training report on bhel
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BHEL AN OVERVIEW
BHEL is the largest engineering and manufacturing enterprise in India in the energyrelated 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
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make efficient use of the high-ash-content coal available in India, BHEL supplies
circulating fluidized bed combustion boilers to both thermal and combined cycle
power plants.
The company manufactures 235 MW nuclear turbine generator sets and has
commenced production of 500 MW nuclear turbine generator sets.
Custom made hydro sets of Francis, Pelton and 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
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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.
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.
INDUSTRIES
BHEL is a major contributor of equipment and systems to industries, cement, sugar,
fertilizer, refinances, petrochemicals, paper, oil and gas, metallurgical and other
process industries. The range of system & equipment supplied includes: captive
power plants, co-generation plants DG power plants, industrial steam turbines,
industrial boilers and auxiliaries. Wate heat recovery boilers, gas turbines, heat
exchangers and pressure vessels, centrifugal compressors, electrical machines,
pumps, valves, seamless steel tubes, electrostatic precipitators, fabric filters,
reactors, fluidized bed combustion boilers, chemical recovery boilers and process
controls.
The Company is a major producer of large-size thruster devices. It also supplies
digital distributed control systems for process industries, and control &
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instrumentation systems for power plant and industrial applications. BHEL is the
only company in India with the capability to make simulators for power plants,
defense and other applications.
The Company has commenced manufacture of large desalination plants to help
augment the supply of drinking water to people.
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.
TELECOMMUNICATION
BHEL also caters to Telecommunication sector by way of small, medium and large
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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 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
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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 2000-2001.
BHEL has introduced, in the recent past, several state-of-the-art products developed
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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. The company is also engaged in research
in futuristic areas, such as application of super conducting materials in power
generations and industry, and fuel cells for distributed, environment-friendly power
generation.
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.
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For fulfilling these obligations, Corporate Policies have been formulated as:
ENVIRONMENTAL POLICY
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;
Enhancement of Environmental awareness amongst employees, customers
and suppliers. BHEL will also assist and co-operate with the concerned
Government Agencies and Regulatory Bodies engaged in environmental
activities, offering the Company's capabilities is this field.
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.
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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, 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
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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
7. Businesses should support a precautionary approach to environmental
challenges;
8. Undertake initiatives to promote greater environmental responsibility and
9. Encourage the development and diffusion of environmentally friendly
technologies.
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 &
Auxiliaries
- Fabric Filters
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- 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 - 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
Stations
- Simulators
- Bus Ducts - Wind Electric Generators
- Rectifiers - Solar Powered Water Pumps
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- Porcelain Insulators - Solar Water Heating Systems
- Ceralin - Photo Votaic Systems
- Defense Equipment
INDUSTRIES/TRANSPORTATION/OIL
& GAS/
- Reverse Osmoses Desalination
Plants
TELECOMMUNICATION/RENEWABL
E ENERGY
SYSTEMS & SERVICES
- 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
- 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) NO. OFSETS
TOTALCAPACITY
(MW)
500 30 15000
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250 9 2250210/200 138 28570120/125/130 20 2420195 1 195
110 38 4180100 6 60070/67.5 6 41060 14 84030 5 150TOTAL(THERMAL)
267 54615
GAS FRAME SIZE/SCOPE
NO. OFSETS
TOTALCAPACITY
(MW)
9 5 7306 17 5805 13 3093 6 48V 94.2 2 2866FA 3 207STG 24 1190GEN 4 87TOTAL (GAS) 74 3437
NUCLEAR RATING (MW) NO. OFSETS TOTALCAPACITY(MW)
500 2 1000220 10 2200TOTAL(NUCLEAR)
12 3200
TOTAL (THERMAL+GAS+NUCLEAR) 353 61252
HYDRO 402 18735
GRANDTOTAL
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-
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integrator. BHEL-manufactured T&D products have a proven track record in
India and abroad.
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. The technology for state-of-the-art Flexible AC
Transmission Systems (FACTS) is being developed.
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
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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,
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diesel-electric multiple units, diesel power car and diesel electric locomotives,
battery-powered vehicles.
A high percentage of the trains operated by Indian Railways are equipped with
traction equipment and controls manufactured and supplied by BHEL. 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
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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.
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.
* Annual Manufacturing capacity for Thermal sets was expanded from 1500
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MW to 3500 MW under LSTG. Project during 1979-85 (Sets upto 500 MW,
extensible to 1000/1300 MW unit sizes with marginal addition in facilities
with the collaboration of M/s KWU-Siemens, Germany.
