A TECHNICAL REPORT on SUMMER INTERNSHIP in

“BHEL-HPVP VISAKHAPATNAM”
Dissertation Submitted in partial fulfilment of the requirements for the

award of the degree in

Bachelor of Technology in ELECTRICAL and ELECTROINCS

Engineering

Submitted By

PITCHIKA BHASKARA NAGA VENKATA TARUN

22035A0220

Under the esteemed guidance of

Mr. P. Manmadha Reddy
Assistant Professor ©
Department of EEE
UCEN-JNTUK

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

University College of Engineering Narasaraopet
Jawaharlal Nehru Technological University
Kakinada
Narasaraopet – 522601 Andhra Pradesh,
India 2023-2024
 DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
University College of Engineering Narasaraopet
Jawaharlal Nehru Technological University
Kakinada
Narasaraopet – 522601 Andhra Pradesh,
India 2022-2023

CERTIFICATE
This is to certify that the technical report on Industrial Training entitled “BHEL-HPVP
VISAKHAPATNAM” that is being submitted by PITCHIKA BHASKARA NAGA VENKATA
TARUN(22035A0220) in partial fulfilment for the award of Bachelor of Technology in Electrical
and Electronics Engineering to the University College of Engineering Narasaraopet, Jawaharlal
Nehru Technological University Kakinada is a record of bona fide work carried out by his under
our supervision.
This report has not been submitted to any other university/institute for the award of any degree.

Project Supervisor Head of Department

Mr. P. Manmadha Reddy Dr .[Link] Babu
Assistant Professor © Associate Professor
Department of EEE Department of EEE
UCEN-JNTUK UCEN-JNTUK
CERTIFICATE
 ABSTRACT

BHEL, is one of the India’s leading PSUs, is today the largest engineering enterprise of its
kind in India. BHEL cater to the needs of sectors of the economy like Power, Transmission,
Industry, Transportation( including railways), Defence , Renewable energy etc. This report is of
BHEL-HPVP which is located in Visakhapatnam. It consist of the details of how BHEL-HPVP is
divided into working groups and it also mentioned about some of the major machinery been using
in the plant for the manufacturing of equipment’s for various industries. It mainly consist of power
system equipment’s which are using in plant and what are the types of protection for power system
equipment been using in plant.
 STUDENT’S DECLARATION

I am PITCHIKA BHASKARA NAGA VENKATA TARUN(22035A0220) student of the

Department of Electrical and Electronics Engineering, UCEN JNTUK Narasaraopet College do
hereby declare that I have completed the mandatory summer internship from 22-May-2023 to 17-
Jun-2023 in BHEL-HPVP Visakhapatnam under the Faulty Guidance of [Link]
Reddy Asst professor ©, Department of Electrical and Electronics Engineering in UCEN-JNTUK-
College.

(Signature and Date)

Faculty Supervisor Head of Department

INDEX
1. INTRODUCTION TO BHEL...............................................................................................................................................1
1.1 OPERATIONS OF BHEL................................................................................................................................................1
1.2 HISTORY OF BHEL........................................................................................................................................................2
1.3 UNITS OF BHEL.............................................................................................................................................................3
1.3.1 MAIN MAUFACTURING UNITS......................................................................................................................4

2. ABOUT BHEL-HPVP ..........................................................................................................................................................5

2.1 INTRODUCTION TO HPVP ..........................................................................................................................................5
2.2 BHEL-HPVP PRODUCTS...............................................................................................................................................6
2.3 SUPPLIES OF BHEL.......................................................................................................................................................7
2.4 DETAILS OF SHOPS IN BHEL-HPVP..........................................................................................................................8

3. SUBSTATION LAYOUT IN BHEL HPVP ......................................................................................................................12

3.1 INTRODUCTION..........................................................................................................................................................12
3.2 DESCRPTION OF 33/11 KV SUBSTAION.................................................................................................................12
3.3 SINGLE LINE DIAGRAM OF 33/11 KV SUBSTATION...........................................................................................14

4. POWER SYSTRM EQUIPMENT AND PROTECTION BEEN USING IN BHEL-HPVP ........................................15

4.1 POWER SYSTEM EQUIPMENT..................................................................................................................................15
4.1.1 TRANSFORMERS.................................................................................................................................................16
4.1.2 UNDERGROUND CABLES.................................................................................................................................18
4.2 POWER SYSTEM PROTECTION.................................................................................................................................19

4.2.1 TRANSFORMER PROTECTION..........................................................................................................................19

4.2.2 CIRCUIT BREAKERS..........................................................................................................................................22

5. MACHINERY IN BHEL-HPVP ........................................................................................................................................25

5.1 BRAZING MACHINEY...................................................................................................................................................25

5.2 LATHE MACHINE..........................................................................................................................................................28

5.3 GRINDING MACHINE...................................................................................................................................................33

5.4 MILLING MACHINE......................................................................................................................................................34

5.5 SHAPER MACHINE........................................................................................................................................................34

 CHAPTER 1
INTRODUCTION TO BHEL
Bharat Heavy Electricals Limited (BHEL) is an Indian central public sector undertaking and
the largest government-owned power generation equipment manufacturer. It is under the ownership
of Government of India and administrative control of the Ministry of Heavy Industries. Established in
1956, BHEL is based in New Delhi with the help of Soviet technology.

1.1 OPERATIONS OF BHEL:

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

It has a network of 16 manufacturing units, two repair units, four regional offices, eight service
centers, eight overseas offices, 15 regional centers, seven joint ventures, and infrastructure allowing it
to execute more than 150 projects at sites across India and abroad. The company has established the
capability to deliver 20,000 MW p.a. of power equipment to address the growing demand for power
generation equipment.

BHEL has retained its market leadership position during 2015–16 with 74% market share in the
Power Sector. An improved focus on project execution enabled BHEL record its highest ever
commissioning/synchronization of 15059 MW of power plants in domestic and international markets in
2015–16, marking a 59% increase over 2014–15. With the all-time high commissioning of 15000 MW
in a single year FY2015-16, BHEL has exceeded 170 GW installed base of power generating
equipment’s.

