An Industrial Internship Report on

Power Systems and CNC Machines

At

BHARAT HEAVY ELECTRICALS LIMITED

HEAVY PLATES & VESSELS PLANT
Visakhapatnam

submitted by
ADITYA BONTALAKOTI
Second Year
522112

Electrical and Electronics Engineering

National Institute of Technology , Andhra Pradesh

Under the Esteemed guidance of

Mr. P.NAGESWARA RAO
Senior Engineer (WE-EM)
B. H.E.L HP&VP (B.H.P.V), Visakhapatnam.

23 July 2024

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CERTIFICATE

This is to certify that Aditya Bontalakoti, a bonafide

student of National Institute of Technology , Andhra Pradesh has
undergone industrial training for 2 months during May 24 to July 23,2024 at
“BHARAT HEAVY ELECTRICALS LIMITED , HEAVY PLATES AND
VESSELS PLANT” (HPVP), VISAKHAPATNAM and has submitted a
industrial training report on “Power Systems and CNC Machines”.

STUDENT NAME ROLLNUMBER

ADITYA BONTALAKOTI 522112

P.NAGESWARA RAO K.P.MISHRA

Dy.Manager (WE-EM) DGM (HRDC)
B.H.E.L HP&VP (B.H.P.V) B.H.E.L HP&VP
(B.H.P.V)

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ABSTRACT

This industrial training report provides a comprehensive overview of the

practical experience gained by an engineering student at Bharat Heavy
Electricals Limited (BHEL), Vizag. The training, spanning a period of eight
weeks, offered an immersive exposure to various facets of industrial
operations, engineering processes, and project management within one of
India's premier engineering and manufacturing companies.
Additionally, the training provided insights into BHEL's organizational
structure, work flow optimization, and the critical role of interdisciplinary
collaboration in achieving operational efficiency. The report also reflects on
the professional growth of the student, focusing on the development of
technical skills, problem-solving abilities, and the practical application of
theoretical knowledge acquired during academic studies.
Overall, the industrial training at BHEL, Visakhaptnam, has been instrumental
in bridging the gap between academic learning and real-world engineering
practices, fostering a deeper understanding of the industrial sector's
challenges and opportunities. This report encapsulates the key learnings,
experiences, and contributions made during the training period, serving as a
valuable resource for future professional endeavors.

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CONTENTS
1.0 INTRODUCTION 1
1.1 BHEL HPVP PICTORIAL VIEW 1
1.2 WORKSHOPS 2
1.3 PRODUCTION SHOPS 2
1.4 SALIENT FEATURES OF DIFFERENT SHOPS 2
1.4.1 MATERIAL PREPARATION SHOP 2
1.4.2 LIGHT MACHINE SHOP 2
1.4.3 MACHINERY USED IN LIGHT MACHINE SHOP 3
1.4.4 HEAVY MACHINE SHOP 3
1.4.5 MACHINERY USED IN HEAVY MACHINE SHOP 3
1.4.6 PRESS SHOP 4
1.4.7 MACHINERY USED IN PRESS SHOP 4
1.4.8 SHELLS SECTION 4
1.5 BHEL-HPVP PRODUCTS 5
1.6 WELDING TECHNOLOGY 6
2.0 VERTICAL TURNING AND BORING MACHINE 6
3.0 CNC SYSTEMS 7
3.1 CONTROL AND DISPLAY ELEMENTS 7
3.2 HORIZONTAL CNC KEYBOARD 8
3.3 MACHINE CONTROL PANEL 8
3.4 MCPA MODULE 9
3.5 PP72/48 I/O MODULE 9
3.6 ADI4 10
3.6.1 SMART LINE MODULE 11
3.7 MCB 11
3.8 MCPB 11
3.9 ELECTRICAL CONTACTORS 12
4.0 PLC 12
5.0 METHODS OF REPRESENTATION 13
6.0 SOFTWARE BLOCKS 14
7.0 COMMUNICATIONS 15
8.0 POSITION FEEDBACK SYSTEM 15
8.1 ENCODER 15
8.2 FEEDBACK CONTROL 15
8.3 OPTICAL TYPE ENCODER 15
8.3.1 ROTARY TYPE ENCODER 16
8.3.2 INCREMENTAL ENCODER 16
8.4 LINEAR ENCODER 17
9.0 MOTION TRANSFER 18
10.0 POWER SYSTEM IN BHVP 19
10.1 SINGLE LINE DIAGRAM OF 33/11KV SUBSTATION19
10.2 PARTS OF SINGLE LINE DIAGRAM 20

