VACATIONAL TRAINING REPORT

2018

Under the Guidance of-

Mr. JAGAT PAL
Sr. Manager, E.S.H. Division
BHEL, BHOPAL

BISHESH
BHOWMICK
B.E. IV SEM (M.E.)
REG NO.-
RA1711002030064
SRM IST (NCR)
 BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

VACATIONAL TRAINING REPORT

Duration: 28 DAYS (11th JUNE, 2018 to 07th JULY, 2018)

Under the Guidance of

Mr. JAGATPAL
Sr. Manager, E.S.H. Division BHEL,
BHOPAL

Submitted By:
BISHESH BHOWMICK
B.E. IV SEM (M.E.)
REG NO- RA1711002030064
SRM IST (NCR)

1
 CERTIFICATE

This is to certify that “BISHESH BHOWMICK” student of 4th semeSter

of Mechanical Engineering branch has successfully completed his Major
Training in BHEL, BHOPAL. This training is vocational training required to
be submitted as a part of syllabus of Semester in SRM IST (NCR) for partial
fulfillment of the Bachelor of Engineering Degree.

DATE: JULY 07, 2018 PLACE: BHOPAL

2
 DECLARATION

I, BISHESH BHOWMICK pursuing Bachelor of Engineering from SRM IST

(NCR), hereby declare that the work presented in this report is outcome of my
work carried out at BHEL from 11/06/2018 to 07/07/2018 is bonafide, correct to
the best of my knowledge and this work has been carried out taking care of
Engineering Ethics. I worked under the rules and regulations of BHEL, BHOPAL.
And the work presented does not infringe any patented work.

Date: JULY 07, 2018 BISHESH BHOWMICK

3
 ACKNOWLEDGEMENT

“It is not possible to prepare a project report without the assistance &
encouragement of other people. This one is certainly no exception.”

On the very outset of this report, I would like to extend my sincere and
heartfelt obligation towards all the personages including the following
instructor, technical staff and supervisor of various sections who helped me in
this endeavour. Without their active guidance, help, cooperation and
encouragement, I would not have made head way in the project.

I would like to express my sincere gratitude to my project guide or better to

say mentor, Mr. JAGAT PAL , (Sr. Manager ESH Division) who gave his valuable
time to me to utilize my time to fullest during industrial training . I was
privileged to experience a sustained enthusiastic and involved interest from his
side in BHEL, Bhopal.

Thanking You

4
INTRODUCTION

Bharat Heavy Electricals Limited (BHEL) owned and founded by the

Government of India, is an engineering and manufacturing company
based in New Delhi. Established in 1964, BHEL is India's largest power
generation equipment manufacturer.

Government of India (Ministry of Heavy Industries and Public

enterprises) has granted the status of MAHARATNA to Bharat Heavy
Electricals Limited on 1st Feb 2013.

BHEL is engaged in the design, engineering, manufacturing,

construction, testing, commissioning and servicing of a wide range of
products, systems and services for the core sectors of the economy,
viz. power, transmission, industry, transportation, renewable energy,
oil & gas and defence.

It has a network of 17 manufacturing units, 2 repair units, 4 regional

offices, 8 service centres , 8 overseas offices, 15 regional centres, 7
joint ventures, and infrastructure allowing it to execute more than
150 projects at sites across India and abroad. The company has
established the capability to deliver 20,000 MW p.a. of power
equipment to address the growing demand for power generation
equipment

5
BHEL, BHOPAL: “Centre of Excellence for Hydro Machines”

BHEL BHOPAL has :-

 Added more than 124000 MW to the country's installed power generating

capacity so far.
 Supplied over 25000 Motors with Drive Control System to power
projects, Petrochemicals Refineries, Steel, Aluminium, Fertilizer, Cement
plant, etc.
 Supplied Traction electrics and AC/DC locos over 12000 kms Railway
network.
 Supplied over one million Values to Power Plants and other Industries.
 BHEL has retained its market leadership position during 2013-14 with
72% market share in the Power Sector, even while operating in a difficult
business environment.

