Professional Documents
Culture Documents
ER
VOCAT
IONAL
TRAINI
NG
2016
By:
Traction Motors
and
Traction
Alternators
VARSHA KHEMKA
Manager
T.M.E. Division, Block IX
BHEL, Bhopal
CERTIFICATE
This is to certify that VARSHA KHEMKA, student of 2013-17
batch of Electrical Engineering branch, 3rd year of University College of
Engineering Rajasthan Technical University, Kota has successfully
completed her industrial training at BHEL, Bhopal from 23 rd May- 16th
July 2016. She has completed the training as per the training report
submitted by her.
DATE:-16/07/16
DECLARATION
VARSHA KHEMKA
ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey
my thanks to complete the training here. I express gratitude to the
Program Manager and other faculty members of Electrical Engineering
Department of University College Of Engineering, Rajasthan Technical
University for providing this opportunity to undergo industrial training
at BHEL, Bhopal.
I do extend my heartfelt thanks to Mr. Suresh Nema, Mr. Vikas Rawtiya,
Mr. Shishu Pal, Mr. Raj Narayan Ram, Mr. HS Gurjar, Mr. Keshav
Trivedi, Mr. Kunal Prasad for providing me this opportunity to be a part of
this esteemed organization and the HR department for their guidance.
I am extremely grateful to all the technical staff of BHEL for their cooperation and guidance that helped me a lot during the course of training. I have
learnt a lot working under them and I will always be indebted of them for this
value addition in me.
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 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
countrys 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 BHELs 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 equipment not only in spectrum of products and services
offered, it is right on top. BHELs 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
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.
The Hydro Laboratory, Ultra High Voltage laboratory and Centre for
Electric Transportation are the only lab of its in this part of the world.
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 organized 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.
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.
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 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.
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.
TELECOMMUNICATION
BHEL also caters to telecommunication sector by way of
small, medium and large switching system.
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.
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 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."
PRODUCTSThermal Power Plants
Steam turbines, boilers and generators of up to 800 MW capacity
for utility and combined-cycle applications ; Capacity to
Siemens AG.
GERMANY
General Electric
CANADA
# Moisture Separator Reheaters
Baloke Duerr
GERMANY
Siemens AG.
GERMANY
Siemens AG.
GERMANY
HERP, Varanasi
Regional Operations Division ARP, New Delhi
TPG, Bhopal
Power Group (Four Regions and PEM)
BHOPAL
HARDWAR
HYDERABAD
TIRUCHY
HARDWAR
TIRUCHY
Electronic Division
Electro Porcelain Division
JAGDISHPUR
Insulator Plant
RUDRAPUR
BANGALORE
BLOCK-10
PRM- press shop mgf.
BLOCK-11
TGM- tool & gauge mgf.
NEW TRANSFORMER BLOCK(1200 KV)
In it heavy transformer are manufactured.
GOLDEN JUBLI- HYDRO BLOCK HYDRO TURBINE.
UHV- ultra high voltage. It is used for testing the turbine and and
equipment comes from all over Asia.
HLX- hydro turbine testing lab.
FUNDAMENTAL TRACTION
Traction is defined as a physical process in which a tangential
force is transmitted across an interface between two bodies through
dry friction or an intervening fluid film resulting in motion,
stoppage or the transmission of power.
Traction refers to max. Frictional force that can be produce b/w
surface without slipping. Or uniform pulling railways.
Railways traction
Classification of trains
LOCOMOTIVES
DIESEL LOCOMOTIVE
Diesel-electric locomotives were introduced in the United States
in 1924, and have become the most widely used type of
locomotive. The modern diesel-electric locomotive is a selfcontained, electrically propelled unit. Like the electric
locomotive, it has electric drive, in the form of traction motors
driving the axles and controlled with electronic controls. It also
has many of the same auxiliary systems for cooling, lighting,
heating, and braking. It differs principally in that it has its own
generating station instead of being connected to a remote
generating station through overhead wires or a third rail. The
generating station consists of a large diesel engine coupled to an
ELECTRIC LOCOMOTIVE
An electric locomotive is a locomotive powered by electricity
from an external source. Sources include overhead lines, third
rail, or an on-board electricity storage device such as a battery,
flywheel system, or fuel cell.
Electric locomotive receives current from overhead line through
pantograph. This high voltage is step down in case of single
phase 25 KV supply and then fed through control and stabilizing
circuit to the motors. In case of DC supply, it is fed to motor
through control equipment.
Multiple units
The term multiple unit or MU is used to describe a self-propelling train
unit capable of coupling with other units of the same or similar type and
still being controlled from one cab. The term is commonly used to
denote passenger train sets that consist of more than one carriage, but
single self- propelling carriages, or rail cars, can be referred to as
multiple units if capable of operating with other units.
