CHAPTER - 1

INTRODUCTION

BHEL or Bharat Heavy Electricals Limited is the largest engineering and manufacturing enterprise
in India in the energy-related/infrastructure sector. BHEL is one of the seven largest Public Sector
Undertakings known as maharatnas. The Maharatnas declared by Indian government are BHEL, NTPC,
ONGC, IOCL, GAIL, SAIL, CIL. Therefore, BHEL is one of the Maharatnas 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.

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 (Heavy Electrical (India)
Ltd. [HE(I)L]) of the country was setup at Bhopal. It progressed rapidly and three more factories went
into production in 1965. Three plants were stabilized under BHEL 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.K.) (JAN 1967)
The main aim of establishing BHEL was to meet the growing power requirement of the country.
BHEL appeared on the power map of India in 1969 when the first unit supplied by it was commissioned
at the Basin Bridge Thermal Power Station in Tamil Nadu. Within a decade, BHEL had commissioned the
100th 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 generating
6000MW. This will grow further to enable BHEL to meet all of Indias projected power equipment
requirements. As well as sizeable portion of export target.

1
 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 BHEL.

Probably the most significant aspect of BHELs growth has been its diversification. The constant
reorientation of the organization to meet the varied needs in time 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.

Bharat Heavy Electricals Limited

Type Public

Founded 1964

Headquarters New Delhi

Industry Electrical power industry

Revenue Rs 9.2 billion USD (2013)

Employees 48,399 (March, 2013)

Website www.bhel.com

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. BHEL has 14 manufacturing divisions, 9 service centers and 4
power sectors regional centers, 18 regional offices and about 150 projects sites enables the
company to its customers and provide them with suitable products, systems and service at

2
competitive prices. Having attained ISO 9000 certification, BHEL is now embarking upon the
total quality management (TQM). BHEL has a consistent track record of growth, performance
and profitability. BHEL operations are organized around three business sectors: i) Power, ii)
Industry-including transmission, transportation and telecommunication & renewable energy and
iii) Overseas business.
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 60 countries in the world over have placed orders with BHEL covering individual
equipment to complete power stations on a turnkey basis.

BHEL has its headquarters at New Delhi. Over 65 percent of power generated in India
comes from BHEL-supplied equipment. Its operations are spread over many 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.

3
 A. 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 40 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's & Transmission,
Industry, Transportation, Telecommunication, Renewable Energy, Defense, etc. The wide
network of BHEL's 14 manufacturing division, 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 as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the total

installed capacity of 99,146 MW in the country, as against nil till 1969-70.

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

unit 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.

4
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 Kapian types for different head discharge

combination are also engineering and manufactured by BHEL.

In all, orders for more than 700 utility sets of thermal, hydro, gas and nuclear have been placed

on the Company as on date. The power plant equipment manufactured by BHEL is based on

contemporary technology comparable to the best in the world and is also internationally

competitive.

The Company has proven expertise in Plant Performance Improvement through renovation

modernisation and uprating of a variety of power plant equipment besides specialised know how

of residual life assessment, health diagnostics and life extension of plants.

POWER TRANSMISSION & DISTRIBUTION (T & D)

BHEL offer wide ranging products and systems for T & D applications. Products manufactured

include power transformers, instrument transformers, dry type transformers, series and stunt

reactor, capacitor tanks, vacuum and SF circuit breakers gas insulated switch gears and

insulators.

A strong engineering base enables the Company to undertake turnkey delivery of electric

substances up to 400 kV level series compensation systems (for increasing power transfer

capacity of transmission lines and improving system stability and voltage regulation), shunt

compensation systems (for power factor and voltage improvement) and HVDC systems (for

economic transfer of bulk power). BHEL has indigenously developed the state-of-the-art

controlled shunt reactor (for reactive power management on long transmission lines). Presently a

400 kV Facts (Flexible AC Transmission System) project under execution.

5
INDUSTRIES

BHEL is a major contributor of equipment and systems to industries. Cement, sugar, fertilizer,

refineries, petrochemcials, paper, oil and gas, metallurgical and other process industries lines and

improving system stability and voltage regulation, shunt compensation systems (for power factor

and voltage improvement) and HVDC systems (for economic transfer of bulk power) BHEL has

indigenously developed the state-of-the-art controlled shunt reactor (for reactive power

management on long transmission lines). Presently a 400 kV FACTS (Felxible AC Transmission

System) projects is under execution.

