BHARAT HEAVY ELECTRICALS LIMITED

JHANSI, U.P.

SUMMER VOCATIONAL TRAINING

"ROTATION REPORT"

DURATION: 08/06/2026 TO 13/06/2026

Submitted to: Training Co-Ordinator:

Mr. Sanjay Mishra Mr. Preetam Singh Rawat
Executive (HRDC) Astt. Engineer (HRDC)

Submitted by:
Raj Karol
[Link] (2nd Year) 2026
Civil Engineering
National Institute of Technology, Tiruchirappalli
Roll No.: 103124080
 BHEL - AN OVERVIEW
BHEL is the largest engineering and manufacturing enterprise in India in the energy related
infrastructure sector today. BHEL was established more than 50 years ago when its first plant was
setup in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India — a dream
which has been more than realized with a well recognized track record of performance. It has been
earning profits continuously since 1971-72.
BHEL caters to core sectors of the Indian Economy viz., Power Generation & Transmission,
Industry, Transportation, Telecommunication, Renewable Energy, Defence, etc. The wide network
of BHEL's 14 manufacturing divisions, four Power Sector regional centres, over 150 project sites,
eight service centres and 18 regional offices, enables the Company to promptly serve its customers
and provide them with suitable products, systems and services efficiently and at competitive prices.
BHEL has already attained ISO 9000 certification for quality management, and ISO 14001
certification for environment management.
Power Generation
Power generation sector comprises thermal, gas, hydro and nuclear power plant business. BHEL
supplied sets account for nearly 64,737 MW or 65% of the total installed capacity in the country.
BHEL has proven turnkey capabilities for executing power projects from concept to commissioning;
it possesses the technology and capability to produce thermal sets with super critical parameters up
to 1000 MW unit rating and gas turbine generator sets of up to 240 MW units rating.
Co-generation and combined-cycle plants have been introduced to achieve higher plant efficiencies.
To make efficient use of the high-ash-content coal available in India, BHEL supplies circulating
fluidized bed combustion boilers to both thermal and combined cycle power plants. The company
manufactures 235 MW nuclear turbine generator sets and has commenced production of 500 MW
nuclear turbine generator sets. Custom made hydro sets of Francis, Pelton and Kaplan types for
different head-discharge combinations are also engineered and manufactured by BHEL.
Transportation
BHEL is involved in the development, design, engineering, marketing, production, installation, and
maintenance and after-sales service of Rolling Stock and traction propulsion systems. In the area of
rolling stock, BHEL manufactures electric locomotives up to 5000 HP, diesel-electric locomotives
from 350 HP to 3100 HP, both for mainline and shunting duty applications. BHEL also produces
rolling stock for special applications viz., overhead equipment cars, special well wagons, Rail-cum-
road vehicles etc. The electric and diesel traction equipment on Indian Railways are largely powered
by electrical propulsion systems produced by BHEL. The company also undertakes retooling and
overhauling of rolling stock. BHEL is geared up to turnkey execution of electric trolley bus systems,
light rail systems etc.
International Operations
BHEL has, over the years, established its references in around 60 countries of the world, ranging
from the United States in the West to New Zealand in the Far East. These references encompass
almost the entire product range of BHEL, covering turnkey power projects of thermal, hydro and
gas-based types, substation projects, rehabilitation projects, besides a wide variety of products like
transformers, insulators, switchgears, heat exchangers, castings and forgings, valves, well-head
equipment, centrifugal compressors, photo-voltaic equipment etc. Apart from over 1110 MW of
boiler capacity contributed in Malaysia, and execution of four prestigious power projects in Oman,
major successes have also been achieved in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta,
Egypt, Bangladesh, Azerbaijan, Sri Lanka, Iraq etc.
 Vision, Mission and Values of BHEL
VISION
A WORLD-CLASS ENGINEERING ENTERPRISE COMMITTED TO ENHANCING
STAKEHOLDER VALUE.
MISSION
TO BE AN INDIAN MULTINATIONAL ENGINEERING ENTERPRISE PROVIDING TOTAL
BUSINESS SOLUTIONS THROUGH QUALITY PRODUCTS, SYSTEMS AND SERVICES IN
THE FIELDS OF ENERGY, INDUSTRY, TRANSPORTATION, INFRASTRUCTURE AND
OTHER POTENTIAL AREAS.
VALUES
• Zeal to Excel and Zest for Change.
• Integrity and Fairness in All Matters.
• Respect for Dignity and Potential of Individuals.
• Strict Adherence to Commitments.
• Ensure Speed of Response.
• Foster Learning, Creativity and Teamwork.
• Loyalty and Pride in the Company.
 Day - 1 (08/06/2026)
Departments Covered: Machine Shop (Bay-3 & Bay-5), Transformer Winding Shop (Bay-4), Traction
Transformer Assembly (Bay-6), Insulation & DTT Assembly (Bay-7)

