Report on One Month’s Industrial Training at BHEL, Hardwar.

A Training Report submitted in partial fulfillment

Of the requirement for the award of degree of
Bachelor of Technology in
“ELECTRONICS & COMMUNICATION ENGINEERING”
Of Rajasthan Technical University, Kota.

Submitted by:
NIKHIL RUHELA
(Roll No. 06ELDEC060)

Submitted to:
Mr. VIJAY KUMAR SHARMA (H.O.D.)

Department of
“ELECTRONICS & COMMUNICATION ENGINEERING”
LAXMI DEVI INSTITUTE OF ENGINEERING & TECHNOLOGY
ALWAR-TIJARA-DELHI HIGHWAY, CHIKANI, ALWAR (RAJ)-301028

I
 CERTIFICATE

(Add Ur Certificate Here……!!!

Don’t Print This Page…...)

II
 ACKNOWLEDGEMENTS

First and foremost, I would like to thank my respected parents, who always encouraged me and
taught me to think and workout innovatively what so ever be the field of life. My sincere thanks
goes to Mr. Vishal Verma (DY-MGR), for his prodigious guidance, persuasion, and painstaking
attitude, reformative and prudential suggestion throughout my summer training schedule.

Special thanks go to Mr.V.K.Joshi (Sr.Technician). Who helped me a lot in giving

minute details of Telecom. Department and enlightened me with the knowledge of Exchange
equipments and their working.

Last but not the least, my sincere thanks to all the staff members and friends for instilling in me a
sense of self-confidence.

BRANCH: (ELECTRONICS & COMM. ENGG.)

Academic Year: 2009 - 2010

Institute:LAXMI DEVI INSTITUTE OF ENGINEERING & TECHNOLOGY

III
TELECOMMUNICATION SYSTEM IN BHEL, HARDWAR.

VOCATION TRAINING REPORT: 2009

CONTENTS
1. Introduction.

2. The Organization.

3. Telecommunications.

4. Electronic Exchange(s).

5. Telephone Lines.

6. Connection Types.

7. General faults occurring in an Exchange.

8. Special User Features of Various Exchanges.

9. Optical Fiber System.

10. Maintenance.

IV
1. INTRODUCTION.

In past few years the field of communication has been developing with no leaps or bounds. It has
become a necessity of each human being to be connected with each other. Telephone is rapidly
becoming a tool to quench this thirst.

In Automatic Telephony, operators are not required to establish connections manually between the
different calling and the called subscribers as are required in the case of manual telephone systems.
In these system subscribers those selves establish required connections by operating the different
switches placed at the central place known as the EXCHANGE from their telephones at remote
place from it. The automatic telephone systems are rapidly replacing manual ones due to their
outstanding merits over the latter types, some of which are enumerated below:

* In Automatic Telephony higher level of secrecy is maintained due to absence of

Operators who can overhear the conversation if they like in the manual telephone
Systems.
The working of an Automatic Telephone system does not depend for its efficiency
On the personal efficiencies of the operators.

* There is no possibility of the calls being missed or wrong metering being done due to faults of
operators or due to phonetic errors between the subscribers and the operators.

As no operator is required, the running cost of the exchange is reduced.

COMMUNICATION Dia.I

V
2. THE ORGANIZATION.

The nine jewels “Navratanas” declared by Indian government are NTPC, VSNL, ONGC, IOC,
HPCL, SAIL, BHEL, IPCLAND, and BPCL. Therefore, B.H.E.L. is one of the Navratanas
and is the largest engineering enterprise of its kind in India with an excellent track record of
performance. The company is engaged in engineering development and manufacturing of a
wide variety of mechanical and electrical equipment for generation, transmission, and
electricity. The company today enjoys National and International presence featuring in the
“Fortunes Internationals 500” and is ranked among the top 12 companies in the world for
manufacturing power generation equipment.

B.H.E.L. has 14 manufacturing divisions, nine service centers and four power sectors regional
centers and about 150 projects sites enables the company to its customers and provide them with
suitable products, systems and service at competitive prices. Having attained “ISO 9000”
certification, B.H.E.L. is now embarking upon the total quality management.

BACKGROUND OF THE B.H.E.L.

