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VOCATIONAL TRAINNING

REPORT ON

BHILAI STEEL PALNT


(4 JUNE 2016 TO 18 JUNE 2016)

PREPARED BY ELECTRICAL AND


NIKHIL DESHMUKH ELECTRONIC
RA1411005010260
COMPANY PROFILE
Eleven times winner of Prime Minister's Trophy for Best
Integrated Steel Plant in the country, Bhilai Steel Plant
(BSP) is India's sole producer & supplier of world class
rails for Indian Railways including 260 metre long rails,
and a major producer of large variety of wide and
heavy steel plates and structural steel. With an annual
production capacity of 3.153 MT of saleable steel, the
plant also specializes in other products such as wire
rods and merchant products. The entire range of TMT
products (Bars & Rods) produced by the Plant is of
earthquake-resistant grade and superior quality. The
plant also produces heavy structurals including
channels and beams. 2
The main consideration for choosing Bhilai was the
availability of iron ore at Dalli Rajhara, about
100 km from the site; limestone from Nandini,
about 25 km from the plant, and dolomite at Hirri,
about 140 km away.
PRODUCTS -

TONNES/ANNUM
SEMIS (533000)
RAIL(750000)
Merchant Products (500000)
Wire Rods(420000)
Plates (950,000) 3
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TRAINING FIELD -
ELECTRICAL REPAIR SHOP

TRANSFORMER REPAIR SHOP

POWER DISTRIBUTION DEPARTMENT

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ELECTRICAL REPAIR SHOP -
TASKS DONE IN ERS :-

Assembles electrical parts such as alternators, generators, starting


devices and switches; following schematic
drawings, using hand, machine
and power tools.

Repairs and rebuilds defective


mechanical parts in electric
motors, generators and related
equipment, using hand tools and
power tools.
Tests for overheating, using
speed gauges and thermometers. 6
Rewinds coils on core while core is in slots, or make replacement
coils, using coil-winding machine.
Replaces defective parts such as coil leads, carbon brushes and
connecting wires using soldering equipment.
Installs, secures and aligns parts using hand tools welding
equipment and electrical meters.
Rewires electrical systems and repairs or replaces electrical
accessories.
Reassembles repaired electric motors to specified requirements
and ratings, using hand tools and electric meters.
Disassembles defective units using hand tools.
Measures velocity, horsepower, r.p.m, amperage circuitry and
voltage of units or parts using electrical meters and mechanical
testing devices.
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Cuts and removes parts such as defective coils and insulation.
Adjusts working parts such as fan belt tension, voltage output,
contacts and springs using hand tools and verifies corrections using
gauges.
Tests charges and replaces batteries.
Inspects parts for wear or damage or reads work order or
schematic drawings to determine required repairs.
Cuts and forms insulation and inserts insulation into armature,
rotor or stator slots.
reams and polishes commutators and machine parts to specified
tolerances using machine tools.

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MOTOR ASSEMBLY SHOP

SCHEMATIC VIEW OF MOTOR DISMANTLE SHOP WHERE THE


MOTORS ARE DISMANTLED AND DELIVERED FOR FURTHER
WORKING. 9
SMALL WINDING SHOP

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Megger equipment basically use for verifying the electrical
insulation level of motor .

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STEPS
Clean your work surface to make sure its free of dirt
and dust.
Remove the motor housing to reveal the armature,
stator, and the windings.
Document the present configuration by taking notes
or photographs.
Take the wire from the tabs on the brush pads.
Cut the coils in the wind free from the armature
and/or stator.
Check the insulation that lines the actual steel
laminate areas of the stator before you rewind an
electric motor.
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Rewind the armature and/or stator using the same
gauge and type of magnet wire that was on the original
motor.
Recreate the exact winding pattern and number of coils
around each winding
Connect the end of the last winding and the loose wire
you left in the first winding to the tab where you
began.
Check to make sure that none of the wires connecting
to the tabs are touching.
Reassemble the motor housing in assembly shop.