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10.3 SINGLE LINE HT & IT DISTRIBUTION NETWORK 20

11.0 PROTECTION SYSTEMS FOR TRANSFORMERS 24
11.1 INTRODUCTION TO TRANSFORMERS 24
11.2 WORKING PRINCIPLE 25
11.3 CONSTRUCTION 25
11.4 PARTS OF A ELECTRICAL TRANSFORMER 26
12.0 CONCLUSION 27

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1.0 Introduction

BHARAT HEAVY PLATES & VESSELS LIMITED is established in

1966 at Visakhapatnam, Andhra Pradesh .It got merged with BHARAT
HEAVY ELECTRICALS LIMITED and is renamed as BHARAT HEAVY
ELECTRICALS LIMITED – HEAVY PLATES & VESSELS PLANT (BHEL-
HP&VP). It became the 17th unit of BHEL and first coastal unit of BHEL.
Expanding its product line day by day including sophisticated technology,
equipment and systems like multilayer vessels, turnkey cryogenic
plants ,storage and distribution systems power plant accessories , heat
exchangers of LAC (light combat aircraft),oil refinery accessories, liquid firing
useful materials for umbilical towers in rocket centers.
This is one company which houses excellent engineering skills,
uncompromising quality control, dedicated erection & commissioning team
under one roof, a combination resulting in India’s self reliance. BHPV acquired
various national and international quality accreditation such as ASME,
national board etc.

1.1 BHEL-HPVP PICTORIAL VIEW

HPVP is easily pictured by dividing the organization into the following

divisions to carry out its functions:
a) Finance b) Material Management c) Personnel and Administration d)
Engineering and commercial e) Quality, research and development f)
Production and Services
Production and Services include planning, production technology, welding
technology and production. Production shops are classified as feeder shops
and assembly shops. M.P shop, L.M.S, H.M.S, Press shop, Shells shop, and
Nozzle shops will under feeder shops while Valve trays, P.V, H.E, and C.P will
come under assemble shops. HPVP is having a shop floor area of over 56000
sq.m.

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1.2 WORKSHOPS

Parts that are used for assembling in Production shop are made in
feeder shops. The feeder shops are subdivided into six types, they are:
a) M.P ------- Material Preparation
b) L.M.S ------- Light Machine Shop
c) H.M.S ------- Heavy Machine Shop
d) Press ------- Bending & Pressing of Plates
e) Nozzles ------- Pipe preparation & Welding
f) Shells ------- Rolling & Welding Operation

1.3 PRODUCTION SHOPS

The parts made in the feeder shop assembled in production shop. The
following five shops come under production shop.
a) P.V -------- Pressure Vessels
b) H.E. -------- Heat Exchangers
c) C.P -------- Cryogenic production
d) C.S.P.I -------- Combustion system products
e) C.S.P.II -------- Combustion system products

1.4 SALIENT FEATURES OF DIFFERENT SHOPS

1.4.1 MATERIAL PREPARATION SHOP

Plate material drawn from stores is cut to size and delivered to
concerned production shops. Gas cutting for carbon & low alloy steels can be
done up at 50 mm thick, square cut, single bevel cut, with or without nose,
double bevel cut with nose can be directly cut plasma cutting stainless steel
plates up to 80 mm thick.

1.4.2 LIGHT MACHINE SHOP

In this shop, all small components machining such as marking holes in
tube sheet, and drilling planning of small items will take up here. Nozzle to
flange welding is done in this shop.