Heavy Electrical (India) ltd. [HE (I) L] was set up in Bhopal in 1956 with a view to reach self-
sufficiency in power equipment’s vital for industrialization of the country, then B.H.E.L. came into
existence in 1964. Three plants were stabilized under B.H.E.L. are as follows :
1. High Pressure Boiler Plant – Tiruchy (T.N.) (MAY 1965).
2. Heavy Power Equipment Plant – Hyderabad (A.P.) (DEC 1965).
3. Heavy Electrical Equipment Plant – Haridwar (U.P.) (JAN 1967).

As there was need for development of power equipment manufacturing in India and also with a
view to optimally utilize the resources HE (I) L. was merged in B.H.E.L.

BHEL Hardwar is one of the premier organizations which is honored by I.S.O.-9002

specifications.

VI
3. TELECOMMUNICATION.

BHEL manufactures EPABX and MAX systems based on C-Dot technology and has plans
to make other ranges of telecommunication equipment also.

These are basically used for connecting links between various modules like peripherals, exchange
and its equipments. It is necessary to run a number of internal cables of suitable conductors
between the following stages and frames:-

1. Handset to exchange's cable chamber

2. Cable chamber to M.D.F.
3. M.D.F. to I.D.F.
4. I.D.F. to Number Block
5. Number Block to Exchange Equipment
6. Between two exchanges
7. Between two cities
8. Between two countries

Prior to advent of Electronic Exchanges inter-connection of various circuits are made by

mechanical contacts that are operated by mechanical movements produced by the attraction of an
iron armature of an electromagnet or by the operation of an electric motor. There are some
disadvantages of such systems for using mechanical contacts, due to following reasons:
• Contacts are subjected to wear and tear.
• Require adjustments time to time.
• Maintenance is highly precise.
• Prone to corrosion. Etc...

But now-a-days Electronic Exchanges are used. In Electronic exchange electronic devices effect
the inter-connection between different transmission circuits and Electro-mechanical relays and
switches are dispensed with. Such electronic devices remove difficulties associated with
mechanical contacts. The greatest advantage of using electronic devices in place of
electromechanical devices is that no time is loosed in making a connection and a very high speed
of operation is possible.

VII
4. ELECTRONIC EXCHANGES.
Electronic Exchanges are of two types:
1. Tone type
1. Pulse type

1. Tone type: In this type of exchange sine waves are used. There speed of dialing for a given
number is more than that of Pulse type.

2. Pulse type: In this type of exchange square wave is used due to which the dialing speed is
lesser. The telephone apparatus used for both types are different in construction. But now days
both types of apparatus are integrated in a single machine in which switch-over can be made via a
selector switch.

TONES USED IN MODERN TELEPHONY

Dial Tone: When handset is picked up from the cradle, then Dial tone is heard if a free line is
available. This means that the instrument is ready to send the signals to the exchange. When the
subscriber takes up the receiver then signals are sent M.D.F. then to I.D.F., line Number block and
to Peripherals where in various line-cards are mounted in a shelf. When corresponding number on
the line-card is free then the Ringer section of that Peripheral generates a signal called tone. This
tone is a continuous burble sound of 400 Hz. modulated by 25Hz. and is sent to the calling
subscriber as soon as his line seizes the free line. The subscriber must not dial before receiving this
tone; otherwise he is liable to get wrong connection. If he does not get this tone, he should try after
some time.

Busy Tone: When the called subscriber is engaged with other call, this tone is heard. It consists of
a sound of 400 Hz. which is regularly interrupted at equal intervals. It is generally on for 0.75 sec.
and off for also 0.75 sec.

Ringing Tone: When a number is dialed then telephone of the called subscriber starts ringing.
Calling subscriber should get this information and this is indicated by sending ringing tone of
interrupted 400 Hz. supplies modulated by 25 Hz. and its durations are generally equal to the
duration of ringing current, which rings the bell. It may be 0.4 sec. on, 0.2 sec. off , 0.4 sec. on and
2 sec. off and so on or it may be 0.75 sec. on and 0.75 sec. Off and so on. When this ringing tone
is received, the calling subscriber knows that the connection is completed and that the bell of the
called subscriber is ringing.

Number Unobtainable Tone: This tone is sent when the number dialed cannot be obtained. If any
subscriber dials which is not actually connected to the exchange, this indication is send. This is
also a tone of 400 Hz. with interruption of 200 msec. every 3 sec.

