A STUDY OF BOILER AUXILIARIES WORKING OPERATIONS AT

BHARAT HEAVY ELECTRICALS LIMITED (BHEL)

(A Government Of India Undertaking)
BOILER AUXILIARIES PLANT
Indira Gandhi Industrial Complex
Ranipet – 632 406

AN INTERNSHIP REPORT
SUBMITTED BY
MADESH S (312421105026)
In partial fulfilment for the award of the degree of
BACHELOR OF ENGINEERING IN
ELECTRICAL AND ELECTRONICS ENGINEERING
ST.JOSEPH’S INSTITUTE OF TECHNOLOGY
(An Autonomous Institution)
OMR CHENNAI – 119
JUNE 2024

UNDER THE GUIDANCE OF:

D.RAMKI
Senior Engineer /M&S
Off.&Maint.plng.6
B.H.E.L./ RANIPET

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 Acknowledgement

We would like to take this opportunity for thanking the almighty for inspiring us
with this internship and for allowing us to complete it successfully.

The contentment and elation that accompany the successful completion of any work
would be incomplete without mentioning the people who made it possible.

Words are inadequate in offering my sincere thanks and gratitude to our respected
and beloved Chairman Dr. B. Babu Manoharan M.A., M.B.A., Ph.D., our
respected Managing Director Mr. B. Sashi Sekar M.Sc., our
respected Executive Director Ms. S. Jessie Priya M.Com and our respected
principal Dr. P. Ravichandran M.Tech., Ph.D., for having encouraged me to do
my under graduation in Electrical and Electronics Engineering in this esteemed
college.
I also express my sincere thanks and most heartfelt sense of gratitude to our
eminent Head of the Department Dr. D. Kirubakaran M.E., Ph.D.
And also my heartful thanks to Mr.S.KARTHICK,Assistant Professor for the
encouragement in completing the internship.

We would like to thank Mr. D RAMKI (Senior Engineer ) for helping us to carry
out our Internship Successfully in BHEL Ranipet.

We would like to thank BHEL Management and Department Staff for their
friendliness and Helping Nature who helped us in successful completion of this
internship and clearing our doubts

We would like to thank our beloved parents for their immense support.

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 ABSTRACT

This paper presents an in-depth study of boiler auxiliaries and their operational mechanisms at Bharat
Heavy Electricals Limited (BHEL), a prominent player in the power generation sector. Boiler
auxiliaries are vital components that support the primary functions of boilers in thermal power plants,
significantly impacting their efficiency and reliability.

The study focuses on various types of boiler auxiliaries such as fans, pumps, air preheaters, and
feedwater heaters, elucidating their roles in the overall boiler operation. Fans are crucial for
maintaining proper air and gas flow within the boiler, essential for combustion efficiency. Pumps play a
pivotal role in circulating water and steam throughout the boiler system, ensuring effective heat transfer
and energy conversion. Air preheaters recover waste heat from flue gases to preheat combustion air,
improving thermal efficiency, while feedwater heaters enhance efficiency by using extracted steam to
heat feedwater before entering the boiler.

Technological advancements and operational strategies implemented at BHEL are also examined.
These include the adoption of advanced control systems, predictive maintenance techniques, and the
use of durable materials to enhance equipment performance and longevity. Such initiatives are crucial
for optimizing operational efficiency, reducing downtime, and improving overall plant reliability.

The paper further discusses the importance of proactive maintenance practices in ensuring continuous
operation and minimizing unplanned outages. By analyzing these aspects comprehensively, this study
aims to deepen understanding of boiler auxiliaries' critical role in power generation infrastructure. It
provides insights that can guide future developments in enhancing the efficiency and sustainability of
thermal power plants worldwide.

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 BHEL-BHARAT HEAVY ELECTRICALS LIMITED

INTRODUCTION:

Bharat heavy Electricals Limited (BHEL) is pioneer in power plant equipment

manufacturing with installed capacity of 20,000MW per year. The wide network of BHEL's 15
Manufacturing Divisions, 4 Power Sectors Regional Centers, 8 Service Centers, 15 Regional
Offices, 4 Offices abroad, 2 subsidiaries and over 150 project sites. In February 2014, it is
recognized as one of the 7 mega Public Sector Undertakings (PSUs) of India clubbed under the
esteemed "Maharatna" status. BHEL caters to core sectors of the Indian Economy viz., Power
Generation and Transmission, Industry, Transportation, Renewable Energy, Defence, etc.

HISTORY:

BHEL was established in 1964. Heavy Electrical (India) Ltd was merged with BHEL in 1974.
In 1982, it entered into power equipment's, to reduce its dependence on the power sector. It
developed the capability to produce a variety of electrical, electronic and mechanical equipment's
for all sectors, including transmission, transportation, oil and gas and other allied industries. In
1991, it was converted into a public limited company. By the end of 1996, the company had
handed over 100 Electric Locomotives to Indian Railway and installed 250 Hydro-sets across
India. As of June 2011, it had cumulatively installed generating capacity of over 8,500 MW
outside of India in 21 countries, including Malaysia, Iraq, UAE, Egypt and New Zealand.

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OPERATIONS:

It is engaged in the design, engineering, manufacture, construction, testing,

commissioning and servicing of a wide range of products and services for the core sectors of
Indian economy, viz. Power, Transmission, Industry, Transportation, Renewable Energy, Oil &
Gas and Defence. It has 15 manufacturing divisions, two repair units, four regional offices, eight
service centers, eight overseas offices and 15 regional centers and currently operates at more than
150 project sites across India and abroad. Most of its manufacturing units and other entities have
been accredited to Quality Management Systems (ISO 9001:2008), Environmental
Management Systems (ISO 14001:2004) and Occupational Health & Safety Management Systems
(OHSAS 18001:2007).