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ENAMELLED ROUND COPPER WIRE & ENAMELLED
ROUND ALUMINIUM WIRE:

TEMP. CLASS Type of Enamel Diameter Range Specification

IEC-60317-12
'B', 105oC / 120oC Polyvinyl Acetal (PVA / PVF)
NEMA MW-15

IEC-60317-03
F, 155oC Polyester
IS-13730-03
Copper:
0.50 to 5.50 mm
IEC-60317-08
H, 180oC Polyesterimide Aluminium:
IS-13730-08
1.50 to 5.50 mm

Polyesterimide (base IEC-60317-13


C, 200oC coat) + IS-13730-13 /
Polyamide-imide (top coat) NEMA MW-35

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BIG MOTOR WINDING SHOP

MOTORS LIKE 5000HP OR MORE COMES TO REPAIRS IN BIG MOTOR


WINDING SHOP AFTER PASSING THROUGH ASSEMBLY SHOP .

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ENAMELLED RECTANGULAR /FLAT COPPER WIRE /
ENAMELLED COPPER STRIP

TEMP. CLASS TYPES OF INSULATION SIZE RANGE SPECIFICATION

IEC-60317-18
'B', 105oC/120oC Polyvinyl Acetal (PVA/PVF)
NEMA MW-18

Area: IEC-60317-16
F, 155oC Polyester 3 - 56 Sq. mm IS-13730-16

Min. Size:
IEC-60317-28
H, 180oC Polyesterimide 3x1 mm (Cu)
IS-13730-28
3x2 mm (Al)
Max. Size:
Polyesterimide (base 14 x 4 mm IEC-60317-29
o
C, 200 C coat) + IS-13730-29/
Polyamide-imide (top coat) NEMA MW- 36
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TRANSFORMER REPAIR SHOP-

A welding transformer is a step down transformer that has thin primary winding with a
large number of turns and its secondary has more area of cross-section and less number of
turns ensuring less voltage and very high current in the secondary. The welding transformer
reduces the voltage from the source voltage to a lower voltage that is suitable for welding.
Usually between 15 and 45 volts. The secondary current is quit high and it may be typically
200A to 600A, but it could be much higher. The secondary may have several taps for
adjusting the secondary voltage to control the welding current. The taps are typically
connected to a several high-current plug receptacles or to a high-current switch. One end
of the secondary is connected to the welding electrode, whereas the other end of the
secondary is connected to the welding electrode, whereas the other end is connected to
the pieces to be welded .If any high current flows, heat is produced due to the contact
resistance between the electrode and the pieces to be welded. The generated heat melts a
trip of the electrode and the gap between the two pieces is filled. Figger shows a simple
welding transformer.
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POWER DISTRIBUTION DEPARTMENT-

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OUTDOOR SWITCHYARDM-
BUSBARS
POWER TRANSFORMERS AND MEASUREMENT TRANSFORMERS
INSULATORS
CIRCUIT-BEAKERS & ISOLATORS
LIGHTNING ARRESTORS
GALVANISED STEEL STRUCTURES FOR TOWERS & EQUIPMENT SUPPORTS.
ROADS, RAILWAY TRACK, CABLE TRENCHES
PLCC EQUIPMENT INCLUDING LINE TRAP, TUNING UNIT, COUPLING CAPACITOR,
ETC.
STATION EARTHING SYSTEM COMPRISING GROUND MAT, RISERS, AUXILIARY MAT,
EARTHING STRIPS, EARTHING SPIKES & EARTH ELECTRODES.
CONTROL CABLES FOR PROTECTION AND CONTROL
INCOMING & OUTGOING LINES

CONTROL BUILDING
IN EVERY SUB-STATION CERTAIN SUPERVISION, CONTROL
AND PROTECTION FUNCTIONS ARE NECESSARY. SO A
CONTROL BUILDING/CONTROL ROOM IS REQUIRED. THE
RELAY AND PROTECTION PANELS AND CONTROL PANELS
ARE INSTALLED IN THE CONTROL ROOM.
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CONTROL ROOM -

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DISTRIBUTOR TRANSFORMER

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COMPONENT OF TRANSFORMER

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CURRENT TRANSFORMER (CT):

MAKE ELECTRIC POWER EQUIPMENT CO.