VIII
Now-a-days push button type telephone apparatus are used. This apparatus can be exploded into
following sections:
1. Ringer section
2. Speech section (Transmitter and Receiver section)
3. Voltage limiter section

From telephone exchange two wires or connectors run for each number, in which one is neutral
and the other is main or positive. For the telephone circuit to work the necessary supply is
provided by the exchange. Like other circuits telephone also operates when a circuit is established
between calling and called subscriber. When one dials a number then the corresponding relays at
the exchange established a circuit automatically. The telephone exchange supplies 40-60 volt D.C.
and 110/20 Hz. to operate this circuit. This is required because of voltage drop that may creep in
long transmission wires. As soon as the handset is picked-up this 48-volt D.C. supply is available
at voltage limiter section, dialing pulse generator and speech section.
In telephone dialing two types of frequencies are used which are:
* High band tone (1216 Hz. to 1645 Hz.)
* Low band tone (701 Hz. to 936 Hz.)

Frequencies used in Telephony

The numbers from 1 to 5 falls in low band and 6 to 9, 0 falls in high band. Till the handset is on-
hook, the ringing section of the apparatus is on through telephone line but on lifting the handset the
ringing section becomes off, also the dialing and speech section becomes ready. On lifting the
handset first the dial tone is received which is amplified by the amplifier of speech section.
When a number is pressed on the keyboard, the dialing pulses are made on and off according to the
number dialed. For example if 5 is pressed then dialing pulses are made on and off 5 times. This
process can be heard on the receiver. There is a gap of 1 sec. between consecutively pressed
numbers.
When the handset is placed on or is lifted from the instrument a switch is operated called the hook-
switch. The main function of this switch is to toggle between telephone-line and ringer, dialing &
speech sections of the telephone. When the handset is on the telephone then ringer section of the
telephone is on while on lifting it ringer section is disconnected and dialing section is connected.

How the telephone call is made:

Telephone call is characterized into two sections:

1. Outgoing calls: Generally a voltage of 48V-60V D.C. always remains on the telephone line but
as the handset is picked-up the voltage limiter drops this voltage to 9-12V. On hearing the dial tone
it is confirmed that the apparatus is ready to work and after dialing the number a ringing pulse is
send to the called party. When the calling party picks-up the handset the billing meter of the
exchange becomes activated. There is a counter in the exchange, which counts the pulse and
converts them into calls.

2. Incoming calls: These are just opposite of outgoing calls. In the incoming calls the telephone
detects the ringing signal from the exchange and provides the ring. At the instance of ringing
signal, there remains a voltage of 75-110V./20 Hz. on the telephone. A high voltage (A.C.) is sent
from the ringer section of the exchange to start the ringer circuit of the telephone. When the
ringing signal is received it should be properly isolated as it may give a shock. This ringing circuit
is on until the handset is not picked-up at the called party. The duration of this tone, if unattended,
is 1 minute after which an engage tone is heard. After lifting the handset a circuit is established and
a call is made.

IX
Electronic Exchange Dig.II

X
  Different Types of Cards Used in Exchange :-
S. Name of Total No. of
No. Card Meaning of Card Cards
1. z-24 Analog Extension Card 35

2. ua 32 Digital Extension Card 3

3. atr 2 DIT Card used through proper line 3

Analog trunk card used as

4. nddi junction to junction 10

5. cpu3 Central processing unit 2

6. intof Interface Card 6

7. mmsfd Floppy drive used by owner 1

Voice card
(like no. is busy try after some
8. suvg time) 1

9. ldtl8 Loop dialing 15

Digital trunk card used through

10. pcm2 OFC 2

11. gpa-1 Conference Call 1

XI
 There are various powers providing circuits available in the exchange to run the circuitry. These
are broadly categorized in two categories:
* Outside the exchange
* Inside the exchange

Outside the Exchange:

Since the voltage supplied in Indian Subcontinent is 220-volts/50 Hz. A.C. but for the normal
working of the exchange 48(46-53) volts of D.C. is required.
Hence a Rectifier circuit, backed with battery array for power-failures, is used. This
rectifier block not only rectifies the input supply but also works as a battery charger. It is known
as Float rectifier cum charger.