BHEL has been catering to the nation's Nuclear Programmer since 1976 by way of design,
manufacture, testing and supply of critical nuclear components like Reactor Headers, Steam
Generators, Steam Turbine Generators, other Heat Exchangers and Pressure Vessels It also has been
exporting its power and industry segment products and services for over 40 years. BHEL's global
references are spread across over 76 countries across all the six continents of the world. The cumulative
overseas installed capacity of BHEL manufactured power plants exceeds 9,000 MW across 21
countries including Malaysia, Oman, Iraq, UAE, Bhutan, Egypt, and New Zealand. Their physical
exports range from turnkey projects to after sales services
1
1.2 HISTORY OF BHEL:

BHEL was established in 1956 ushering in the heavy electrical equipment industry in
India. Heavy Electricals (India) Limited was merged with BHEL in 1974.[3] When it was set up in
1956, BHEL was envisaged as a plain manufacturing PSU, with technological help from the Soviet
Union

In 1980's it was cutting edge in thyristor technology. In 1991, BHEL was converted into a
public company. Over time, it developed the capability to produce a variety of electrical, electronic,
and mechanical equipment for various sectors, including transmission, transportation, oil and gas, and
other allied industries. However, the bulk of the company's revenue is still derived from the sale of
power generation equipment such as turbines and boilers. As of 2017, equipment supplied by BHEL
constituted around 55% of the total installed power generation capacity in India.

The company also supplies electric locomotives to the Indian Railways and defence equipment
such as the Super Rapid Gun Mount (SRGM) naval guns manufactured in partnership with the
Ordnance Factory Board and simulators to the Indian Armed Forces.

It also has been exporting its power and industry segment products and services for over 40
years. BHEL's global references are spread across over 76 countries across all the six continents of the
world. The cumulative overseas installed capacity of BHEL manufactured power plants exceeds 9,000
MW across 21 countries including Malaysia, Oman, Iraq, UAE, Bhutan Egypt, and New Zealand. Their
physical exports range from turnkey projects to after sales

Fig 1.1 wagon 7 Fig 1.2 Two-seat training monoplane Bharat Swati built by BHEL

2
1.3 UNITS OF BHEL

Fig 1.3 Map of units of BHEL in India

3
1.3.1 MAIN MANUFACTURING UNITS

 Centralized Stamping Unit & Fabrication Plant (CSU & FP), Jagdishpur
 Insulator Plant (IP), Jagdishpur
 Electronics Division (EDN), Bangalore
 Industrial Systems Group (ISG), Bangalore
 Electro-Porcelains Division (EPD), Bangalore
 Heavy Electrical Plant (HEP), Bhopal
 Industrial Valves Plant (IVP), Goindwal
 Heavy Electrical Equipment Plant (HEEP), Ranipur (Haridwar)
 Central Foundry Forge Plant (CFFP), Ranipur (Haridwar)
 Heavy Power Equipment Plant (HPEP), Hyderabad
 Transformer Plant (TP), Jhansi
 Boiler Auxiliaries Plant (BAP), Ranipet
 Component Fabrication Plant (CFP), Rudrapur
 High Pressure Boiler Plant (HPBP), Tiruchirappalli
 Seamless Steel Tube Plant (SSTP), Tiruchirappalli
 Power Plant Piping Unit (PPPU). Thirumayam
 Heavy Plates & Vessels Plant (HPVP). Visakhapatnam

The company is also setting up a new Greenfield Power Equipment Fabrication Plant
(GPEFP) at Bhandara, Maharashtra, the foundation stone for which was laid on 14 May 2013.
Further, BHEL is planning to enter solar manufacturing in a big scale, as it has announced its plans
for a 600 MW Solar Module Factory.

4
 CHAPTER 2
ABOUT BHEL – HPVP VISAKHAPATNAM

2.1 INTRODUCTION TO HPVP

FIG 2.1 Main Block of BHEL-VISAKAPATNAM

After coming as a manufacturing plant in 1966 at Visakhapatnam, Andhra Pradesh as a Public

Sector Undertaking under the Department of Heavy industry (DHI) to manufacture and supply custom
built process plant equipment’s for Core Sector Industries like Fertilizers, Oil Refineries,
Petrochemicals, Steel Plants, Nuclear, Space, Defence and Power Sectors with the technical
collaboration of SKODA Export, Czechoslovakia. The Company is located on NH-5 near to Airport,
Railway Station and Sea Port in Visakhapatnam, Andhra Pradesh. The Company is spread over a total
area of 386 Acres.

HPVP is a premier manufacturing unit specializing in design, fabrication, supply and erection of
Heat Exchangers, Columns, Storage Spheres, Reactors and Strippers, Multilayer Vessels Reactor
Regenerator Package, Air Separation Plants, Purge Gas Recovery Units, Oxygen Plants, Nitrogen
Plants, Hydrogen Plants, Sulphur Recovery Units, Crude Stabilization Units, Mounded Storage
5
Systems, Compact Heat Exchangers, On Board Oxygen generating system etc., to Oil Refineries,
Fertilizer Plants,

6
Steel Plants, Defence sector etc., and has been contributing to the Nation building during the past four
decades. The Company has good potential to cater to the growing needs envisaged in Power, Oil and
Gas, Nuclear, Defence and other strategic sectors in future. Also, HPVP is highly reputed for the
Quality and reliability of its products and possesses several National & International Quality
accreditations besides ISO 9001:2000 certification.

Erstwhile BHPV started production in the year 1971-72 with a turnover of just Rs.1.95 Cr and
crossed Rs.300Crs in the year 1996-97. The Company contributed around Rs.1000Crs to the national
exchequer during the past 20 years.

HPVP (erstwhile BHPV) is the largest fabricator of process equipment in India for the petroleum,
fertilizer, chemical and allied industries. It is a unit of maharatna Central Public Sector Enterprise –
Bharat Heavy Electrical Limited.

Situated in the city of destiny, Visakhapatnam on the eastern sea coast of the Deccan plateau,
HPVP is accessible by road, rail, and sea and is well connected to all metropolitan cities by air. BHEL-
HPVP has been selected for the study. The topic selected is “A study on financial statements analysis”
with reference to BHPV.

2.2 BHEL-HPVP PRODUCTS

Products manufactured at BHEL – HPVP include:-

 Pressure Vessels:
With different kinds of steels like carbon steel, stainless steel, clad steel, Monel etc. and any
combination of there off.

 Columns:
Both shop and site fabricated columns with or without internals

 Heat Exchangers:
From low pressure atmospheric fin coolers to high pressure heat exchangers employing
forged heads channels with test pressure as high as 500kg/[Link] and designs like U-tube, kettle
type, etc.