TRANSPORTATION

BHEL is involved in the development design, engineering, marketing, production, installation,

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 duly applications. BHEL

is also producing rolling stock for special applications viz., overhead equipment cars, Special

well wagons, Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use,

BHEL manufactures traction propulsion systems for other rolling stock producers of electric

locomotives, diesel-electric locomotives, electrical multiple units and metro cars. The electric

and diesel traction equipment on India Railways are largely powered by electrical propulsion

systems produced by BHEL. The company also undertakes retooling and overhauling of rolling

stock in the area of urban transportation systems. BHEL is geared up to turnkey execution of

electric trolley bus systems, light rail systems etc. BHEL is also diversifying in the area of port

handing equipment and pipelines transportation system.

6
TELECOMMUNICATION

BHEL also caters to Telecommunication sector by way of small, medium and large switching

systems.

RENEWABLE ENERGY

Technologies that can be offered by BHEL for exploiting non-conventional and renewable

sources of energy include: wind electric generators, solar photovoltaic systems, solar lanterns

and battery-powered road vehicles. The Company has taken up R&D efforts for development of

multi-junction amorphous silicon solar cells and fuel based systems.

INTERNATIONAL OPERATIONS

BHEL has, over the years, established its references in around 60 countries of the world, ranging

for 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 1110MW of boiler capacity contributed in Malaysia, and execution of four prestigious

power projects in Oman, Some of the other major successes achieved by the Company have been

in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan, Sri

Lanka, Iraq etc.

The Company has been successful in meeting demanding customer's requirements in terms of

complexity of the works as well as technological, quality and other requirements viz extended

7
warrantees, associated O&M, financing packages etc. BHEL has proved its capability to

undertake projects on fast-track basis. The company has been successful in meeting varying

needs of the industry, be it captive power plants, utility power generation or for the oil sector

requirements. Executing of Overseas projects has also provided BHEL the experience of

working with world renowned Consulting Organisations and inspection Agencies.

In addition to demonstrated capability to undertake turnkey projects on its own, BHEL possesses

the requisite flexibility to interface and complement with International companies for large

projects by supplying complementary equipment and meeting their production needs for

intermediate as well as finished products.

The success in the area of rehabilitation and life extension of power projects has established

BHEL as a comparable alternative to the original equipment manufactures (OEMs) for such

plants.

TECHNOLOGY UPGRADATION AND RESEARCH & DEVELOPMENT

To remain competitive and meet customers' expectations, BHEL lays great emphasis on the

continuous upgradation of products and related technologies, and development of new products.

The Company has upgraded its products to contemporary levels through continuous in house

efforts as well as through acquisition of new technologies from leading engineering

organizations of the world.

The Corporate R&D Division at Hyderabad, spread over a 140 acre complex, leads BHEL's

research efforts in a number of areas of importance to BHEL's product range. Research and

product development centers at each of the manufacturing divisions play a complementary role.

BHEL's Investment in R&D is amongst the largest in the corporate sector in India. Products

developed in-house during the last five years contributed about 8.6% to the revenues in 2000-

8
2001.

BHEL has introduced, in the recent past, several state-of-the-art products developed in-house:

low-NQx oil / gas burners, circulating fluidized bed combustion boilers, high-efficiency Pelton

hydro turbines, petroleum depot automation systems, 36 kV gas-insulated sub-stations, etc. The

Company has also transferred a few technologies developed in-house to other Indian companies

for commercialisation.

Some of the on-going development & demonstration projects include: Smant wall blowing

system for cleaning boiler soot deposits, and micro-controller based governor for diesel-electric

locomotives.

HUMAN RESOURCE DEVELOPMENT INSTITUTE

The most prized asset of BHEL is its employees. The Human Resource Development Institute

and other HRD centers of the Company help in not only keeping their skills updated and finely

honed but also in adding new skills, whenever required. Continuous training and retraining,

positive, a positive work culture and participative style of management, have engendered

development of a committed and motivated work force leading to enhanced productivity and

higher levels of quality.

HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT

BHEL, as an integral part of business performance and in its endeavour of becoming a world-

class organization and sharing the growing global concern on issues related to Environment.

Occupational Health and Safety, is committed to protecting Environment in and around its own

establishment, and to providing safe and healthy working environment to all its employees.

For fulfilling these obligations, Corporate Policies have been formulated as:

ENVIRONMENTAL POLICY
9
 Compliance with applicable Environmental Legislation/Regulation;

Continual Improvement in Environment Management Systems to protect our natural

environment and Control Pollution;

Promotion of activities for conservation of resources by Environmental Management.