Battery backup is utilized for smooth operation of the exchange during power failures. For battery
back-up lead acid battery array is used in parallel to the supply from the rectifier block, so that
during power failures the exchange supplies are not terminated.

Inside the Exchange:

Inside the telephone exchange various types of power supplies are used for powering various
modules (for example: - Line-cards, Ringer). Some of them are: -
# -5 V. 12 A
# +5 V. 12 A
# +12 V. 6A.

From M.D.F. a number of cables, based upon the requirement of a place, are connected to
cabinets. On the cabinets these cables are divided into cables of 20 pairs. Now every 20 pair cable
goes to the distribution box (D.B.). At the D.B. this 20 pair cable is further divided into two parts
of 10 pairs each. These pairs are then connected to the subscriber ports via jumpers. The line from
these ports then goes to the subscribers through single pair cables which are usually of P.V.C. type.
These wires are connected to the instrument via Rosette-Box.

XII
M.D.F.: -
This frame serves the following purposes: -
• It is place where both external and internal cables are terminated. The external individuals
cable carry conductors from subscribers who are necessarily from the same locality and as such
their numbers cannot be in numerical order. On the other hand, the internal cable conductors
come from apparatus side in numerical order. This cross-section between the two cables is
done on the M.D.F. through jumper wires.
• It carries all the protectors used in the exchange. The different protectors that are used are (a)
Fuses, (b) Heat coils, and (c) lightning protectors.
• This M.D.F. is an ideal place for testing purpose. Both the internal and the external cables
are available at this frame and, therefore, both external and internal wiring and lines can be
tested for this purpose.

I.D.F.: -
These frames like M.D.F. consists of a large number of verticals with horizontal cross-arms
fitted with tag blocks at both the ends. The cable from M.D.F. is terminated on the multiple sides
from where connections are extended to metering and from the exchange side cables are run to the
respected line-cards. The two tag blocks are joined by means of jumper wires as in the M.D.F., so
that any subscriber can be given connection to any uniselector on the line-card. The subscriber and,
therefore, their uniselector are divided into different groups and it is necessary for these groups to
originate more or less the same amount of traffic for smooth distribution among different trunks.

XIII
OLD MDF Dig.III

NEW MDF Dig.IV

XIV
5. TELEPHONE LINES.

In BHEL-Hardwar three types of telephone lines are used. They are: -

MAX Lines

EPABX Lines

C-DOT Lines

MAX Lines:
Before MAX Ex. Lines are used only Internal Exchange. But New (CORAL) MAX lines
are used for both internal (Intercom) and external communication links BHEL.

EPABX Lines:
EPABX lines are used for both internal and external communication links in BHEL. If the
user wants to dial outside the periphery of BHEL, he can use these lines. There are about 500 lines
available here. These lines are distributed in 17 line-cards with 24 line numbers in each. Its I.D.F.
section has 40 tag blocks. 96 numbers available here are connected via digital lines in which a host
of facilities are provided that can be accessed using code 69.

C-DOT Lines:
These lines are the direct telephone lines from C-DOT The facility they provide is called
DID (Direct Inward Dialing). It has 24 lines and any BHEL number starting with digit 5 can be
accessed using code 48.

XV
6. CONNECTION TYPES.
• Types of Connections:
* With wires i.e. Cables
* Wireless Microwave Links through Satellite

Cables: Two types of Cables are used. They are:

1) Underground cables: These types of cables run under the earth and are basically used to connect
the exchange to the subscriber's Distribution Box (D.B.). They are further of two types based upon
their construction and the insulating material used.

a. Paper core A.T.C. (Armored Tin Cable)

b. Jelly filled A.T.C. (Armored Tin Cable)

2) Overhead cables: These types of cables are used to connect the equipments inside the exchange
and to connect the peripheral devices to the subscriber's Distribution Box
(DB) They are generally of P.V.C. type.
In an exchange, based upon the number of conductor pairs, following types of cables are used:
* Single Pair cable
* 2 Pairs cable
* 5 Pairs cable
* 10 Pairs cable
* 20 Pairs cable
* 50 Pairs cable
* 100 Pairs cable