7
  Storage Spheres:
Storage Sphere Of any size (up to 60m), any thickness (up to 60mm) to handle any fluid or
gases like ammonia, ethylene, propylene, LPG etc.

 high pressure multilayer vessels:

Ammonia and urea reactors-built ply wall design to suit high pressure of the order of
300kg/[Link] hydraulic test pressure.

 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.

 Air & Gas Separation 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.

2.3 SUPPLIES OF BHEL

 Systems Division

 Systems for Oil & Natural Gas

 Vacuum Ejector/Condenser System
 Multiple Effect Evaporation Plants
 Ammonia /LPG Storage Systems
 Mounted Storage Packages
 Turnkey Sub-Systems for Process industries
 Consultancy Services
 SRU/ARU/SWS Turnkey Packages

 Oil & Natural Gas

 Separating Heating and Oil Treating Systems

 H2S & CO2 Removal Systems

8
 Sulfur Recovery and Tail Gas Treating Systems

9
  Water Treating Systems
 Hydrocarbon Recovery & Dehydration Systems

 Refineries

 Ejector/Surface Condenser Systems

 Sub-systems
 LPG Bottling, Storage and Handling systems

 Paper & Pulp

 Evaporation Plants(Alumina)
 Coke-Oven bi-product facilities
 Sub-Systems in Steel Sector

 Process Plants Division

 Pressure Vessels
 Columns, Towers & Reactors
 Shell and Tube Heat Exchanges
 Air Cooled Heat Exchanges
 Double Pipe Heat Exchanges
 Multilayer Vessels
 Storage Vessels
 Tank Wagons
 Exchangers for Nuclear Power Plants

 Fertilizers

 Urea Plant
 Ammonia Plant
 Caprolactam Plant
 Ammonia Sulphate Plant

10
2.4 DETAILS OF SHOPS IN BHEL-HPVP

2.4.1 WORKSHOPS:

Parts that are used for assembling in Production shop are made in feeder shops. The feeder shops
are subdivided into six types, namely
MP Material Preparation

LMS Light Machine Shop

HMS Heavy Machine Shop

Press Bending & Pressing of Plates

Nozzles Pipe preparation

Shells Rolling & Welding Operation

2.4.2 PRODUCTION SHOPS:

The parts made in the feeder shop assembled in production shop. The following five shops come
under production shop.
PV Pressure vessels

HE Heat exchangers

CP Cryogenic production

CSP Combustion system production

CSP II Combustion system production

2.4.3 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.

11
2.4.4 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

2.4.4. a) Machinery used in press shop :

Section bending roll 1no.

Pneumatic hammer 2no.

Pipe bending 2no.

Hydraulic press 250T 1no.

Hydraulic press 400T 1no.

Hydraulic press 1600T 1no.

Bending roll 1no.

2.4.5 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.

2.4.5.a) Machinery Used in Light Machine Shop:-

Small and medium lathes, Auto lathe ,Radial drilling machines, Small horizontal boring, Medium
horizontal boring ,Heavy lathe ,Plane drilling machine ,CNC drilling machine, CNC deep hole drilling
machine (HMT) ,Cylinder grinding machine ,Horizontal surface grinder CNC lathe machine.

12
2.4.6 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 2000 mm.2.4.6.a).Machinery
Used in the Heavy Machine Shop :

Radial drilling 2no.

Universal drilling 1no.

Single column planning 1no.

Double column planning 1no.

Large horizontal boring 2no.

2.4.7 CRYOGENIC PRODUCTION:

Tanks and vessels for sub-zero temperature supplications are fabricated here. Not only cryogenic
tanks are produced in this section but also vast variety of equipment, which include: Air separation
units of capacity ranging from 50Nm/hr. and up to 2200TPD produce oxygen, nitrogen & argon are
available. Storage tanks of horizontal & vertical designs starting form 500 liters and above up to 2,
00,000 liters capacity to hold liquid oxygen, nitrogen, argon and other vacuum insulate.

2.4.8 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 8 machines available in this shop. This can weld
upped 350mm thick with groove width about 20-24mm.

13
2.4.8.a) Machinery Used In The Shells Shop:

1. Plate edge planning 1200x80mm thick 2 no.

2 Plate bending rolls 235x3025mm thick 1 no.

3 Plate bending rolls 4000x22mm thick 1 no.

4 Plate bending rolls 3000x75mm thick 1 no.

14
 CHAPTER 3
SUBSTATION LAYOUT IN BHEL HPVP
3.1 INTRODUCTION:
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 two 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 by APEPDCL.

Generator produces power at 6.3KV voltage which is step up to 11KV and supplied to MRS.
During power supply failure of APEPDCL, the power will be supplied by the captive power plant of
1000KVA capacity.

3.2 DESCRPTION OF 33/11KV SUBSTATION:

BHEL HPVP is 33 KV HT customers for one of the state distribution boards
(APEPDCL).Power at 33KV is being fed 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 be grounded through the lightning arrestor. It is used to protect the insulation and
conductors of the system from the damaging effects of lightning (T'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 he high currents or high voltages measured by the CT's and PT's tripping
coil of this relay will be activated and trips the circuit breaker. Transformers will step down the voltage
from 33 to 11KV.

3.2.1 PARTS OF SINGLE LINE DIAGRAM:

 Electrical Isolator: Isolator is a manually operated mechanical switch which separates a part of
the electrical power system.

15
 Lightning arrestor or Surge arrestor: It is a device used on electrical power systems and
telecommunications systems to protect the insulation and conductors. of the system from the
damaging effects of lightning. The typical lightning arrester has a high-voltage terminal and a
ground terminal. When a lightning surge travels along the power line to the arrester, the current
from the surge is diverted through the arrestor, in most cases to earth. If protection fails,
lightning that strikes the electrical system introduces thousands of KV that may damage the
transmission lines, and can also cause severe damage to transformers and other electrical or
electronic devices. Lightning- produces extreme voltage spikes in incoming power lines which
can damage electrical home appliances.

 Earthing Switches: Earthing switches are mounted on the base of mainly line side isolator.
Earthing switches are normally vertically break switches. Earthing arms are normally aligned
horizontally at off condition. During switching on operation, these earthing arms rotate and
move to vertical position and make contact with earth female contacts fitted at the top of the
post insulator stack of isolator at its outgoing side. The earthing arms are so interlocked with
main isolator moving contacts that it can be closed only when the main contacts of isolator are
in open position. Similarly the main isolator contacts can be closed only when the earthing
arms are in open position.