OCCUPATIONAL HEALTH AND SAFETY POLICY

Compliance with applicable Legislation and Regulations;

Setting objectives and targets to eliminate/control/minimize risks due to Occupational

and Safety Hazards;

Appropriate structured training of employees on Occupational Health and Safety (OH&S)

aspects;

Formulation and maintenance of OH&S Management programmes for continual

improvement;

Periodic review of OH&S Management System to ensure its continuing suitability,

adequacy and effectiveness;

Communication of OH&S Policy to all employees and interested parties.

The major units of BHEL have already acquired ISO 14001 Environmental Management System

Certification, and other units are in advanced stages of acquiring the same. Action plan has been

prepared to acquire OHSAS 18001 Occupational Health and Safety Management System

certification for all BHEL units.

In pursuit of these Policy requirements, BHEL will continuously strive to improve work particles

in the light of advances made in technology and new understandings in Occupational Health,

10
Safety and Environmental Science.

PARTICIPATION IN THE "GLOBAL COMPACT" OF THE UNITED

NATIONS

The "Global Compact" is a partnership between the United Nations, the business community,

international labour and NGOs. It provides a forum for them to work together and improve

corporate practices through co-operation rather than confrontation.

BHEL has joined the "Global Compact" of United Nations and has committed to support it and

the set of core values enshrined in its nine principles:

PRINCIPLES OF THE "GLOBAL COMPACT"

HUMAN RIGHTS

1. Business should support and respect the protection of internationally proclaimed human

rights; and

2. Make sure they are not complicit in human rights abuses.

Labour Standards

3. Business should uphold the freedom of association and the effective recognition of the

right to collective bargaining;

4. The elimination of all form of forces and compulsory labour.

5. The effective abolition of child labour, and

6. Eliminate discrimination.

Environment

11
 7. Businesses should support a precautionary approach to environmental challenges;

8. Undertake initiatives to promote greater environmental responsibility and

By joining the "Global Compact", BHEL would get a unique opportunity of networking with

corporate and sharing experience relating to social responsibility on global basis.