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1.4.3 MACHINERY USED IN LIGHT MACHINE SHOP

A) Small and medium lathes
B) Auto lathe
C) Radial drilling machines
D) Small horizontal boring
E) Medium horizontal boring
F) Heavy Lathe
G) Plane drilling machine
H) CNC drilling machine
I) CNC deep hole drilling machine (HMT)
J) Cylinder grinding machine
K) Horizontal surface grinder
L) CNC lathe machine

1.4.4 HEAVY MACHINE SHOP

Machining, drilling, and surfacing of components which are more
largely than the capacity of L.M.S will be carried out here. The shop is
equipped with one 5000mm, one 4000mm, one 2500mm diameter heavy
double column vertical turning and boring machines besides a number of
smaller machines. Horizontal boring machine is capable of bore max. Depth
2000mm.

1.4.5 MACHINERY USED IN HEAVY MACHINE SHOP

a) Radial drilling ----------- 2no.
b) Universal drilling ----------- 1no.
c) Single column planning ----------- 1no.
d) Double column planning ----------- 1no.
e) Large horizontal boring ----------- 2no.

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1.4.6 PRESS SHOP

The dished ends required for vessels are prepared with single plate
and with petal construction in this shop. Hydraulics presses upped max
capacity of 1600T used for pressing dished ends, petals of storage spheres
and various other parts. Max diameter of dished ends that can be prepared in
the shop is 5000mm and max thickness that can be handled be ion single
stroke is 80mm, while upped 120mm thick plates are also parade in stages.

1.4.7 MACHINERY USED IN PRESS SHOP

a) Section bending roll ----------- 1no.
b) Pneumatic hammer ----------- 1no.
c) Pipe bending ----------- 2no.
d) Hydraulic press 250 T ----------- 1no.
e) Hydraulic press 400 T ----------- 1no.
f) Hydraulic press 1600 T ----------- 1no.
g) Bending roll ----------- 1no.

1.4.8 SHELLS SECTION

In this shop, plates are rolled to required size and long seam and
circumferential seam welding will be done. Major welding is done by
submerged arc welding process. Max thickness welding done in this shop is
220mm. special narrow gap welding machines available in this shop. Which
can weld upped 350mm thick with groove width about 20 24mm.

1.4.9 MACHINERY USED IN SHELL SHOP

a) 1. Plate edge planning -------- 1200x80mm thick 2 no.
b) 2. Plate bending rolls -------- 235x3025mm thick 1 no.
c) 3. Plate bending rolls -------- 4000x22mm thick 1 no.
d) 4. Plate bending rolls -------- 3000x75mm thick 1 no.
e) 5. Submerged arc welding -------- 3 no.

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1.5 BHEL-HPVP PRODUCTS

Products manufactured at BHEL – HPVP plant include:
a) PRESURE VESSELS: With different kinds of steels like carbon steel,
stainless steel, clad steel, Monel etc. and any combination of there off.
b) COLUMNS: Both shop and site fabricated columns with or without
internals.
c) HEAT EXCHANGERS: From low pressure atmospheric fin coolers to high
pressure heat exchangers employing forged heads channels with test
pressure as high as 500kg/sq.cm and designs like U-tube, kettle type, etc.
d)STORAGE SPHERES: Of any size (up to 60m), any thickness (up to
60mm) to handle any fluid or gases like ammonia, ethylene, propylene, LPG
etc.
e) HIGH PRESSURE MULTILAYER VESSLES: Ammonia and urea reactors
built ply wall design to suit high pressure of the order of 300kg/sq.cm
hydraulic test pressure.
f) CRYOGENIC VESSELS: There are double wall construction with stainless
inner shell and carbon steel outer casing with evacuated inter space filled with
pearlier (insulating material) for guaranteed low evaporation rates.
g) AIR & GAS SEPERATION PLANTS: These plants are custom built mainly
for production of oxygen, nitrogen, argon and for separation of coke oven gas,
converter gas for ammonia production. The design include simple cycle with
purification by absorption or with reversing exchangers and capacities
handling different feed stocks like bamboo, hard woods etc.
h) EVAPORATION PLANTS: Plants designed for the concentration of solids
in different types of spent liquors in multiple effect evaporation bodies using
steam heating. The application includes paper & pulp and alumina industries.
All the above equipment’s are fabricated according to standard code to
ensure the safety during testing and service. The most commonly used codes
are ASME, BS5500, AD Mark Blotter, IS 2825, TEMA, ANSI, API etc. For
fabricating all the above equipment, welding is the best suited operation in
terms of strength and safety with standing at high pressure. In B.H.P.V,
production is also mostly carried out by welding. It involves lot of work
including preparation of technologies, procedure, conducting tests and