TRM BAY-3 — Machine Shop

There are basically three sections in this Bay:
1. Machine Section
2. Copper Section
3. Tooling Section

1. MACHINE SECTION:
The operations to form small components of power and traction transformer are made in this section.
The shop consists of following machines:
a.) CENTRAL LATHE: It consists of tailstock, headstock & cross slide. In this machine, the job
rotates and the tool is fed through the cross slide. On this machine, facing, turning and threading is
done.
b.) TURRET LATHE: Its function is the same as central lathe but it is used for mass production.
Here turret head is used in place of tailstock because turret head contains many tailstocks (around
six).
c.) CAPSTAN LATHE: Its function is also same as central lathe.
d.) RADIAL ARM DRILLING MACHINE: It is used for drilling operation. In this machine, drills
are used to make holes into metal.
e.) HORIZONTAL BORING MACHINE: It is computerized and used for making bore & for
facing etc.
f.) MILLING MACHINE: It is of two types — Horizontal milling machine (used for making gear
and cutting operations) and Vertical milling machine (used for facing and T-slot cutting).

2. COPPER SECTION:
All the operations related to copper are done here. The machines used in this section are:
a.) TUBE SLITTING MACHINE: It is used for cutting the tube along its length and across its
diameter. Its blade thickness is 3mm.
b.) SHEARING MACHINE: It is operated hydraulically and its blade has a V shape with a
thickness of 15mm.
c.) DIE AND PUNCHING MACHINE: It is also hydraulically operated and has a die and punch
for making holes.
d.) BENDING MACHINE: It is used for bending the job. It is also hydraulically operated.

3. TOOLING SECTION:
In this section the servicing of tools is done.
a.) BLADE SHARP MACHINE: It sharpens the blade using a circular diamond cutter. Blade of the
CNC cropping line machine is sharpened here.
b.) MINI SURFACE GRINDER: It serves grinding purpose. It has a grinding wheel made of
Aluminium oxide.

TRM BAY-5 — Core & Punch Shop

Bay-5 is the core and punch section. The lamination used in power, dry, ESP transformers etc. for
making the core is cut in this section. CRGO (Cold Rolled Grain Oriented) silicon steel is used for
lamination, which is imported in India from Japan, U.K. & Germany. It is available in 0.27 & 0.28
mm thick sheets, 1m wide, and measured in Kg. The sheets are coated with a very thin layer of
insulating material.
For the purpose of cutting and punching the core, three machines are installed in this shop:
a.) SLITTING MACHINE: It is used to cut CRGO sheets in different widths. It has a circular
cutter whose position can be changed as per requirement.
b.) CNC CROPPING LINE PNEUMATIC: It contains only one blade, which can rotate 90° above
the sheet. It is operated pneumatically.
c.) CNC CROPPING LINE HYDRAULIC: It is also used to cut the CRGO sheets. It contains two
blades — one is fixed and the other rotates 90° above the sheet. It is operated hydraulically.