 Current Transformers: This is used for measurement of electric currents. Current

transformers, together with voltage transformers (VT) are known as instrument transformers.
When current in a circuit is too high to directly apply to measuring instruments, a current
transformer produces a reduced current accurately proportional to the current in the circuit,
which can be conveniently connected to measuring and recording instruments. A current
transformer also isolates the measuring instruments from what may be very high voltage in the
monitored circuit. Current transformers are commonly used in metering and protective relays in
the electrical power industry.
Rating of CT: 200A/100A/1A.

 Potential Transformers: Also called Voltage transformers (VI) are a parallel connected type of
instrument transformer, used for metering and protection in high-voltage circuit's or phase shift
isolation. They are designed to present negligible load to the supply, being measured and to
have an accurate voltage ratio to enable accurate metering.
16
  Feeder: A feeder is a conductor which connects the sub-station (or localized generating station)
to the area where power is to be distributed

 Distributor : A distributor is a conductor from which tapings are taken for supply to the
consumers. Due to the taping is done at various places in a distributor, the current being not
same throughout its length. The main design consideration of a distributor is the voltage drop
across its length because the statutory limit of voltage variations is ± 6 % of rated voltage at the
consumer’s terminals

3.3 SINGLE LINE DIAGRAM OF 33/11KV SUBSTATION:

17
 CHAPTER 4

POWER SYSTEM EQUIPMENT AND PROTECTION BEEN USING

IN BHEL-HPVP
4.1 POWER SYSTEM EQUIPMENT:

By the advancement of power system equipment, the following are been using in the BHEL-
HPVP plant. The list is mentioned below.

 Transformers
 Motor Generator set
 Underground cables
 Induction motors
4.1.1 TRASNFORMERS:

[Link] WORKING PRINCIPLE OF TRANSFORMERS:

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 If the second coil circuit is closed, a current flows in 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 AC. supply mains, is called primary winding and the other form which energy 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

18
[Link] PARTS OF A TRANSFORMER:

A transformer majorly consists of three parts:

 Core: The transformer core serves as a support for the winding. Additionally, it offers a
magnetic flux flow channel with minimal resistance. As seen in the image, the winding is
looped around the core. To cut down on losses in a transformer, it has a laminated soft iron
core. Core composition is determined by variables including operational voltage, current, and
power, among others. The core diameter is negatively correlated with iron losses and directly
correlated with copper losses.
 Windings: The copper wires that are wound over the transformer core are known as windings.
Copper cables are used because Copper’s high conductivity reduces transformer loss because
resistance to current flow lowers as conductivity rises. And copper’s high degree of ductility
makes it possible to produce incredibly thin wires out of it. The two basic types of windings are.
Windings for the primary and secondary coils. The primary winding is the group of winding
turns that receive supply current. The number of winding turns from which output is derived is
known as secondary winding. Insulation coating agents are used to insulate the primary and
secondary windings from one another.
 Insulation Agents: Transformer requires insulation to keep the windings apart and prevent
short circuits. This makes mutual induction easier. Transformer stability and durability are
influenced by insulation agents. In a transformer, the following are employed as insulating
mediums: Insulating fluid, tape, Paper, and Lamination made of wood.
 Tank: A transformer main tank serves two purposes:
 The core and the windings are protected from the elements, such as rain and dust.

 It functions as an oil container as well as a support for all other transformer attachments.

 Transformer Oil: The majority of the huge transformer are submerged in oil. The transformer
oil adds insulation between the conductors, improves heat dissipation from the coils, and has
fault-detecting capabilities. Transformer oil is typically made of hydrocarbon mineral oil.

 Oil Conservators: The oil conservator is situated above the transformer tank and bushings.
Some transformer oil conservators contain a rubber bladder. When a transformer is loaded, the
ambient temperature rises, causing the amount of oil inside the transformer to increase. The

19
transformer

20
 conservator tank has enough room for the increased transformer oil. It also serves as a reservoir
for oil that is used to insulate buildings.
 Breather: All oil-immersed transformers with conservator tank include it. It aids in the
protection of the oil against moisture.
 Radiators and Fans: The majority of the power lost in the transformer is dissipated as heat.
Radiators and fans aid in the dissipation of heat generated by the transformer and provide
protection against failure. The majority of dry transformers are cooled by natural air.

Fig 4.1 pictorial view of Transform

MAKE : NGEF MADE IN INDIA Transformer

Sl. No. 2800047877
Type: OF TU 4000/30
Switch: HV
Standard : IS 2026
KVA: : 33000/3600
Volts at HV :11000volts
no load LV :433volts
impedance volts :7.87%
vector group :DyN11
Phase HV/LV :3/3
Frequency HZ 50
type of Cooling :ON AN/ ON AF
Year of Manufacture 1988
21
Untacking Mass :Kg.4860
Mass of Oil :Kg.1945
Total Mass :Kg.9660
Value of Oil :2186 liters
Guaranteed Max. Temp rise : 45° C

4.1.2 UNDERGROUND CABLES:

Electric power can be transmitted or distributed either by overhead transmission systems or by

underground cables. Cables are mainly designed for a specific requirement. Power cables are mainly
used for power transmission and distribution purposes. It is an assembly of one or more individually
insulated electrical conductors, usually held together with an overall sheath. The assembly is used for
transmission and distribution of electrical power.

[Link] Construction of power cables:

There are various parts of a cable to be taken care of during construction. The power cable mainly
consists of ,

 Conductor
 Insulation
 LAY for Multicore cables only
 Bedding
 Beading/Armouring (if required)
 Outer Sheath

Fig 4.2 construction of cable

22
4.2 POWER SYSTEM PROTECTION:

As the equipment is advanced, they needed a protection for further operation and successful
completion of desired work. The objective of a protection scheme is to keep the power system stable by
isolating only the components that are under fault, whilst leaving as much of the network as possible in
operation. The devices that are used to protect the power systems from faults are called protection
device. The protections devices used in BHEL-HPVP plant are described in this section.

4.2.1 TRANSFORMER PROTECTION:

Different types of Transformer faults: include earth, Interturnes, tank, Phase 2 phase, and open
circuit faults.