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selecting suitable processes and suitable consumables. These works are

carried out by the WT department.

1.6 WELDING TECHNOLOGY

As BHEL-HPVP plant is a fabrication industry, it is mainly based on welding
technology. All welding operations done in the company are governed by
welding technology department. For its manufacturing techniques welding
technology has been playing a vital role. Welding technology department
prepares the procedures to be followed. Welding technology department will
take care of all requirements of welding in production shops. Its main function
is to release the required technology to shops to follow and perform their job.
The other functions are estimating welding cost, replying to commercial
enquiries and replying constructional problems. The equipment and
consumables required to the shop will also be selected by the same
department.

2.0 Vertical Turning and Boring Machine

A Turning Machine is a machine that turns work-pieces into various shapes.

This process involves rotating a part while a single-point cutting tool moves
parallel to the axis of rotation.The machine is called Vertical because, the
spindle is oriented in vertical axis.The phenomenon of beveling the edges of
the vessel is called Boring.
SK-25 is one of the Vertical Turning and Boring Machine manufactured Skoda
company. The number 25 represents the diameter of the bed/spindle. The
diameter measures 2.5 meters. It has a left hand tool and a right hand tool.
We can operate the RHT in Auto mode and LHT in manual mode. It has 3
Axis CNC drilling machine. Those three axes are X,Z,spindle.

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During Beveling After Beveling

3.0 CNC Systems

CNC stands for Computer Numerical Control and this is a manufacturing

method that automates the control, movement and precision of machine tools
through the use of programmed computer software, which is embedded inside
the tools.It interfaces with the external world for the communications,remote
diagnosis,program uploading and downloading,program management
including storage,simulation,retrieval and editing.
SINUMERIK 802D SL is a CNC System that is combination of various parts.

3.1 Control and display elements

The main display is called Human Interface Display (HMI). It acts as the
communication source between the CNC Machine and the engineer. At the

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outer edges it has some softkeys. They are Vertical softkeys and Horizontal
softkeys. They carry a function to execute for the user graphic interface. At
the top of the box we have ports for peripheral to dump the code from the
external source. It has basically three area i.e. Status area , Application area ,
Softkey area.

3.2 Horizontal CNC Keyboard

It is basically the same Alphabetic keyboard for hardware peripheral to
interact with the HMI. This peripheral is just to control the things in the
software only.The following picture shows all the keys present in the CNC
Keyboard.

MCPA Module

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3.3 Machine Control Panel

This panel consists all the utilities for controlling the CNC Machine directly. In
short it has Emergency Button to stop the machine at emergency, position
control button to move the cross slide , buttons to control the rpm of the motor
inside the machine, buttons to switch the modes of the machine and button to
control speed of the machine.Machine control panel MCP to connect via a PP
72/48 I/O module.
Machine control panel MCP 802D sl to connect via an MCPA module.The
following picture is the reference for the MCP.

3.4 MCPA Module

MCPA module features interfaces for the connection of an analog
spindle the mcp 802d sl machine control panel and terminal strips for
additional, high speed NC inputs and outputs.It is mounted on the rear side of
PCU of the SINUMERIK 802D SL.