ACTIVITY PROFILE

PRODUCTS - Industrial Fans

Power Generation & Transmission - Seamless steel Tubes

- Steam Turbine-Generator Sets & - Fabric Filters

Auxiliaries

- Boiler and Boiler Auxiliaries - AC DC Motors, Variable speed

- Once-through Boilers - AC Drive

- Nuclear Power Generation Equipment - Electronic Control Gear &

Automation

- Hydro Turbine-Generator Sets & Auxiliaries - Equipment

- Mini/Micro Hydro Generator Sets - DDC for Process Industry

- Gas Turbine-Generator Sets - Thruster Equipment

- Waste Heat Recovery Boilers - Power Devices

- Heat Exchangers - Energy Meters

- Condensers - Transformer

- Bowi Mills and Tube Mills - Switch gear

12
- Gravimetric Feeders - Insulator

- Regenerative Air Pre-Heaters - Capacitors

- Electrostatic Precipitators - Broad Gauge AC, AC/DC Loco

Motives

- Bag Filters - Diesel-Electric Shunting

Locomotives

- Valves - Traction Motors & Control

Equipment

- Pumps - Electric Trolley Buses

- Electrical Machines - AC/DC Electric Multiple Units

- Piping Systems - Drives and Controls for Metro

Systems

- Power, Distribution & Instrument Transformers - Battery-Operated Passengers

Vans

- Reactors - X-Mas Trees and Well Heads

- Synchronous Condensers - Cathodic Protection Equipment

- Switchgear - Digital Switching Systems

- Control gear - Rural Automatic Exchange

- Distributed Digital Control for Power - Simulators

Stations

- Bus Ducts - Wind Electric Generators

13
- Rectifiers - Solar Powered Water Pumps

- Porcelain Insulators - Solar Water Heating Systems

- Ceralin - Photo Votaic Systems

- Defense Equipment

INDUSTRIES/TRANSPORTATION/OIL - Reverse Osmoses Desalination

& GAS/
Plants

TELECOMMUNICATION/RENEWABLE SYSTEMS & SERVICES

ENERGY
- Steam Turbine-Generator Sets - Turkey Utility Power Stations/

EPC

- Gas Turbine-Generator Sets - Contracts

- Diesel Engine-Based Generators - Captive Power Plants

- Industrial Steam Generators - Co-generation Systems

- Heat Recovery Steam Generators - Combined Cycle Power Plants

- Fluidised Bed Combustion Boilers - Modernisation & Renovation of

Power

- Drive Turbine Stations and FLA Studies

- Manne Turbines - Switch yards and Substations

- Industrial Heat Exchangers - HVDC Transmission Systems

- Centrifugal Compressor - Shorts sines condensation

Systems

- Industrial Valves - Power system analysis

14
- Reactors - Electron comissionly and

Operation

- Columns - Consultancy services

- Pressure Vessels - Consultancy Services

- Pumps

SUMMARY OF BHEL'S CONTRIBUTION

TO VARIOUS CORE SECTORS
Power Generation
THERMAL RATING (MW) TOTAL CAPACITY
NO. OF (MW)
SETS
500 30 15000
250 9 2250
210/200 138 28570
120/125/130 20 2420
195 1 195
110 38 4180
100 6 600
70/67.5 6 410
60 14 840
30 5 150
TOTAL 267 54615
(THERMAL)

GAS FRAME SIZE/ TOTAL CAPACITY

SCOPE NO. OF (MW)
SETS
9 5 730

15
 6 17 580
5 13 309
3 6 48
V 94.2 2 286
6FA 3 207
STG 24 1190
GEN 4 87
TOTAL (GAS) 74 3437

NUCLEAR RATING (MW) TOTAL CAPACITY

NO. OF (MW)
SETS
500 2 1000
220 10 2200
TOTAL 12 3200
(NUCLEAR)

TOTAL (THERMAL+GAS+NUCLEAR) 353 61252

HYDRO 402 18735

GRAND TOTAL 755 79987

SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS CORE

SECTORS

POWER TRANSMISSION & DISTRIBUTION

In the T&D sector, BHEL is both a leading equipment-manufacturer and a system-

integrator. BHEL-manufactured T&D products have a proven track record in India and
abroad.

16
In the area of T&D systems, BHEL provides turnkey solutions to utilities. Substations and shunt

compensation installations set up by BHEL are in operation all over the country. EHV level

series compensation schemes have been installed in KSEB, MSEB, SMPSEB and POWERGRID

networks. Complete HVDC systems can be delivered by BHEL.

INDUSTRIES

Since inception in 1982, the Industry Sector business has grown at an impressive rate and, today,

contributes significantly of BHEL's turnover.

BHEL, today, supplies all major equipment for the industries: AC/DC machines, alternators,
centrifugal compressors, special reactor column, heat exchangers, pressure vessels, gas turbine
based captive co-generation and combined-cycle power plants, DG power plants, steam turbines
and turbo-generators, complete range of steam generators for process industries, diesel engine-
based power plants, solar water heating systems, photovoltaic systems, electrostatic precipitators,
fabric filters, etc.

The industries which BHEL serves include: Steel, Aluminium, Fertiliser, Refinery,
Petrochemicals, Chemicals, Automobiles, Cement, Sugar, Paper, Mining, Textile etc.

TRANSPORTATION

In the transportation filed, product range covers: AC locomotives, AC/DC dual-voltage

locomotives, diesel-electric shunting locomotives, traction motors and transformers, traction

elections and controls for AC, DC and dual voltage EMUs, diesel-electric multiple units, diesel

power car and diesel electric locomotives, battery-powered vehicles.

17
 B. HEEP : AN OVER VIEW
Over the years, Bharat Heavy Electricals Limited has emerged 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 in the world, manufacturing power generation equipment. BHEL has now 14

Manufacturing Divisions, 8 Service Centres and 4 Power Sectors Regional Centres besides a

large number of project sites spread over India and abroad.

The Company is embarking upon an ambitions growth path through clear vision, mission and

committed values to sustain and augment its image as a world class enterprise.

VISION

World-class, innovative, competitive and profitable engineering enterprise providing total

business solutions.

MISSION

The leading Indian engineering enterprise providing quality products systems and services in the

fields of energy, transportation, infrastructure and other potential areas.

VALUES

Meeting commitments made to external and internal customers.

Foster learning creativity and speed of response.

Respect for dignity and potential of individuals.

Loyality and pride in the company.

18
 Team playing.

Zeal to excel.

Integrity and fairness in all matters.

HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)

At Hardwar, against the picturesque background of Shivalik Hills, 2 important manufacturing

units of BHEL are located viz. Heavy Electrical Equipment Plant (HEEP) & Central Foundry

Forge Plant (CFFP). The hum of the construction machinery woke up Shivalik Hills during early

60s and sowed the seeds of one of the greatest symbol of Indo Soviet Collaboration Heavy

Electrical Equipment Plant of BHEL. Following is the brief profile of Heavy Electrical

Equipment Plant:-

1. ESTABLISHMENT AND DEVELOPMENT STAGES:

* Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the area of

Scientific, Technical and Industrial Cooperation.

* DPR prepared in 1963-64, construction started from October '63.

* Initial production of Electric started from January, 1967.

* Major construction / erection / commissioning completed by 1971-72 as per original DPR

scope.

* Stamping Unit added later during 1968 to 1972.

* Facilities being modernized continually through Replacements / Reconditioning-

Retrofitting, Technological / operational balancing.

2. INVESTMENTS:

19
* Gross Block as on 31.3.95 is Rs. 355.63 Crores (Plant and Machinery Rs. 285.32

Crores).

* Net Block as on 31.3.95 is Rs. 113.81 Crores (Plant & Machinery Rs. 76.21 Crores).

3. CLIMATIC AND GEOGRAPHICAL:

* Hardwar is in extreme weather zone of the Western Uttar Pradesh of India and

temperature varies from 2oC in Winter (December to January) to 45oC in Summer (April-

June); Relative humidity 20% during dry season to 95-96% during rainy season.

* Longitude 78o3' East, Latitude 29 o55'5" North.

* Height above Mean Sea Level = 275 metres.

* HEEP is located around 7 KMs on the Western side of Hardwar city.

4. COMMUNICATION & TRANSPORTATION:

* Telegraphic Code "BHARAT TELEC, HARDWAR"

* TLX Lines: 05909-206 / 207

* Telephones : P&T / STD (01334) 427350-59, 423050-423954

FAX : (0091) (1334) 426462 / 425069 / 426082 / 426254

* Direct Board gauge train lines to Calcutta (Howrah), Delhi, Bombay, Lucknow,

Dehradun and other major cities; Railway Siding for goods traffic connected to Hardwar

Railway Station.

5. POWER & WATER SUPPLY SYSTEM:

- 40 MVA sanctioned Electric Power connection from UP Grid (132 KV / 11KV / 6.6

20
 KV) (Connected load around 185 MVA)

- 26 deep submersible Tube Wells with O.H. Tanks for water supply.

- A 12 MW captive thermal power station is located in the factory premises.

6. FIRE PROTECTION:

- Managed by CISF with around 40 personnel and a host of latest fire fighting

equipment and fire tenders.

7. MANPOWER:

Total strength is 9904 as on 31.3.96 which includes around 3000 qualified Engineers and

Technicians (including substantial number of Post graduates), 5200 skilled artisans and

the rest in other categories.

8. TOWNSHIP AND PERIPHERAL INFRASTRUCTURES:

* A large modern township for employees and allied personnel with social and welfare

amenities.

* Medical: - Main Hospital (200 beds) 1

- Dispensaries in various 9

townships sectors

- Occupational health center 1

* Educational: No. of Schools (including 19

Intermediate levels)

Science Degree College 1

21
* Residential: Around 6780 quarters.

* Other amenities:

- Good Road network

- Shopping Centres

- Central Stadium

- Community Centres

- Police Stations

- CISF Complex for over 500 CISF personnel.

- Parks.

9. HEEP PRODUCT PROFILE:

* THERMAL AND NUCLEAR SETS

(Turbines, Generators, Condensers and Auxiliaries of unit capacity upto 1000 MW)

* HYDRO SETS INCLUDING SPHERICAL AND DISC VALVES

(Kaplan, Francis, Pelton and reversible Turbines of all sizes and matching generators and

auxiliaries maximum runner dia 6600 mm)

* ELECTRICAL MACHINES:

(For various industrial applications, pump drives & power station auxiliaries, Unit

22
 capacity upto 20000 KW AC / DC)

* CONTROL PANELS

(For Thermal / Hydro sets and Industrial Drives)

* LARGE SIZE GAS TURBINES

(Unit Rating : 60-200 MW)

* LIGHT AIRCRAFT

* DEFENSE PRODUCTS

10. HEEP: FACILITIES AND INFRASTRUCTURE

Modernisation and regular Upgradation / up gradation of facilities and other

infrastructure is a continuous endeavor at HEEP, BHEL. After initial setting up of the plant

during the year 1964-72, in collaboration with the Soviet Union, the plant facilities and

infrastructures have since been continuously upgraded under various investment projects vise,

Stamping Unit Project, LSTG Project, Motor Project, Governing Components Project, TG

Facilities Modernisation, TG Facilities Augmentation, Quality Facilities Augmentation, EDP

projects, Gas Turbine Project, Facilities have also been added and establishments have been

created for new projects in Defense and Aviation Project. Additionally, R &D facilities have also

been created under Generators Research Institute, Pollution Control Research Institute, HTL

modernization and other such schemes.

