Deepika Final Report

8/8/2019 Deepika Final Report

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A

Seminar Report

On

Practical Training Undergone At

BHARAT HEAVY ELECTRICALS LIMITED

Submitted For

In partial fulfillment for the award of the degree for

Bachelor of Technology

In

Electrical Engineering

(2009)

SUBMITTED TO :SUBMITTED BY:

Er. A.K.DhimanDeepika Mittal (Sr. ENGR.)

Roll No:12

Block - IV Electrical

Engineering

B.H.E.L. Haridwar

DEPARTMENT OF ELECTRICAL ENGINEERING

ARYA INSTITUTE OF ENGINEERING AND TECHNOLOGY

RAJASTHAN TECHNICAL UNIVERSITY

PREFACE


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Practical knowledge means the visualization of the

knowledge, which we read in our books. For this, we perform

experiments and get observations. Practical knowledge is very

important in every field. One must be familiar with the problems

related to that field so that he may solve them and become a

successful person.

After achieving the proper goal in life, an engineer has to

enter in professional life. According to this life, he has to serve an

industry, may be public or private sector or self-own. For the

efficient work in the field, he must be well aware of the

practical knowledge as well as theoretical knowledge.

To be a good engineer, one must be aware of the industrial

environment and must know about management, working in such a

industry, labor problems etc., so that he can tackle them

successfully.

Due to all the above reasons and to bridge the gap between

theory and practical, our engineering curriculum provides a practicaltraining of 30 days. During this period, a student works in the

industry and gets all type of experience and knowledge about

the working and maintenance of various types of machinery.

I have undergone my 30 days training (after VI Semester) at

BHARAT HEAVY ELECTRICALS LIMITED. This report is

based on the knowledge, which I acquired during my 30 days

training period at the plant.


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INDEX

S.No.

01. INTRODUCTION

02. BHEL-A Brief Profile

03. BHEL - AN OVERVIEW

04. HEEP: AN OVERVIEW

05. BRIEF SUMMARY OF THE BAR SHOP

06. TYPES OF TURBOGENERATORS

07. MATERIAL CHECKING

08. CONDUCTOR CUTTING AND END CLEANING

09. TRANSPOSITION OF CONDUCTORS

10. CROSSOVER INSULATION

11. PRESSING

12. ISS- TEST

13. FORMING OF BAR

14. ZERO PICKLING OF BAR END

15. COIL LUG MOUNTING

16. MAIN BRAZING

17. CONDUCTOR CUTTING, DEBBERING AND FACE MILLING

`18. FIRST PICKLING


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INTRODUCTION

In 1956, India took a major step towards the

establishment of its heavy engineering industry when Bharat

Heavy Electrical Ltd., the first heavy electrical manufacturing

unit of the country was setup at Bhopal. It progressed rapidly and

three more factories went into production in 1965. The main aim of

establishing BHEL was to meet the growing power requirement of the

country.

B.H.E.L appeared on the power map of India in 1969 when the

first unit supplied by it was commissioned at the Basin BridgeThermal Power Station in Tamil Nadu. Within a decade, BHEL

had commissioned the 100 unit at Santaldih. West Bengal.

BHEL had taken India from a near total dependence on imports to

complete self-reliance in this vital area of power plant equipment

BHEL has supplied 97% of the power generating equipment.

BHEL has already supplied generating equipment to various

utilities capable of generating over 18000 MW power. Today

BHEL can produce annually; equipment capable of generating6000MW. This will grow further to enable BHEL to meet all of

Indias projected power equipment requirement. As well as sizeable

portion of export targets.

Probably the most significant aspect of BHELs

growth has been its

diversification. The constant reorientation of the organization to meet

the varied needs intime with time a philosophy that has led to the development of

a total capability from concepts to commissioning not only in

the field of energy but also in industry and

transportation.


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In the world power scene, BHEL ranks among the top ten

manufactures of power

plant equipment and in terms of the spectrum of products and services

offered, it is right

on top. BHELs technological excellence and turnkey capabilities

have won it worldwide

recognition. Over 40 countries in the world over have placed orders

with BHEL covering

individual equipment to complete power stations on a turnkey basis.

In 1978-79 export earnings reached Rs. 122 crores, the highest

for any one-year.

BHEL has its headquarters at New Delhi. Its operationsare spread over 11

manufacturing plants and number of engineering and service divisions

located across the

country/ the service divisions includes a network of regional

branch offices throughout

India.