 Overheating fault: One of the common issues that you can face with TR’s is that the
temperature gets high. This issue has some causes which you should check step by step to
overcome it. cooling fans are not working properly. Check fans and oil pumps if found. The
radiator is not clean. Check it and remove any dirt, dust, or plastic bags. Overcurrent, check the
current of the TR and reduce loads if necessary to be suited to the rated current of the tr. On hot
day, the surrounding atmosphere temperature affects the TR temperature. If so, increase cooling
stations. Low oil level, Oil main purpose is cooling the transformer, check the level and increase
the oil. But check for any leakage.

 Earth Faults: Earth faults occur due to the earthing of transformer windings to the ground. In
this case, the current depends upon the value of earthing impedance. Earth fault also occurs
when the winding turns come between neutral and fault point. There are different conditions
during the earth fault conditions. In the first case, the current flows into and out of windings.
While in the second case ampere-turns balance is maintained between windings

 Interturnes faults: This type of transformer fault is caused due to the winding turns flashover
by line surges. When several turns in the same winding short circuit. A decrease in the terminal
current occurs. This type of fault is also referred to as winding short circuit faults.

 Tank Faults (oil level):This type of fault is related to the oil in the transformer. When the oil
reduces in tanks, it causes winding insulation reduction. Tank fault causes an abnormal

23
 temperature rise of the transformer. This oil loss usually happens due to leakage, While the
leakage can be checked visually on the tank body.
 Phase to phase Faults: These are common-to-earth faults. It occurs due to the
phase disturbance of the transformer. However, these types of Faults are rare to
occur.
[Link] Common Types of Transformer Protection:

1. Overheating protection
2. Overcurrent protection
3. Differential Protection of Transformer
4. Earth Fault Protection (Restricted)
5. Buchholz (Gas Detection) Relay

1. Overheating Protection in Transformers:

 Transformers overheat due to the overloads and short circuit conditions. The allowable
overload and the corresponding duration are dependent on the type of transformer and class
of insulation used for the transformer.

 Higher loads can be maintained for a very short amount of time if it is for a very long, it can
damage the insulation due to temperature rise above an assumed maximum temperature. The
temperature in the oil-cooled transformer is considered maximum when its 95*C, beyond
which the life expectancy of the transformer decreases and it has detrimental effects in the
insulation of the wire. That is why overheating protection becomes essential.

 Large transformers have oil or winding temperature detection devices, which measure oil or
winding temperature, typically there are two ways of measurement, one is referred to hot-
spot measurement and second is referred to as top-oil measurement, the below image shows a
typical thermometer with a temperature control box from reinvasion used to measure the
temperature of a liquid insulated conservative type of transformer.
2. BUCHHOLZ RELAY

 The Buchholtz relay is fitted in between the main transformer unit and the conservator tank
when a fault occurs within the transformer, it detects the resolved gas with the help of a float

24
switch.

25
 If you look closely, you can see an arrow, gas flows out from the main tank to the conservator
tank, normally there should not be any gas in the transformer itself. Most of the gas is referred
to as dissolved gas and nine different types of gasses can be produced depending on the fault
condition. There are two valves at the top of this relay, these valves are used to reduce the gas
build-up, and it's also used to take out a gas sample.

FIG 4.3 BUCHHOLTZ RELAY

 When a fault condition occurs, we have sparks between the windings, or in between windings
and the core. These small electrical discharges in the windings will heat the insulating oil, and
the oil will break down, thus it produces gases, the severity of the breakdown, detects which
glasses are created.

 A large energy discharge will have a production of acetylene, and as you may know, acetylene
takes a lot of energy to be produced. And you should always remember that any type of fault
will produce gases, by analysing the amount of gas, we can find the severity of the fault.

22
4.2.2 CIRCUIT BREAKERS:

[Link] Introduction:

Circuit Breaker is a switching device which can be operated manually as well as

automatically for controlling and protection of electrical power system respective. As the modern
power system deals with huge currents, the special attention should be given during designing of circuit
breaker to safe interruption of arc produced during the operation of circuit breaker.

Modern power system deals with huge power network and huge numbers of associated
electrical equipment. During short circuit fault or any other types of electrical fault these equipment as
well as the power network suffer a high stress of fault current in them which may damage the
equipment and networks permanently. For saving these equipment's and the power networks the fault
current should be cleared from the system as quickly as possible. Again, after the fault is cleared, the
system must come to its normal working condition as soon as possible for supplying reliable quality
power to the receiving ends. In addition to that for proper controlling of power system, different
switching operations are required to be performed. So, for timely disconnecting and reconnecting
different parts of power system network for protection and control, there must be some special type of
switching devices which can be operated safely under huge current carrying condition. During
interruption of huge current, there would be large arcing in between switching contacts, so care should
be taken to quench these areas in safe manner. The circuit breaker is the special device which does all
the required switching operations during current carrying condition. This was the basic introduction to
circuit breaker.

[Link] Working Principle of Circuit Breaker:

The circuit breaker mainly consists of fixed contacts and moving contacts. In normal "on"
condition of circuit breaker, these two contacts are physically connected to each other due to applied
mechanical pressure on the moving contacts. There is an arrangement stored potential energy in the
operating mechanism of circuit breaker which is realized if switching signal given to the breaker. The
potential energy can be stored in the circuit breaker by different ways like by deforming metal spring,
by compressed air, or by hydraulic pressure. But whatever the source of potential energy, it must be
released during operation. Release of potential energy makes sliding of the moving contact at extremely
fast manner. All circuit breaker has operating coils (tripping coils and close coil), whenever these coils
23
are energized by switching pulse, the plunger inside them displaced. This operating coil plunger is
typically

24
attached to the operating mechanism of circuit breaker, as a result the mechanically stored potential
energy in the breaker mechanism is released in forms of kinetic energy, which makes the moving
contact to move as these moving contacts mechanically attached through a gear lever arrangement with
the operating mechanism. After a cycle of operation of circuit breaker, the total stored energy is
released and hence the potential energy again stored in the operating mechanism of circuit breaker by
means of spring charging motor or air compressor or by any other means. Till now we have discussed
about mechanical working principle of circuit breaker. But there are electrical characteristics of a
circuit breaker which also should be consider in this discussion of operation of circuit breaker

[Link] Types of Circuit Breakers Using In BHEL-HPVP Plant:

According to there are quenching media the circuit breaker can be divided as

A. Oil Circuit Breaker

B. Air Circuit Breaker

C. Vacuum Circuit Breaker

A. Oil Circuit Breaker: In Minimum Oil Circuit Breaker the fixed contact and moving contact are
immerged inside the insulating oil. Whenever there is a separation of current carrying contacts in the
oil, the arc is initialized now of separation of contacts, and due to this are the oil is vaporized and
decomposed in mostly hydrogen gas and ultimately creates a hydrogen bubble around the arc. This
highly compressed gas bubble around the arc prevents re-striking of the arc after current reaches zero
crossing of the cycle. The minimum oil circuit breaker is one of the oldest type of circuit breaker.
When the circuit breaker is in ON condition the spring will be in discharging position and whenever a
fault occur, the relay sends signal to circuit breaker it will be trip off and the spring will be in charging
position.