23
 CHAPTER-2

TURBINE AND AUXILIARY BLOCK-III

1.0 GENERAL

1.1 Block-III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and Turbines

Blades. Special Toolings for all products are also manufactured in the Tool Room located

in the same block. Equipment layout plan is a per Drawing appended in Section III.

Details of facilities are given in Section II.

1.2 The Block consists of four Bays, namely, Bay-I and II of size 36x378 metres and 36x400

metres respectively and Bay-III and IV of size 24x402 metres and 24x381 metres

respectively. The Block is equipped with the facilities of EOT Cranes, compressed air,

Steam, Overspeed Balancing Tunnel, indicating stands for steam turbine, rotors, one Test

stand for testing 210 MW steam turbines Russian Design, one Test Stand for Hydro

Turbine Guide Apparatus and two separate Test Stands for the testing of Governing

Assemblies of Steam and Hydro Turbines.

1.3 All the parts are conserved, painted and packed before dispatch.

24
2.0 MANUFACTURING FACILITIES

2.1 HYDRO TURBINES

For manufacturing of Hydro Turbines, Bay-I has the following sections:

(a) Circular Components Machining Section This section is equipped with a

number of large/ heavy size Horizontal and Vertical Boring Machines, Drilling

Machines, Centre Lathes, Marking Table and Assembly Bed. The major components

machined in this section are Spiral Casing with Stay Ring, Spherical and Disc Valve

bodies and Rotors.

(b) Runner and Servo Motor Housing Machining Section This section is
equipped with NC/CNC and conventional machines comprising Heavy and Medium size

vertical and Horizontal Boring Machines, Centre Lathes, Grinding machines and Drilling

Machines, Marking Table, Assembly Bed, Assembly Stands for Steam Turbine and Gas

Turbine assemblies and Wooden Platform for overturning heavy components. Hydro

Turbine Runners, Servomotors, cylinders, Labyrinth Ring, Regulating Ring, Stay Ring,

Turbine Cover, Lower Ring, Kaplan Turbine Runner Body and Blades are machined

here.

(c) Guide Vanes and Shaft Machining Section This section is equipped with
Heavy duty Lathe machines upto 16 metres bed, CNC turning machines, Horizontal

Boring Machine, Heavy planer, Deep Drilling Machine, Boring Machines, marking

Table, Marking Machines and Assembly Beds. Turbine shafts, Guide Vanes, Journals

and Rotors of Spherical and Disc Valves are machined here. Rotors of Steam Turbines

are also machined in this section.

25
(d) Assembly Section In this section, assembly and testing of Guide Apparatus, Disc
Valve, Spherical Valves, Servo motor shaft and combined Boring of coupling holes are

done.

(e) Preservation and Packing Section Final preservation and packing of all the
Hydro Turbine components / assemblies is done here.

(f) Small components Machining Section This is equipped with Planetary Grinding
Machine, Cylindrical Grinding Machines, small size Lathes, Planers, Vertical and

Horizontal Boring Machines. Small components like Bushes, Levers, Flanges etc. and

Governing assemblies and machines here.

(g) Governing Elements Assembly and Test Stand Section This section is
equipped with facilities like oil Pumping Unit, Pressure Receiver, Servomotors etc. for

assembly and Testing of Governing Elements.

2.2 STEAM TURBINES

The facilities and parts manufactured in the various sections of Steam Turbine

manufacture are as follows:

(a) Turbine casing Machining Section It is equipped with large size Planer, Drilling,
Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines etc.

Fabrication work like casings, Pedestals etc. are received from Fabrication Block-II.

(b) Rotor Machining Section It is equipped with large size machining tools like
Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree

Groove Milling Machine etc. Some rotor forgings are imported from Russia and

Germany and some are indigenously manufactured at CFFP, BHEL, Haridwar.

(c) Rotor Assembly Section This is equipped with Indicating Stand, Small size
26
 Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and

Discs. Machined Rotor, Discs and Blades are assembled here. Balancing and over

speeding of Rotor is done on the dynamic balancing machine.