MSR INDUSTRIES ESTATE, BANGALORE 560054
TYPE OHCDB-R
HSV 36KV
SERIAL NO. 33193
FREQ 50 HZ.
RATED VOLTAGE 33KV
SHORT TIME THERMAL CURRENT 15.15KA FOR 3 SECS

INSULATION 70/170KV
QTY OF OIL/WT. 20 LTR./ 24 KG APRX.
DYNAMIC CURRENT 65.6 KAP
YEAR 1999
TOTAL WT. 150 KGS (APRX)
MAX. TEMP. RISE - WINDING - 45C
INSULATION A
OVER AMBIENT (45C) OIL - 40C
CONTINUOUS THERMAL CURRENT 780 A

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POTENTIAL TRANSFORMER (PT):

MAKE MODERN ELECTRONIC


TYPE OPT
RATIO 33KV3 / 1103V /1103V.
HSV 36KV,
PHASE 1,
FREQ- 50 HZ
INSULATION CLASS A
CORE - I II
BURDEN - 100 100
CLASS - 0.2 3P
V.F - 1.2 CONT. & 1.9 FOR 30 S
CONN PH E
BIL 70/170KV
TEMP. RISE OVER WDG OIL
45C 35C
OIL QTY. 20 LTR.
TOTAL WT. 90KG
ISS 3156,
SL. NO.- ME/PT/411/08
P.O NO. CE(T)/P 4/ST BB/2087 25
lighting arrester-
A lightning arrester 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.

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Circuit Breakers:
MAIN FUNCTION OF CIRCUIT BREAKER IS TO SWITCH OFF AND SWITCH ON
THE NORMAL CURRENT AND TOP TRIP THE CIRCUIT AT THE OCCURANCE OF
ANY FAULT.
Type - 3AP1F1
Year of Manufacturing/No - 2006/IND/01/2276
Rated Voltage 245 kV
Rated lightning impulse withstand voltage 1050 kVP
Rated Power Freq. withstand voltage 460 kV
Rated Frequency 50 Hz
Rated Normal Current 3150 A
Rated S. Circuit breaking current 40kA
Rated S. Circuit Duration 3S
Rated out of phase breaking current 10Ka
First -pole-to-clear factor 1.3
Rated line charging breaking current 125 A
Rated pressure of SF6 at +20C (gauge) 6.0 bar rel
Rated operating sequence O-0.3S-CO-3 m-CO
Weight of SF6 filling Approx 22 Kg
Weight including SF6 (excluding structure) Approx 3000 Kg
Make - SIEMENS
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Isolators:
ISOLATORS GIVE PHYSICAL SEPARATION BETWEEN LIVE PART AND DEAD PART.
PHYSICAL SEPARATION CAN BE SEEN BY NAKED EYE FROM A DISTANCE.

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PROTECTION & CONTROL:

Objectives of Protection:
I) TO DISCONNECT THE FAULTY CIRCUIT WITH
MINIMUM DAMAGE DUE TO FAULT.
II) TO LEAVE THE REST OF THE POWER
SYSTEM IN A HEALTHY STATE.
III) COST OF REPAIR OF DAMAGE TO BE KEPT
MINIMUM.
IV) TO RESTRICT POSSIBILITY OF SPREADING
AND INVOLVING OTHER EQUIPMENT.
V) TO REDUCE TIME THE EQUIPMENT OUT OF
SERVICE.
VI) TO MINIMIZE COST OF REVENUE LOSS.
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THANK YOU

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