Color-coding:
TYPE OF CABLECOLOR OF WIRES
Single pair Blue-White

2 Pair cable Blue-White/Orange-White

5 Pair cable Blue-White/Orange-White/Green-White/Brown-White/Grey-White

10 Pair cable Blue-White/Orange-White/Green-White/Brown-White/

Grey-White/Blue-Red/Orange-Red/Green-Red/Brown-Red/Grey-Red
20 Pair cable
Blue-White/Orange-White/Green-White/Brown-White/Gray-White/Blue-
White-Blue/Orange-White-Blue/Green-White-Blue/Brown-White-Blue/
XVI
 Gray-White-Blue/Blue-White-Orange/Orange-White-Orange/Green-White
-Orange/Brown-White-Orange/Gray-White-Orange/Blue-White-Green/
Orange-White-Green/ Green-White-Green/Brown-White-Green/
Gray-White-Green.

For 100 pairs cable the color-coding is same as that of the above 20 pairs cable except
That the mate color is changed after each bunch of 20 pairs.
PAIRMATE COLOR1st 20 pairs White2nd 20 pairsYellow3rd 20 pairsBlack4th 20
pairsViolet5th 20 pairs Red

XVII
7. General faults occurring in an Exchange.
There are mainly two types of faults that often occur in the Exchange. These are basically
* Faults that occur from Line
* Faults that occur due to Instrument
A. Faults that occur from Line:
Due to line three types of faults may occur. They are categorized as under:
1. Break fault: They are also called as Disconnection faults. They can occur in the connectors at
home, in line or in exchange. In common they are broadly called as "Telephone is dead".
2. Loop fault: They are also called as Line-Shorting faults. In this fault connectors are shorted
prior the instrument forming a local loop. If unattended for a long time they may cause severe
damage to the Exchange.
3. Earth fault: This fault may occur due to:
* wetting of connectors
* Water in Rosette-Box
* Weak insulation or
* Oxidation of copper wire
Connectors can either touch from earth, with other connector or with any conductor (such as
metallic table, frame etc.)
 Problems that can occur due to line faults:
1. Subscriber can not dial a number.
2. Ring Trip i.e. connection from the exchange breaks after one ring.
3. False Ring
4. Low speech
5. One sided speech
 Faults that occur due to instrument:
These may be:
* The number is not being dialed
* One way speech
Receiver coil is faulty

 Faults that occur due to instrument:

* Plunger or Push switch faulty. Dial tone breaks after two or three rings.
From second subscriber bell is heard to be going but at first subscriber only dial tone
Is heard.
* Instrument circuitry faulty.
When loop or earth fault is received than exchange can be affected so it is wedged as soon as
possible because if not wedge for longer it can damage line-card too.

XVIII
 To sense these faults first line-side is checked and then exchange side is checked at
exchange. If however exchange side is correct then line faults after detection are handed over to
the concerned lineman for further checking.

Testing Procedure Dig.V

XIX
Testing Procedure Dig.VI

Testing Procedure Dig.VII

XX
Testing Procedure Dig.VIII

Testing Procedure Dig.IX

Testing Procedure Dig.X

XXI
Testing Procedure Dig.XI

Testing Procedure Dig.XII

XXII
8. LIST OF SPECIAL USER FEATURES ON VARIOUS EXCHANGES.
A) MAX (CORAL INDIA PVT.LTD.NOIDA)
Manufacturer: - JEUMONT SCHINEDIER, FRANCE
Capacity: - 2700 lines

 CALL PICK UP: 89-xxxx to pick up a call ringing at another location xxxx.

 CALL TRANSFER: 2 Parties conversing, any party can dial 3rd party, then
Conversation among them Hang-up. The party on line now
Talks to 3rd party.

 PARTY CONFERENCE: While speaking with a party:

(From Pulse Instrument: -- If CALLER requires dialing 3rd party
During conversation and maintaining talks, then dial 4.
(From Tone Instrument: -- If CALLER requires dialing 3rd party
During conversation and maintaining talks, then flash, and dial 4.

 MALICIOUS CALL TRACE: Dial 29 during conversation, to trace a

malicious call From a MAX Extension. Then enquire from 4999 or 4424.

 APPOINTMENT REMINDER: Dial 80-xx-yy {xx=hr, yy=min}.

To Cancel: Dial 27.