6
PRODUCTS OF BHEL, BHOPAL
 AC Motors and Alternators
 Transportation Equipments
 Hydro Generator
 Excitation Control Equipment
 Turbine
 Oil Rings
 Transformer
 Switch gear
 Control and Relay Panel

7
BHEL BHOPAL is broadly divided into 9 BLOCKS:

-1:
Water Turbine Manufacturing

-2:
Heavy Electrical Machine and IMM and LEM

-3:
Transformer, Capacitor and Bushing Manufacturing and Ultra High
voltage testing

-4:
SCR (Switchgear, Control Gear and Rectifier)

-5:
Press & foundry shop

-6:
CIM (Coil & Insulation Manufacturing)

-7:
RSMG

-8:
Fabrication

-
9:
Transportati
on group
(Traction
Motors And
Alternator)

8
BLOCK 1:
WATER TURBINE MANUFACTURING
 Turbine:
A water turbine is a rotary machine that converts kinetic energy and
potential energy of water into mechanical work.

 Types:
There are two main categories of hydro turbines: impulse and reaction.
The type of hydropower turbine selected for a project is based on the
height of standing water—referred to as "head"—and the flow, or volume
of water, at the site. The most common type of impulse turbine is Pelton
turbine.
On the other side, the most common reaction turbine is Francis turbine
but there are also Kaplan turbine, Tyson turbine, Gorlov helical turbine.

 PELTON TURBINES:
Pelton turbine or wheel is an impulsive turbine used mainly for high head
hydroelectric schemes. The Pelton wheel is among the most efficient types of
water turbines. The fluid power is converted into kinetic energy in the nozzles.
The total pressure drop occurs in the nozzle. The resulting jet of water is
directed tangentially at buckets on the wheel producing impulsive force on
them.

Pelton wheel has the following main components:

 Nozzle
 Runner and buckets
 Casing
 Breaking jet

Function
Nozzles direct forceful, high-speed streams of water against a rotary series of
spoon-shaped buckets, also known as impulse blades, which are mounted
around the circumferential rim of a drive wheel

9
 As the water jet
impinges upon the
contoured bucket-
blades, the direction
of water velocity is
changed to follow
the contours of the
bucket. Water
impulse energy
exerts torque on the
bucket and wheel
system, spinning the
wheel, the water stream itself does a "u-turn" and exits at the outer sides of the
bucket, decelerated to a low velocity. In the process, the water jet's
momentum is transferred to the wheel and thence to a turbine.

Thus, "impulse" energy does work on the turbine. For maximum power and
efficiency, the wheel and turbine system is designed such that the water jet
velocity is twice the velocity of the rotating buckets.

A very small percentage of the water jet's original kinetic energy will remain in
the water, which causes the bucket to be emptied at the same rate it is filled and
thereby allows the high-pressure input flow to continue uninterrupted and
without waste of energy.

Typically two buckets are mounted side-by-side on the wheel, which permits
splitting the water jet into two equal streams. This balances the side-load forces
on the wheel and helps to ensure smooth, efficient transfer of momentum of
the fluid jet of water to the turbine wheel.

 FRANCIS TURBINES:
The Francis turbine is a reaction turbine where water changes pressure as it
moves through the turbine, transferring its energy. A watertight casement
is needed to contain the water flow.

Generally such turbines are suitable for sites such as dams where they are
located between the high pressure water source and the low pressure water exit.
Francis turbines are the most common water turbine in use today.

10
They operate in a water head from 40 to 600 m (130 to 2,000 ft) and are
primarily used for electrical power production.

Francis turbine has the

following main components:
 Spiral casing.
 Stay ring and stay
vanes.
 Runner.
 Draft tube.

Function
Water flows from the
penstock into the spiral
casing. In the spiral casing
the water is distributed
around the complete periphery. The water is then guided by the stay vanes and
guide vanes in the correct angle towards the runner.

