BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

Academic session

2015-2016A Minor Training Report on

Control Equipment Engineering

Under the Guidance of : Submitted By:

MR AJAY DHOTE AYUSHI PANDEY

Sr. DGM (Design) ELECT. & COMM. ENGINEERING

C.E.E., BHEL Bhopal MANIPAL UNIVERSITY JAIPUR

CERTIFICATE

This is to certify that the project report entitled “Control Equipment Engineering ” is a piece of project work done by AYUSHI PANDEY student of Electronics & Communication Department, Manipal University Jaipur under my guidance and supervision for partial fulfillment of the requirement for the award of the degree of B.Tech in Electronics & Communication Engineering at Manipal University Jaipur.

To the best of my Knowledge and belief, the project report:

1) Embodies the work of candidate herself;

2) Has duly been completed;

3) Fulfills the requirement of the ordinance relating to the B.TECH. degree

of the University;

4) Is up to the standard both in respect of content and language for being

referred to the examiner.

PROJECT GUIDE:

Mr. AJAY DHOTE

Sr. DGM (Design) DATE: 4TH JULY’15

C.E.E., BHEL Bhopal

ACKNOWLEDGEMENT

I would like to thank the project co-coordinator Mr. AJAY DHOTE for providing all the material possible and encouraging throughout the course. It is great pleasure for me to acknowledge the assistance and contributions of all the engineers of various departments of BHEL BHOPAL for their prompt and timely help in the official clearances and valuable suggestions during the time of this training. I am also thankful to numerous BHEL engineers especially Mr. PRAMOD KUMAR MEHER, who helped me in understanding the products of their respective product groups.

Secondly, I am thankful to Mr. Pramod Kumar, for his support, cooperation, and blessings.

Thirdly, I would like to express sincere gratitude to Mr. Dinesh Dubey, for and to Mr. Ankur Saxena, under whose guidance I completed my training, for their constant support, cooperation and guidance during the course of my training.

I also extend my sincere appreciation to all staff members of C.E.E Division BHEL, Bhopal who provided there valuable suggestions and precious time in accomplishing my project report.

I would also like to express my profound gratitude to Control Equipment Engineering for constant and valuable suggestions while doing the training work.

Last but not least, I express my heartiest gratitude to Almighty god, our Parents for their love and blessings to complete the training successfully

Submitted By:

AYUSHI PANDEY

PREFACE

In this growing age of technology, the extent of correctness is a major point. This correctness and pin pointed guess is achieved only through hard work, experience and well guided practice. As a new comer to this field we required to have professional knowledge that will help in improving our skills and efficiency. Having a training work on the same topic increased our interest and made the work simpler.

The most vital part is the presence of a guide whose knowledge and practical experience built our self-confidence and helping hand by which we finished this project successfully. So we all are indebted to Mr. AJAY DHOTE who acted as a burning candle and enlightened us about this training.

TABLE OF CONTENT

Introduction of BHEL Bhopalo Manufacturing Units of BHEL Bhopalo Product Profileo BHEL objective

Introduction to C.E.EOil Rig Controlo System Descriptiono Drillingo SCRo DC/AC Module

Plant Controlo Automatic voltage regulator

o Electro Hydrolic Governor

o Large Current Rectifier

o Electronic Controller

Transportation controlo Electric traction system

BibliographyConclusion

BHARAT HEAVY ELECTRICALS LIMITED

Bharat Heavy Electricals Limited (BHEL) is one of the oldest and largest state owned engineering and manufacturing enterprise in India in the energy-related and infrastructure sector which includes Power, Railways, Transmission and Distribution, Oil and Gas sectors and many more. It is the 12th largest power equipment manufacturer in the world. In the year 2011, it ranked ninth most innovative company in the world by US business magazine Forbes. BHEL is the only Indian Engineering company on the list, which contains online retail firm Amazon at the second position with Apple and Google at fifth and seventh positions, respectively. It is also placed at 4th place in Forbes Asia's Fabulous 50 List of 2010. BHEL was established more than 50 years ago, ushering in the indigenous Heavy Electrical Equipment industry in India.] The company has been earning profits continuously since 1971-72 and paying dividends since 1976-77.74% of the total power generated in India is produced by equipment manufactured by BHEL.

It is one of India's nine largest Public Sector Undertakings or PSUs, known as the Navratnas or 'the nine jewels'. In June 2012, BHEL commissioned a 250 MW power generating unit at Harduaganj in Uttar Pradesh.This would add six millin units of electricity on a daily basis.