3.5 PP72/48 I/O module

The PP72/48 I/O module is a user-friendly and low-cost module
(without a separate housing) for connecting digital inputs/outputs within the
framework of an automation system based on PROFIBUS-DP. The module
has the following important features:

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– Peripherals interface for connecting an external machine control panel

(MCP) or a terminal strip converter for the digital inputs and outputs (X111,
X222, X333)
– PROFIBUS-DP connection (max 12 Mbits/s)
– 72 digital inputs and 48 digital outputs

3.6 ADI4 (Analog drive interface for 4 axes)

This module facilitates an analog drive interface for 4 axes/spindles,
with or without an incremental encoder.
Module features includes :
Profibus DP connection(max. 12Mbps)
4 Servo interfaces
Inputs: TTL/SSI encoders for incremental and absolute measuring system.
outputs : +10V analog
3.General and drive specific digital input/output signals.
4.Onboard status display by means of 4 diagnostic LEDS.
5.Power supply : + 24 V DC supply.

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3.61 Smart Line module

Power can flow into and out of the SLM depending on the power
differential between the three-phase AC supply and the DC link. The
Encoders and Smart Line module are communicated each other by DRIVE-
CLiq. The communication between Smart Line module and PCU is done by
PROFIBUS-DP. A combination of Smart Line module are connected to HUB
for better coordination and working.

3.7 MCB
Miniature Circuit Breaker is a safety accessory with an electro-
mechanical mechanism of action. MCB is an automatic switch that opens
when excessive current flows through the circuit. It can be reclosed without
any manual replacement.

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3.8 MPCB
Motor protection circuit breakers are a specialized type of electrical
protection device that is designed specifically for electric motors, like their
name implies. Electric motors have plenty of applications and are used to
drive mechanical devices of all types, so it is very important to protect them
adequately with MPCBs. There are different types of MPCB depending upon
the load used. These have small variable switches for controlling the current
flow.

3.9 Electrical Contactors

An electrical contactor is a switch that's electrically controlled and used to turn
circuits on and off repeatedly. Contactors are a type of electromagnetic switch
called a relay, which uses an electromagnetic coil to open and close
contacts. Contactors are often used in high-voltage circuits to control lighting,
heating, motors, and other high-voltage loads. A big Contactor is also used for
protection of DC motor under the bed/spindle.

4.0 Programmable Logic Controller

CNC use PLC to do the miscellaneous task like coolant on off,automatically
tool change,Job loading and unloading ,Job clamping and unclamping. The
programmable logic controller is defined as a digital electronic device that
uses a programmable memory to store instructions and to implement
functions such as logic, sequencing, timing, counting and arithmetic words to
control machines and processes. It consists of A central controller with central
processing modules and memory modules One or several expansion units
where I/O modules can be plugged.

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5.0 Methods of representation

STEP 5 programming language can be represented in 3 different ways.
Those are Ladder Diagram(LAD) , Control System Flow Chart(CSF) ,
Statement List (STL). Absolute or symbolic designations can be used for
operands with all three methods of representation.

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6.0 Software Blocks

There are 5 Types of blocks available in step 5 programming language:
Organization Block:
To organize and manage the user program.
Program Block:
To structure the user program into sections.
Functional Block:
For recurring and complex functions
Data Block:
To store the data.
Sequence Block:
For the simple programming of sequence controls.

7.0 Communications
The computer is connected to the PLC through Ethernet , RS-232, RS-485 or
RS-422. The programming software allows entry and editing of the ladder
style logic. PLCs are armored for severe conditions. This nature connects the
PLC to sensors and actuators. On the actuator side,PLCs operate electric
motor,hydraulic cylinders,magnetic relays,solenoids or analog outputs.

8.0 Position Feedback System

8.1 Encoder
The device that detects the current position for position control is called
an encoder and , generally is built into the end of the power-transmission
shaft, It is a way of counting pulses generated in unit time and a means of
detecting the interval between pulses together. An encoder that detects
rotation is called a rotary encoder, and an encoder that detects linear
displacement is called a linear encoder.
8.2 Feedback control
The method of controlling the motor rotation by detecting the motor
rotation,speed and angle using an encoder is called Feedback control.