The guide vanes are adjustable and can change the angle depending on the inlet
and outlet conditions of the turbine, they are controlled by a governor servo
motor. The runner transfers the energy from the pressure and velocity in the
water to a rotational momentum. The water exits through a draft tube that
extracts the remaining energy in the water.The torque produced in the runner is
transferred to a power producing generator through a shaft.

KAPLAN TURBINES:
The Kaplan turbine has adjustable blades. The main advantage of Kaplan
turbines is its ability to work in low head sites which was not possible with
Francis turbines.

11
Kaplan turbines are widely used in high-flow, low-head power productionThe
Kaplan turbine is an inward flow reaction turbine, which means that the working
fluid changes pressure as it moves through the turbine and gives up its energy.

The design combines

radial and axial features.
The inlet is a scroll-
shaped tube that wraps
around the turbine’s
wicket gate. Water is
directed tangentially
through the wicket gate
and spirals onto a
propeller shaped runner,
causing it to spin.

The outlet is a specially

shaped draft tube that helps decelerate the water and recover kinetic energy. The
turbine does not need to be at the lowest point of water flow, as long as the
draft tube remains full of water. A higher turbine location, however, increases
the suction that is imparted on the turbine blades by the draft tube that may lead
to cavitations due to the pressure drop.

Typically the efficiencies

achieved for Kaplan turbine are over 90%, mainly due to the variable geometry
of wicket gate and turbine blades. This efficiency however maybe lower for
very low head applications. Since the propeller blades are rotated by high-
pressure hydraulic oil, a critical design turbine is to maintain a positive seal to
prevent leakage of oil into the waterway.

12
BLOCK -2:

Heavy Electrical Machine and IMM and LEM:

STATOR :
Stator is starting part of machine .It is constructed by DC or AC supply. The
term, "stator" is derived from the word stationary. The stator then is the
stationary part of the AC motor. The rotor is the rotating electrical component.
It also consists of a group of electro-magnets arranged around a cylinder, with
the poles facing toward the stator poles.

The first DC generators (known as dynamos) and DC motors put the field coils
on the stator, and the power generation or motive reaction coils on the rotor.
This is necessary because a continuously moving power switch known as the
commutator is needed to keep the field correctly aligned across the spinning
rotor.

 The slots on the periphery

of stator core of the three
phase induction motor
carries three phase
winding or Stator winding.
This three phase winding is
supplied by three phase
AC supply.

 The three phases of the winding are connected either in star or delta
depending upon which type of starting method is used.

 The squirrel cage motor is mostly started by star-delta stater and

hence the stator of squirrel cage motor is delta connected.

 The slip ring three phase induction motor are started by inserting
resistances, so the stator winding of slip ring induction motor can be
connected either in star or delta.

13
  When this winding is excited by three phase ac supply it produces
RMF(Rotating Magnetic field).

ROTOR-
Rotor as the name suggests it is a rotating part of an electrical machine, in which
current is induced by transformer action from rotating magneticfield. Induction
motor rotor is of two types:-
1. Squirrel Cage Rotor
2. Wound Type Rotor or Slip Ring Type Rotor

Squirrel Cage Rotor:

In this type of rotor, the rotor winding consists of conductors, in form of copper
or aluminium bars embedded in semi-closed slots of a laminated rotor core. To
facilitate a closed path in the rotor circuit, both sides of the rotor bars are
short- circuited by end rings.

Features of Squirrel Cage Rotor:

This type of rotor does not have a definite number of poles, but the same
number of stator poles will be induced in the rotor automatically
through induction. Hence for a squirrel cage rotor
The squirrel cage rotor has very low leakage reactance as it does contain any
winding on the rotor and it results in low starting torque and maximum running
torque.