TRM BAY-4 — Transformer Winding Shop

Bay-4 is the winding section where the coils for various types of transformers are wound.
Types of Winding:
1. Reverse Section (RS) Winding: This type of winding is done to maintain the resistance same for
both the inner and outer conductor. Basically it is a special type of disc winding in which multiple
no. of conductors run at a time. In this type of winding, alternate layers are continuously transposed.
All HV coils are RS type.
2. Helical Winding: This is a special type of spiral winding in which ducts are given in between two
layers. LV coils are helical type.
3. Interleaved Winding: This type of winding is used in power transformers to increase the series
capacitances. It is done to protect the transformer from impulse stress.

There are four types of coils fixed in a transformer:

4. Low Voltage Coil (LV)
5. High Voltage Coil (HV)
6. Tertiary Coil
7. Tap Coil
The types of winding depend upon job requirement. Conductor used for winding is in the form of
very long strips wound on a spool; the conductor is covered by cellulose paper for insulation. The
winding is done according to the specification given in the drawing.
 TRM BAY-6 — Traction Transformer Assembly

Single-phase traction transformer for AC locomotives is assembled in this section. These freight
locomotive transformers are used where there is frequent change in speed. In this bay, core winding
and all the assembly and testing of traction transformer is done.
Three-phase transformers for ACEMU are also manufactured in this section. The supply line for this
transformer is of 25 KV and the power of the transformer is 6500 KVA.
The tap changer of rectifier transformer is also assembled in this bay. Rectifier transformer is used in
big furnaces like the thermal power stations/plants.

TRM BAY-7 — Insulation & DTT Assembly Shop

This is the insulation shop. Various types of insulations used are:
8. AWWW (All Wood Water Washed Press Paper): The paper is 0.2–0.5 mm thick cellulose
paper and is wound on the conductors for insulation.
9. Pre-Compressed Board: This is widely used for general insulation & separation of conductors
in the form of blocks.
10. Press Board: This is used for separation of coils e.g. L.V. from H.V. It is up to 36 mm thick.
11. UDEL (Undemnified Electrical Laminated wood / Permawood): This is a special type of
plywood made for insulation purposes.
12. Fibre Glass: This is a resin material & is used in fire prone areas.
13. Bakelite: A kind of plastic insulator highly resistive to heat.
14. Gasket: It is used for protection against leakage.
15. Silicon Rubber Sheet: It is used for dry type transformer.

Machines used for shaping insulation material:

• Circle Cutting Machine
• Scraping Machine
• Punching Machine
• Drilling Machine
• Bench Saw (special for OD)
• Jig Saw (special for ID)
• Circular Saw
 Day - 2 (09/06/2026)
Departments Covered: Instrument Transformer Assembly (Bay-8), Transformer Assembly (Bay-9),
Transformer Testing, Central Quality Services (CQX)

TRM BAY-8 — Instrument Transformer & HVR Manufacturing

1. INSTRUMENT TRANSFORMER:
These are used for measurement. Actual measurement is done by measuring instruments but these
transformers serve the purpose of stepping down the voltage to protect the measuring instrument.
They are used in AC systems for measurement of current, voltage & energy and can also be used for
measuring power factor, frequency and for indication of synchronism. They find application in
protection of power systems & for the operation of over voltage, over current, earth fault and various
other types of relays.
They are of two types:
16. Current Transformer (CT)
17. Voltage Transformer (VT)

2. HVR TRANSFORMER (Electrostatic Precipitator):

The Electro Static Precipitator transformer is used for environmental applications. It is used to filter
suspended charged particles in the waste gases of the industry. They are of particular use in thermal
power stations and cement industry.