MANUFACTURING UNIT OF BHEL

First Generation Units:- BHOPAL Heavy Electrical Plant

HYDERABAD Heavy Electrical Equipment Plant

HYDERABAD Heavy Electrical Power Equipment Plant

TIRUCHY High Pressure Boiler Plant

Second Generation Units:- JHANSI Transformer and Locomotive Plant

HARIDWAR Central Foundry and Forge Plant

TIRUCHY Seamless Steel Tube Plant

New Manufacturing units:- RANIPAT Boiler Auxiliaries Plant

JAGDISHPUR Insulator Plant

RUDRAPUR Component and Fabrication Plant

BANGALORE Industrial System Group

BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

Heavy Electrical Plant, Bhopal is the mother plant of Bharat Heavy Electricals Limited, the largest engineering and manufacturing enterprise in India in the energy-related and infrastructure sector, today. It is located at about 7 kms. From Bhopal Railway station, about 5 kms . From Habibganj Railway station and about 18 kms. From Raja Bhoj Airport. With technical assistance from Associated Electricals (India) Ltd., a UK based company; it came into existence on 29th of August, 1956.  Pt. Jawaharlal Nehru, first Prime minister of India dedicated this plant to the nation on 6th of November, 1960. BHEL, Bhopal with state-of-the-art facilities, manufactures wide range of electrical equipments. Its product range includes Hydro, Steam, Marine & Nuclear Turbines, Heat Exchangers, Hydro & Turbo Generators, Transformers, Switchgears, Control gears, Transportation Equipment, Capacitors, Bushings, Electrical Motors, Rectifiers, Oil Drilling Rig Equipments and Diesel Generating sets. BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving towards excellence by adopting TQM as per EFQM / CII model of Business Excellence. Heat Exchanger Division is accredited with ASME ‘U’ Stamp. With the slogan of “Kadam kadam milana hai, grahak safal banana hai”, it is committed to the customers. 

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

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

BHEL caters to core sector of Indian economy viz. Power Generation and Transmission, Industry, Transportation, Telecommunication, Renewal energy defense etc. The wide network of BHEL 's, 14 manufacturing divisions, 4 Power sector regional centers, 8service centers ,18 regional office and a large numbers of project sites spread all over India and abroad enable the company to promptly serve its customer and provide them with suitable products, system and services at competitive prices. BHEL has already attained ISO 9000 and all the major units/divisions of BHEL have been upgraded to the latest ISO-9001: 2000 version quality standard certification for quality management. All the major units/divisions of BHEL have been awardedISO-14001certification for environmental management systems and OHSAS 18001 certification for occupational health and safety management systems.

POWER SECTOR:Generation:Power sector comprises of thermal, nuclear and hydropower plant business. Today BHEL supplied sets account for nearly 6473 MW or 68% of the total installed capacity of 99146 MW in company as against nil in 1969-70.Transmission:BHEL also provides a wide range of transmission products and systems of up to 400 KV class. These include high voltage power and distributed transformer, capacitor, insulator etc. For economic transmission of bulk power over long distances High voltage Direct Current (HVDC) systems are supplied.

INDUSTRY SECTOR:BHEL is a major contributor of equipment and systems to industries like cement, fertilizers, Refinery, petrochemicals, etc.

TRANSPORTATION:Most of the trains operated by the India Railways including Metro in Kolkata are equipped With BHEL’s traction control equipment.

TELECOMMUNICATION:BHEL also caters to the telecommunication sector by way of small, medium and large switching systems.

RENEWABLE ENERGY: Technologies that can be offered by BHEL for its exploiting non-conventional and renewable Sources of energy include: wind-electric generator, solar power based water pumps, lighting And heating systems.INTERNATIONAL OPERATIONS:BHEL has over the years, established its reference in over 60 countries worldwide, ranging from USA to New Zealand in the Far East.

NATIONAL CUSTOMERS OF BHEL : Punjab state electricity board(PSEB) Uttar Pradesh state electricity board(UPSEB) National thermal power corporation(NTPC) Appolo tyres Bakco Sail Birla tyres and birla cement Grasim industries IOC Essar oil ONGC Larsen and turbo Jk cement Kirloskar Siemens etc.

INTERNATIONAL CUSTOMERS OF BHEL:

M/S ESBARA CORPORATION, JAPANM/S ZEECO IN CORPORATION, USA

SIMMCO INTERNATIONAL SIEMENS, GERMANY SIEMENS, SINGAPORE BIEJI PROJECT, IRAQ LMZ, RUSSIA, etc.TECHNOLOGICAL UPGRADATION AND RESEARCH &DEVELOPMENT:

 To remain competitive and meet customers' expectations, BHEL lays great emphasis on the continuous up gradation of products and related technologies, and development of new products. BHEL's commitment to advancement of technology is reflected in its involvement in the development of futuristic technologies like fuel cells and superconducting generators. BHEL's investment in R&D is amongst the largest in the corporate sector in India. During the year 2010-11, BHEL invested Rs.10, 050 Million on R&D efforts- 21% higher than the previous year.

PRODUCT PROFILE OF BHEL BHOPAL

1. Ac motors and alternators

2. Hydro turbines

3. Hydro generators

4. Heat exchangers

5. Excitation control equipment

6. Steam turbines

7. Transformer

8. Switch gear

9. OLTC

10. Large current rectifiers

11. Control and relay panels

1. AC MOTORS & ALTERNATORS

Figure 1 Alternator

BHEL is a leading AC Machines manufacturer and in the last four decades have supplied more than 20000 HT & LT A.C. Machines for various applications to Indian as well as Export market.

The applications include Power Plants, Nuclear Energy, Petrochemicals, Fertilizers, Refineries, Cement & Steel Industries, Irrigation Projects, Pipelines, etc.

The manufacturing plant in Bhopal was established in technical collaboration with AEI UK. Commercial production of A.C. Machines commenced in the year 1963. Technology was upgraded by collaborating with Siemens AG, Germany from 1980-1990 and subsequently from 1996-2006. Motors are offered both in standard as well as tailor made designs to meet customer's specific needs. High performance is achieved through optimum utilization of the active materials and components. BHEL A.C. Machines offer high efficiency, exceptional reliability, quick installation and minimal maintenance costs.