Multiple units are of three main types:
6. Assembly
7. Testing
ARMATURE
An armature generally refers to one of the two principal electrical
components of an electrical machine generally in
a motor or generator but it may also mean the pole piece of
a permanent magnet or the moving iron part of a solenoid or relay.
The other component is the magnetic field (magnetic flux) in the air-gap,
which the armature interacts with, thus the field component can
comprise either permanent magnets, or electromagnets formed by a
conducting coil, such as another armature.
COMMUTATOR
A commutator is a moving part in certain type of electric motors and
electrical generators that periodically reverses the current direction
between the rotor and the external circuit. It consists of a cylinder
composed of multiple metal contact segments on the
rotating armature of the machine. The windings (coils of wire) on
the armature are connected to the commutator segments.
Commutators are used in direct current (DC) machines. In a motor the
commutator applies electric current to the windings. By reversing the
current direction in the rotating windings each half turn, a steady
rotating force (torque) is produced. In a generator the commutator picks
off the current generated in the windings, reversing the direction of the
current with each half turn, serving as a mechanical 0rectifier to convert
the alternating current from the windings to unidirectional direct
current in the external load circuit.
Testing of COMM
There are two type of testing:Bar to bar testing
This is the testing in which short circuit between the copper bars of
COMM checked. If there is any breakage in mica sheet, overlapping,
dust particle or burr then short circuit will occur.
HV testing
This the testing done for separator mica. By this we check insulation is
proper or not.
Seasoning
In this basically rotation of COMM is done. Around 3000rpm is checked
according to rotation of railway engine shaft. We rotate the COMM
ARMATURE WINDING
The armature winding is the main current-carrying winding in which the
electromotive force or counter-emf of rotation is induced. The current in
the armature winding is known as the armature current. The location of
the winding depends upon the type of machine. The armature windings
of dc motors are located on the core, since they must operate in union
with the commutator.
Temporary Bending
FT
Wedging & Patching
First Turning
IT
TIG Welding
IT
Oven for5-6 hrs. at 160-165deg.
HV /FT TestingThis the testing done for coil insulations like hostrip & captain
paper. By this we check insulation is proper or not.
TM 4907- 4.5 kV for 15 sec
Impulse TestingThis the testing done for checking interturns & coil
separation.
In this test HV is given to armature only for few micro sec.
TM 4907 After 1st turning 1.5 kV
After TIG Welding 1.5 kV
After PB/final 0.75 kV
ROTOR
A rotor is the rotating part used in the most common form
of AC induction motor. It consists of a cylinder of steel with aluminum
or copper conductors embedded in its surface.
The motor rotor shape is a cylinder mounted on a shaft. Internally it
contains longitudinal conductive bars (usually made of aluminum or
copper) set into grooves and connected at both ends by shorting rings
forming a cage-like shape. The name is derived from the similarity
between this rings-and-bars winding and a squirrel cage.
The solid core of the rotor is built with stacks of electrical steel
laminations. The rotor has a smaller number of slots than the stator and
must be a non-integer multiple of stator slots so as to prevent magnetic
interlocking of rotor and stator teeth at the starting instant.
The rotor bars may be made either of copper or aluminum. Some larger
motors have aluminum or copper bars which are welded or brazed to
end-rings. Since the voltage developed in the squirrel cage winding is
very low, no intentional insulation layer is present between the bars and
the rotor steel.
ASSEMBLY SECTION
In this area the armature and stator is assembled together .Brush holder
and fixture are attached & bearing assembly is done. Clearance is also
checked.
The
The
TESTING
1. Light Run TestTesting used to test vibration, temperature, sound, rpm. For measuring
rpm optical tachometer is used.
In this test firstly machine is driven at a fix speed for some time then
at some more speed then finally at over speed for 2 min.
TRACTION ALTERNATOR
An alternator is an electrical generator that converts mechanical energy
to electrical energy in the form of alternating current.
The traction alternator generates AC electricity which is used to
provide power for the traction motors mounted on the trucks (bogies).
In older locomotives, the alternator was a DC machine, called a
generator. It produced direct current which was used to provide power
for DC traction motors.
The traction alternator is single bearing machine designed for operating
directly connected to the diesel engine with a flexible disc type coupling.
The high voltage capability of the alternator provides a wide
locomotive speed range without the need for field weakening.
The traction alternator has salient rotating field, which provides
low Inductance design of field circuit and contributes to quick
response of the alternator in cooperation with static exciter.
The main pole field winding is provided with mechanical rigidity
and good heat transfer characteristics.
Coil supports are provided to prevent distortion of the main pole
coils due to centrifugal forces.
The armature of the exciter consisting of low loss steel laminations
is also mounted on the shah.
The class H Insulation System with solvent less resin provides best
protection against moisture, sand, salt, humidity and corrosive
atmosphere ensuring trouble free operations under the most
demanding conditions.
Transient voltage dips are lower.