(d) Turbine casing Assembly Section Machined casings are assembled and
hydraulically tested by Reciprocating Pumps at two times the operating pressure.

(e) Test Station - Test station for testing of 210 MW USSR Steam Turbine at no load is
equipped with condensers, Ejector, Oil Pumps, Oil containers Steam Connections etc,

required for testing. Overspeed testing is done for emergency Governor. Assembly Test

Stands for different modules of Siemens design are equipped with accessory devices.

(f) Painting Preservation and Packing Section All the parts are painted, preserved
and packed here for final dispatch.

(g) Bearings and Miscellaneous Parts Machining Section This section is

equipped with small and medium size basic machine tools, e.g., lathes, Milling M/c,

Horizontal Borer, Vertical Borer, drilling M/c etc. for manufacture of bearings and other

miscellaneous parts of turbine.

(h) Governing Machining Section This section is equipped with medium size and
small size lathes, medium CNC lathe, Milling, Grinding, Drilling, Slotting and Honing

Machines. Governing assembly parts are machined here.

(i) Diaphragm and Governing Assembly Section It is equipped with deflection

testing equipment for Diaphragms, Dynamic Balancing Machine for balancing Impeller

of Centrifugal Oil Pumps and small fittings and assembly equipment. Governing test

stand is equipped with the facilities like Oil Pumping Unit, Pressure Receiver,

27
 Servomotor, overspeed testing of Emergency Governor etc.

2.3 GAS TURBINE

All the components of Gas Turbine are machined and assembled using the facilities

available for manufacturing of steam and hydro turbines except the following facilities

which are procured exclusively for the manufacturing of Gas Turbine and are installed in

the areas specified for gas turbine manufacturing.

a) Hydraulic Lifting Platform

This facility is used for assembly and disassembly of G.T. Rotor. This is a hydraulically

operated platform which travels upto 10 M height to facilitate access to different stages of

Rotor. This is installed in Bay-I assembly area.

b) CNC Creep Feed Grinding M/c.

This is installed in Gas Turbine machining area Bay-II Extn. This M/c grinds the hearth

serration on rotor disc faces. Hirth serrations are radial grooves teeth on both the faces of

rotor discs. Torque is transmitted trough these serrations, which are very accurately

ground.

c) External Broaching Machine

This machine is installed in GT machining area and is used to make groove on the outer

dia of rotor discs for the fitting of moving blades on the discs.

d) CNC Facing Lathe

This machine is installed in GT machining area and is used basically for facing rotor disc

but can turn other components also.

28
e) CNC Turning Lathe

This machine is installed in Bay-I Heavy Machine Shop and is used to turn Tie Rods of

Gas Turbine, which have very high length / diameter ratio. Tie-Rod is a very long bolt

(length approx. 10 meter & dia 350 mm) which is used to assembly and hold the gas

turbine rotor discs to form a composite turbine rotor.

f) Wax Melting Equipment

This is low temp. electric furnace installed in Gas Turbine blading area in Bay-II. It is

used to mix and melt Wax and Colaphonium, which is required to arrest the blade

movement during the blade tip machining of stator blade rings.

g) Gas Turbine Test Bed

This test bed is installed near the Gas Turbine Machining area in Bay-II. This facility is

used to finally assemble the gas turbine. Combustion chambers are not assembled here,

which are assembled with main assembly at the site.

29
3.0 MANUFACTURING PROCESS

3.1 HYDRO TURBINES

The major processes involved in various Hydro Turbine Sections are as follows:

- Marking and checking of blanks manual as well as with special marking M/c.

- Machining on Horizontal Boring, Vertical Boring, Lathes etc. as the case may be on

CNC /Conventional Machines.

- Intermediate assembly operation is carried out on the respective assembly beds

provided.

- Then the assembly is machined as per requirement.

- The sub-assemblies are further assembled for hydraulic/functional testing. Hydraulic

testing is done using a power driven triple piston horizontal hydraulic pump which

can generate a pressure of 200 Kg/Cm2. It can also be carried out using a power

pack.

- On Governing elements / assembly and test stand, the components / sub-assemblies /

assemblies are tested up to a hydraulic pressure of 200 Kg / c m2 using the piston

pump. Oil testing upto 40 Kg / c m2 is carried out with oil pumping unit, which is

permanently installed on this bed.

3.2 STEAM TURBINE

Processes carried out in various sections of steam turbine manufacture are based on the

following main phases.