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BHEL-A Brief Profile

BHEL is the largest engineering and manufacturing enterprise

in India in the energy-related / infrastructure sector, today. BHEL isushering in the indigenous Heavy Electrical Equipment industry in

India-a dream that has been more than realized with a well-

recognized track record of Performa

A widespread network comprising of 14 manufacturing

companies, which have international recognition for its commitment

towards quality. With an export presence in more than 60 countries,

BHEL is truly Indias ambassador to the world. BHELs vision isto become world class engineering enterprise, committed to

enhancing stakeholder value.

BHEL has:-


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Installed equipment for over 90,000MW of power

generation for Utilities, captive and Industrial users.

Supplied over 25000 Motors with Drive Control System to

power projects, Petrochemicals Refineries, Steel, Aluminum,

Fertilizer, Cement plant, etc.

Supplied Traction electrics and AC/DC locos over

12000 kms Railway network.

Supplied over one million Values to Power Plants and other

Industries

BHEL - AN OVERVIEW


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The first plant of what is today known as BHEL was established

nearly 40 years ago at Bhopal & was the genesis of the Heavy

Electrical Equipment industry in India.

BHEL is today the largest Engineering Enterprise of its

kind in India with excellent track record of performance, making

profits continuously since 1971-72.

BHEL business operations cater to core sectors of the Indian

Economy like.

Power

Industry

Transportation

Transmission

Defenses etc.

Today BHEL has

14 Manufacturing Divisions

9 Service Centers

4 Power Sector Regional Centers

150 Project sites

BHELs vision is to become world -class engineering

enterprise, committed to enhancing stakeholder value. The


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greatest strength of BHEL is its highly skilled and committed

44,000 employees.

Spread all over India & abroad to provide prompt and effective

service to customers.

BUSINESS SECTOR

BHEL operations are organized around business sectors to

provide a strong market orientation. These business sectors are

Power Indus and International operations.

POWER SECTOR

Power sector comprises of thermal, nuclear, gas and hydro

business. Today BHEL supplied sets account for nearly 65% of

the total installed capacity in the country as against nil till 1969-

70.

BHEL has proven turnkey capabilities for executing power projects from concept to commissioning and manufactures boilers, thermal turbine generator set and auxiliaries up to500MW.

It possesses the technology and capability to procurethermal power generation equipment up to 1000MW.

Co-generation and combined cycle plants have also beenintroduced.

For efficient use of the high ash content coal-BHEL suppliescirculating fluidized boiler.


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BHEL manufactures 235MW nuclear sets and has alsocommenced production of 500MW nuclear set.

Custom-made huge hydro sets of Francis, Elton and Kaplan types

for different head- discharge combinations are also engineered andmanufactured by BHEL.

INDUSTRY SECTOR

BHEL is a major contributor of equipment and system toimportant industries like

Cement

Petrochemicals

Fertilizers

Steel paper

Refineries

Mining and Telecommunication

The range of system and equipment supplied including captive powerstations


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High speed industrial drive turbines

Industrial boilers and auxiliaries

Waste heat recovery boilers

Gas turbines pump, valves, seamless steel tubes

Heat exchangers

Process control etc.

TRANSPORATION :-

BHEL supplies a wide equipment and system to Indian

Railways.

Electric locomotive

Traction electric and traction control equipment

TELECOMMUNICATION:-

BHEL also caters to Telecommunication sector by way of

small, medium and large switching system.

BHEL has divided into many blocks:-


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1). Block-1:-

In block one turbo generator, generator, exciter motors

(A.C&D.C) are manufactured & assembled

2). Block-2:-

In block two large size fabricated assemblies\component for

power equipment are manufactured & assembled.

3) Block-3:-

In block -3 steam turbine, hydro turbines, and gas turbines,

turbines blade are manufactured & assembled

4) Block-4:-

In block -4winding for turbo generator, hydro generator,

insulation of A.C&D.C motors insulating component for turbo

generator, hydro generator motors are manufactured &

assembled

5) Block-5:-

In block -5 fabricated parts of steam turbine water box,

hydro turbine turbines parts are manufactured & assembled

6) Block-6:-

In block -6 fabricated oil tanks hollow guide blades, rings,

stator frames rotor spiders are manufactured & assembled

7) Block-7:-

In block -7all types of dies including stamping dies,

stamping for generators &motors are manufactured & assembled

8) Block-8:-

In block -8 LP heaters, ejectors, steam coolers, oil coolers, ACG

coolers, oil tanks are manufactured & assembled

MANUFACTURING DIVISIONS


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Heavy Electrical Plant, Piplani, Bhopal

Electrical Machines Repair Plant (EMRP), Mumbai

Transformer Plant P.O. BHEL, Jhansi.