14
Wound Type Rotor or Slip Ring Type Rotor:
This type of rotor is also made up of laminated cold rolled grain oriented silicon
steel to reduce eddy current loss and hysteresis loss. The operation of an
induction motor is not possible with an unequal number of stator and rotor
poles, and this type of rotor does not respond automatically to change in a
number of stator poles. Hence the number of rotor poles must be made equal to
the number of stator poles.
Skewed Rotor Bars:
One of the purposes of skewing the rotor bars is to increase the value of rotor
resistance so that starting torque can be improved. We know that resistance is
proportional to length hence by skewing the rotor bars length of bars is
increased hence resistance increases so does the torque
ROTOR SHAFT:
The rotor shaft, more commonly called the “mast” is the vertical shaft on which
the rotor head and blades are attached. It comes up from the transmission and it
is what spins the rotor and supports the entire flight loads of the rotor down
into the helicopters structure.

15
BLOCK 3:
Transformer, Capacitor and Bushing Manufacturing and Ultra
High voltage test:

BUSHING AND CYLINDERS:

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

CAPACITORS:
 Shunt Capacitor banks with all film dielectric impregnated with non PCB
Impregnate of desired ratings from 6.6 to 400 kV complete with
manual / automatic control equipment for Industrial and power system
application.
 Pole mounted Capacitors for mounting in line with Rural Electrification
scheme up to 11 KV.

 Roof Capacitor in Traction Motor application: 4 microfarad, 2 KV DC

Series capacitors for Reactive compensation and voltage regulation in
power system from 33kV to 400 KV.
 Capacitor to improve power factor of traction substations suitable for
Railway Electrification.
 Surge Capacitor for protection of Rotating Machine and Generator
transformers winding 15 kV and 40 kV, 0.125 micro farad.

TRANSFORMERS:
 Power Transformers upto 420kV class, 50/60 Hz 945 MVA, 3-phase
Bank.
 Power Transformers upto 420kV class, 50/60 Hz 500 MVA, 3-phase
Unit.
 HVDC Converter Transformers and Smoothing Reactors.
 500 MVA, ± 500kVDC, 3 winding, 1- Phase. Convertor
Transformer.
 254 MVAR, 360mH, 1568A, ±500 kVDC 1 –Phase Smoothing
Reactor.

REACTORS: 16
 Gapped core Shunt Reactors up to 420 kV class, 125 MVAR 3 Phase
Unit.
  Types- Series and Neutral Grounding Reactors.
 Controlled Shunt Reactor up to 420 kV class, 80 MVAR 3 Phase Unit.

ULTRA HIGH VOLTAGE LABORATORY:

UHV Laboratory at BHEL is shielded and acoustically treated Laboratory

35x67x35 m (H) Hall is one of the biggest in Asia and in World
one of the largest electromagnetically screened laboratories and offers the most
modern and sophisticated testing facilities for a wide range of transmission
equipment and products. The laboratory is designed essentially for
comprehensive testing of power transformers and shunt reactors.

The impulse test plant and AC high voltage test plants are adequate for test
levels appropriate upto 1100 kV transmission systems.
The AC power test plant is suitable for performing test on equipment up to
800
kV class with provision of enhancing the capacity in future for conducting tests
on 1100 kV equipment.

The DC test plant is adequate for test levels suitable up to + 800 kV HVDC
transmission systems. Together with these facilities, performance testing of 315
MVA three-phase transformers; 200 MVA single-phase transformers; 80
MVAR shunt reactors for 400 kV AC systems, 315 MVA, + 500 kV DC single-
phase converter transformers and 800 kV bushings & CVTs have been
satisfactorily established in laboratory.

17
SALIENT FEATURES OF UHV LAB:
 Offers very low background level during PD and RIV measurements.

 Major test equipment are mobile on air-cushion transport system, thus

provides flexibility of placement of test objects and test equipment in the
hall with no space constraint up to the highest test voltages.

TESTS AC TRANSFORMERS & SHUNT REACTORS:

 Impedance, loss and temperature rise tests Separate source voltage
withstand test Induced over
 voltage withstand test.
 Lightning impulse full and chopped wave Tests.
 Switching impulse tests, Other Routine and Type Tests.
 Special Test on Reactors-
1.Vibration and stress measurement.
2.Measurement magnetization characteristics.