BHEL has a share of 59% in India's total installed generating capacity contributing 69%
(approx.) to the total power generated from utility sets (excluding non-conventional capacity) as
of March 31, 2012. The company has been exporting its power and industry segment products
and services for over 40 years. BHEL's global references are spread across 75 countries.

The cumulative overseas installed capacity of BHEL manufactured power plants that
exceeds 9,000 MW across 21 countries including Malaysia, Oman, Iraq, the UAE, Bhutan, Egypt
and New Zealand. Its physical exports range from turnkey projects to after sales services.
In June 2012, BHEL commissioned 250 MW power generating unit at Harduaganj in Uttar Pradesh.
This would add six million units of electricity on a daily basis.

SCENARIO OF BOILER AUXILIARIES PLANT (BAP)

Boiler Auxiliaries Plant, the 13th manufacturing unit if BHEL which was setup at Ranipet in
March-1980 as a part of the relocation of facilities from BHEL, Trichy. BAP is located in a 1400
acres site near Ranipet around 120 Kms from Chennai towards Bangalore.BHELRanipet is first
and only public sector and the first Engineering & Manufacturing organization to receive the
International Asia Pacific Quality Award.
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 The capacity of BAP (tonnage) is 57,000 tons/year. It stated its production activities by
manufacturing ESP (Electro Static Precipitators), APH (Air Pre-Heater) and FANS as its main
products. After a decade, new products like Heat Exchangers, Desalination Plants, Wind Electric
Generators and Damper for louvers were added to the product line. The units has also
manufactured fuel tanks for ISRO's SAT, INSAT and IRS P5 application. It has the capacity of
fabrication, machine and assemble launcher for TRISHUL Missiles.

BHEL is committed to Total Quality Management, in line with CII/EFQM guidelines and
improvement action plans are being implemented in BHEL., Ranipet using techniques like bench
marking, six sigma, Kaizen etc., The TQM efforts are aimed at improving quality of products,
customer focus, timely delivery, Technology and process up gradation on continuous basis. ISO-
9000 recertification was successfully completed for the second consecutive time and activities
are initiated for ISO-14000 certification.

GENERAL INFRASTRUCTURE OF BAP:

The manufacturing unit was established with the following facilities. The Production Shop
supported by Material Preparation Shop and a Fan Testing Station perform the manufacturing
activities. The Production Shop consists of 7 Bays. One Bay is allocated for Material Preparation
and one bay is allocated for Machines (F3 Bay) and these two are called feed Bays for the 5
assembly Bay A1, A2, A3, (Air Pre-heater Bays) F1 and F2. (Fan Bays) F3 Bay is the machine
shop, which is divided into light machine shop and heavy machine shop.

Office accommodation is provided in three main buildings namely Engineering Building, Shop
Office and Administrative Office. The P&A department, GM Secretariat, Purchase Department,
Account department and Ancillary department are accommodated in the administration Building.
The design, Engineering, Informatics Center, Marketing, Commercial departments are located in
the Engineering Building. The other buildings available house the R&D Laboratories (APH &
AQCS), 'HRDC, Time Office, Welfare, Erection Services, Stores Department, Maintenance and
services, Safety Engineering & Industrial Engineering department etc. An Oxygen plant,
acetylene plant and compressor plant along with a stores complex consisting of raw material
stores, inflammable stores are also available.

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 The main products of BAP, Ranipet are:

➤ Electrostatic precipitator (ESP)

➤ Air Pre Heater (APH)

➤Fans for Power and Industrial application

➤Gates and Dampers

➤Flue Gas Desulphurization (FGD)

➤ Ammonia Flue Gas Conditioning System (AFGCS)

➤Water Treatment System

➤Fabric Filters

BAP is a total solution provider in the domain of Power plant auxiliaries and water treatment systems.

INTERNSHIP:

BAP UNIT PRODUCTS

1. FANS

BHEL is India's largest manufacture of FANS, an important auxiliary, for Power and Industrial
applications for efficient combustion and improved, drought, BHEL offers a wide range of FANS
of axial impulse, axial reaction and radial types. The equipment supplied conforms to the latest
design and technological practices - derived from the technical collaboration with M/s.
KUHNLE, KOPP & KAUSCH of Frankethal Pfalz, Germany BHEL can also supply heavy duty
FANS for refineries, petrochemicals, steel, cement, fertilizer, palletizing and sinter plants and for
ventilation applications. FANS may be defined as rotating machines with bladed impeller, which
maintains a continuous flow of air or gas. In fans, blowers, compressors, pumps, etc., the energy
transfer occurs from the machine to the fluid. The may be classified as Arial flow fans and radial
flow fans.

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2. AIR PRE-HEATER

Air Pre-heater is auxiliary equipment for Steam boilers. It is a heat exchanger that absorbs heat
from exit flew gas in boiler and transfers the heat to the cold air. In utility and process boilers it
is used to heat the air required for combustion purpose and to dry and transport coal. Airpre
heater, a boiler auxiliary is used to reviver economically the millions of costly calories normally
lost up the stack and to put them back to work in the boiler or process equipment, thereby
increasing overall plant efficiency. In India more than 400 Air pre heaters manufactured by BHEL
are in service performing this vital function of energy conservation.

• Air pre heaters are used for reclaiming heat from the flue gases at lower temperature levels,
than is possible with economizer. By using air pre-heaters much lower gas exit
temperatures can be achieved, with consequent improved
boiler efficiencies due to reduction in heat rejected to the chimney for every 20 degree, drop in
flue gas exit temperature.

• The boiler efficiency increases by about 1%. Increases boiler efficiency.

• Stability of combustion is improved by use of hot air.

• Intensified and improved combustion.

• Permitting to burn poor quality coal.

• High heat transfer rate in the furnace and hence less heat transfers area requirement.