Bharat Heavy Electrical Limited :

Central Foundry Forge Plant., Ranipur, Hardwar

Heavy Equipment Repair Plant, Varanasi.

Insulator Plant, Jagdishpur, Distt. Sultanpur.

Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad

High Pressure Boiler Plant & Seamless Steel Tube Plant,

Tiruchirappalli.

Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex,

Ranipet.

Industrial Valves Plant, Goindwal.

Electronics Division :

Electronics Systems Division.

Amorphous Silicon Solar Cell Plant (ASSCP).

Electro porcelains Division.

BANGALORE


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Component Fabrication Plant, Rudrapur.

Piping Centre, Chennai.

Heavy Electrical Equipment Plant,

Regional Operations Division, New Delhi

HEEP: AN OVERVIEW

Over the years, Bharat Heavy Electrical Limited hasemerged as world class engineering and Industrial giant, the best of

its kind in entire South East Asia. Its business profile cuts across

various sectors of engineering/power utilities and industry. The

company today enjoys national and international presence

featuring in the " fortune international-500 and is ranked among

the top 12 companies of the world, manufacturing power generation

equipment. BHEL has now 14 manufacturing division, 8 service

centers and 4power power sectors regional centers besides alarge number of project sites spread over India and abroad.

The company is embarking upon an ambitious growth path

through clear vision, mission and committed values to sustain and

augment its image as a world-class enterprise.

VISION

A world-class innovating, competitive and profitable

engineering enterprise providing total business solution.


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MISSION

To be the leading Indian engineering enterprise providing

quality products system and services in the field of energy,transportation, infrastructure and other potential areas.

VALUES

Meeting commitments made to external & internal

customers

Foster learning creative and speed of response

Respect for dignity and potential of individual

Loyalty and pride in the company

Team playing


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MANUFACTURING PROCESS OF

TURBO GENERATOR & STATOR BAR

BRIEF SUMMARY: ABOUT THE BAR SHOP

This shop is meant for manufacturing of stator winding coils of

generator that may be turbo generator or hydro generator.

HR BARS

Manufacturing of bars of different capacity depends upon the

water head available at site. The hydro generator is air called

generator of lesser length.

TURBO GENERATOR BAR

For the turbo generator the manufacturing of bars of standard

capacity such as 100 MW, 130MW, 150MW, 210/235MW,

210/250MW. This plant has capacity and technology to

manufacturing 800 MW generators.


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TYPE OF GENERATORS

The generator may be classified based upon the cooling

system used in the generators such as;

THRI, TARI, THDI, THDD, THDF, THFF, THW

T =i.e. Turbo Generator or Hydro Generator.

H/A =i.e. Hydrogen Gas or Air.

R/D/F/I =i.e. Radial, indirect, forced, direct etc.

I/D/F =i.e. Indirect cooling, direct cooling, forced cooling.

W =i.e. cooling media used for cooling of stator coil

e.g. water.

MATERIAL CHECKING

First we check the material of the conductor. And the total

insulation upon the conductor. The width of the copper

conductor should be:

a. For Lower bar = 8 x 2.8mm (Solid)

b. For Upper bar = 8 x 1.3mm (Solid)

c. For Hollow conductor= 8 x 4.6 x 1.5mm (Solid)


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CONDUCTOR CUTTING AND END CLEANING

This process is done by the automatic CNC machine, in this

process the length of lower bar & upper bar is decided as

following as per drawing-

Lower Bar

a. Solid conductor length = 10,200mm (10

Plates)

b. Hollow conductor length = 10,200mm (10 Plates)

Upper Bar

a. Solid conductor length = 10,050mm (10

Plates)

b. Hollow conductor length = 10,050mm (10 Plates)

This insulation is removed from both ends after the cutting of

conductor i.e. 500mm for both lower & upper bar.

TRANSPOSITION OF CONDUCTOR

Transposition means changing or shifting of position of each

conductor in active care (slot) part. After cutting the requirednumber of conductors are arranged on the comb in staggered

manner and than bands are given to the conductor with the

help of bending die at required distance.


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Setting of die

a. Comb of setting for lower bars

Die 1st Die 2nd Die 3rd

2200.2mm 3735.3mm 6586.2mm

b. Comb of setting for Upper bars

Die 1st Die 2nd Die 3rd

2109mm 3620.2mm 6496.2mm

This process is repeated to making another half of the bar.