TESTS ON DC CONVERTER TRANSFORMERS &

SMOOTHING REACTORS:
 Long duration DC voltage test DC polarity reversal test with partial
discharge measurement.
 Temperature rise test with DC voltage supply.
 Lightning & switching impulse tests.
 AC power frequency test.
 Loss measurement.

TESTS ON INSTRUMENT TRANSFORMERS:

 Partial discharge and RIV measurements.
 Dry and wet power frequency dielectric tests.
 Lightning and switching impulse tests.
 Transient & Ferro-resonance tests.
 Fast transient test.

TESTING FACILITIES:
o Conforming to IS 2026/ IEC 76
o 1200kV, 30mA HVDC Test System for DC Testing of converter
Transformers & Smoothing Reactors.
o 1500kV, Cascade connected, 50 Hz AC Test Transformer.
o 1500kV, AC Potential Divider.

18
o 160 MVA, 66/650kV, 3 Phase Testing Transformer
o 2 MVA (50 - 180 Hz), 40 MVA (50 Hz) & 9 MVA (50 - 200 Hz),
Synchronous Motor Generator.
o Full-fledged Calibration and Testing Laboratory for Instruments and
Materials.
o 300 MVA 650 kV testing transformer.
o 180 MVA 138/1200 kV testing transformer.
o 40 MVA 156 kV testing transformer.

ADDITIONAL TEST RESUOUCES IN OTHER TEST

AREAS:
2500 kV, 73 kWs impulse generator
1.2 MV, 1200 pF impulse voltage divider
800 kV, 2A series resonant test system
250 kV, 2A series resonant test system
15 kV, 1000 kV series resonant test system
150 kV, 10 mA DC voltage test set
500 kV, 50 pF SF6 - filled standard
capacitor

19
BLOCK-04:
SCR (Switchgear, Control Gear and Rectifier):

SWITCHGEAR:
A switchgear or electrical switchgear is a generic term which includes all the
switching devices associated with mainly power system protectiOn. It also
includes all devices associated with control, metering and regulating of
electrical power system. Assembly of such devices in a logical manner forms
switchgear. In other words apparatus used for switching, controlling and
protecting the electrical circuits and equipment is known as switchgear.

CONTROL GEAR:
Controlgear provides electrical protection for both equipment and persons in
several different cases. Electrical devices such as motors are protected against
cases of sudden current overloads that could damage or destroy equipment. In
addition, controlgear protects against short circuits caused by the failure of
insulation or mechanical failures. Finally, controlgear protects electric motors
against abnormal conditions such as overcurrent or overheating.

Typical Controlgear Components-

 Contactors
3and 4-pole contactors up to 55kW used for switching motors (AC-3 and AC-4) and
other high power loads (mainly AC-1); combinations of 2 or 3 contactors for
reverse/star delta star); Includes IEC contactors and NEMA rated IEC contactors.

 Contactor Relays
4pole to 10-pole contactor relays based on 3-phase AC motor contactors for
switching of auxiliary circuits (AC-15, AC-14, DC-13)

 Overload Relays
5phase AC thermal and electronic overload relays up to 800 A for protection against
overload mainly for motors (based on thermal motor model).

 Solid State Relays

1- to 3-pole AC solid state relays and contactors; heavy-duty solid state relay, used
for switching electric heaters, small electric motors and lighting loads; max. 100A
(AC-1).

20
  Motor Starter Protectors (MSP)
3phase AC circuit breakers mainly for motor start protection up to 100A against
short circuit and overload.

 Motor Management Systems

Multifunctional, electronic motor protection in most cases with communication
interface; motor protection and control functions; typically communicates operational,
diagnostic and statistical data.

 Centralized Motor Starters

Combination of MSP and contactor with connector module (direct and reversing
starters); combinations of contactor with overload relay; all for use in cabinets (IP20).
Typically sold as complete unit; may have communication interface.

 Decentralized Motor Starters

Motor starters for decentralized automation periphery; enclosed motor starter
protectors for manual starting; may have communication interface.