3. ELECTRO STATIC PRECIPITATOR

ESP is pollution control equipment, which filters and removes the dust particles from the flue gas
before releasing into the atmosphere. Electro static precipitation utilizes the forces acting on
electrically charged particles in the presence of an electric field to effect the separation of solid
or liquid particles from a gas steam. In the precipitation process dust suspended in the gas in
electrically charged and passed through an electric field where electrical forces because the
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 particles to migrate towards the collection surface the dust separated from the gas by retention
on the collection electrode and subsequently removed from the precipitator.

4. GATES AND DAMPERS

These are equipments in a thermal power plant for regulating the flow of air, steam and flue gas.
It is used to isolate different components (fans, APH etc) for the purpose of testing and
maintenance.

In chimney, a damper closes off the flue to keep the weather out and warm or cool air in. It may
also be partly closed to help control the rate of combustion. It is usually a handle on the vent duct
as in an air conditioning system.

Gates and dampers are mechanical devices used in various engineering and industrial applications to control
the flow of fluids (such as air, gas, or liquid) or to regulate the operation of systems.

1. Gates:
- Function: Gates are used to completely block or allow the flow of fluids through a passage. They operate
on a simple principle of movement (typically linear or rotational) to open or close a pathway.
- Types: Common types include slide gates, knife gates, and sluice gates, each designed for specific
applications like irrigation, water control, or industrial processes.
- Applications: Found in dams, water treatment plants, irrigation systems, and industrial piping systems
where precise control of fluid flow is necessary.

2. Dampers:
- Function: Dampers are used to control the flow rate or pressure of gases or air within ducts or chimneys
by modulating the cross-sectional area of the passage.
- Types: Common types include butterfly dampers, louvre dampers, and diverter dampers, each with
different mechanisms for adjusting airflow.
- Applications: Widely used in HVAC systems, industrial ventilation systems, and power plants to regulate
temperature, pressure, and airflow direction.

Both gates and dampers play crucial roles in ensuring efficient and safe operation of various systems by
allowing operators to adjust flow rates, pressure levels, and fluid directions as needed. Their design and
selection depend on factors such as the type of fluid, operating conditions, and specific requirements of the
application.
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TYPES OF MACHINES:

Old machines are machines that were made before the advent of computers. They were
typically operated by hand or with the use of mechanical controls. Old machines were often less
accurate and less efficient than modern machines.

Programmable logic controllers (PLCs) are digital devices that are used to control Industrial
machines. PLCs are typically used in applications where a high degree of accuracy and
repeatability is required. PLCs can be programmed to perform a wide variety of tasks, such as
controlling the movement of machine tools, monitoring and controlling process variables, and
sequencing operations.

Computer numerical control (CNC) machines are machines that are controlled by a computer.
CNC machines are used to machine a wide variety of materials, including metal, plastic, wood,
and composites. CNC machines are capable of performing a wide variety of operations, such
as milling, turning, drilling, and tapping. CNC machines are typically more accurate and
efficient than old machines or PLC-controlled machines.

In general, old machines are less accurate and efficient than PLCs and CNC machines. However,
old machines are often less expensive than PLCs and CNC machines. PLCs are a good choice
for applications where a high degree of accuracy and repeatability is required, but they are more
expensive than old machines. CNC machines are the most accurate and efficient type of
machine, but they are also the most expensive.

The choice of machine type will depend on the specific application. For example, if you need
to machine a complex part with a high degree of accuracy, a CNC machine is the best choice.
If you need to machine a simple part with a lower degree of accuracy, an old machine or a PLC-
controlled machine may be a better choice.

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 CNC MACHINE:

A CNC machine is a computer-controlled machine tool that uses numerical control (NC) to
perform operations on a workpiece. CNC machines are used in a wide variety of industries,
including manufacturing, aerospace, and automotive.

The basic parts of a CNC machine include:

• Input device: This is the means by which CNC programs are loaded into the machine. Input
devices can include a keyboard, a mouse, a joystick, or a touchscreen.

• Machine control unit (MCU): The MCU is the heart of the CNC machine. It is responsible for
reading the CNC program and translating it into instructions that can be executed by the
machine's actuators.

• Machine tools: The machine tools are the components that actually perform the machining
operations on the workpiece. These can include spindles, cutting tools, chucks, and vises.

• Driving system: The driving system provides the power and force necessary to move the machine
tools. This can be accomplished by using electric motors, hydraulic motors, or pneumatic motors.

• Feedback system: The feedback system monitors the position and speed of the machine tools.
This information is used by the MCU to ensure that the CNC program is executed accurately.

• Display unit: The display unit provides the operator with information about the

• CNC program and the machine's status. This information can include the current

• position of the tool, the spindle speed, and the feed rate.

• Bed: The bed is the main body of the CNC machine. It provides a stable platform for the machine
tools and the workpiece.

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• Headstock: The headstock is the part of the CNC machine that houses the spindle. The spindle is
the rotating axis that holds the cutting tool.

• Tailstock: The tailstock is an optional component of the CNC machine. It is used to support the
workpiece and to provide additional cutting force.

• Tool turret: The tool turret is a rotating platform that holds the cutting tools. The tool turret can
be indexed to select the desired cutting tool.

• Chuck: The chuck is a device that holds the workpiece. The chuck can be tightened to secure the
workpiece in place.

• Control panel: The control panel is the interface between the operator and the CNC machine. The
control panel allows the operator to load CNC programs, start and stop the machine, and adjust
the machine's settings.

In addition to these basic parts, CNC machines can also be equipped with a variety of other
features, such as:

• Automatic tool changer

• Coolant system

• Chip conveyor

• Tool presetter

• Machine vision system

These features can help to improve the productivity and accuracy of the CNC machine.

The basic operation of a CNC machine is as follows:

1. The operator loads a CNC program into the machine.

2. The MCU reads the CNC program and translates it into instructions.

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 3.The driving system moves the machine tools according to the instructions.