CROSS OVER INSULATION

Cross over insulation is give to the conductor for the protection

in which the insulating spacer are provided at the cross over

portion. In this insulation the No-max paper is used.

Here the filter material (insulating putty of moulding

micanite) spacer is provided along the high of bar to maintain

the rectangular shape. The size of spacer should be

1st Band = 146mm

2nd Band = 219mm

3rd Band = 292mm


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STACK CONSOLIDATION OR PRESSING

The core part of the bar stack is pressed in press under the

pressure between 70kg to 80kg (various from product to

product) and the temperature between 90 Deg.C to 160 Deg.C

for a given period. Here four bars is pressed in one time and six

to eight plates are used for pressing. After that the consolidated

stack is withdrawn from the press.

INTER STAND SHORT TEST (I.S.S.Test)

In this test first we make the distance to the non insulating

portion of the bar. Here we check the short between any two

conductor. After this test the bars are again go for the second

pressing. In which attached full slot separator between two halfbar no-max paper and tapped with transparent film. In this test if

any error is found then it has to be rectified.

FORMING OF BAR

In this operation the straight bar stack is formed as per overhang

profile. In this process bars should be formed on universal

former and marked for the thermal space. After it they are

moved for cutting of extra conductor.


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COIL LUG MOUNTING

In this process contact sleeve and the bottom part of the water

box are adjust at the give dimensions. The operation of

mounting of contact sleeve and bottom part of water box is

complete in following steps-

a. Check the dimension of contact sleeve and water box bottom

part.

b. Stand by bar for setting of lug.

c. Setup to the solid conductor in each row as per drawing.

d. Then insert the contact sleeve upon the solid and hollow

conductor and temporally installed to it. And also installed thebottom part of water box.

e. Maintain the gap between contact sleeve and bottom part of

water box approx 20mm.

After the lug mounting cutting of extra solid conductor.


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MAIN BRAZING

There are the following steps to brazed the lug.

a. Stand by bar of setting for brazing.

b. Then heated the lug point through the two indictor at the

temperature of 700 Deg.C .

c. For brazing use brazing alloy L-Ag-15P by four person. This is

the silver platinum alloy wire of melting point 700 Deg.C to 750Deg.C.

d. This Temperature is give through the laser rays.

CONDUCTOR CUTTING, FACE MILLING AND DEBBERING

After the main brazing bars is moved for cutting of extra part ofconductors as per drawing. Here cut the end part of the bottom

part of water box and taken for face milling.

In this process the conductor is given the accurate shaped as per

the measurement and it is taken in account that any part of the

surface is not left uneven and dull.

Then in Debbering, the bars edges are many a time left with

twigs and sharp needle type mettle cutting known as bar and this

process of removing is known as Debbering.


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FIRST PICKLING

This is the same process of pickling which is done before the lug

mounting or zero pickling. After this pickling process the bar is

moved the brazing of top part of water box in both side.

BRAZING OF TOP PART

Thought the induction process the top part of water box is

brazed in both side.

As per the previous main brazing first we stand by bars of

setting for brazing then we attached the top part from the bottom

part of water box. Then healed the top part by top inductors at the

temperature of 400Deg.c.

For this type of brazing use L-Ag-40Cd. This is the alloy

silver academy which have 40% cadmium and the melting point is

400 Deg.C to 500 Deg.C. This brazing is done for both end.

After the brazing the bars is go for second pickling which is the

same process as previously explain.


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WATER FLOW TEST

Thought this test check the flow water equivalently in the

hollow conductor of the bar. There is the following steps of

checking-

a. Water should be exit all the total hollow conductor.

b. If some burrs are jammed it should be removed to give very

high pressure of water and clean with the help of solid wire.c. The main point of testing is that the water flow into the bar and

exit from the water box fall down approximately to cover 1 Mtr.

From each conductor.

NITROGEN LEAK TEST

In this test the bar is tested for leakage into the components of

bar. In this test flow of nitrogen gas with pressure of 10kg/Cm2

to check the leakage in to the hollow conductor. If leakage

found the bar is rejected.


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THERMAL SHOCK TEST

The cycles of hot (80 Deg.C) and cold (30 Deg.C) water are

flew thought the bar to ensure the thermal expansion and

contraction of the joints. The time of low of hot & cold water

should be approx 32 to 40min and give the time between to flow

of hot & cold water is 5 min. this process is applied atleast 8

hours.

HELIUM LEAKAGE TEST

In this test the bars end is tested to flow of helium gas with the

given pressure if the end part of the bar is leakage then the

helium gas is covered the surface of water box and indicator

indicate the point of leakage.