* Motor manufacturing technology updated with Siemens collaboration during
1984-87.
* Facilities being modernized continually through Replacements /
Reconditioning-Retrofitting, Technological / operational balancing.
2. INVESTMENTS:
* 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.
* Situated within 60 to 100 KMs of Foot-hills of the Central Himalayan
Ranges; Ganges flows down within 7 KMs from the Factory area.
* HEEP is located around 7 KMs on the Western side of Hardwar city.
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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 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),
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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
* Residential: Around 6780 quarters.
* Other amenities:
- Good Road network
- Shopping Centres
- Central Stadium
- Community Centres
- A Club
- Police Stations
- CISF Complex for over 500 CISF personnel.
- Convention Hall (a Most modern Air Conditioned Auditorium with 1500
seating capacity).
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- 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 capacity upto 20000 KW AC / DC)
* CONTROL PANELS
(For Thermal / Hydro sets and Industrial Drives)
* LARGE SIZE GAS TURBINES
(Unit Rating : 60-200 MW)
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* 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.
Today the Plant has unique manufacturing and testing facilities,computerized numerically controlled machine-tools, Blade shop, heavy duty lathes,
milling machines, boring machines, machining centers and many more. The Over
Speed Vacuum Balancing Tunnel created for rotors up to 1300 MW (32T, 6.9 M
dia bladed rotor, 6 rpm up to 4500 rpm) is one of the 8 of its kind in the entire
world.
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The total spectrum of sophisticated, unique and other facilities at HEEP,
Hardwar are the state-of-the-art in manufacturing processes and can be utilized for a
variety of products' manufacture.
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.
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
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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.
(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
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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, Hardwar.
(c) Rotor Assembly Section This is equipped with Indicating Stand, Small
size 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
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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) Sealing and Diaphragm Machining Section It is equipped with medium
size Vertical Boring, Horizontal Boring, Planning, Drilling Machines etc.
wherein castings of sealing Housings, Liner housings, Forgings of Rotor
Discs, castings and fabricated Diaphragms and components are machined. It
is also equipped with CNC machining center.
Precision Horizontal Boring, Plano-Milling machines etc, are for
manufacture of Governing Casting, Servo Casings and other medium parts of
governing and Main Turbine assemblies.
(i) 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.
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(j) 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, Servomotor, overspeed testing of
Emergency Governor etc.
(k) Light machine shop In addition to normal conventional machine tools it is
equipped with CNC Lathes, CNC Milling, CNC Vertical Boring, Precision
Milling, planetary grinding machines etc. for manufacture of small and
medium precision components of governing and other turbine parts.
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
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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.
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.
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h) Combustion Chamber Assembly Platform
This facility is a 3 Tier Platform installed in Bay-I assembly area and is used
for assembly of Combustion Chambers of Gas Turbine.
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
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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.
(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
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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 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.
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B.
BLADE SHOP
1. Introduction:
Major part of Turbine Blade Machining Shop is located in Bay-IV of Block-
III. In this shop various types of Steam Turbine and Gas Turbine Compressor
blades are machined from bar stock, drawn profile, precision and envelope
forgings. It is a batch production shop comprising of various kinds of CNC
Machines and Machining Centers, besides various special purpose and
general purpose machines. The layout of equipments is as per technological
sequence of the manufacturing process. Blade shop implements various On
Line Quality Control Techniques through Run Charts and Control charts.
This shop is divided into four distinct areas. Details of facilities are given in
various schedules of Section-II.
2. Manufacturing Facilities:
i) Plain Milling Section
It prepares accurate reference surfaces on the blade blanks by milling
and grinding operation. It also manufactures the brazed type blades by
induction brazing of drawn profile and suitably machined spacers.
This section carries out banking by Band Saws, rhomboid grinding on
Duplex grinding machines and thickness grinding on Surface grinders.
ii) Copy Milling Section
The Semi blanks prepared from plain milling section are further
machined by copy Milling Machines / CNC machines (CNC Heller
and BSK Bed type Klopp, BFH / BEK Knee type Machines) for
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concave and convex aero-dynamic profile forms, (HTC-600, BFK
Machines) for expansion angles, Compound taper grinding of radial
plane is carried out by Surface grinders. It comprises of T-root
machining centers for machining of T-root.
iii) LP Section
This area deals with all types of free standing and forged blades for
steam Turbine Compressor. The free standing blades are cerrobend
casted in boxes to hold the blade with respect to the profile. These
blades roots are subsequently machined on NTH, MPA-80A and T30
Machining Centers. There is a five station 360o circular copy milling
machine for machining the profile of envelope forged blades / stocks
for Steam Turbine and Gas Turbine Blades. It also has 3D copy
Milling and CNC Machines with digitizing features for Tip-thinning,
Fitted milling. The inlet edge of the last stage of Low pressure Turbine
Moving blades are hardened on a Special Purpose Flame Hardening
equipment.
iv) Polishing Section
Blade Contours are ground and polished to achieve the desired surface
finish and other aerofoil requirements.