Our engineers combine their extensive experience with state-of-the-art analytical design tools, latest machine tools, Six Sigma methodology and advanced material development to deliver the best product.

Installed Capacity: 1500 machines per annum.

2. HYDRO TURBINES

Figure 2 Hydro Turbine

A leading turbine manufacturer offering a wide range of Hydro Turbine, Valves, Governors, Turbine and Station Auxiliary systems, balance of plants for Hydro Power Station and related Services.

Installed manufacturing capacity:2500 MW/annum. Two units manufacturing hydro turbines. In the market for more than three decades. Dedicated shop area of over 100000 sq. meters. Ultramodern model development and testing facilities. Sophisticated CAD/CAM facilities. ISO 9001 Certification. ASME "Q" stamp for fabrication facilities.

3. HYDRO GENERATORS

Figure 3 Hydro Generator

Hydro generator is a synchronous alternator driven by a hydraulic turbine. Motor is synchronous motor to drive pump. BHEL Bhopal is a leading supplier of large, medium& small hydro generators, motors, bulb generators and related services.

Installed manufacturing capacity : 2500 MW Sophisticated CAD facilities ISO-9001 certification

4. HEAT EXCHANGERS

Thermal group of BHEL-Bhopal was formulated in year 1968 (Initial collaboration with M/s AEI -U.K. took place in year 1970) and started its production from year 1971 onwards.  Subsequently, new collaboration agreement with M/s BALCKE DURR- Germany for Moisture Separator Re-Heater (MSR) took place in 1987.  MSR to this new design were manufactured and supplied for 236 MW RAPP 3, 4 & KAIGA 1, 2 and 500 MW TAPP 3&4 Nuclear plants.  

BHEL-Bhopal Thermal group  products manufactured and supplied all over India to different State Electricity Boards and exported to countries like LIBYA, Malaysia, Azerbaizan, Bangladesh, OMAN etc. major customers of thermal equipment’s are State Electricity Boards and NTPC. Similarly Industrial Heat Exchangers have been supplied to IFFCO, FEDO, RELIANCE, GAIL, ONGC, IOCL, etc. Production of some of the other products like Rubber Expansion Joints, Flash Tanks, Miscellaneous storage tanks and Butterfly valves added in subsequent years.

All the Thermal products are tailor made and customer specific product and Customer requirements are continuously captured through pre-tender and post tender discussions, contract review etc. Perception is collected through customer surveys. 

Thermal group products are Technology intensive and therefore Technology development is of strategic importance. Product technology is continuously upgraded through in house development projects/ or Technical Collaboration.

AUXILIARY HEAT EXCHANGERS

Different types of auxiliary heat exchangers are being manufactured at BHEL. Depending upon application these auxiliary Heat Exchangers are named as

Air Coolers (CACW) Oil Coolers (Shell & tube type / Frame and tube type (Single tube &Concentric double

tube construction) / OFAF), Plug in type Water Cooler (Shell & Tube type) Hydrogen Cooler etc. (Frame and tube type). Air Cooler CACA ( Duct and tube type)

These coolers are accessories to main equipment’s such as Generator, Turbine, Transformer, Motors, etc. hence special attention is given to make these coolers compact in design and for trouble free service.

To ensure long life of these coolers materials for different components is decided carefully considering its application and water chemistry. Constructionally these coolers are very easy to maintain.

5. EXCITATION CONTROL EQUIPMENT

Excitation control equipment (automatic voltage regulator (AVR) and static excitation equipment-(SEE) for semi-static, static and brushless type of excitation system.

Complete range of Digital AVR and SEE available to suit all types of systems and generators added to product profile in the year 2003.  More than 35 years of field experience.

More than 600 AVRs are operating satisfactorily at various Hydro, Thermal and Industrial Power Plants. A number of captive power plant installed in Sugar, Chemicals, Paper and other industries are also equipped with BHEL make AVRs. Total system solutions on offerretrofitting of old excitation control system with latest state of art digital systems.There is a dedicated shop area with modern manufacturing and testing facilities

                                                                           

Figure 5 Excitation Control equipment for Hydro, Thermal Nuclear, Naval and Industrial applications.

6. STEAM TURBINES1) Design, Manufacturing, Erection, Commissioning and Services of :

30 MW, 120 MW Steam Turbines 236 MW Nuclear Turbines. 15000 SHP Marine Turbines 210 MW Steam Turbines.

2) Supply of Spares and Repairs of above Steam Turbines.3) R & M and Life assessment studies of BHEL & Non BHEL TG sets.

4) Repair and Supply of Spares of 210 MW and 500 MW KWU Turbines.

5) Repair and supply of Spares for Non BHEL TG Sets.

7. TRANSFORMER

A Leading Engineering Enterprise which Supplies wide Spectrum of Power Transmission Systems/ Solutions from a single entity

A Leading Transformer Manufacturer Offering wide range of Transformers Installed manufacturing capacity: 18000 MVA/Annum with dustproof facility in critical

areas. The capacity is being augmented by another 12000 MVA/Annum with totally dust proof

facility Having nearly 4 decades or over 30,000 man-years of experience Dedicated shop area of over 80000 sq. meters and unique Ultra High Voltage testing

facility

8. SWITCHGEAR

Leading Switchgear Group involved in Design, manufacturing, installation, commissioning and services of Switchgear.