INSULATION

For the insulation sunmika therm tape or sunmika pleese tape is

used which is the combination of mica + glass + varnish. It is

used for corona protection. In this insulation to layer of pleese

tape + to layer of therm tape and after them again to mica pleese

tape is used.


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Process of Insulation

a. Clean the bar.

b. Clean with chemical or thinner.

c. Taping

d. Realizing film from the mica plastic section.

In insulation the wall thickness of insulation is subjected to the

generating voltage of the machine.

IMPREGNATION AND BAKING

1. Thermoreactive system: In case of rich resin insulation the bar

is pressed in closed box in heated condition and baked under

pressure and temperature as per requirement for a given period.

2. Micalastic system: In case of poor resin system the insulated

bars are heated under vaccum and impregnated (dipped) in

heated resin so that all the air gaps are filled, layer by layer with

resin then extra resin is drained out and bars are heated and

baked under pressed condition in closed box fixture.

VPI Micalastic System

The bars already laid in closed fixture and full fixture is

impregnated in resin and then fixture with box is baked under

given temperature for the given duration.


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VIP Micalastic System

The individual bar is heated in vaccum and impregnated in

resin. Then bar is taken out and pressed in closed box fixture

and then baked at given temperature for given duration.

FINISHING

The baked and dimensionally correct bars are sanded-off to

smoothen the edges and surface calibrated if required for the

dimension.

CONDUCTING VARNISH COATING

OCP (Outer Corona Protection) Coating: The black semi-

conducting varnish coating is applied on the bar surface on the

core length.

ECP (End Corona Protection) Coating: The grey semi-

conducting varnish is applied at the bend outside core end of

bars in gradient to prevent from discharge and minimize the end

corona.


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TESTING

1. Tan Test: This test is carried out to ensure the healthiness of

dielectric (insulation) i.e. dense or rare and measured the

capacitance loss.

2. H.V. Test: The each bar is tested momentarily at high voltage

increased gradually to three times higher than rated voltage.

DISPATCHED FOR WINDING

If the bar is passed in all the operation and testing after

completing then the bar is send for stator winding.


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TURBO GENERATORS

(a) Air Cooled Generators Upto 200 Mw Range (Type:

TARI ) Salient Design Features

Stator core and rotor winding direct

air-cooled

Indirect cooling of stator winding

Horizontally split casing design of

stator

Vertically side mounted coolers in a

separate housing

Micalastic bar type insulation system

Separately assembled stator core and

winding for reducing the manufacturing cycle

Brushless/static excitation system


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(b) Hydrogen Cooled Turbogenerators Of 140-260 Mw Range(Type: THRI ) Salient Design Features

Stator core and rotor winding directly

hydrogen cooled

Indirect cooling of stator winding

Rigid core bar mounting

Micalastic insulation system

End shield mounted bearings

Top ripple springs in stator slots

Ring type shaft seals

Symmetrical ventilation.


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MOTOR WINDING

9.1 Technical Requirements

(1) Count the coil groups in the anti clock wise direction locking

from the connection end.

(2) Leads of the coils groups lying on the outer periphery of the

overhang position shall be the finish and those lying on the inner

periphery shall be the start to coil groups.

(3) Leads shall be taken form the coil side lying at inner periphery of

slot No.1.

(4) The coil group No.1 shall Lie at top with its axes coinciding with

the vertical axis of the frame.

(5) Take out terminal leads 02 U2, V2, W2 for left hand side terminal

box and 02 U1, V1, W1 for right hand side terminal box. When

looking form the connection end.


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Circuit diagram:-

WINDING DIAGRAM OF MOTOR WINDING


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9.2 Winding data

9.3 Connection of motor winding

NO. OF PHASE 3

NO. OF POLES 6

PHASE CONNECTION Y

NO. OF PARELLEL PATH 2

NO. OF COIL GROUP 18


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CONCLUSION

The second phase of training has proved to be quite

faithful. It proved an opportunity for encounter with such huge

machines like turbo-generator hydro generator etc.

The architecture of B.H.E.L., the way various units are

linked and the way working of whole plant is controlled make the

students realize that Engineering is not just structural description but

greater part is planning and management. It provides an

opportunity to learn tech. Used at proper place and time can save a lotof labour.

But there are few factors that require special mention.

Training is not carried in true spirit. It is recommended that there

should be projectors especially for trainees where presence of

authorities is ensured.

However, training has proved to be satisfactory. It has allowed

us an opportunity to get an exposure of the practical implementation

of theoretical fundamentals.

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