4. The feedback system monitors the position and speed of the machine tools.

5. The MCU compares the actual position and speed of the machine tools to the instructions in
the CNC program.

6. If there is a discrepancy, the MCU sends a correction signal to the driving system.

7. The process continues until the CNC program is complete.

CNC machines are highly versatile and can be used to machine a wide variety of materials,
including metal, plastic, wood, and composites. CNC machines are also capable of performing
a wide variety of operations, including milling, turning, drilling, and tapping..

If you are considering using a CNC machine, there are a few things you should keep in mind:

• The type of CNC machine you need will depend on the materials you will be machining and the
operations you will be performing.

• The cost of a CNC machine can vary widely, depending on the features and capabilities of the
machine.

• CNC machines require specialized training to operate.

If you are not sure whether a CNC machine is right for you, it is a good idea to consult with a CNC
machine expert.

Different types of CNC machines:

• CNC milling machine: Milling machines are used to remove material from a workpiece by
rotating a cutting tool. CNC milling machines can be used to create a wide variety of shapes and
features, such as slots, holes, and contours.

• CNC lathe: Lathes are used to turn a workpiece on an axis. CNC lathes can be used to create a
wide variety of shapes and features, such as cylindrical shapes, spheres, and cones.

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• CNC drilling machine: Drilling machines are used to create holes in a workpiece.

• CNC drilling machines can be used to create a variety of hole sizes and depths.

MOTOR CONTROL UNIT:

A motor control centre (MCC) is an assembly to control some or all electric motors in a central
location. It consists of multiple enclosed sections having a common power bus and with each
section containing a combination starter, which in turn consists of motor starter, fuses or circuit
breaker, and power disconnect. A motor control center can also include push buttons, indicator
lights, variable-frequency drives, programmable logic controllers, and metering equipment. It
may be combined with the electrical service entrance for the building.

MCC's are typically found in large commercial or industrial buildings where there are many
electric motors that need to be controlled from a central location, such as a mechanical room or
electrical room.

The main functions of a motor control centre are:

• To distribute power to the motors

• To protect the motors from overloads and other faults

• To control the operation of the motors

• To provide a central location for monitoring and troubleshooting the motors

MCC's are an important part of the electrical infrastructure in many commercial and industrial
buildings. They help to ensure the safe and reliable operation of the motors, which are essential
for many of the processes that take place in these buildings.

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TYPES OF MOTOR STARTER:

• Direct-on-line (DOL) starter is the simplest type of motor starter. It simply connects the
motor to the power line, allowing it to start up at full voltage. This type of starter is not
suitable for large motors, as it can cause a surge in current that can damage the motor.

• Reduced-voltage starter uses a resistor or reactor to reduce the voltage applied to the
motor at startup. This reduces the inrush current and helps to protect the motor.
Reduced-voltage starters are commonly used for large motors.

• Star-delta starter is a type of reduced-voltage starter that uses a star-delta connection to

reduce the voltage applied to the motor at startup. The motor is initially connected in a
star configuration, which reduces the voltage by a factor of 3. After the motor has started
up, it is switched to a delta configuration, which provides full voltage.

• Rotor resistance starter is a type of reduced-voltage starter that uses resistors connected
in series with the rotor windings of the motor. This reduces the current flowing through
the rotor windings, which reduces the starting torque. Rotor resistance starters are
commonly used for large motors that require a high starting torque.

• Autotransformer starter is a type of reduced-voltage starter that uses an

autotransformer to reduce the voltage applied to the motor at startup. The
autotransformer is a transformer with a variable tap changer, which allows the voltage
to be adjusted.

• Soft starter is a type of motor starter that uses electronic control to reduce the voltage
applied to the motor at startup. This type of starter provides smooth and controlled
acceleration, which helps to protect the motor and extend its life. Soft starters are
commonly used for all types of motors, including large motors.

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Power and Control of motor starter:

Direct online Starter:

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Forward and reverse Motor:

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Star delta starter:

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MAINTENANCE & SERVICES

SUBSTATION:

Substations are the transfer points for energy flows within the electrical grid. Each substation
contains transmission line termination points, as well as circuit breakers and bus bars that
interconnect the transmission lines with various circuits. Major substations also contain
transformers that reduce intertie transmission line voltages to network transmission levels. Each
substation contains metering equipment, protection relays, and that control the operation of the
connected generation, transmission, and distribution supplies.

BUSBAR:

A busbar is a metallic bar in a switchgear panel used to carry electric power from incoming feeders
and distributes to the outgoing feeders. In simple terms, busbar is a electrical junction where
incoming and outgoing currents exchange.

Types of busbar:

1. Main Busbar

2. Auxiliary Busbar

TRANSFORMER:

A transformer is a static device that transfers electrical energy from one electrical circuit to another
electrical circuit by means of a common magnetic circuit.

Types of Transformer:

Distribution transformer:

Substation distribution transformers have cover-mounted, primary and secondary bushings and
can be provided with load tap changers (LTC). They are generally connected directly to
overhead utility power lines.

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Current transformer:

Current transformers are used for protection, measurement and control in high- voltage electrical
substations and the electrical grid. Current transformers may be installed inside switchgear or in
apparatus bushings, but very often free-standing outdoor current transformers are used.

Potential transformer:

Potential transformer is a voltage step-down transformer which reduces the voltage of a high
voltage circuit to a lower level for the purpose of measurement. These are connected across or
parallel to the line which is to be monitored.

INSULATOR:

Insulators are essential to the safe and stable distribution of electricity generated at power plants.
The station post (SP) insulators found in power handling equipment at power plants and
substations support electric cables and other equipment, isolating them from the ground.

CIRCUIT BREAKER:

Circuit breakers are used to open and close circuits. They can be operated manually to perform
maintenance or will automatically trip if a short circuit occurs. This function in the power system
is similar to that of the fuses or breakers in a household distribution panel.