There are also other small sections e.g. Fitting Section, Tool and
Cutter Grinding, Toolings Repair Section in Blade Shop.
v) Inspection Device
- 3 D Coordinate Measuring Machines for taper and rhomboid checking.
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- Moment weighing Equipment
- Real time Frequency analyzer for checking frequency of free standing
blades.
- Contour plotter for plotting of blade profile with various magnifications.
- Fir tree root inspection device.
- Magna spray crack detection equipment.
vi) Miscellaneous
There are other important facilities e.g. High rack storage system for
fixtures. Compactor system storage for finish blades. Jib cranes and
EOT cranes for material handling. The semi finished batch of blades
are kept in special boxes for inter-operation movements. An AGV
(Automated Guided Vehicle) is also located in LP Section of Blade
Shop for better material movement.
A.
QUALITY CONTROL FACILITIES
As in BHEL Customer Focus is of prime significance, Quality Control Function
assumes vital role. Quality Control facilities get priority in investment planning.
The Group is equipped with the state-of-the-art testing, measuring and analytic
facilities. This chapter covers Facilities existing in various sections under Quality
Management Deptt.
1.0 FACILITIES IN QUALITY CONTROL TURBINE BLOCK
Each Quality Control Station is equipped with conventional measuring
instruments as well as sophisticated testing machine to suit the inspection
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requirements of the related area. Some of the important facilities are:-
i) CNC 3D Coordinate Measuring Machine a fully computer
controlled modern machine for automatic inspection of complex or
precision components of size upto 2000x1200x1000 mm. The
important features of this machine are high speed computer, versatile
software, universal probe head for scanning, digitization and plotting
of known and unknown curves etc.
ii) 2-D Coordinate Measuring Microscope Used for highly accurate
and precise measurements of small and intricate components of the
turbine. The machine is equipped with multiple feature digital
readouts of resolution 0.0001 mm, a separate light generator connected
through fiber cables for better accuracy, optical templates for various
inspection purposes etc.
iii) Vibration Measuring Equipments Three no. of vibration
measuring equipments are available for checking of blade frequency at
various stages.
iv) Portable hardness testers it is being used for checking of hardness
of plane hardened-Nitrided and stellited components. It can measure
upto a range of HV 999.
v) MPI Machine This is used for carrying out magnetic particle test
for crack detection on finished blades.
vi) Surface Finish Measuring Equipment This is used for checking
the surface finish of machined components. Can measure in R, Rz and
Ra.
vii) Hardness Testers of different configurations
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* SAROJ (VICKER CUM BRINELL) HV to BH 5 to 250 KG
* SAROJ B-3000 (BRINELL) BH 250 to 3000 Kg
* USSR (ROCKWELL) HRC 150 Kg
* USSR (BRINELL) BH 250 to 3000 Kg
* SAROJ (ROCKWELL CUM BRINELL) HRC/HB 60 to 250 Kg
* SAROJ (ROCKWELL) HRC 60 to 150 Kg
B.HYDRO TURBINE LABORATORY
1. INTRODUCTION
Hydro Turbine Laboratory at HEEP, Hardwar was set up in late '60s. It
comprises of three Test Beds with electronic Instrumentation Laboratory for
test bed operation/maintenance and for carrying out Site Investigations. It has
a modest Workshop to manufacture hydro turbine models. Till December '95
about 160 number of tests have successfully been performed in the
Laboratory which include Contractual as well as Developmental tests on
Hydro Turbine Models, Calibration of Hydraulic Valves, Nozzles and Flow
Measuring Devices for 210 MW Thermal Sets. Besides performing the main
function of design/ development of hydraulic passages of hydro turbines,
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design of models, their manufacture and testing, the Laboratory has also been
engaged in Field Test Studies at various Hydro Power Sites for conducting
Index Tests, Head Loss Measurement, Uprating Studies and attending to
various Site Problems.