TRM BAY-9 — Power Transformer Assembly

In this bay, power transformers are assembled. After taking different inputs from different bays,
assembly is done. Power transformer is used to step down voltage at generation and sub stations.
Various ratings — 11 KV, 22 KV — are manufactured. They are:
18. Generator Transformer System
19. Auto Transformer
A transformer in the process of assemblage is called a job. The design of the transformer is done by
the design department & is unique for each job; it depends upon the requirement of the customer.
The design department provides drawing to the assembly shop, which assembles it accordingly.
Steps involved in assembly:
1. CORE BUILDING: Initially laminations are cut at 45°. The punched core is sent into this shop
where it is assembled with the help of drawing. A set of four laminations is called a packet. The
vertical portion of the core is called 'leg' and the horizontal one is called 'yoke'. Packets of both are
interleaved; it is undesirable to keep the X-section core circular — it should be kept to provide low
reluctance path without air space. Whatever spaces are left are filled with thin wooden rods. After
core building, the end frames are bolted.
2. CORE LIFTING: The core is lifted by a crane and is placed vertical. The rest of assembly is
done in this position.
3. UNLACING & CORE COIL ASSEMBLY: The Yoke of the core is removed using a crane.
Bottom insulation in the form of 50 mm thick UDEL sheets is placed. PCB and Press board are also
used for filling the gap and to provide a good base for the coil to rest. The coil is then lowered —
primary, secondary, tertiary and tap — in that sequence.
4. REPLACING AND END FRAME MOUNTING: After lowering a coil, the top insulation
similar to the bottom one is provided. The removed yoke is placed and end-frame bolted back into its
position. The connections are then made as per drawing. All the conductors are insulated using crepe
paper. The following tests are done during Relaying: (i) Megger test, (ii) Ratio test, (iii) High voltage
test. Testing at this stage is called pre-testing.
5. HIGH VOLTAGE TERMINAL GEAR & L.V.T.G.: The terminal gears are accessories
provided at high voltage and low voltage terminals. The main device used is tap changer. Tap
changer can be on-load or off-load. In off-load type, the supply has to be tripped, then the tapings
change; but in on-load type, the tapings can be changed while the supply is on.
6. VAPOUR PHASING & OIL SOAKING: The process of moisture removal from the transformer
is called vapour phasing. The job is put in a dummy type shell and then in a vacuum vessel. It is an
air-tight chamber with heating facilities. The job is heated in vacuum and all the solvent vapours are
sucked out with moisture. After moisture removal, the tank is filled with transformer oil and soaked
for at least three hours so that every part gets wet with oil.
7. FINAL SERVICING AND TANKING: After tanking the job out of the dummy tank, all the
parts are retightened and any other defects are rectified. The job is reinserted in the mild steel tank
after oil is filled.
8. CASE FITTING: The accessories are fixed and final touches given to the job. Accessories
include tank cover, fixing bushing, fixing valves etc. The terminals are marked and the R&D (Rating
and Drawing) plate is fixed by bolting. The bottom chamber is a mild steel tank with a steel frame
attached to its base for earthing.

Transformer Testing Department

Transformer Testing Department is a crucial part of the facility that specializes in production and
testing of transformers. This department ensures that the transformers manufactured meet standard
quality and performance. The main key functions of this department are as follows:
• Routine Testing: Test to ensure that each transformer meets operational standards.
• Type Testing: Comprehensive test on transformer prototype to ensure they meet all design
specifications.
• Special Testing: Custom test tailored to specific requirements of customer.
• Quality Assurance: Ensuring that all transformers adhere to National and International
standards.
• Diagnostics
• Troubleshooting

C.Q.X — Central Quality Services

The department provides various services related to customer support and quality management.
Quality: It is the extent to which products and services satisfy the customer needs.
Quality Assurance: All those plans and systematic actions necessary to provide adequate
confidence that a product or service will satisfy the given requirement.
Quality Control: The operational techniques and activities that are used to fulfil requirements for
quality.
Quality Inspection: Activities such as measuring, testing, gauging one or more characteristics of a
product or service and comparing these with specified requirements to determine conformity.
 Day - 3 (10/06/2026)
Departments Covered: Transformer Commercial (TRC), Transformer Engineering (TRE),
Transformer Planning (TRP), Technology Department

TRC — Transformer Commercial

The objective of the TRC department is interaction with customers. It brings out tenders and notices
and also responds to them. It is this department that bags contracts for building transformers. After
delivery regarding faults, this department handles failures and maintenance. One of the major tasks
of this department is to earn decent profits over all negotiations.
Transformer industry has become very competitive. The company offering the lowest price gets the
contract, but this process may lead to work on very low profits. To avoid such a situation, a body by
the name of India Electrical Manufacturers Association (IEMA) was set up. This association helps to
maintain a healthy competitive atmosphere in the manufacturing of electrical appliances.
The main work of TRC is classified as:
20. Tender and notices
21. Interaction with design department
22. Place of the work
23. Approximate cost of the work
24. Earnest money
25. Place & time of viewing contract documents
26. Place & time of obtaining tender documents
27. Deciding time up to which tender documents will be sold
28. The amount if any, to be paid for such documents
29. The place, date and time of submission of tenders and opening of tenders

