

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  The lead exits (if applicable) and the lead supports and beams are
installed. All winding connections and tap lead connections to the tap changer(s)
are made before drying the complete core and coil assembly in the vapor phase
oven.

 PROCESSING OF CORE AND COIL ASSEMBLY

The completed core and coil assembly is thoroughly dried to pre-determined power
factor readings by the vapor phase drying process , providing the fastest, most
efficient and most effective drying of the transformer insulation available. The vapor
phase process uses the standard kerosene cycle method. In this system, kerosene is
vaporized and drawn by vacuum into a heated autoclave where the transformer has
been placed. Condensation of the vapor on the core and coil assembly rapidly causes
the temperature to rise and allows moisture to be drawn out of the insulation by the
vacuum. High temperature and pressure are used to accelerate the drying process.

When the power factor measurements and the removal rate of moisture have reached
the required levels, the flow of kerosene vapor is stopped and a high vacuum is used
to boil off the remaining moisture and kerosene. Because so much water is removed
in this process, the insulation physically shrinks in size. Following removal from the
autoclave, the transformer is repacked as required and then undergoes its final
hydraulic clamping to ensure maximum short-circuit strength in the finished product

 TAP CHANGING

Power Systems transformers can be equipped with either a de-energised tap changer
or a load tap changer or with both.Should load tap changing be required, BHEL can
provide a resistive bridging type or reactor type LTC. Both types offer up to 500,000
operations between contact replacement and substantially reduce maintenance
intervals.

The LTC can be installed in the transformer tank with the diverter switch in its own
oil compartment, so that no contamination of the transformer oil occurs due to arcing
during switching, or can be mounted on the main tank.

To prevent voltage surges on the tap changer during switching MOV surge sup-
pressors can be installed.

 DRYING OUT PROCESS

In order to ensure power supply is completely reliable it depends on high

performance transformers and in order to achieve that the drying out process is

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extremely important. Under this process, the paper insulation and pressboard
material, which make up a significant proportion by volume of transformer winding,
have the capacity to absorb large amounts of moisture from atmosphere. The
presence of this moisture brings about the reduction in the dielectric strength of the
material and also an increase in its noise.

 TANK FABRICATION AND FITTINGS

The tanks are made of high quality steel and can withstand vacuum and pressure test
as specified in IS as well as by the customers. All welds are checked ensuring 100 %
leak proof seems and mechanical strength. All tanks are pressure tested before
tanking the active part.

The Pressed steel radiators are used to dissipate heat generated at rated load. The fin
height and length are calculated according to the rating of transformers as well as
customers' specifications. The fins can be plain or embossed. The radiators are fitted
variably according to the rating of transformer. For smaller rating radiators are
directed welded to the main tank while for higher rating detachable type radiators are
provided with valves to facilitate during transportation and handling at site.

The tanks are fabricated from MS plates and is weldwd construction. They are tested
at a pressure of 0.35 Kg./Sq. cm. for oil leakage output and they are normally welded
directly to the tank. How ever, transformers, can be supplied with detachable
radiators.

 TANKING

After vaccum drying process the active part is removed from the Oven and all
components subject to the shrinkage are tightened again. The core & coil assembly is
then placed into the tank and properly lacked up during the transformer
manufacturing process. The temperature and exposure time is monitored during this
time to ensure that the transformer is not too cool by the time it is get off from the
oven. While in higher rating transformer, the vacuum is drawn for a period of time
dependent on the voltage of the unit and time for which the active part was exposed
to the atmosphere and the humidity at the time. The vacuum period is between 12 to
35 hours. Meanwhile the external wiring and termination work to be completed as
per customer requirements.

 PAINTING

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The outside surface of tank including all fittings and accessories are cleaned
properly. Necessary chipping and grinding applied for smooth surface and finishing.
After cleaning of the tank, one coat of hoi oil resistance pint is applied on the
internal surface of the tank during the transformer manufacturing process. The
outside surface is painted with one coat of Red Oxide Primer and subsequently one
coat of enamel paint as per customer's requirement.

The transformers are fitted with Bare Porcelain Bushings and metal parts
conforming to IS specification 3347 "Dimension for Procelain transformer
Bushings." The electricals characteristics of the bushings conform to IS 2099
"Specification for High Voltage Porcelain Bushings". Alternatively transformers are
supplied, fitted with Cable Box either with Wiping type of glands suitable for
PVC/XLP cables.

Paintings :

The inside of the transformer tank and frame parts are given a coating of Oil and
heat resistance paint. The transformer is given an external anticorrosive primer coat
and two fiising coats usually of admirally grey.

 TESTING

The testing room is climatically controlled and is fully equipped with facilities for
conducting all routine tests and temperature- rise tests. The transformers are tested at
various stages of manufacture and various rating transformers are tested at
independent institution to establish short circuit and insulating capacity of the
transformers and also the impluse withstanding withstanding capacity.

Prior to shipment, all transformers manufactured BHEL are tested in accordance

with the latest applicable standards according to customer specifications. All

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industry standard and optional tests with the exception of short-circuit tests, can be
performed in-house by trained personnel using accurate and modern test equipment.

 Impulse Testing

A state-of-the-art digital impulse recording system, the Haefely HIAS system,

provides the most accurate analysis of impulse results available today. Electronic
recording of the impulse current and voltage waveforms allows quick mathematical
comparisons to be made, including the difference between the two waveforms under
scrutiny. Accurate printed and plotted final results are quickly available. If required,
photographic transparencies from the impulse oscilloscope can be supplied.

The construction of the test area incorporates a complete copper mesh ground mat
system, with extensive grounding points provided. This eliminates high impedance
grounds and provides exceptionally clean test records. The impulse generator is rated
at 200 kV per stage for a total of 2.8 MV, with 210 kJ total stored energy. For precise
triggering, this generator is equipped with a pressurized polytrigatron gap in each
stage. For chopped wave tests, a Haefely multiple chopping gap is used. Our plants
are fully capable of performing lightning impulse, switching impulse and front-of-
wave tests as required.

 Induced Testing

For induced testing, a variable voltage alternator, rated 1500/1000 kVA, 3/1-phase,
170/240 Hz, is used. Voltage control is by solid state automatic voltage regulator,
and solid state speed control of the 1000 kW DC driving motor. During the induced
test, partial discharge measurements both in pC and μV are taken and equipment is
available to locate internal partial discharges by the triangulation method.

 Loss Measurement

Power is provided to the loss measuring system by a 5/10 MVA regulating trans-
former feeding three single-phase 10 MVA variable ratio transformers and a 110
MVAR capacitor bank. Losses are measured by an automated system using CTs for
current and gas capacitors for voltage. This system has a fully automated digital
readout and printer.

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 AC Testing

A test supply with an output voltage infinitely adjustable from 3-350 kV is available
for high voltage AC testing. To measure the applied voltage level, a digital peak-
responding RMS calibrated voltmeter capable of measuring up to 1600 kV is used.

 Short-circuit testing

 SHIPING AND INSTALLATION

 Depending on transportation considerations, BHEL Power Systems

transformers may be shipped either with or without bushings, radiators, fans,
conservator and oil.

 BHEL experience in delivering power transformers to over countries

throughout the world guarantees fast and reliable transportation.

 Installation of the transformer can either be done by the customer or by an

experienced BHEL Field Service Crew.

*****

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