A wide spectrum of switchgear catering to various applications like power station auxiliaries, power distribution, process industries, rural electrification, open cast mines, electric traction and other special applications.

Market leaders in India. Experience of 5 decades Thousands of various types of breakers working satisfactorily in India and abroad. Unique distinction of widest range of medium voltage Switchgear meeting every

requirement of the customer in stringent Indian conditions. Strong R & D infrastructure. Dedicated shop and design area of over 50,000 sq  meters. Regular facilities updating with new capital investment. Clear room facility for GIS Strengths:

   - Reliable and problem free product   - Proven product in service   - Repeated successful type testing and special testing   - Largest range to suit various application requirements viz Power Stations,

Distribution, Industrial & Railways.   - 100% routine testing as per IS & IEC.

Switchgear design fully type tested as per IEC:62271

9. ON LOAD TAP CHANGER

A leading On Load Tap Changer (OLTC) group involved in Design, manufacturing, commissioning and services of Tap Changers.

Latest Technology incorporating high speed resistor switching of  OLTC Complete system for parallel operation of transformers and remote Tap changer control

panel. Market leaders in India Capacity to supply 500 nos. OLTC Experience of more than 4 decades. Dedicated shop area of over 10,000 sq meters

ATRAINING

REPORT ON

CONTROL EQUIPMENT ENGINEERING

(CEE)

INTRODUCTION OF CEE

The Control Equipment Engineering (CEE) group is engaged in serving all the Industries i.e. Industry sector, Power sector, Transportation sector, Oil Rig sector and Defence sector.

There are more than 30 main products each having 4/5 variety w.r.t. rating, specification, features, etc. are being engineered and pioneered in SCR division. Besides, more than 100 variety of sub-assemblies / apparatus are also being catered to meet customer's need.

The different controls are:

1. Transportation controls

2. Plant and Industrial Controls

3. Oil Rig Controls

4. Defence Controls

OIL RIGS CONTROL

System description

The system consist of six 670 KW , 12.5 KVA, 3 phase, 50 Hz diesel generator feeding a common 600V collecting bus. The system can be operated with any number of generators running on the line and control of each generated frequency and volume is set individually on the respective switch gear cubicle.

Six SCR plant power cubicles are connected to the common bus and draw AC power from which ever generator running, converting it to DC power for driving various DC motors.

The SCR drive automatically selects the correct speed control function suitable for the motor to which it is assigned, as soon as the main DC contactors are energized. There are two 600 V feeder breaker which supply the 500 KVA transformer to feed the 380V distribution.

DRILLING ASSIGNMENT

a. Single Assignment switch

The main control centre for the drilling operation is the drillers console usually fixed on or close to the draw works. The main drilling assignment switch allows the driller to assign each of the SCR bridges he has for drilling to anyone of the pre-arrange programs shown on the console engraving.

b. Multiple assignment switch

A separate switch is provided for each function allowing assignment of each function to one of several SCR

DRILLING INSTALLATIONS

Types of oil rigs:• OFF SHORE RIGS

• ON SHORE RIGS (LAND RIGS)

MAIN DRILLING EQUIPMENTS

1. TYPE-I RIG : E760 RIG-Up to 3600 mtrs

2. TYPE-II RIG : E1400 RIG-Up to 4900 mtrs

3. TYPE-III RIG : E2000 RIG- Up to 6100 mtrs4. TYPE-IV RIG : E3000 RIG- Up to 9000 mtrs

Deep Drilling

E 760 RIG

SALIENT SPECIFICATIONS OF THE RIG EQUIPMENT ARE:

- BHEL E760 AC SCR RIGS ARE SUITABLE FOR DRILLING UPTO 3600 MTRS.- MAST CLEAR HEIGHT 142 FEET- FLOOR HEIGHT 25 OR 18 FEET- CASING LOAD CAPACITY IS 500,000 LBS- E760 DW (1000HP) SUITABLE FOR DRIVE WITH TWO MOTORS & ECB.- ROTARY IS EITHER CHAIN DRIVEN THROUGH DW OR INDEPENDENT

ROTARY DRIVE.- RIG EQUIPPED WITH 3 AC POWER PACKS 1215/1430 KVA RATED- DCPCR WITH 3 GEN AND 3/4 SCR PANELS ( 4 IN CASE OF IRD RIG)- 2 NOS 850PT MUD PUMPS WITH RATED INPUT HP 850. MAX WORKING

PRESSURE 5000PSI- 5 TANK MUD SYSTEM

Deep Drilling

E1400 RIG

SALIENT SPECIFICATIONS OF THE RIG EQUIPMENT ARE :

- BHEL E1400 AC SCR RIGS ARE SUITABLE FOR DRILLING UPTO 4900 MTRS.- MAST CLEAR HEIGHT 142 FEET- FLOOR HEIGHT 25 FEET- CASING LOAD CAPACITY IS 800,000 LBS- E1400 DW (1400 HP) SUITABLE FOR DRIVE WITH TWO MOTORS & ECB.- ROTARY IS EITHER CHAIN DRIVEN THROUGH DW OR INDEPENDENT

ROTARY DRIVE.- RIG EQUIPPED WITH 4 AC POWER PACKS 1215/1430 KVA RATED

- DCPCR WITH 4 GEN AND 4 SCR PANELS- 2 NOS 1100PT MUD PUMPS WITH RATED INPUT HP 1100. MAX WORKING

PRESSURE 5000PSI- 6 TANK MUD SYSTEM.- AC TOP DRIVE CAN BE FITTED.