BATTERY:

A battery is a device that converts chemical energy into electrical energy. It consists of two or more
electrochemical cells that are connected together. Each cell contains two electrodes, called the
anode and the cathode. The electrodes are immersed in an electrolyte, a substance that conducts
electricity.

When the battery is connected to a load, electrons flow from the anode to the cathode through the
electrolyte. This flow of electrons creates an electric current.

Lead acid battery:

Lead acid batteries are the most common type of rechargeable battery. They are used in a wide
variety of applications, including cars, trucks, forklifts, and solar panels. Lead acid batteries work
by using the chemical reaction between lead and lead oxide. The lead is the negative electrode,
and the lead oxide is the positive electrode. The electrolyte is a solution of sulfuric acid and water.
When the battery is charging, the lead and lead oxide react with the sulfuric acid to produce lead

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sulphate. The lead sulphate is deposited on both electrodes. The water in the electrolyte is also
split into hydrogen and oxygen gases. When the battery is discharging, the lead sulphate on the
electrodes is reversed back into lead and lead oxide. The hydrogen and oxygen gases recombine
to form water. The lead acid battery is a reversible electrochemical cell. This means that it can be
used to store energy (when charging) or to release energy (when discharging). Here is a more
detailed explanation of the lead acid battery's working principle: The lead acid battery consists of
two lead plates, immersed in a solution of sulfuric acid and water. The plates are connected to each
other by a metal rod.

The lead acid battery works by the following chemical reactions:

Charging:

At the positive electrode, lead oxide (PbO2) reacts with sulfuric acid (H2SO4) to form lead sulfate
(PbSO4) and water (H2O):

PbO2+4H++2SO4^2- PbSO4+2H2O

At the negative electrode, lead (Pb) reacts with sulfuric acid (H2SO4) to form lead sulfate (PbSO4)
and hydrogen gas (H2)

Pb+SO4^2---→PbSO4 + H2

Discharging:

At the positive electrode, lead sulphate (PbSO4) reacts with water (H2O) to form lead oxide
(PbO2) and sulfuric acid (H2SO4):

PbSO4+4H2O→PbO2+4H++2SO4^2-

At the negative electrode, lead sulphate (PbSO4) reacts with hydrogen gas (H2) to form lead (Pb)
and sulfuric acid (H2SO4):

PbSO4+H2-→Pb + H2SO4

As the battery discharges, the lead sulphate on the plates builds up. When the battery is fully
discharged, all of the lead oxide on the positive electrode has been converted to lead sulphate.

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To recharge the battery, an external source of electricity is applied to the electrodes. This reverses
the chemical reactions that occur during discharge.

The lead acid battery is a relatively inexpensive and reliable type of battery. However, it has a
limited lifespan and requires regular maintenance.

ENGINE:

The term engine is often used interchangeably with motor. In reality, an engine converts energy
into motion, while a motor is a specific type of engine that converts electrical energy into
motion.

An engine is a machine that converts one form of energy into mechanical energy. The most
common type of engine is the internal combustion engine, which converts the chemical energy
of fuel into mechanical energy. Other types of engines include steam engines, diesel engines,
and electric motors.

Working of engine:

1. The driver turns the ignition key.

2. This sends a signal to the starter solenoid.

3. The starter solenoid engages, which allows current to flow from the battery to the starter
motor.

4. The starter motor turns the crankshaft.

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 5. The crankshaft turns the pistons, which compress the air-fuel mixture in the cylinders.
6. The spark plugs ignite the air-fuel mixture, which creates an explosion.

7. The explosion forces the pistons down, which turns the crankshaft further.

8. The crankshaft continues to turn, which causes the engine to run.

Here is a more detailed explanation of the steps involved in starting an engine.

1. Turning the ignition key: When the driver turns the ignition key, it sends a signal to the starter
solenoid. The starter solenoid is a switch that allows current to flow from the battery to the
starter motor.

2. Engaging the starter solenoid: When the starter solenoid is engaged, it allows current to flow
from the battery to the starter motor. The starter motor is an electric motor that turns the
crankshaft.

3. Turning the crankshaft: The starter motor turns the crankshaft, which turns the pistons. The
pistons are connected to the crankshaft by connecting rods.

4. Compressing the air-fuel mixture: When the pistons are turned, they compress the air-fuel
mixture in the cylinders. The air-fuel mixture is a mixture of air and fuel that is ignited by the
spark plugs.

5. Ignition of the air-fuel mixture: When the spark plugs ignite the air-fuel mixture, it creates an
explosion. The explosion forces the pistons down, which turns the crankshaft further.

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6. Continuing to turn the crankshaft: The crankshaft continues to turn, which causes the engine to
run. The engine will continue to run as long as there is fuel and spark.

The engine will stop running if the fuel runs out or if the spark is not generated. The engine may
also stop running if the starter motor fails, or if the battery is too weak to turn the crankshaft.

Here are some additional things to keep in mind about starting an engine:

• The battery must be in good condition in order to start the engine.

• The fuel system must be working properly in order to provide fuel to the engine.

• The spark plugs must be working properly in order to ignite the air-fuel mixture.

• The engine must be properly tuned in order to run efficiently.

INSTRUMENTATION:

• Instrumentation is the science of measuring physical quantities. It involves the use of

instruments to measure a variety of quantities, such as temperature, pressure, force, and
current. Instruments can be used to measure both static and dynamic quantities. Static
quantities are those that do not change over time, such as the temperature of a room.
Dynamic quantities are those that change over time, such as the current in an electrical
circuit.

• There are many different types of instruments, each designed to measure a specific
quantity. Some common types of instruments include thermometers, pressure gauges,
voltmeters, and ammeters. Instruments can be classified into two main categories:
analog and digital. Analog instruments display the measured quantity on a scale, such
as a thermometer or a pressure gauge. Digital instruments display the measured quantity
in a numerical format, such as a voltmeter or an ammeter.