Higher rating diodes have been used in rotating rectifier assembly
to ensure high product reliability & performance.
The rotating diodes are protected by a surge suppressor, which has
the ability to chop the high voltage transients.
Stator
Rotor
Rectifier Bridge.
Slip rings, brushes
STATOR
Stator is the stationary part of the alternator and contains 3phase armature windings. Stator core is built up of silicon
steel laminations to reduce eddy current losses.
STATOR WINDING The three phase windings are placed in the slots and serves as
the armature windings of the alternator.
The stator winding has three sets of windings. Each is formed
into a number of evenly spaced coils around the stator core
Common properties of armature winding.
1. First and most important property of an armature winding
is, two sides of any coil should be under two adjacent
poles. That means, coil span = pole pitch.
2. The winding can either be single layer or double layer.
3. Winding is so arranged in different armature slots, that it
must produce sinusoidal emf.
There are different types of winding used in alternator. The windings can
be classified as
Lap winding
wave winding
After winding the job of alternator TA-1010 is put into VPI Plant
containing varnish RE-009 for 3hrs & then into oven for 10 hrs.
[5hrs at 140deg. & 5hrs at 170deg].
The job of alternator TA-9901 & 9201 is dipped into poly buta dyne
varnish & then into oven for 10 hrs. [2hrs at 120deg, 2hrs at 150deg. &
6hrs at 175deg.].
TestingTwo types of testing is done during and after winding.
1) Resistance test(at 20deg) for checking brazing.
2) HV testIt is done two times.
a) After winding & before brazing
b) After VPI & before dispatch
After this job is dispatched to assembly section.
ROTOR The rotor is rotating part of the alternator. It carries a field
winding which is supplied with dc current through two slip
rings by a separate dc source.
This dc source (exciter) is generally a small dc generator
mounted on the shaft of the alternator.
The rotor contains the field winding wound over an iron core
which is part of the shaft.
Each end of the rotor field winding is attached to a slip ring.
Stationary brushes connect the alternator to the rotor.
Diode Rectifier BridgeThe Diode Rectifier Bridge is responsible for the
conversion or rectification the AC voltage into DC voltage.
Two diodes are connected to each stator lead. One positive the other
negative.
A rectifier bridge can contain 3, 6, or sometimes 8 diodes depending on
its design. Diodes are like one way check valves that allow current to
flow in only one direction. A positive biased diode allows only positive
voltage to pass through and a negative bias diode allows only negative.
The bridge's job is to convert AC voltage to DC voltage. This process is
known as rectification. It allows the positive voltage to pass onto the
Bat+ terminal and onto the battery, while allowing negative voltage to
pass to the ground. Most alternators have 3 or 6 diodes. If one of these
fail, it will reduce alternator output by approximately 1/3.
Diodes are mounted in a heat sink to dissipate the heat generated by the
diodes. Diodes redirect the AC voltage into DC voltage so the battery
receives the correct polarity.
Voltage Regulator
The regulator will attempt to maintain a predetermined charging system voltage level.
When charging system voltage falls below this point, the regulator will
increase the field current, thus strengthening the magnetic field, which
results in an increase of alternator output.
When charging system voltage raises above this point, the regulator
will decrease field current , thus weakening the magnetic field, and
results in a decrease of alternator output.
Working of alternatorAs the rotor assembly rotates within the stator winding.
hour. Then vibrations, temperature, air outlet & inlet all are measured on
each side, all should be under limit.
3) Open Circuit TestIn This test field voltage & output of both
rectifier are measured by varying field current.
The open-circuit test or the no-load test, is performed by driving
the generator at its rated speed while the armature winding is left
open. The field current is varied in suitable steps and the
corresponding values of the open-circuit voltage varied in suitable
steps and corresponding values of the open-circuit voltage
between any two pair of terminals of the armature windings are
recorded. The OCC follows a straight-line relation as long as the
magnetic circuit of the synchronous generator does not saturate. In
the linear region, most of the applied mmf is consumed by the airgap; the straight line is appropriately called the air-gap line. As the
saturation sets in, the OCC starts deviating from the air-gap line.
4) Short Circuit TestIn this test field voltage & field current are
measured by varying load current. The short-circuit test
provides information about the current capabilities of a
synchronous generator. It is performed by driving the generator
at its rated speed when the terminals of the armature winding
are shorted. An ammeter is placed in series with one of the
three shorted lines. The field current is gradually increased and
the corresponding value of the armature current is recorded.
When the per phase short-circuit current is plotted as a function
of the field current, the graph is called the short circuit
characteristic of a generator.
The current for the traction motor is obtained from traction alternator.
The 6 traction motor on the locomotives will work either in parallel (6P)
or series parallel (2S-3P), with or without field weakening (49%FF).
BIBLIOGRAPHY
www.bhelbpl.co.in
www.wikipedia.org
www.electrical4u.com
www.coep.vlab.co.in