XXIII
LIST OF SPECIAL USER FEATURES ON VARIOUS EXCHANGES

B) EPABX=ALCATEL 4400
Manufacturer: - ALCATEL, FRANCE
Capacity: - 500 lines (96 DIGITAL, 404 ANALOG)
Technology used: - P.C.M. - T.D.M.

1. TONE MODE DIAL: Dial # before no.{If instrument is not tone enabled )

2. CALL TRANSFER: Hook FLASH: Do Hook Flash -

On hearing prompt "Please dial." Dial the no., wait for party to respond, then
Disconnect.

3. ENQUIRY CALL: FLASH (from Tone mode instrument.) or 2 (from Pulse mode)
During converse’s, to put the party on HOLD. Then, dial a 3rd party and speak.

4. BROKER CALL: (After ENQUIRY CALL): Dial 1

To go BACK & FORTH, between two parties (one party in conversation & other
On HOLD)

5. CONFERENCE-3 PARTY: While talking to 1st party, first make ENQUIRY CALL
(Put on hold){FLASH from Tone; or 2 from Pulse}.
Then - Dial 3rd party - Flash-- Dial 3.

6. AUTO CALLBACK: Dial 5 to book auto-callback when a busy PABX hangs up.
( To cancel auto-callback request: Dial 67 or/and 848)

7. PASSWORD MODIFICATION: 847-0000-xxxx (0000=old password; xxxx = new

Password). This facility is available on STD enabled extensions only.

8. LAST CALLER CALLBACK: 851 {to ring the last unattended PABX Caller}

9. APPOINTMENT REMINDER: 852 then dial the time as {xx (hr) xx (min)}
To cancel: 853

10. LAST NO. REDIAL: 854 User can use this if instrument. Doesn’t have a Redial
Button.

11. CALL PICKUP: 72 - XXXX to pickup a call ringing at another extension.

12. CALL-PARK / RETRIEVE: It is used during an incoming or outgoing call, to speak

From a different set.
(To park from own (speaking) set: FLASH-855- dial own extension number. Then
"Hang-up". The call is now parked, and the other party is kept on hold.
(To pick up from a different set: 855- dial own extension number)
(To pick up from own set (later, if not taken elsewhere) 855)

XXIV
9. OPTICAL FIBER SYSTEM.

Fiber optical transmission medium is fast emerging as an alternative and strong competitor
to coaxial cables in telecommunication networks.

Long distance data transmission in electrical cables suffers from ground loop problems.
The merits of the optical fiber stem from the fact tat the basic material used in their construction is
nonmetallic and electrically non conductive.

In contrast, the nonmetallic and totally dielectric fiber optical cable are immune to radio
frequency an other electromagnetic interferences. Ground loop and common mode voltage
problem do not exist and data can be transmitted between points of vastly different potential. In
optical cables the information is transmitted by packets of photons which have no charge. There is
no possibility of sparks or short circuit when a fiber is cut. The bandwidth high compared to that of
the electrical cables. The standard RG-58 coaxial cable has bandwidth distance product of a typical
optical fiber is about 100 MHz-Km.

Fiber cables are about the thickness of a human hair any dirt obstructing the optical port causes
poor transmission. The thin dimension results in a low weight for given length when compared to
electrical cables. However, being thin and somewhat brittle in nature, fiber tend to break easily if
bent beyond a certain limit a direct viewing into the optical point can be harmful to the eyes.

XXV
10. MAINTENANCE.

The subject of maintenance of Automatic Telephone Exchange can be broadly divided under two
categories: -

1. Prevention of Service Failures.

2. Location of Faults and their removal.

Prevention of Service Failures can be done in following ways: -

1. Suitable design and adoption of suitable adjustment standards of the equipment parts of the
exchange can minimize failures in service.

2. Some preventive measures may also reduce service failures viz. keeping the rooms dust free,
maintaining temperature and humidity under tolerable limits using air-conditioners etc...

3. Routine inspection, routine tests and routine adjustments also help in preventing service failures.
When faults occur in some parts of the exchange, they should be detected and removed as quickly
as possible.

Various tools are also used to check the faults in the telephone lines.
For checking fault inside the exchange

XXVI
 REFERENCES

www.bhel.com
www.bhelhwr.co.in

XXVII