RECTIFIER:
An AC drive contains a rectifier, which converts AC voltage to DC voltage; a
DC bus (also referred to as a DC voltage intermediate circuit), which stores the
DC power; and an inverter, which converts the DC power back to AC at the
necessary frequency and voltage, making it suitable for the motor.

The job of the rectifier is simple: convert incoming AC voltage to DC voltage.

The process of rectification results in DC power that consists of pulses of

21
current, so when a device requires steady DC current, the DC bus acts as a low-
pass filter and smooths the current.

Each phase of power requires two rectifiers—one that allows current to pass
through when the voltage is negative, and one for when the voltage is positive.
Thus, three-phase power requires six rectifiers.

22
BLOCK 5:
FOUNDRY & PRESS SHOP:

 Electric induction furnace:

Electric induction furnaces use a high power alternating current flowing through
a coil to induce eddy currents in the metal thus generating heat, and are most
commonly found in production foundries today.

The principle of induction melting is that a high voltage electrical source from a
primary coil induces a low voltage, high current in the metal, or secondary
coil. Induction heating is simply a method of transferring heat energy.

Induction furnaces are ideal for melting and alloying a wide variety of metals
with minimum melt losses, however, little refining of the metal is possible.
There are two main types of induction furnace: coreless and channel.

CORELESS:- The heart of the coreless induction furnace is the coil, which
consists of a hollow section of heavy duty, high conductivity copper tubing
which is wound into a helical coil. Coil shape is contained within a steel shell
and magnetic shielding is used to prevent heating of the supporting shell. To
protect it from overheating, the coil is water-cooled, the water bing recirculated
and cooled in a cooling tower. The shell is supported on trunnions on which
the furnace tils to facilitate pouring.

23
CHANNEL:- The channel induction furnace consists of a refractory lined steel
shell which contains the molten metal. Attached to the steel shell and connected
by a throat is an induction unit which forms the melting component of the
furnace. The induction unit consists of an iron core in the form of a ring around
which a primary induction coil is wound. The heat generated within the loop
causes the metal to circulate into the main well of the furnace. The circulation
of the molten metal effects a useful stirring action in the melt.

 Shot Blasting:

Shot blasting is a finishing process used to clean castings and prepare them for
further treatment. It is widely used in many industrial areas, such as the
automotive, aviation, rail and shipbuilding sectors. At Haworth Castings, we use
this technique in all our sand casting work.

How shot blasting works-

Shot blasting is the first process carried

out after the casting has been removed
from the sand mould. It is also
sometimes carried out a second time after
heat treatment to improve the surface
finish. Firstly, the casting is placed in an
enclosed cabinet on a rotating turntable.
As the casting is rotated, small steel balls
(shots) are accelerated towards the workpiece at high speed and at varying
angles through a pressurised nozzle.

Various shot media can be used in shot blasting, with different shapes, sizes,
densities and materials (such as ceramic, glass and steel). The choice of material
and size is dependent on the surface treatment required. At Haworth Castings,
we use stainless steel shots.

 Castings:
Casting is a manufacturing process in which a liquid material is usually poured
into a mold, which contains a hollow cavity of the desired shape, and then

24
allowed to solidify. The solidified part is also known as a casting, which is
ejected or broken out of the mold to complete the process.

 Safety developments:

Working in a foundry is a hazardous occupation. There are numerous chemical,

mechanical, and temperature hazards that must be controlled in order to
eliminate potential harm to workers.

Cranes were introduced to lift ladles into position for pouring, but the noise of
the production environment and line of sight constraints still meant crane
drivers were vulnerable to causing incidents. Process cranes are the latest
development where ladles run on preset tracks with lifts, eliminating the chance
of an operator being in the path of the moving ladle under normal operating
conditions.

25
BLOCK-06:
CIM (Coil & Insulation Manufacturing):

CWIEME (Coil Winding, Insulation & Electrical Manufacturing Exhibition) is a

leading international exhibition, aimed at the electro-magnetic, insulation
materials, coil, electric motor and transformer manufacturing industries.
CWIEME Bangalore is part of the leading global CWIEME event portfolio,
encompassing Europe, Asia and North America.