Deep Drilling

E2000 RIG

SALIENT SPECIFICATIONS OF THE RIG EQUIPMENT ARE :

- BHEL E2000 AC SCR RIGS ARE SUITABLE FOR DRILLING UPTO 6100 MTRS.- MAST CLEAR HEIGHT 142 FEET - FLOOR HEIGHT 25 FEET- CASING LOAD CAPACITY IS 800,000 LBS- E2000 DW (2000 HP) SUITABLE FOR DRIVE WITH TWO MOTORS & ECB.- ROTARY IS EITHER CHAIN DRIVEN THROUGH DW OR INDEPENDENT

ROTARY DRIVE.- RIG EQUIPPED WITH 4 AC POWER PACKS 1215/1430 KVA RATED- DCPCR WITH 4 GEN AND 4 SCR PANELS- 2 NOS 1400PT MUD PUMPS WITH RATED INPUT HP 1400. MAX WORKING

PRESSURE 5000PSI- (ALTERNTIVELY 1700PT MUD PUMPS WITH INPUT OF 1700HP CAN BE USED)- 8 TANK MUD SYSTEM.- AC TOP DRIVE CAN BE FITTED

Super Deep Drilling

E3000 RIG

SALIENT SPECIFICATIONS OF THE RIG EQUIPMENT ARE :

- BHEL E3000 AC SCR RIGS ARE SUITABLE FOR DRILLING UPTO 9000 MTRS.- MAST CLEAR HEIGHT 152 FEET- FLOOR HEIGHT 35 FEET- CASING LOAD CAPACITY IS 1500,000 LBS- E3000 DW (3000 HP) SUITABLE FOR DRIVE WITH THREE MOTORS & ECB.- ROTARY IS EITHER CHAIN DRIVEN THROUGH DW OR INDEPENDENT

ROTARY DRIVE.- RIG EQUIPPED WITH 6 AC POWER PACKS 1215/1430 KVA RATED

- DCPCR WITH 6 GEN AND 6 SCR PANELS- 3 NOS 1700PT MUD PUMPS WITH RATED INPUT HP 1700. MAX WORKING

PRESSURE 5000PSI- 6 TANK MUD SYSTEM WITH HIGHER CAPACITY OF EACH TANK.

Main drives of oil rigs:

1. DRAW WORKS-A2. DRAW WORKS-B3. MUD PUMP-14. MUD PUMP-25. ROTARY

AC PCR SYSTEM

PRIME MOVER:

• ENGINE D399/ KTA 3067 : 1000rpm

• KTA-50-G/KTA 3067-G : 1500 rpm

ALTERNATOR:

• ALTERNATOR KATO:1000 rpm1215 KVA

• BHEL OA7001: 1000 rpm1215 KVA

• BHEL OA6301: 1500 rpm,1430 KVA

DC CONTROL MODULE

SCR

Silicon controlled rectifier is a solid state switching device that is used to rectify on AC to produce DC. It provides controlled rectification, this enable a fixed voltage AC supply to be converted into a variable voltage DC supply. By applying this variable voltage to a DC motor armature, can control both its speed and current hence maintaining complete and accurate control of any equipment to which motor is coupled.

Operating an Engine

i) Starting an engine

Check the over speed device is reset The engine may hunt for a period of time until the actuator warms up. The engine will automatically ramp up to full speed and voltage

ii) Stopping an engine

Check that another engine is running on line and can take the load. Open the AC circuit breaker Select the governor control switch to ‘Idle’ Allow the engine to cool

Energizing an SCR cubicle

Reset the SCR AC circuit breaker Check that the fuse and over temperature indicator on the logic display

panel mounted on the cubicle door are lit. Charge and close the AC circuit breaker Ensure that :

i) SCR blower are runningii) SCR ON lamp is litiii) Circuit breaker closed indicator on the logic display panel is lit.

Running the motorsA. Electrician step up Procedure

i) Turn field supply controls is ‘Auto’ii) Turn blower started control to ‘Auto’iii) Check that motor lock out switch is in the ‘run positions’iv) Check that AC control supply is on

B. Running the draw works

i) Check that SCR are onii) Select assignment position iii) Turn switch to ‘forward ‘ or ‘reverse’ iv) When regenerative breaking is provided the motors will slow down

rapidly (10 sec) to catch hold speedv) Use foot throttle to give rapid acceleration up to top speed.

C. Running the Mud pumps

i) Check that SCR are onii) Select assignment positionsiii) Turn driller’s console lockout switch on ‘On’iv) The blower auxiliary motors and filed supply will start

automatically when the console lockout switch is turned on.v) Wait until the “MP READY’’ lamp is on.vi) ‘Turn MP hand throttle to give desired strokes/ press.