TRE — Transformer Engineering

The transformers manufactured in BHEL Jhansi range from 10 MVA to 315 MVA and up to 400
KV. The various transformers manufactured are:
Power Transformers:
30. Generator Transformer
31. System Transformer
32. Auto Transformer
Special Transformers:
33. HVR/ESP Transformer
34. Instrument Transformer
35. Cast Resin Dry Type Transformer
The objective of this department is to create drawings and designs of the transformers which is
further based on pure calculation and programming. Softwares are used to create these designs. Each
design is unique to the customer's requirement.
 TRP — Transformer Planning
The transformer planning department is responsible for strategic planning and coordination involved
in the production of transformers. This department ensures that the production processes are
streamlined and efficient, meeting both the company's and customer's requirements.
Key functions of the department:
• Production Scheduling: Creating detailed schedules for the manufacturing process to ensure
timely delivery of transformers.
• Resource Allocation: Managing and allocating resources such as material, manpower and
machinery to optimise production efficiency.
• Coordination with Other Departments: Coordinating with design, quality control,
procurement and testing departments to ensure seamless production.
• Capacity Planning: Assembling and planning for production capacity to meet current and
future demand.
• Cost Control: Monitoring and managing production costs to stay within budget while
maintaining quality standards.
• Workflow Optimisation: Continuously analysing and improving production workflow to
enhance efficiency and reduce waste.

Technology Department
This department analyses the changes taking place in the world and suggests changes and upgrades
accordingly. This is a very important department for keeping the facility updated with modern
manufacturing techniques.
Technology functions can be classified as:
• Processing Sequence
• Operation Time Estimate
• Facilities Identification
• Special Process Certification
• Special Tools Requirements
• Productivity Projects Compilation
 Day - 4 (11/06/2026)
Departments Covered: Transportation Production (LMM), Transportation Testing (LMT),
Transportation Commercial (LMC), Transportation Engineering (LME)

LMM — Locomotive Manufacturing (Transportation Production)

This unit was started in 1985. This department of Jhansi consists of two sections — manufacturing &
design. The Diesel, AC, and AC/DC locomotives are manufactured here.
a. THE DIESEL LOCOMOTIVE
Salient features:
36. Flat bed under frame.
37. All pneumatic valves provided in single panel.
38. All electrical equipments provided in single panel.
39. Improved filtration system.
40. Brush-less traction alternators.
41. Fault display on control desk with alarm.
42. Simple driving procedure.
43. Automatic wheel slip detection & correction.
44. Multiple unit operation up to three locomotives.
45. Air & vacuum brakes.

b. THE AC LOCOMOTIVE
Salient features:
46. Operates on 25 KV AC Single-phase lines.
47. Driving cab at both ends.
48. Corridors on both sides for maintenance.
49. All pneumatic valves at one place.
50. Automatic wheel slip detection & correction.
51. Multiple unit operation up to three locomotives.
52. VCB in AC circuit.
53. Air and Vacuum Brakes.

c. THE AC/DC LOCOMOTIVE

Salient features:
54. Designed to operate both on 1500 V DC & 25 KV AC lines.
55. Driving cab at both ends.
56. High adhesion bogie.
57. Corridors on both sides for maintenance.
58. All pneumatic valves at one place.
 59. Automatic wheel slip detection & correction.
60. Multiple unit operation up to three locomotives.
61. Fault display on driver's desk.
62. Static inverter for auxiliary supply.
63. FRP control desk.
64. VCB in AC circuit.
65. Air & Vacuum brakes.
66. Air dryer for brake system.