Types of Oil Circuit Breakers

There are two types of oil circuit breakers which are explained below.

 Bulk Oil Circuit Breaker: Bulk oil circuit breakers, also known as BOCBs, are circuit
breakers that use oil as an arc quenching medium as well as an insulating medium between

25
current-carrying

26
 contacts and earthed parts of the breaker. The oil used in this case is the same as transformer-
insulating oil.
 Minimum Oil Circuit Breaker: Oil is used as the interrupting medium in these circuit
breakers. A minimum oil circuit breaker, on the other hand, places the interrupting unit in an
insulating chamber at live potential, as opposed to a bulk oil circuit breaker. Only the
interrupting chamber has insulating oil. MOCBs are designed with the goal of reducing the
amount of oil required, hence the name “minimum oil circuit breaker.”

B .Vacuum Circuit Breaker:

In vacuum circuit breakers, facilities shall be provided for monitoring the contract erosion and
any change in contact gap. The vacuum bottles shall be easily replaceable on site and the mechanism
shall be conveniently adjustable to permit resetting the contact gap. The vacuum circuit breaker poles
shall be sealed to prevent contamination of the spaces surrounding the interrupters. The Bidder shall
demonstrate how this is achieved by supplying technical details with the bid.

Requirements:

The circuit breakers to be supplied against this specification shall be required to control the
primary side of 33/11 KV power transformers in the primary sub-stations (incoming 33KV feeders) or
Bus coupler or the outgoing feeders in these sub-stations. The circuit breakers shall be suitable for 3
phase 50Hz solidly grounded neutral system and shall have normal current carrying capacity and
symmetrical short circuit current breaking capability as mentioned hereunder.

A mechanically operated circuit breaker position indicator of non-corroding material shall be

provided in a location visible from the operating side of the breaker without the necessity to open the
mechanism door. The word 'OFF' in white letter on green background shall be used to indicate that the
breaker is in the opening position and the word 'ON' in white letters background to indicate that the
breaker is in the closed position. The drive for the device shall be positive in both directions and
provision shall be made for local and remote electrical indication

27
 CHAPTER 5
MACHINERY IN BHEL -HPVP VISAKHAPTNAM
MACHINERY:
The following are the some of the machinery used in the BHEL-HPVP plant which is located in
Visakhapatnam Andhra Pradesh.

5.1 BRAZING MACHINERY:

Brazing is the process for joining two pieces of metal that involves the application of heat and the
addition of a filler metal. This filler metal, which has a lower melting point than the metals to be
joined, is either pre-placed or fed into the joint as the parts are heated.

There are basically four types of brazing methods.

 Torch Brazing: In this method, the heat required melting and flow filler metal is supplied by a
fuel gas flame. The fuel gas can be acetylene, hydrogen, or propane and is combined with
oxygen or air to form a flame. This process is readily automated and requires low capital
investment. Torch brazing requires the use of a flux, so a post braze clean is often required.

 Induction Brazing: High frequency induction heating for brazing is clean and rapid, giving
close control of temperature and location of heat. Heat is created by a rapidly alternating
current which is induced into the workpiece by an adjacent coil.
 Resistance Brazing: This is a process in which heat is generated from resistance to an
electrical current (as for induction brazing) flowing in a circuit which includes the workpieces.
The process is most applicable to relatively simple joints in metals which have high electrical
conductivity.
 Furnace Brazing: Furnace brazing offers two prime advantages: protective atmosphere
brazing (where high purity gases or vacuum negate the need for flux) and the ability to control
accurately every stage of the heating and cooling cycles. Heating is either through elements, or
by gas firing

28
5.1.1 VACCUM BRAZING

Furnace brazing is a semi-automated process by which metal components are joined using a
dissimilar lower filler metal. Furnace brazing allows design and manufacturing engineers to join simple
or complex designs of one joint or multi-joint assembly.

One of the most common forms of furnace brazing is accomplished in a vacuum furnace and
referred to as vacuum brazing. Parts to be joined are cleaned, brazing filler metal applied to the
surfaces to be joined and then placed into the furnace. The entire assembly is brought to brazing
temperature, after the furnace has been evacuated of air, to eliminate any oxidation or contamination
occurring as the braze filler metal melts and flows into the joints.

1. Process of vacuum brazing:

 Basically, brazing is a process that combines elements with the use of a brazing material.
Prepared elements with applied brazing material are placed in a vacuum furnace and heated
up to brazing temperature (from 800 to 1150°C)

 This is higher than the liquid temperature. At this temperature, the parts are held for a short
time (10 min) and then are slowly cooled to solidus temperature. This also allows for the
joining of different materials like for example ceramic to steel.

 During the process, the appropriate level of vacuum needs to be kept. Brazing in a vacuum
furnace can also take place in a protective atmosphere, most often an argon atmosphere.

Fig 5.1 Process of Brazing

29
 FIG 3.2 VACCUM BRAZING MACHINE

2. Application & material

 Aerospace components
 Industrial gas turbine components
 Medical, scientific and general engineering components
 Automotive components
 Space applications
 Electronic devices
 Nuclear components

 Furnace brazing offers the flexibility to join a wide range of metals such as nickel based alloys,
stainless steels, carbon and alloy steels. Other non-ferrous materials can also be brazed
including aluminum, titanium and copper.

30
  The materials being joined dictate the type of atmosphere in which the assembly is heated to
join its components. In addition to vacuum, protective or reactive atmospheres include
hydrogen, nitrogen, a blend of hydrogen and other inert gases, exothermic and endothermic gas,
as well as argon, and helium.