ELECTRICAL EQUIPMENTS

1. POWER PACKS

Diesel engines. Alternators. Housing with oil field skid.

2. DC PCR

Generator panel SCR panel Feeder panel Field supply panel

SCR DRIVE SPECIFICATION:

Three phase AC input. Voltage: 600VAC frequency: 50 HZ DC output per SCR unit: 0-750VDC Zero to current limit value AMPS continuous throughout maximum

voltage. Different limits are selected to allow maximum horsepower and torque to

be obtained from the rig equipment without exceeding the manufacturer’s ratings.

The over temperature switch, associated with each SCR is set for 165°F (74°C).

3. AC PCR

Incomer panel MCC Baylor controls Transformers incomer panel.

3. DRILLER’S CONSOLE

Indication panel metering drive selection drive control.

4. DC MOTORS

- Shunt motor - Separately excited - 1000HP

5. RIG LIGHTING PACKAGE

• Flame proof• Explosion proof• Weather proof• Heavy Duty• Hazardous AreaClass-1 Zone-1, Division-1, Gas group-IIA & IIB

6. INTERCONNETION PACKAGE

- Plug and sockets- Power and control cable- Cable trays/cable boxes.

7. ELECTRICAL CREW ROOM

- Elect. office- workshop- Store room.

TRANSPORTATION CONTROL

ELECTRIC TRACTION SYSTEM

DEFINITION:

• Traction means to move forward a vehicle ... and so a system when move forward by means by electric is known is electric traction system. In electric traction mainly we have to run a motor by means of electricity and for running a motor we need some power circuit and control circuit.

REQUIREMENTS OF AN IDEAL TRACTION SYSTEM:

• High starting pulling effort in order to have rapid acceleration.

• It should be self-contained and able to run on any route.

• Capability of withstanding voltage fluctuations and temporary interruption of supply.

• Parallel running usually more than one motor (two or four motors) should be possible.

CLASSIFICATION OF ELECTRIC TRACTION SYSTEMS:

Electric - receive electricity externally

- Self-contained locomotives

NOMENCLATURE IN INDIAN RAILWAYS:

Name consists of four parts

e.g. WDP2: Diesel-Electric Passenger train running on broad gauge

W/Y/Z(Gauge type)

A/C/D/CA (Mode of traction)

P/G/M/S/U

2/4/6/2C(Model No.)

W B.G.

Y M.G.

Z N.G.

A AC Traction

C DC Traction

D Diesel-Electric

CA Dual Power

AC-DC Traction

P Passenger

G Goods

MMixed(Passenger and Goods)

S Shunting

U EMU

TYPES OF GAUGES USED:

SL No. Type of Gauge Gauge Width

1 Broad Gauge (B.G) 1.676 m

2 Meter Gauge (M.G) 1.0 m

3 Narrow Gauge (N.G) 0.762 m

4 Narrow Gauge (N.G) 1.48 m

TYPES OF RAILWAY SERVICES:

Main line service : LOCO

City service or urban service: EMU

Sub-urban service: EMU

EMU:

An electric multiple unit or EMU is a multiple unit train consisting of self-propelled carriages, using electricity as the motive power. An EMU requires no separate locomotive, as electric traction motors are incorporated within one or a number of the carriages. EMUs are popular on commuter and suburban rail networks around the world due to their fast acceleration and pollution-free operation.

ADVANTAGES OF EMU:

• Multiple units have cabs at both ends , the train may be reversed without uncoupling/re-coupling the locomotive, giving quicker turnaround times, reducing crew costs, and enhancing safety

• As multiple unit trains have multiple engines, the failure of one engine does not prevent the train from continuing its journey. A locomotive drawn passenger train typically only has one power unit, meaning the failure of this causes the train to be disabled

ADVANTAGES OF LOCO:

Maintenance - It may be easier to maintain one locomotive than many self-propelled cars.

• Large locomotives can be substituted for small locomotives when more power is needed. Also, different types of passenger cars (such as reclining-seats, compartment cars, couchettes, sleepers, restaurant cars, buffet cars, etc.) can be easily added to or removed from a locomotive-hauled train

• The passenger environment of a multiple unit is often noticeably noisier than that of a locomotive-hauled train, due to the presence of underfloor machinery. The same applies to vibration

SYSTEMS OF TRACK ELECTRI-FICATION:

Direct current system : 550V DC,750V DC,1500V DC

550V DC used in Kolkata Trams

750V DC used in Kolkata Metro trains, Bangalore Metro trains

1500V DC used in some area of Mumbai region, presently they are switching over to 25KV AC

Single phase 25KV AC, 50Hz used in Main lines, Delhi Metro and all other remaining regions of EMU’s

100kVA AUXULIARY CONVERTOR:

Auxiliary convertor is used to provide power to locomotives. It is called auxiliary because it feeds power to the auxiliary of main converter. It doesn’t provide

variable power. It gives constant power. 300 kvA auxiliary converter, so 100 kvA auxiliary converter is used and we give three 100 kvA auxiliary converter.

If one of the auxiliary converter fails then the rest two auxiliary converter will take the load of the failed one. This is known as redundancy.

It converts 1 phase AC to 3 phase AC.