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 CALIBRATION:

• Calibration is the process of ensuring that an instrument is accurate. It is important to

calibrate instruments regularly, as they can drift over time. Calibration involves
comparing the output of the instrument to a known standard. This can be done by using
a reference instrument or by using a standard sample.

• There are two main types of calibration: primary and secondary. Primary calibration is
the most accurate type of calibration. It involves comparing the output of the instrument
to a standard that is traceable to a national metrology institute. Secondary calibration is
less accurate than primary calibration. It involves comparing the output of the
instrument to a standard that is not traceable to a national metrology institute.
• Calibration is an important part of ensuring the accuracy of measurements. It is used in
a wide variety of fields, such as manufacturing, healthcare, and research.

Calibrating a Thermocouple:

1. Assemble the calibration equipment. You will need a thermocouple, a reference

thermocouple, a digital multimeter, and a heat source.

2. Connect the thermocouples to the multimeter. The negative lead of the reference
thermocouple should be connected to the negative lead of the multimeter, and the
positive lead of the reference thermocouple should be connected to the positive
lead of the multimeter. The negative lead of the thermocouple to be calibrated
should be connected to the COM port of the multimeter, and the positive lead of
the thermocouple to be calibrated should be connected to the V port of the
multimeter.

25
 3. Heat the reference thermocouple. The reference thermocouple should be heated
to a known temperature. A good reference temperature is 32 degrees Celsius.

4. Record the reading on the multimeter. The reading on the multimeter should be
the same as the known temperature of the reference thermocouple.

5. Heat the thermocouple to be calibrated. The thermocouple to be calibrated should

be heated to the same temperature as the reference thermocouple.

6. Record the reading on the multimeter. The reading on the multimeter should be
the same as the reading on the multimeter for the reference thermocouple.

7. If the readings are not the same, adjust the calibration of the thermocouple to be
calibrated. The calibration adjustment screws are usually located on the back of
the thermocouple. Turn the screws clockwise to increase the reading, and turn the
screws counterclockwise to decrease the reading.

8. Repeat steps 5-7 until the readings are the same.

Calibrating a Pressure Gauge:

1. Assemble the calibration equipment. You will need a pressure gauge, a reference pressure
gauge, a digital multimeter, and a source of compressed air or gas.

2. Connect the pressure gauges to the multimeter. The negative lead of the multimeter should
be connected to the negative lead of both pressure gauges, and the positive lead of the
multimeter should be connected to the positive lead of both pressure gauges.

3. Connect the pressure gauges to the source of compressed air or gas. The pressure gauges
should be connected to the source of compressed air or gas in such a way that the pressure in
both gauges is the same.

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 4. Record the reading on the multimeter. The reading on the multimeter should be the same as
the reading on the reference pressure gauge.

5. If the readings are not the same, adjust the calibration of the pressure gauge to be calibrated.
The calibration adjustment screws are usually located on the side or bottom of the pressure
gauge. Turn the screws clockwise to increase the reading, and turn the screws
counterclockwise to decrease the reading.

6. Repeat steps 4-5 until the readings are the same.

TRANSPORT:

PLATFORM TRUCK:

The Jumbo Electrical Platform Truck is a specialized vehicle designed primarily for industrial and
commercial applications where heavy lifting and transporting of goods are required. Here are detailed
points explaining its features and functionalities:

1. Electric Power:

The truck is powered by an electric motor, making it environmentally friendly with zero emissions
during operation. This is advantageous for indoor use and areas where exhaust fumes are a concern.

27
2. Load Capacity:

It typically has a high load capacity, capable of carrying heavy loads ranging from several hundred
kilograms to several tons, depending on the model and specifications.

3. Platform Design:

The truck features a large platform or bed where goods or materials can be securely placed. This
platform is often flat and sturdy to accommodate various types of cargo.

4. Maneuverability:

- It is designed for ease of maneuverability within warehouses, factories, distribution centers, and other
industrial settings. This includes tight turning radius capabilities and ergonomic design features for
efficient handling.

5. Controls and Safety Features:

Operated by a driver from a standing or seated position, the truck typically includes intuitive controls for
acceleration, braking, and steering. Safety features such as horns, lights, and in some cases, proximity
sensors or cameras, enhance operational safety.

6. Battery and Charging:

The electric truck is equipped with a rechargeable battery pack that powers the motor. Depending on
usage and model, the battery capacity can vary, with charging times typically ranging from a few hours
to overnight.

7. Applications:

Common applications include:

Material Handling: Transporting pallets, crates, and heavy machinery within industrial facilities.

Logistics and Distribution: Loading and unloading goods in warehouses or distribution centers.

Manufacturing: Moving raw materials or finished products along assembly lines.

28
 Retail: Stock replenishment and handling in large retail stores or supermarkets.

8. Customization Options:

Manufacturers often offer customization options to tailor the truck to specific operational needs. This
can include adjustable platform sizes, additional safety features, or specialized attachments for handling
unique types of cargo.

9. Cost and Efficiency:

While typically more expensive upfront compared to traditional diesel or gas-powered trucks, electric
platform trucks offer long-term savings through reduced fuel costs and maintenance expenses. They also
contribute to lower operational noise levels and improved air quality.

10. Environmental Benefits:

By using electric power, these trucks contribute to reducing carbon emissions and noise pollution
compared to their fossil fuel counterparts, aligning with sustainability goals of many businesses.

In summary, the Jumbo Electrical Platform Truck is a versatile and efficient solution for heavy-duty
material handling tasks in various industrial and commercial settings, offering benefits in terms of
sustainability, efficiency, and operational safety.