2. DESIGN:
3. MANUFACTURING:
4. TESTING:
5. TESTING CAPABILITIES:
- Runaway speed tests of reaction and impulse turbine.
- Determination of MW output of prototype turbine under specified
operating conditions.
6.4 INSTRUMENTATION LABORATORY
The Instrumentation Laboratory is equipped with the most modern
instrumentation for carrying out accurate measurements during testing in the
Laboratory as well as during field testing. The major facilities are:
- Ultrasonic Flowmeter for field tests.
- Magnetic Tape Recorder with Waveform Analyzer.
- Microprocessor based Pressure Pulsation Measuring System.
- Microprocessor based Wicket Gate Torque Measuring System.
- Microprocessor based Hydraulic Thrust Measuring system.
7. RESEARCH AND DEVELOPMENT
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The continuous inhouse research and development efforts of the Laboratory
have enabled it to establish new measurement methods for carrying out
special tests, to bridge know-how / know-why gaps, to resolve certain site
problems and to evolve and establish better and more efficient designs. The
benefits of research and development activities are passed on to the
customers through implementation of new concepts of existing sites and for
future projects.
8. FIELD TESTING
The Laboratory is equipped to perform field efficiency and index tests on
prototype turbines at hydro power sites. Many site problems of hydraulic and
mechanical nature have been successfully solved as a result of extensive filed
tests and analysis carried out by the Laboratory. The Laboratory has
successfully carried out uprating studies at many hydro sites resulting in
augmentation of power generating capacity of the units at no extra or
minimum cost. Extensive work has been done by the Laboratory to tackle the
problem of silt erosion of runner blades at several hydro power stations
situated in the Himalayan region.
9. CALIBRATION
The Laboratory is equipped with the required facilities for calibration of load
cells, pressure pulsation transducers, weights, volumetric tanks and torque
wrenches. Calibration of these terms is performed with respect to standards
with history traceable to N.P.L., Delhi.
10. FUTURE PLANS
Upgradation and modernization of Hydro Turbine Laboratory has been
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planned in the following areas:
- Renovation of Test Beds to the cater for the requirements of IEC-995.
- Modernisation in the field of instrumentation.
- Addition of instantaneous in-siti calibration facility.
- Incorporation of Computerisation and Data Acquisition System
- Modernisation of Workshop facilities.
C.
HUMAN RESOURCE DEVELOPMENT CENTRE
INTRODUCTION
HRDC Workshop caters to the needs of skill training of various trainees at
HRDC. These trainees include Engineering Trainees & ACT Apprentices amongst
others. Any other type of trainees who are to be given imported training can be
given skill training in areas of machining, turning, fitting, welding, electrical,
carpentry & electronics. In a year, about 500 ACT Apprentices are given training on
various machines.
VARIOUS SECTIONS OF HRDC WORKSHIP
There are 7 different sections in HRDC Workshop in which facilities exist
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for training.
(i) Turning Section has facilities for practical training of Turner Apprentices
& trainees. There are 18 Lathes, which include HMT lathes H22, LB 17, LM
001, Russian lathe No. 163, Kirloskar lather D 1 and one CNC Trainmaster
T-70 of HMT make.
(ii) Fitting Section has facilities for training in the area of fitting e.g. 36 bench
vices for fitting work.
(iii) Machining Section has 24 milling machines for skill training, 1 shaper, 1
slotter and 10 grinding machines. A CNC machining center also exists for
training in CNC operations.
(iv) Welding Section has facilities to give practical training in gas welding and
electric welding. The section has transformer, MG set, rectifier & an
electrode oven.
(v) Electrical Section has facilities for providing practical training in
electrician field. Areas in which practical training is given are laying of
house wiring, joints making & motor winding.
(vi) Carpentry Section facilities for providing practical training in the field of
carpentry. It has various wood working machines, like surface planer lathe,
thickness planer, circular saw, pedestal grinder & drilling machines.
(vii) Electronics Trade In this section practical training is given in making
circuits & repair work of TVs, tape recorders, amplifiers etc.
FACILITIES IN MANAGEMENT DEVELOPMENT / TRAINING
Audio visual facilities Facilities exist for video projection through a video
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include development of methods for recovery and recycling of industrial wastes.
Most modern facilities for monitoring and analysis in the area of air, water, noise
and solid waste are available at the Institute. It has full-fledged computer facilities
for prediction and forecasting pollution impact. It also has workshop and other
support services.