3. Benefits

 Cost effective process

 Reproducible high integrity metal joining process
 Allows the joining of unwieldable, dissimilar and non-metallic materials
 Brazing provides design and manufacturing engineers an opportunity to join simple as well
as complex designs with one joint or several hundred joints

5.2 LATHE MACHINE

A lathe is a machine tool that rotates a workpiece about an axis of rotation to perform various
operations such as cutting, sanding, knurling, drilling, deformation, facing, and turning, with tools that
are applied to the workpiece to create an object with symmetry about that axis.

Lathes are used in woodturning, metalworking, metal spinning, thermal spraying, reclamation,
and glass-working. Lathes can be used to shape pottery, the best-known design being the Potter's
wheel. Most suitably equipped metalworking lathes can also be used to produce most solids of
revolution, plane surfaces and screw threads or helices.

Ornamental lathes can produce three-dimensional solids of incredible complexity. The

workpiece is usually held in place by either one or two centers, at least one of which can typically be
moved horizontally to accommodate varying workpiece lengths. Other work-holding methods include
clamping the work about the axis of rotation using a chuck or collet, or to a faceplate, using clamps
or dog clutch.

Here is the list of lathe machine types commonly used in the real world:

 Speed Lathe Machine

 Center Lathe or Engine Lathe Machine

31
  Turret Lathe Machine

 Tool room Lathe Machine

 Bench Lathe Machine

 Automatic Lathe Machine

 Special Purpose Lathe Machine

 CNC Lathe Machine

5.2.1 CNC LATHE MACHINE:

CNC Lathe Machines are the most up-to-date lathe machines in terms of technology they come
with a modern computer numeric control system (CNC). You can use this control system to add a
CAD/CAM program and after that, whenever you command the machine, it will start and perform the
machining operation according to your program input.

There are tons of features in CNC lathe machines; some important features are as below:

 It has an automatic tool change system

 The accuracy of the finished job is pretty darn better than any other type of lathes• The
power consumption and routine maintenance cost of this machine is higher
 It can cheaply and speedily perform complex machining operations
 Mass productions become fast with this machine
 It comes with a hydraulic chuck, which means it’s easy and fast to clamp workpieces.

Many people think that you do not need special skills to operate this machine, however, no one
should operate this machine without proper training, it is a very expensive machine, and with a new
operator, the chances of an accident increases.

32
 Fig 5.3 CNC Lathe Machine

5.2.2 AUTOMATIC LATHE MACHINE:

 These are machine tools in which components are machined automatically.

 The working cycle is fully automatic that is repeated to produce duplicate parts without
participation of operator.
 All movements of cutting tools, their sequence of operations, applications, feeding of raw
material, and parting off, unloading of finished parts all are done on machine.
 All working & idle operations are performed in definite sequence by control system adopted in
automatic which is set up to suit a given work.
 Only operation required to be performed manually is loading of bar stock/ individual casting/
forged blanks.
 These machines are used when production requirements are too high for turret lathes to produce
economically

Advantages:
 Greater production over a given period.
 More economy in floor space.
 More consistently accurate work than turrets.
 More constant flow of production.
 Scrap loss is reduced by reducing operator error.
33
  During machine operation operator is free to operate another machine/ can inspect completed
parts

Fig3.4 Automatic lathe machine

5.2.3 CENTRE LATHE MACHINE:

The Centre Lathe is used to manufacture cylindrical shapes from a range of materials including;
steels and plastics. Many of the components that go together to make an engine work have been
manufactured using lathes. These may be lathes operated directly by people (manual lathes) or
computer controlled lathes (CNC machines) that have been programmed to carry out a particular task.

The headstock of a center lathe can be opened, revealing an arrangement of gears. These gears
are sometimes replaced to alter the speed of rotation of the chuck. The lathe must be switched off
before opening; although the motor should automatically cut off if the door is opened while the
machine is running (a safety feature).The speed of rotation of the chuck is usually set by using the gear
levers. These are usually on top of the headstock or along the front and allow for a wide range of
speeds. Our center lathe turning machine is one of our essential pieces of high precision engineering
equipment. The center lathe is ideal for running a “one off” machining job.

The center lathe turning machine is very similar to the other CNC lathes, and operates with a
chuck rotating in the center of the machine. This action allows for the tools to come into the chuck, and
machine the piece of material.

34
The center lathe is operated manually rather than automated (which is how our other CNC machines
are used). This means there is always someone working on the turning machine, allowing them to
measure and check the machining process at various stages, to avoid any errors or changes in the metal
that is being machined.

It is because of this manual operation that the center turning lathe is often used for
manufacturing prototype products. Normally, a CNC lathe would be preprogrammed to run a
machining “job”, which would take the engineer time to set up and then monitor. This is not cost effect
to the client wanting a single item, due to the time needed to set up the CNC machinery. Having a
center lathe turning machine allows us to offer every type of high precision engineering service from a
one piece item through to thousands of safety critical parts

 Bed: The bed is a heavy, rugged casting in which are mounted the working parts of the lathe. It
carries the headstock and tail stock for supporting the workpiece and provides a base for the
movement of carriage assembly which carries the tool.

 Legs: The legs carry the entire load of machine and are firmly secured to floor by foundation
bolts.

 Headstock: The headstock is clamped on the left-hand side of the bed and it serves as housing
for the driving pulleys, back gears, headstock spindle, live center and the feed reverse gear. The
headstock spindle is a hollow cylindrical shaft that provides a drive from the motor to work
holding devices.

 Gear Box: The quick-change gear-box is placed below the headstock and contains a number of
different sized gears.

 Carriage: The carriage is located between the headstock and tailstock and serves the purpose
of supporting, guiding and feeding the tool against the job during operation. The main parts of
carriage are:

 The saddle is an H-shaped casting mounted on the top of lathe ways. It provides
support to cross-slide, compound rest and tool post.

 The cross slide is mounted on the top of saddle, and it provides a mounted or automatic
cross movement for the cutting tool.

35
  The compound rest is fitted on the top of cross slide and is used to support the tool post
and the cutting tool.

 The tool post is mounted on the compound rest, and it rigidly clamps the cutting tool or
tool holder at the proper height relative to the work center line.