CRAWLER CRANE:

A crawler crane is a heavy-duty construction machine mounted on crawler tracks, equipped with a
telescopic boom and designed for lifting and moving heavy loads in various terrains and environments. It
operates using a diesel engine and hydraulic systems, controlled from a cab on the upper part of the
crawler base, and is commonly used in large-scale construction, infrastructure projects, and industrial
applications due to its stability, lifting capacity, and mobility.

29
1. Capacity:
A 150-ton crawler crane refers to its maximum lifting capacity, which is 150 metric tons
(approximately 165 U.S. tons). This makes it suitable for lifting heavy loads in construction,
infrastructure projects, and other industrial applications.

2. Crawler Tracks:
Unlike traditional mobile cranes with wheels, a crawler crane is mounted on a set of robust crawler
tracks (similar to a tank's tracks). This design provides stability and allows the crane to traverse various
terrains, including soft or uneven ground.

3. Boom Length:
The crane is equipped with a telescopic boom that extends to varying lengths, typically ranging from
around 10 meters (33 feet) to over 100 meters (330 feet) depending on the model and configuration. This
allows it to reach heights and distances necessary for lifting and placing heavy loads.

4. Counterweights:
To stabilize and balance the crane during lifting operations, counterweights are strategically positioned
on the crane. These can be adjusted or added/removed based on the specific lifting requirements to
ensure safe and efficient operation.

5. Power Source:
Crawler cranes are powered by diesel engines, providing the necessary horsepower and torque to
operate the crane's hydraulic systems for lifting and moving loads.

30
6.Hydraulic System:
The crane's hydraulic system controls the extension and retraction of the boom, as well as other
operational functions such as slewing (rotation), lifting/lowering loads, and adjusting the crane's
configuration.

7. Cab and Controls:

The operator controls the crane from a cab located on the upper part of the crawler base. The cab is
equipped with ergonomic controls and instrumentation for precise operation, including joysticks or levers
for boom movement, load monitoring systems, and safety features.

8. Safety Features:
Modern crawler cranes are equipped with advanced safety features such as load moment indicators
(LMI) to prevent overloading, anti-two block systems to prevent damage from improper cable handling,
and emergency stop mechanisms for immediate shutdown in case of emergencies.

9. Mobility and Transportability:

While crawler cranes are not as mobile as wheeled mobile cranes, their crawler tracks allow them to
move short distances on construction sites without needing to be disassembled and transported by trucks.
Larger models may require disassembly for long-distance transport.

10. Applications:
Crawler cranes are used in a wide range of applications including:
Heavy construction projects such as building skyscrapers, bridges, and dams.
Infrastructure projects for lifting and placing components like beams, columns, and precast elements.
Industrial projects such as power plant construction, shipbuilding, and maintenance of large
machinery.

11. Maintenance and Service:

Regular maintenance and servicing are crucial to ensure optimal performance and longevity of the
crane. This includes inspections, lubrication of moving parts, and replacement of worn-out components
as per manufacturer recommendations.

31
12. Cost and Efficiency:
Owning and operating a 150-ton crawler crane involves significant costs due to its size, capacity, and
specialized components. However, its efficiency in handling heavy loads and its capability in challenging
terrain justify its use in large-scale projects where precision and reliability are paramount.

In summary, a 150-ton crawler crane is a powerful and versatile piece of equipment designed for heavy
lifting tasks in construction and industrial settings, offering robust capabilities, advanced safety features,
and adaptability to various working conditions.

DIESEL LOCOMOTIVE:

A Diesel Locomotive is a self-powered railway vehicle that moves along the rails and pulls or
pushes a train attached to it using a huge internal combustion engine running on Diesel fuel as
the prime mover or the primary supplier of power.

However unlike conventional automobiles, modern diesel locomotives have no direct

mechanical connection between the engine and the wheels, hence the power generated by the
engine does not really "turn the wheels". The purpose of the diesel engine is not to run the train
but to turn a huge electricity generator/alternator which produces electric current (earlier Direct
Current, nowadays Alternating Current), then passed through a rectifier to convert the AC to
DC if required and is then transmitted to traction motors which then produce the actual
(rotational) torque that turns the wheels of the locomotive. Hence, the function of the diesel
engine is only to generate power for the traction motors and auxiliary equipment like
compressors, blowers etc. Most Indian diesel locomotives have six traction motors, one for each
axle except the WDP4 with only four traction motors for six axles. Indian Railways engines

32
 have 16 cylinders in V configuration (V16) except for some of the lower powered ones
including the WDM2 with only 12 cylinders and the WDGS which has a V20 engine!

SOLAR POWER PLANT

Solar power is harnessed using Solar Photovoltaic (PV) technology that converts sunlight (Solar
radiation) into electricity by using semiconductors. When the sun hits the semiconductor within
the PV cell, electrons are freed and bus bars collect the running electrons which results in
electric current.

PURPOSE OF SOLAR POWER PLANT

A solar power plant uses sunlight to get energy. As the sunlight is ample and renewable, one can
use it to power up the home and business premises. If you install a solar power plant, you might
need to spend upfront. However, it will minimize your energy consumption significantly.

Types of Panels:

1.Mono Crystalline

2. Poly Crystalline

Mono Crystalline Panel:

A monocrystalline solar panel is a solar panel comprising monocrystalline solar cells. These
cells are made from a cylindrical silicon ingot grown from a single crystal of silicon of high
purity in the same way as a semiconductor. The cylindrical ingot is sliced into wafers forming
cells.

33
Poly Crystalline Panel:

PolyCrystalline or MultiCrystalline solar panels are solar panels that consist of several
crystals of silicon in a single PV cell. Several fragments of silicon are melted together to form
the wafers of polycrystalline solar panels.