The laboratories of Pollution Control Research Institute have been recognized by
Ministry of Environment and Forests, Govt. of India; Department of Science and
Technology, Govt. of India; Madhya Pradesh Pradushan Nivaran Mandal; UP State
Pollution control Board; Bihar State Pollution Control Board; Punjab State Council
for Technology; Haryana State Pollution Control Board; Karanataka State Pollution
Control Board.
E.
AVIATION PRODUCTS
MANUFACTURING FACILITIES
1. LIGHT TRAINER AIRCRAFT PROJECT
In 1991, BHEL Entered into Aviation Sector as part of its diversification
efforts and has taken up manufacturing of two-seater light trainer aircraft
"SWATI". The aircraft was designed and developed indigenously by R&D
Wing of Directorate General of Civil Aviation, India. Requisite
organizational facilities and services infrastructure has been developed in
Sector X at BHEL, Hardwar.
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"SWATI" is a general purpose aircraft powered by 116 HP horizontally
opposed piston engine with fixed pitch propeller and has wide range of
applications like flying training, sports, touring, surveillance, photography,
courier & personal use.
2. WORKSHOP & FACILITIES:
2.1 General:
Hangar / Manufacturing Workshop consisting of one bay of size 45x90 mtrs
with expansion provision on eastern side have been developed at Aviation
Project Site in Sector X.
2.2 Manufacturing:
Following major components, sub-assemblies & assemblies are
manufactured in different sections:
- Fuselage
- Landing Gear
- Engine Mount
- Fuel Tank
- Pair of Wings
- Pin, Bush, Axle, Stud, etc.
- Lever, Brackets, Controls, etc.
- Fin, Rudder, Tailplane, Elevator, etc.
2.3 Facilities:
i) Fabrication / Welding Section
Equipped with TIG welding machines, this section is meant for fabrication of
fuselage, engine mount, landing gear and welding of lugs, brackets and other
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items on fuselage.
ii) Wing Manufacturing Section
This section is located in WWM shop (Block-VII) of HEEP, as all the
required wood working facilities are available in that Shop.
iii) Machine Shop
The Shop is equipped with medium capacity center lathes, milling machines
and drilling machine. Small components like pins, bush, axle, wing to wing
attachment fitting etc. are routed through this Section.
iv) C.M. Section (Chrome Moly-Steel Section)
Components of CM steel like lugs, brackets, levers, control system etc. are
manufactured in this Section. This section is equipped with fitter tables,
vices, hand shear machine, screw press etc.
v) Alclad Section
All components / sub-assemblies made of Alclad material like Fin, Rudder,
Tailplane, Elevator, Cowling etc. are manufactured in this Section. This
Section is equipped with fitter tables, vices, compressed air, Hand shear
machine, Sheet folding machine, 160 T Hydraulic press, 25 T Crank press
etc. Fuel tank is manufactured in Sheet Metal Shop of ACM (Block-IV).
vi) FRP Section
FRP Components like fairing, nose cap upper & lower, drag reduction items
etc. are made in this Section.
vii) Assembly Section
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Trial Assembly / Final assembly of components on fuseldge is carried out in
this Section like mounting of fin, rudder, tailplane, engine, fuel tank,
controls, instruments etc.
viii) Test Flying Facilities
To establish performance characteristics of aircraft before delivery to the
customer, an airstrip of size 23M in width and 914 M in length has been
developed in Sector IX near the Project Site.
F.
MEDICAL LINAC PROJECT
Introduction:
Medical Linac, a machine for treatment of Cancer by Radiation Therapy has been
taken up for commercial manufacture at HEEP, Hardwar with know-how from (1)
Department of Electronics (DoE), Govt. of India, (2) SAMEER, Bombay, (3)
Central Scientific Instruments Organisation (CSIO), Chandigarh and (4) Post
Graduate Institute of Medical Education & Research (PGIMER), Chandigarh.
Medial Lines test station equipped with facilities for testing of Medical Linac
machines upto 15 MeV (Mega Electronic Volt) has been established at HEEP,
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Hardwar and first 4MeV machine jointly manufactured by SAMEER, CSIO,
PGIMER and BHEL, Hardwar has been successfully integrated and tested in newly
established test station. Efforts are also afoot to declare this test-station as National
Test House.
Littion USA make Hydrogen brazing furnace, model 4401 (specifications below)
has been installed near the Medical Linac test station. This shall be used to carry out
brazing process of parts made of Oxygen-free high- conductive (OFHC) copper.