WORKING-

1 phase AC is given to switching device(rectifier) which then converts to DC which is then passed through 3 phase inverter and then it becomes 3 phase AC. The input is not stable (700kv-1000kv) so for stability we use controlled rectifier

25 KVA STATIC INVERTER (ON BOARD TYPE) FOR ROOF MOUNTED AC PACKAGE UNITS OF SELF GENERATING AC COACHES OF

INDIAN RAILWAYS:

Equipment description:

The static inverter is designed to feed 415 V, 3 phase, 50 Hz power to the roof mounted AC package units for AC coaches of Indian railways. This is achieved by locating the +110 VDC input voltage to establish a DC line voltage and subsequently inverting this link voltage to produce pulse width modulated 3 phase output voltage.

Constructional features:

The equipment is housed in a cubicle. The cubicle structure is of welded construction made up of situational steel angles. Sheet steel covers on sides, near and top and two hinged doors on front are provided side top and bottom covers are provided with necessary louvers and holes for ventilation. The various assemblies are firmly fixed to the frame using suitable hardware so as to meet the traction duty requirement.

Electronic controls are modular type housed in a control rack with plug in type of cards. Booster circuit consisting of IGBT and link capacitor is also of modular construction. The inverter portion is a self-sufficient modular limit.

Indications and metering are provided on front LHS door. The unit is forced cooled with air duct at rear top cover and covered with a canopy.

Applications:

The booster /static inverter is specially designed to power the roof mounted AC package units of AC coaches of Indian Railways.

Principle of Operation:

Inverter consists of step up chopper which converts the input 100V DC supply (from battery plus alternator) to 550 V DC link voltage. Subsequently this DC link voltage is inverted 415V/50Hz/3phase AC by the static inverter.

Operating sequence:

Switch on the control MCB and fan MCB located behind RHS cubicle door. Switch on 110V DC input to the cubicle and check that input power ON.

LED indication starts growing. Booster voltage starts building up (through soft start) and when it reaches approx. 500V booster output OK indication appears. Once the booster voltage has reached to 550+/- 25V “inverter fault” LED goes off and ‘inverter ON’ LED starts glowing within 2 to 5 sec. Booster cooling fan also starts working as soon as inverter voltage appears. Direct measurement meters for input DC voltage and DC current are provided on front door AC voltage and AC current meters are provided with selector switches for different phases.

3 Phase (AC/DC) EMU

These are small trains. EMU basically stands for electrical manufactures units. Each unit in an EMU has three bogies.

DRIVER TRAILER CAR TRAILER CAR MOTOR CAR

1) motor car2) trailer car3) driver car

The motor car is basically the driving unit here unlike in normal trains where the engine is either at start or at end. These units can be connected in series for adding more bogies to the train multiple units is connected. These machines are run by electricity so these are called electrical multiple units. These emu’s are basically used in metro cities like Bombay and Delhi where power supply is both AC and DC. The switching of power from AC to DC is still going. So, these emu’s are AC / DC. Now 3 Phase supply is needed for the motors which drive the wheel.

FIGURE

This is a simple circuit diagram for an EMU system.

The separate components for a DC system are:

i) High voltage distribution ii) Four quadrant controlleriii) Inverteriv) Low power module v) Low voltage system

Circuit component description

A. Pantograph(25 KV AC/1500 V DC) (211 W1) The pantograph is mounted on the roof of the motor coach and feeds the power from the overhead line either 25 KV AC or 1500 V DC operation. Operation is by a pneumatic control valve. Since pantograph is connected to only one line, we get only one phase in case of AC. This single phase is first converted to DC by rectifier and then 3 Phase AC by inverter.

B. Surge Arresters (25 KV AC) (211F2, 211F6)

The 25 KV AC surge arrester protects the traction system against overhead line voltage surges. These are two types:

One is directly connected to the pantograph and protects the supply voltage sensing unit.

Other protects the main transformer and the 4 Q controllers, in case of opening the VCB.Both surge arresters are mounted on the vehicle roof.

C. DC Surge Arrester (211F3)

A surge arrester for 1500 VDC is mounted on the pantograph side of the system selector switch in this way train is always protected against over voltage coming from a 1500 VDC supply.

D. Primary current transformer (211T1)

The primary current transformer is a part of the roof bushings. With this transformer any over current is detected, in which case a protection system opens the VCB.

E. High voltage detection unit

The supply voltage sensing circuit senses the overhead line supply i.e. 25 KV AC or 1500 V DC and communicates the type of overhead supply to relay logic a well also the traction converter controls, to ensure activation of the proper mode of operation.

F. Vacuum Circuit breaker (211Q2)

In the AC mode of operator the VCB supplies 25 KV AC to the primary of the main traction transformer. The VCB is operated by pneumatic pressure through an electric solenoid valve. The VCB is mounted on the roof.

G. AC Earthing Switch (211Q12)

This earthing switch ensues proper supply of roof mounted power equipment as well as HT room and under frame mounted power equipment i.e. pantograph, main transformer, traction converters etc. The AC earthing switch is double pole double throw type switch, connected across the VCB.

H. DC circuit breaker (211Q6)

When operating from 1500 VDC the traction converter is protected by a DC circuit breaker. The circuit breaker has a built in over current and provides short circuit protection. This DC circuit breaker is located in the switch gear rack in the HT roof.