Fig 3.5 Centre Lathe Machine

 The apron is fastened to the saddle and it houses the gears, clutches and levers required
to move the carriage or cross slide. The engagement of split nut lever and the automatic
feed lever at the same time is prevented she carriage along the lathe bed.

 Tailstock: The tailstock is a movable casting located opposite the headstock on the ways of the
bed. The tailstock can slide along the bed to accommodate different lengths of workpiece
between the centers. A tailstock clamp is provided to lock the tailstock at any desired position.
The tailstock spindle has an internal taper to hold the dead center and the tapered shank tools
such as reamers and drills.

36
5.3 GRINDING MACHINE:
A grinding machine is a machine tool with an abrasive wheel that is used to achieve fine
finishes or light cuts on metals and other materials. It is a machining operation that is used to improve
the accuracy of a product that has previously been machined. Grinding is used to finish workpieces that
need a high level of surface quality and accurate form and dimension and removes relatively little
metal, roughly 0.25 to 0.50 mm depth.

Grinding machines come in a variety of shapes and sizes with various types of grinder wheels.
Their wheels are constructed of numerous stones, diamonds, and other inorganic materials and vary in
size and texture. These machines include the:

 Belt grinder: which is usually used as a machining method to process metals and other
materials, with the aid of coated abrasives. Analogous to a belt sander (which itself is often
used for wood but sometimes metal). Belt grinding is a versatile process suitable for all kind of
applications, including finishing, deburring, and stock removal.

 Bench grinder: which usually has two wheels of different grain sizes for roughing and
finishing operations and is secured to a workbench or floor stand Its uses include shaping tool
bits or various tools that need to be made or repaired. Bench grinders are manually operated.

 Cylindrical grinder: which includes both the types that use centers and the center less types. A
cylindrical grinder may have multiple grinding wheels. The work piece is rotated and fed past
the wheel(s) to form a cylinder. It is used to make precision rods, tubes, bearing races,
bushings, and many other parts.

 Surface grinder: which has a head that is lowered to a work piece, which is moved back and
forth under the grinding wheel on a table that typically has a controllable permanent magnet
(magnetic chuck) for use with magnetic stock (especially ferrous stock) but can have a vacuum
chuck or other fixture means. The most common surface grinders have a grinding wheel
rotating on a horizontal axis, cutting around the circumference of the grinding wheel. Rotary
surface grinders, commonly known as "Blanchard" style grinders, have a grinding head that
rotates the

37
 grinding wheel on a vertical axis cutting on the end face of the grinding wheel, while a table
rotates the work piece in the opposite direction underneath.

This type of machine removes large amounts of material and grinds flat surfaces with
noted spiral grind marks. It can also be used to make and sharpen metal stamping die sets, flat
shear blades, fixture bases or any flat and parallel surfaces. Surface grinders can be manually
operated or have CNC controls.

 Tool and cutter grinder: which usually can perform the minor function of the drill bit grinder
or other specialist tool room grinding operations.

 Jig grinder: which as the name implies, has a variety of uses when finishing jigs, dies,
and fixtures. Its primary function is in the realm of grinding holes for drill bushings and
grinding pins. It can also be used for complex surface grinding to finish work started on a mill.

Fig 3.5 Cylindrical Grinder

 Gear grinder: which is usually employed as the final machining process when manufacturing a
high-precision gear. The primary function of these machines is to remove the remaining few
thousandths of an inch of material left by other manufacturing methods (such as gashing or
hobbling).

38
  Centre grinder: which is usually employed as a machining process when manufacturing all
kinds of high-precision shafts. The primary function of these machines is to grind the centers of
a shaft very precisely. Accurate round center holes on both sides ensure a position with high
repeat accuracy on the live centers.

 Die grinder: which is a high-speed hand-held rotary tool with a small diameter grinding bit.
They are typically air-driven (using compressed air), but can be driven with a small electric
motor directly or via a flexible shaft.

 Angle grinder: another handheld power tool, often used in fabrication and construction work.

5.4 MILLING MACHINE

Milling machine, device that rotates a circular tool that has a number of cutting edges
symmetrically arranged about its axis; the workpiece is commonly held in a vise or similar device
clamped to a table that can move in three perpendicular directions. Disk- or barrel-shaped cutters are
clamped through holes in their centers to arbors (shafts) attached to the machine spindle; they have
teeth on their peripheries only or on both peripheries and faces. An end mill is a cutter shaped like a
pencil with a tapered shank that fits into the machine spindle; it has cutting teeth on its face and spiral
blades on the lateral surface.

In the milling operation the workpiece is carried on a table that is driven either manually or by
power against the rotating cutter. Milling machines usually produce flat surfaces, but any shape that
can be ground on the cutter will be reproduced on the work. To mill the teeth of a spur gear, a disk-type
cutter with its cutting edges in the shape of the space (groove) between the teeth of the gear is used,
milling the gear blank one space at a time.

39
 FIG 3.6 MILLING MACHINE

5.5 SHAPER MACHINE

Shaper, metal-cutting machine in which the workpiece is usually held in a vise or similar device
that is clamped to a table and can be manually operated or power driven at right angles to the path of a
chisel like cutting tool with only one cutting edge held on the end of a reciprocating ram. A moving
table feeds the workpiece in small, discrete increments at the end of each stroke of the tool, and a
scalloped but essentially flat surface is generated on the workpiece. The adjustable mounting of the
tool permits the cutting of grooves and the generation of surfaces at almost any angle to one another.

The rams on most shapers reciprocate horizontally. Shapers with vertical rams are known as
slitters, or die shapers, and are frequently provided with rotary tables. Means are provided on all
shapers for varying the length of stroke and speed of the ram.

40
 CONCLUSION

As mentioned earlier that the BHEL is one of the Leading PSUs in India, BHEL-HPVP is contributing
in their style as well the growth of BHEL. It is great opportunity for me to do internship in BHEL-
HPVP plant because of that , I visually seen some of the power system equipment like circuit breakers,
isolators, Induction motors(10hp-25hp) which have doubled my knowledge because of this internship
and also learned about some of the machine’s function like Vacuum Brazing Machinery, Automatic
Edge cutting machinery

41
REFERENCES:
[Link].[Link]
2.[Link]
3.[Link]
4 Text book ”principles of power system” by VK Mehta and Rohit Mehta
5.[Link]
6.[Link]
7.[Link]

42