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8.3 Optical Type Encoder

Optical Encoder interpret data in pulses of light. The shaft rotates a
disc with opaque segments that represent a particular pattern. These encoder
can determine the movement of an object for rotary or shaft applications while
determining exact position in linear functions. There are two types of optical
encoders.
8.3.1 Rotary Type Encoder
Absolute encoder
The optical encoder's disc is made of glass or plastic with transparent and
opaque areas. A light source and photo detector array reads the optical
pattern that results from the disc's position at any one time. The Gray code is
often used. This code can be read by CPU to determine the angle of the shaft.
The absolute analog type produces a unique dual analog code that can be
translated into an absolute angle of the shaft.

8.3.2 Incremental Encoder

A rotary incremental encoder has two output signals, A and B, which

issue a periodic digital waveform in quadrature when the encoder shaft
rotates. This is similar to sine encoders, which output sinusoidal waveforms in
quadrature (i.e., sine and cosine), thus combining the characteristics of an
encoder and a resolver. The waveform frequency indicates the speed of shaft
rotation and the number of pulses indicates the distance moved, whereas the
A-B phase relationship indicates the direction of rotation.

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8.4 Linear Type Encoder

The linear transducer operate on the photo electric scanning principle

with line gratings on glass as the measuring standards. By displacing the
scale relative to the scanning unit, solar cells generate cyclic sinusoidal
signals which are phase shifted to each other by 90 degrees. Suppose that for
positioning in the X direction, the tool has to move through a distance of 50
mm. This distance is converted into pulses which is given as feedback by
encoder and one pulse for each micrometer (1/1000 of a mm).
EX: For 50 mm distance, a command signal of 50000 pulses is generated by
the control system

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9.0 Motion Transfer

a) Servo Driving Mechanism
The command from NC makes the servo motor rotate, the rotation of
the servo motor is transmitted to a ball screw via a coupling, the rotation of the
ball screw is transformed into linear movement of a nut, and finally the table
with the workpiece moves linearly.In summary, the servo driving mechanism
controls the velocity and torque of the table via the servo driving device of
each axis based on the velocity commands from NC.

b) Spindle Driving Mechanism

Spindle unit consists of a spindle motor and power transmission
device. The rotation of the spindle motor is transmitted to the spindle body via
a belt and the velocity ratio is dependent on the ratio of pulley sizes between
the motor and spindle body(In our VTB the ratio is 1:3).

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10.0 POWER SYSTEM IN BHVP

Power taken at 33kv from the APEPDCL substation located within the
plant premises is supplied to all the loads by eight substations. Power
distribution at 33KV voltage level is brought down to 440V in two stages at
different substations. Power from 33kv yard substation is fed to two
transformers of 3.3/3.6 MVA capacity whose vector group is YNd11. From the
switch yard through underground cables power to the MAIN RECEIVING
STATION (MRS) is fed by two feeders. From main receiving station, all the six
substations are fed by two feeders Load monitoring is done at MRS All the
substations are independently fed by two feeders for the to transformers of
the substations. Distribution system of the factory is of under Radial type.
Factory have captive power plant to meet the power requirements during the
power shutdowns IAPEPDCL
Generator produces power at 6.3KV voltage which is step up to 11KV
and supplied to AIRS. During power supply failure of APEPDCL, the power
will be supplied by the captive power plant of 1000K VA capacity. The
complete HT single line diagram of BHPV is shown in Figure 4.1

10.1 SINGLE LINE DIAGRAM OF 33/11KV SUBSTATION:

BHPV is 33 KV HT customers for one of the state distribution boards

(APEPDCL). The below figure shows single line diagram of 33/11KV Switch
Yard. Power at 33KV is being fest to the transformers through an isolator. The
isolator is a manually operated switch which separates a part of the system
normally at off load condition and the high voltage will h grounded through the
lightning arrestor. It is used to protect the insulation and conductors of the
system from the damaging effects of lightning CT's and PT's are used to
measure current and Voltage. Relay gets input from CT's and PT's and output
is connected to the tripping coil of the circuit breaker. Whenever the high
currents or high voltages measured by the CT's and PT's tripping coil of the
relay will be activated and trips the circuit breaker Transformers will step down
the voltage from 33 to 11KV.