CWIEME Bangalore 2013 saw record visitor numbers and leading quality
exhibitors alongside a packed out conference
Highlights of CWIEME BHEL 2013 included:

 A bustling show floor with plenty of eager visitors, leading exhibitors and
machinery demonstration
 Inauguration Ceremony of TRAFOSEM Conference where large crowds
gathered to hear from Hon’ble Minister of State – Micro, Small &
Medium Enterprises, Shri K H Muniyappa.
 Networking opportunities – humming with discussions between visitors,
speakers and exhibitors
 Technical sessions presenting ground-breaking Transformer topics to a
captivated audience

Coil Winding Insulation and Electrical

Manufacturing Exhibition is leading
exhibition for coil winding, electric
motor and transformer manufacturing
technologies. It provides the attendees
with the opportunity to meet new and
existing suppliers, invest in innovative
products and solutions, network with
industry peers, and stay up-to-date with
the latest industry trends.

26
BLOCK-8:
Fabrication

The committee shall give an overview about new developments in the field of
ship and offshore materials and fabrication techniques with focus on trends
which are highly relevant for practical applications in the industry in the recent
and coming years. Particular emphasis shall be given to the impact of welding
and corrosion protection techniques on structural performance, on the
development of lighter structures and on computer and IT technologies and
tools.

Modernization efforts in BHEL:

With a view to cope up with technological advancement and continuous
improvement in equipment in the transportation systems and to cater to the on-
going requirement of Indian Railway – one of the major customers of BHEL,
steps are being taken by BHEL for Modernization of its facilities with state-of-
art technology to meet the challenges and expectations. This has resulted into:

 Increase in productivity by automation, quality

improvement and managing operations
 Improvement in material handling & storage facilities
 Shorter deliveries
 ·Low level rejection
 Reduced failures
 Capable to cater to the need of Indian & Export market
·Better performance of product.

27
BLOCK-09:
Traction Motors and Alternator:

The traction motor is a four pole DC series motor in which field winding is
connected in series with armature. It is a forced ventilated machine arranged for
axle mounting on sleeve bearing. Transverse movement is limited by the flanges
of axle suspension bearing. An electric locomotive as well as diesel-electric
locomotive in Indian railway contain six dc traction motors at once.
The high permeability
cast steel magnet frame
is machined to insure
alignment of the end
shields, pole bores &
axle way bores. The
main poles are built
from steel laminations.
There are four brush
holder per motor, each
carrying 3 split carbon
brushes. Each brush holder is carried on two insulated support pins.
The armature is supported on grease lubricated roller bearing. Bearing
assemblies are sealed type, so necessity of lubrication in about 2or 3
years.

 Construction:
The armature core is made from high permeability silicon steel stampings and
these stampings are separated by thin coating of varnish as insulation with each
other. The armature is lap wounded with 100% equalization. The commutator is
built up with hard drawn silver bearing copper segment which are insulated with
micanite segment. After the commutator is statically and dynamically seasoned
to insure stability ,the complete armature is dynamically balanced.

 Rating:
A traction motor has following ratings: Voltage - 285 volts Current - 980
ampere Speed - 360 rpm Power - 248 kw.
28
 Principle:
When a current carrying conductor is placed in a magnetic field, a force is
exerted on it and direction of force is determined by fleming’s left hand rule.
In a dc motor, dc supply is provided to field winding. As a result,
unidirectional magnetic field is produced and magnetic field lines cut the
rotor conductors which carry current equal to field current. Since the
conductors are on circumference of rotor, force acts in tangential direction to
the rotor. Thus a torque is developed on the rotor and it starts to rotate.
 Operation:
To understand the operation of a traction motor, three transition panels
are studied. Transition panels perform transition events. These events
correspond to field weaking and changing the connections of traction
motor. Three transition panels are performed at three different speeds –
First transition at 30 km/hr speed Second transition at 50 km/hr speed
Third transition at 80 km/hr speed.

29