WORKING OF SOLAR POWER PLANT

1.SUNLIGHT ACTIVATES THE PANELS

Each individual panel is constructed of a layer of silicon cells, a metal frame, a glass casing
surrounded by a special film, and wiring. For maximum effect, the panels are grouped together
into "arrays" (an ordered series) and placed on rooftops or in large outdoor spaces. The solar
cells, which are also referred to as photovoltaic cells, absorb sunlight during daylight hours.

2. THE CELLS PRODUCE ELECTRICAL CURRENT

Within each solar cell is a thin semiconductor wafer made from two layers of silicon. One layer
is positively charged, and the other negatively charged, forming an electric field. When light
energy from the sun strikes a photovoltaic solar cell, it energizes the cell and causes electrons
to 'come loose' from atoms within the semiconductor wafer. Those loose electrons are set into
motion by the electric field surrounding the wafer, and this motion creates an electrical current.

3. THE ELECTRICAL ENERGY IS CONVERTED

You now have solar panels working efficiently to transform sunlight into electricity, but the
electricity generated is called direct current (or DC) electricity, which is not the type of
electricity that powers most homes, which is alternating current (or AC) electricity. Fortunately,
DC electricity can easily be changed into AC electricity by a gadget called an inverter. In

34
modern solar systems, these inverters can be configured as one inverter for the entire system or
as individual microinverters attached behind the panels.

4.THE CONVERTED ELECTRICITY POWERS YOUR HOME.

Once the solar energy has been converted from DC to AC electricity, it runs through your
electrical panel and is distributed within the home to power your appliances.

It works exactly the same way as the electrical power generated through the grid by your
electric utility company, so nothing within the home needs to change. Since you still remain
connected to your traditional power company, you can automatically draw additional electricity
to supplement any solar shortages from the grid.

5. A NET METER MEASURES USAGE

On cloudy days and overnight, your solar shingles or panels may not be able to capture
enough sunlight to use for energy, conversely, in the middle of the day when nobody is home,
they may collect surplus energy more than you need to operate your home. That's why a meter
is used to measure the electricity flowing in both directions to and from your home. Your
utility company will often provide credits for any surplus power you send back to the grid.
This is known as net metering.

35
 DAY 1:
Introduction of BHEL and their departments.

DAY 2:
Introduction on Products manufactured in machine shop: Fans, air pre-heater, electrostatic
precipitator, gates, and dampers.

DAY 3:
Introduction about types of machines in the FAN SHOP and types of CNC machine and parts
of CNC machines and how they are controlled by drives

DAY 4:
Gained knowledge on Machine shop and seen different types of CNC machines such Lathe,
drilling, boring, milling and beam balance.

DAY 5:
Theoretical knowledge on Motor starter and different types of starters.

DAY 6:
Theoretical knowledge on Motor starter and different types of starters.

DAY 7:
Wiring of Direct online starter and seen how it is used in machines.

DAY 8:
Wiring of Forward and reverse of motor and seen how it is used in machines.

DAY 9:
Wiring of start delta starter and seen how it is used in machines.

At first supply is connected to OFF button and connected to ON button and then connected to
DELTA NC to prevent the operating of DELTA coil while running of STAR and DELTA together,

36
if it runs the coil will damage and connected to TIMMER NC to stop the working of TIMMER
while not needed and connected with STAR and TIMMER coil. And there is parallel connection
from ON button to MAIN coil through STAR NO it is same as the production of running of both
coils together. That parallel is split and connect with the DELTA coil through the STAR NC for
the protection. There is one hold current between the OFF and ON button to hold it to continuous
flow of supply. And the all coil another side re connected with Y phase.

DAY 10:

Role of substation in BHEL and what all transformer and relay used.

DAY 11:

Visual observation 3 DG generator connected in parallel synchronous and how they supply power
to BHEL and what all fault can occur in BHEL

DAY 12:

Learnt about battery and types of battery used in the transport department how to use the
instrument such clamper meter, multimeter, IR thermometer, tachometer and stroboscope and
principle behind it.

DAY 13:
Introduction to automotive engines and principle of engines and how they work.

DAY 14:
Go to instrumentation department and know about the different types of sensors and calibrate
the ammeter, voltmeter, thermocouple and pressure gauge.

DAY 15:
Visited the loco pilot and seen the engines and how does the wagon are pulled the engines.

The loco pilot use caterpillar engine for the running of train

37
The train has 2 engine if there is minimum load l engine will run if the load is maximum load
both engine will run to get the pull power. The engine is connected with the de alternator and
compressor. The compressor is used to increase the pressure in the tank for the brake of the loco
pilot. The dc alternator is used to produce dc power for the dc series motor and the dc motor is
connected with the gear system with the help of gear system the speed will easily controlled.
The gear system is directly connected with the wheel line to drive the train. This is the loco
pilot working.

DAY 16:
Visited the crane from the China that lifting capacity in nearly 100t.

DAY 17:
SLDC of solar power plant and observed how the cranes work.

DAY 18:
Visited and gain knowledge about the parallel connection of diesel generator and how is gives
supply to bhel.

38
CONCLUSION:

During Internship Training in Production/Manufacturing department, I had leamed the

working principles of machineries and Manufacturing of boiler auxiliary parts & production
process of manufactured products in Boiler Auxiliaries Plant (BAP), Bharat Electricals
Limited, Ranipet from

03/06/2024 to 01/07/2024

REFERENCES:

The following content has been taken from the

https 3a%2f%2fbapscm.bhel.in%2f/RK-2/RS-4DraOeA2zccoSMr.lxLDep7OlHzo-

https%3a%2f%2fbhel.com%2f/RK=2/RS=wnHa5qvO6az_tgHJPuCn _Fsttg-

https%3a%2f%2fwww.bhel.com%2fsites%2fdefault%2ffiles%2f5e4236c78a2c3EOL_FS

W_0.pdf RK-2/RS=wn3erXlqPqJ4ndW9KtXs74j3kzU-

39
40