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10.2 Parts of single line diagram:

Electrical Isolator: Isolator is a manually operated mechanical switch
which separates a part of the electrical power system.
Lighting arrestor or Surge arrestor: It is a device used on electrical power
systems and telecommunications systems to protect the insulation and
conductors.

10.3 SINGLE LINE HT & IT DISTRIBUTION NETWORK:

From APEPDC. the 33KV electrical power will he step down to 11KV power
and supplied to MRS by to feeders. We have to distribute 11KV power by
using Feeder1 and Feeder2. From feeder1 & feeder2 this 11KV power is
going to MRS and then this power is distributed to all six substations. Each
substation consists of two transformers one is live and other is standby.
Feeder consists of six transformers and feeder2 consists of six transformers.
In each substation this 11KV power will be step down to 440V From T1
substation to T5 substation we have two incoming and one Bus coupler Air

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circuit breakerstand T6 we have two incoming and one Bus coupler oil circuit
breakers to distribute are present. From each substation the power will be
distributed to Main Panel (MP) and then to Distribution Panel (DP) there after
the power will be distribute to Power Panel (PP).

Control system for all substations are present in MRS. 33KV is step-
down to IKV and fed through MRS by two feeders at switch yard through
underground cables. These two feeders are connected to bus 1 and bus in
MRS. The two busses can be connected with a BUS- COUPLER. Each
substation consists of 2 transformers of which one is being fed by feeder 1
and other by feeder 2 from MRS. Always one transformer will be in standby.
During the power failure of APEPDCL. the captive power plant owned by
BHPV will operate and the supply will give to the factory without any time
delay. The captive power plant consists of two generators of 63 KV,
1000KVA. This 5.3 KV generator output will be stepped-up to 11KV using
6.3/11KV transformers and this 11FV output will give to control room to
distribute power. This 11KV output steps down power to 440V level at all the
six substations and supplies power to respective loads. Figures given below
shows all the six substations supplying power to various loads.

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11.0 PROTECTION SYSTEMS PROVIDED FOR TRANSFORMERS

11.1 INTRODUCTION TO TRANSFORMERS:

The development of modern power systems has been reflected in the

advances in transformer design. This has resulted in a wide range of
transformers with sizes ranging from a few KVA to several hundred MVA
being available for use in a wide variety.

Applications
The considerations for a V protection package vary with the application
and importance of the transformer. To reduce of the effects of thermal stress
and electro dynamic forces, it is advisable to ensure that the protection
package used minimizes the time for disconnection in the event of a fault
occurring within the transformer. Small distribution transformers can be
protected satisfactorily, from both technical and economic considerations, by
the use of fuses or over current relays. This results in time-delayed protection
due to downstream co-ordination. requirements However, time delayed fault
clearance is unacceptable on large power transformers used in distribution,
transmission and generator applications, due to system operation/stability and
cost of repair/length of outage considerations.

11.2 WORKING PRINCIPLE OF TRANSFORMER:

A transformer is a static device it transfers the electric power from one
circuit to another. circuit without change of frequencies. It can raise or lower
the voltage in a circuit but with a corresponding decrease or increase in
current. The physical basis of a transformer is mutual induction between two
circuits linked by a common magnetic flux. In its simplest form, it consists of
two inductive coils which are electrically separated but magnetically linked
through a path of low reluctance. The two coils possess high mutual
inductance. If one coil is connected to a source of alternating voltage, an
alternating flux is set up in the laminated core, most of which is linked with the
other in which it produces mutually induced E.M.F (according to Faraday's
Law of Electro Magnetic Induction e-Mdl/dt). If the second coil circuit is