30
(a) Machine section Castings, Forgings, welded structures and other blanks are
delivered to this section. The manufacturing process is based on the use of high

efficiency carbide tipped tools, high speed and high feed machining techniques with

maximum utilization of machine tool capacity and quick acting jigs and fixtures.

(b) Assembly Section Casings and Governing assemblies are hydraulically tested for
leakage on special test Bed. Assembled unit of governing and steam distribution systems

are tested on Governing Test Bed. General Assembly and testing of Steam Turbine is

carried out on the main Test Bed in Bay-II.

(c) Painting, Preservation and Packing After testing the turbine, it is disassembled
and inspected. Then the parts are painted, conserved and packed for final dispatch.

3.3 GAS TURBINE

The major processes involved in manufacturing Gas Turbine in various sections of Bk-III

are as follows:

a) Machining

Castings, Forgings, welded structures and other blanks are received from concerned

agencies in the respective sections. These are machined keeping in view optimum

utilization of machine tools and toolings. Special jigs and fixtures are made available to

facilitate accurate and faster machining. Proper regime and tool grades have been

established to machine the materials like inconel, which have poor machinablity.

b) Main Assembly

Final assembly is done on test bed. Parts are assembled to make sub-assemblies. These

sub-assemblies are again machined as per technological and design requirements and are

made ready for final assembly. After assembly and insulation assembled Gas Turbine is

31
 sent to site.

c) Rotor Assembly

The rotor is assembled on Hydraulic Lifting Platform and sent to main assembly, where

after checking clearances, it is sent for machining. After balancing, turbine side of rotor

is disassembled, inner casing is fitted and rotor reassembled. This work is also carried out

on Hydraulic Lifting Platform. Finally rotor is sent for assembly on test bed.

d) Combustion Chamber Assembly

This assembly is carried out on 3 tier platform installed for this purpose in Bay-I

assembly. After machining of all components, ceramic tiles are fitted in flame tube.

Burner and piping etc. is fitted in dome and combustion chamber is finally assembled. It

is directly sent to site after insulation.

32
SPECIFICATIONS

BOARD OF DIRECTORS
K.G. Ramachandran Chairman & Managing Director
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi 110 049
A.V. Singh Additional Secretary & Financial Advisor
Ministry of Industry. Deptt. of Heavy Industry
Udyog Bhawan, New Delhi 110 011
Pradeep Kumar Joint Secretary
Ministry of Industry. Deptt of Heavy Industry
Udyog Bhawan, New Delhi 110 011
Dr. Jamshed J. Irani Managing Director
Tata Iron & Steel Company Limited
Jamshedpur 831 001
Shekhar Datta Ex-Managing Director & President
Greaves Limited, E/8, Sea Face Park
Bhulabhai Desai Road, Mumbai 400 001
Ms. Tarjani Vakil Ex-CMD, EXIM Bank of India
A-1, Ishwar Das Mansion, Nana Chowk
Mumbai 400 007
J. Jayaraman Ex-CMD, Cochin Refineries Limited
39/4, Ashwin Apartment
C.P. Ramaswamy Road, Chennai 600 018

33
K.C. Lahiry Director (Power)
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi 110 049
K.S. Rao Director (IS&P)
Bharat Heavy Electricals Limited
Integrated Office Complex
Lodhi Road, New Delhi 110 003
Ishan Shankar Director (Personnel)
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi 110 049
M.K. Mittal Director (ER&D)
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi 110 049

34
 CONCLUSION

I fell highly overwhelmed as I got such opportunity of being a part of BHEL as a trainee.
It was a great experience and i learnt a lot from it. I find no suitable words to express my
profound, indebtness and heartful thanks to BHEL for their prestigious guidance, support and
supervision. There occasional words of advice would surely act as a beacon of light. It was due
to their cheerful and sincere co-operation which made my training a fruitful, pleasant and life
time experience.

This report is the outcome of four weeks training at the industry. The report is the
outcome of the practical knowledge that I acquired during my training. It presents the brief
summary of my industrial training. I had the privilege of receiving such training at BHEL,
Ranipur, Haridwar. There could not be a better place to learn. This study not only makes me
familiar with the big organization like BHEL but also provided the practical view that how the
functions and theories are applicable in an organization.

The working parameters followed in BHEL are very impressive for aspiring engineers.
The work culture followed there gave me the glimpse of working environment of the industrial
sector. In short I can say that I have acquired a lot of valuable knowledge and practical
experience that will help me in future.

35