PLANT & INDUSTRIAL

CONTROL

AUTOMATIC VOLTAGE REGULATOR

TYPE VXB32MPrincipal of Operation:-

The automatic voltage regulator ensures stable operation of the synchronous generators in the entire load range. It ensures very fast recovery of generator voltage following changes in load demand. The protective features ensure safe operation of the generator.

The equipment automatically regulates the output voltage of a synchronous generator by providing it with a controlled field supply via an exciter generator. The equipment is active over the entire load range with negligible dead band.

The basic system consist of two completely independent channel the ‘AUTO CHANNEL’ with closed loop current regulation. Both the auto and manual channel separate signal phase fully controlled Thyristor as their element. The auto control loop compares the generator voltage with a fixed voltage to produce the auto control signal, which calls for an increase or decrease in excitation, as and when necessary. Potentiometer 90A sets the required generator output voltage when the excitation is being controlled manually field connections are switched over from the AUTO thyristor bridge to the MANUAL thyristor bridge and the AVR output is determined by the position of the motorized pot 90M. Both the AUTO AND MANUAL control alp stages are normally fed from a 415 VAC, 1 phase 50 Hz unit supply through a suitable step down generator terminals the converter alp controls the exciter field current, which is determined by the firing control signal to the thyristor bridges for auto and manual channels.

Constructional Features

The equipment is housed in a signal cubicle is complete with ventilated top cover. It is provided with full height front and rear hinged doors. The doors have been provided with louvers for ventilation and rubber sealing strips vermin protection. The cubicle is fitted with anti-condensation heater and illuminating lamps. Cable entries are through a removable palate mounted on the cubicle bottom. Terminal blocks for external connections are accessible from the rear door. The regulator circuit makes use of solid state electronic components. The voltage regulation and other control and protection circuits are contained in separate control racks. The circuits within the racks are mounted on plug in printed circuit cards. The racks are provided with card guides and wire wrapping type female connectors for the cards. Potentiometer for various controls is fitted on the front of racks. Distribution of the circuits in the racks is on functional basic. Distribution of components on sub panels is also on functional basis.

SILICON POWER RECTIFIER

LARGE CURRENT RECTIFIER FEATURES

The large current rectifier equipment provides dc power for electrolytic/process chemical and aluminum industry.

The rectifier unit basically consists of a regulating transformer having configuration of double star with IPT or 30 bridge connections, transducers having variable voltage characteristics and one or two rectifier cubicle.

The voltage range required for starting and controlling the output of the process is obtained with help of transduction in conjunction with an on load top changer mounted on regulating transformer.

The large current is achieved by high power silicon diodes connected in parallel on a heat sink for each phase. The heat sink are either forced air cooled or forced de-mineralized water cooled depending upon rating and application.

The water cooled rectifier are compact and the compactness of equipment is achieved by mounted the silicon diodes on hollow heat sink cooled by circulating water. The thermal impedance of the heat sinks is improved about 20 times as compared to air cooling.

Applications

i) Electroplating ii) Aluminum smeltingiii) Caustic soda plantiv) Graphite Furnacev) Potassium chlorate production vi) Manganese diode plantvii) Hydrogen production

Description

Rectifier equipment comprises an assembly of silicon diodes on heat sink together with fuse and surge voltage protection components, al suitably enclose and a separately mounted transformer for large current applications above 25 KVA important advantages are gained by mounted the rectifier assembly in close association with the transformer known as rectiformer.

ELECTRONIC CONTROLLER-HVR

The EC-HVR is high voltage DC power supply equipment for electrostatic precipitator used for extracting fly ash from exhaust gases. The equipment is supplied in two parts:

1. The high voltage transformer rectifier (HVR)

2. The electronic controller (EC)The transformer rectifier unit (HVR) consists of oil immersed step up transformer, ac reactor, high voltage rectifier, high frequency chock, and measuring and protection components.The electronic controller (EC) contains the antiparallel connected thyristor pair for controlling the input voltage to the rectifier unit along with, a microprocessor based control module BAPCON.The complete equipment is designed to provide continuously adjustable rate peak DC output voltage across the precipitator electrodes. The controller operates as constant current source adjustable up to rated DC output average current. Occurrence of spark at the electrodes is sensed and made to block the output voltage for fixed duration of 20 ms and voltage is build up again in a specified manner to provide optimum operational efficiency of the precipitator.A simplified block scheme of electronic controller and HVR set is shown below:

CONCLUSION“An Engineer with theoretical knowledge is not a complete engineer. Practical knowledge is very important for an engineer to develop and apply engineering skills”.

BHEL Bhopal is a vast service center. The headquarters of the services of BHEL is in Bhopal. It was a great experience for me to interact with the engineers and learn about the working of such a huge organization of the stature of BHEL. I learned about the manufacturing of various products used in almost all sectors of the economy and numerous industries. It is one of India's

nine largest Public Sector Undertakings or PSUs, known as the “Navratnas” or 'the nine jewels'. The Switchgear department is one of the largest of its kind in India today.

This is the only place in India to manufacture Gas Insulated Switch Gear with a clean room facility. BHEL Bhopal houses Asia’s largest Ultra High Voltage Lab (UHV Lab) operating at voltages as high as 3 million volts!!!!

BIBLIOGRAPHY