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closed, a current flows în it and so electric energy is transferred (entirely

magnetically) from the first coil to the second coil. The first coil, in which
electric energy is fed from the a.c. supply mains, is called primary winding and
the other form which clergy is drawn out, is called secondary winding In brief,
a transformer is a device that
1. Transfers electric power from one circuit to another
2. It does so without a change of frequency
3. It accomplishes this by electromagnetic induction and

11.3 TRANSFORMER CONSTRUCTION:

The simple elements of a transformer consist of two coils having
mutual inductance and a laminated steel core. The two coils are insulated
from each other and the steel core. Other necessary pts are: some suitable
container for assembled core and windings; a suitable medium for insulating
the core and its windings from its container, suitable bushings (either of
porcelain. it-filled or capacitor-type) for insulating and bringing out the
terminals of windings from the tank.

In all types of transformers, the core is constructed of transformer

sheet steel laminations assembled to provide a continuous magnetic path with
a minimum of air-gap included. The steel used is of high silicon content.
sometimes heat treated to produce a high permeability and a low hysteresis,
loss at the usual operating flux densities. The eddy current loss is minimized
by laminating the core, the laminations being insulated from each other by a
light coat of core plate varnish or by an oxide layer on the surface. The
thickness of laminations varies from 0.35mm for a frequency of 50 Hz to
0.5mm for a frequency of 25 Hz.
Constructionally, the transformers are of two general types, the two types are
known as Core-type Transformer and Shell-type Transformer.
Core type: Copper windings surround core. Shell type: Iron core surrounds
the copper windings. To reduce the eddy currents induced in the core, thin

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laminations are used. To reduce the hysteresis loss, heat treated grain
oriented silicon steel laminations are used Generally, distribution transformers
are of Core type.

11.4 PARTS OF AN ELECTRICAL TRANSFORMER

Constructional details:
Silicon steel or sheet steel with 4% silicon is used. The core plates of a
transformer are made of silicon steel or sheet steel The sheets are used for
core plates contain 4% silicon. The sheets are laminated and coated with an
oxide to reduce iron losses. The core provides a path of low reluctance.The
relative permeability for the core material is of the order of 1,000 In a spiral
core transformer Higher flux densities can be used. A spiral core transformer
has a lower loss per kg Weight.
Windings: Conventional transformer has two windings.
The winding which receives electrical energy is called primary winding. The
winding which delivers electrical energy is called secondary winding Windings
are made up of High grade copper if the current is low. Stranded conductors
are used for windings carrying higher currents. Two types of losses: core
losses and copper losses, occur during operation.
Methods of cooling:
Natural Radiation- low voltage and output ratings. (500 V, 5 KVA). Oil filled
and self-cooled- large sized transformers (132KV, 100 MVA). Forced cooling
with air blast-Transformers with ratings higher than 33 KV and 100 MVA IN
BHPV Forced cooling with air biast is used for HT side transformer and
Natural Radiation is used for LT side transformer.
Conservator Tank:
Due to variations in load and climatic conditions, the oil in oil-filled, self-
Cooled transformers expands or contracts. In the absence of a conservator
tank, high pressures are developed which may burst the tank.
Bushings:
To provide proper insulation to the output leads to be taken from the
conservator tank. Porcelain type bushings are used up to 33 KV. Condenser
type and oil-filled type bushings are used beyond 33 KV.
Breather:

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Absorption of oil and dust by oil must be prevented. To prevent

moisture and dust from entering the conservator tank oil, breather is provided.

12.0 CONCLUSION
CNC machining is demonstrating how a new generation of computer
programmers and design engineers has transformed the practice of
machining into a precision art. There might be fine conventional machining
techniques available today, but many manufacturers now opt for CNC
machining because of the many advantages that its process has been
offering. Some of them are:

 CNC machines can be used continuously 24 hours a day, 365 days a

year and only need to be switched off for occasional
maintenance. Hence these can be used even in processing plants.

 They can easily be updated by changing the software and can be re-
programmed in a very short span.

 They can produce thousands of identical parts in a relatively short

amount of time, much faster than conventional machining.

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