This sector deals with the production of WAG-7 with regenerative braking feature. It also
manufactures WAG-9, 9H, 9HC under electrical engine systems and some diesel control systems are
also produced here. The Pantograph is the most important part as it completes the circuit and
connects the superstructure to the power supply. A maximum of 7 to 8 working days leads to a fully
manufactured superstructure consisting of two driver cabins and a machine room in between. Parts
like transformer, sandbox, tanks and other various parts are attached near the bogie part where the
axle of the wheel is connected. Silica gel is used in the machine to absorb moisture.

LMT — Transportation Testing

After the production of locomotive and its completion, it is handed over to this department to check
if any faults are present. Tests like connection check, electrical parts check, and gas leaks or wiring
check are done before the final dispatch.
Locomotive testing procedure generally involves:
1. Preliminary Checks: Visual inspection for any physical damage or defects. Documentation
review to ensure all design and manufacturing documents are complete.
2. Static Testing: Electrical systems test (verify functionality of electrical components, wiring, and
circuits), mechanical systems test (check integrity and alignment of mechanical components), and
control systems test.
3. Dynamic Testing: Initial run at low speeds to identify immediate issues, performance testing
under various conditions, and load testing with varying loads.
4. Safety Testing: Brake test to ensure braking systems are effective and reliable. Emergency
systems test to check functionality of emergency systems, fail-safes and backups.
5. Environmental Testing: Temperature and climate tests, noise and vibration tests.
6. Compliance Testing: Regulatory compliance and emissions testing.
7. Final Inspection and Sign-Off: Comprehensive review, documentation, and approval from
regulatory bodies.

LMC — Transportation Commercial (Locomotive Commercial)

The main objective of this department is interaction with customers. It brings out tenders and notices
and also responds to them. It bags the contracts to manufacture locos. After delivery, it further takes
care of and investigates faults and failures, taking appropriate actions to solve problems.
Its functions can be broadly classified as:
• Tender: Technical specification/requirement, Estimated cost of project/equipment, Estimated
time of completion of project, Other information.
 • Enquiry
• Offer and Contract Agreement

LME — Transportation Engineering (Locomotive Engineering)

It forms a link between the locomotive commercial department and the manufacturing unit. It takes
the technical specification of the job from the commercial department and prepares the drawing of
the job required, taking all the constraints into consideration. Various softwares such as AutoCAD,
Catia, Ansys are used; however, manual drawings are also required sometimes.
The department is presently working on the designing of WAG-9. WAG-9 is an upgraded model of
WAG-45 with improved performance parameters and energy efficiency features.
 Day - 5 (12/06/2026)
Departments Covered: Transportation Engineering (LME — continued), Transportation Planning
(LMP), Fabrication Department

LME — Transportation Engineering (Continued)

Continuing from Day 4, a deeper understanding of the engineering design process was gained. The
department coordinates closely with manufacturing and commercial departments to ensure that
drawings are translated accurately into finished products. The use of advanced simulation tools like
Ansys helps in stress analysis and optimization of locomotive components before physical
manufacturing begins.

LMP — Transportation Planning (Locomotive Planning)

It looks after how a certain project is to be executed so that it turns out smoothly. The various
functions performed include customer enquiry, receipt of order, issue of work order from
commercial department, issue of manufacturing information from Engineering, product specification
and routing sheet, indenting of items etc.
Key responsibilities include:
• Receiving customer orders and converting them into work orders.
• Coordinating between commercial, engineering, and manufacturing departments.
• Preparing routing sheets and manufacturing schedules.
• Indenting raw materials and components from stores.
• Tracking production milestones to ensure timely delivery.

Fabrication Department
This department deals with raw materials and their processes in the manufacturing of transformers as
well as superstructures and bogies. Raw material such as mild steel is categorised into various
grades:
• Grade A: Used to make pipeline structures.
• Grade B: Used to make cards and such other structural products.
• Grade C: Used to manufacture transformer tanks and wagon bogies.
Machines such as punching, flattening, cutting etc. are present in this sector. Various other small and
big parts are simultaneously created or assembled here. The fabrication department plays a crucial
role as it supplies the structural components to both the transformer and locomotive manufacturing
sections.
 Day - 6 (13/06/2026)
Departments Covered: Works Engineering Services (WES), Electronics Lab

W.E.S — Works Engineering and Services

As the name suggests, this section deals with services and maintenance. It has the following sections:
• Plant Equipment: This has electronics & electrical/mechanical maintenance.
• Services: This section deals with air, steam & Power equipment.
• Telephone Exchange.
• Township Electrical Maintenance.
• W.E. & S Planning.
This section deals with stores & new machines procurement & other general things. There are three
maintenance centres at Bay-2, Substation 1 & Loco. This section is also responsible for power
distribution in BHEL.
The power distribution is of two types:
1. HT Power Distribution: This is at 11 KV; OCBs are used for protection. There are four
substations for this distribution.
2. LT Distribution: This is for the auxiliary in each shop & other section of BHEL.
This department looks after the commissioning and maintenance of all machinery used in the factory.
It also has 3 two-stage air compressors for supplying compressed air to the various bays.
The department has 03 different divisions:
• Electrical Engineering
• Electronics Engineering
• Mechanical Engineering
The factory has a feeder of 11 KV. The total load sanctioned is 2500 MVA but the maximum
demand reaches the range of 1700–2000 MVA. There are various sub-stations (SS) inside the factory
for distribution of power to different sections:
67. SS-1 supplies Bay-6 to Bay-9
68. SS-3 supplies Bay-1 to Bay-4
69. SS-4 supplies Boiler and Loco Plant
70. SS-5 supplies Bay-5
71. SS-6 supplies Administrative Building

Electronics Lab
The Electronics Lab ensures the reliability and performance of electronic systems used in
locomotives and transformers.
Key Functions and Responsibilities:
• Equipment Checks: Testing and Calibration of all electronic instruments.
• Spare Parts Storage and management.
• Inventory Management.
• Quality Control of electronic components and systems.
• Research and Development.
• Prototype Testing.
• Upgrades to existing electronic systems.
• Troubleshooting and Repair.
• Diagnostic Services.
• Documentation and Reporting.
 CONCLUSION AND RESULTS
This six-day Summer Vocational Training at BHEL Jhansi (08/06/2026 to 13/06/2026) provided an
invaluable industrial exposure, covering 20 departments across transformer manufacturing,
locomotive production, and supporting services. The rotation training offered a comprehensive view
of how a large-scale public sector undertaking operates — from raw material processing to final
product dispatch.
As a Civil Engineering student, this internship broadened my technical horizon significantly. While
civil engineering deals with infrastructure, structures, and construction materials, the industrial
environment at BHEL demonstrated how engineering principles are universal. The fabrication
department — dealing with mild steel grading, structural sections, and heavy machine operations —
was particularly relatable, as it mirrors construction material handling concepts. The understanding
of large-scale project planning through TRP and LMP departments also reinforced concepts of
project management and resource allocation that are integral to civil engineering projects.
The transformer manufacturing process — from CRGO sheet cutting in Bay-5 to final assembly and
vapour phasing in Bay-9 — highlighted the importance of precision engineering, quality control and
systematic production flow. The locomotive manufacturing unit (LMM) showcased how complex,
multi-system products are built in a coordinated environment involving commercial, engineering,
planning and fabrication teams working in sync.
The Works Engineering Services (WES) section gave insight into how industrial electrical
infrastructure — substations, HT/LT distribution, compressed air systems — is maintained, which is
directly relevant to understanding utility systems in large civil construction projects. The Electronics
Lab demonstrated the importance of diagnostics and quality assurance in ensuring system reliability.
In conclusion, this training at BHEL Jhansi was a transformative experience. It helped bridge the gap
between theoretical academic knowledge and real-world industrial application. The exposure to one
of India's largest engineering enterprises — its systems, departments, and manufacturing philosophy
— will be deeply beneficial in shaping my approach as an engineering professional.

"Powering Progress, Brightening Lives, Touching Every Indian Home"

— Bharat Heavy Electricals Limited