Layout proposed for the Medical Linac block is enclosed. No special facilities have
been established for manufacture of controls for Excavator.
Dedicated equipment like vacuum brazing furnace, double vacuum baking furnace,
low power test equipment including vector network analyzer etc. required for the
manufacture of complete machine will be added in future.
CENTRAL PLANT STORES
General
Materials from suppliers, sub-contractors, other unitsand ancillaries enters the
factory premises from eastern gate.
Material Receipt
The materials are unloaded at receipt area, identified in the Central Plant Stores and
subsequently shifted to respective custody areas after inspection. In case of heavy
materials, receipt areas are adjacent to custody areas.
Material Issue
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All the materials are received by Central Plant Stores and issued to users /
manufacturing blocks. Manufacturing blocks have their own sub-stores to receive
material from Central Plant Stores and further issue it to the shop / sections
concerned.
Stores Custodies
The locations, where various types of material are stored by Central Plant Stores,
have been classified as custody-I, II, III, IV & V.
Custodies & Materials Stores
Custodies and the main categories of materials stored are as below:
MATERIALS SPECIFICATION
X20 Cr 13
A. 13% Cr. Stainless Steel Bars (Hardened & Tempered)
1. General : This specification governs the quality of
stainless steel bars of grade X20 Cr. 13
2. Application : For machining of moving and guide blades of
steam Turbine.
3. Condition of Delivery : Hot rolled / Forged & hardened and tempered.
The bars shall be straight and free from
waviness.
4. Complete with standards: There is no Indian standard covering this
material.
5. DIMENSIONS & TOLERANCES :
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Dimension : Bars shall be supplied to the dimensions
specified in the purchase order unless otherwise
specified in the order. The bars shall be suppliedin random length of 3 to 6 meters with a
maximum of 10% shorts down to meter.
Forged bars shall be supplied in length of 1.5 to 3 meters.
Tolerance : The tolerance on cross sectional dimensions
shall be as per table.
5.1. Hot Rolled Bars : Tolerance on hot rolled flat bars shall be as
specified below :
"b" width across flates
mm
Allowable deviation on
"b" mm
"s" thickness
mm
Allowable devi.
on 'S' mm
Up to 35 + 1.5 Up to 20 +1
Over 35 and Upto 75 + 2 Over 20 and
Upto 40
+ 2
Over 75 + 3 Over 40 + 3
Note : Other tolerances shall be as per DIN 1017. Twisting and bending off the bars
shall not exceed 0.001X length of the bar. Bulging on the sides shall not be
more than 0.01 x b and 0.01 x s respectively.
5.2 Forged Bar : Tolerances on size for forged bars shall be +8% of
the size.
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6. MANUFACTURE :
6.1 The steel shall be manufactured in basic electric furnace process and
subsequently vacuum degassed or electric slag refined (ESR). Any other
process of meeting shall be subjected to mutual agreement between
supplier & BHEL.
6.2 For manufacture of flat bars, if initial material is other than ignot (e.g.
continuous casting), supplier shall mention it in his quotation for prior
approval from BHEL.
7. HEAT TREATMENT :
7.1 The bars shall be heat treated to get the desired mechanical properties
specified in this specification. The hardening temperature shall be in the
range of 980 10300C and the tempering temperature shall not be below
6500C As per DIN-19440.
7.2. Minimum possible residual stress shall be aimed with slow cooling and
longer duration of tempering treatment.
7.3. If the bars require straightening after heat treatment, the bars shall be
stress relieved after straightening operation at 300C below the actual
tempering temperature.
8. FREEDOM FROM DEFECTS :
8.1 The bar shall be free from lamination cracks, scabs, seams, shrinkage
porosity, inclusions and other harmful defects.
8.2 Decarburisation and other material defects shall not exceed the
dimensional tolerances and machining allowances.
9. FINISH :
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11.2 For Mechanical Test
11.2.1 One tensile & 3 impact test samples shall be selected for mechanical
testing per melt per heat treatment batch basis from lot of size.
11.2.2 The uniform strength of a delivery shall be certified through
hardness test. In case of bars with sectional dimensions more than
120mm, all the bar shall be tested for hardness. In case of bars with
sectional dimension less than or equal to 120mm hardness shall be
checked on 10% of the bars or 10 numbers of bars which ever is
higher.
11.2.3 The mechanical and notch impact test is to be done in longitudinal
direction on the hardest and softest bars. Test sample shall be to Km.
at 1/3rd below the surface of the bars.
12. Mechanical Properties :
12.1 The material shall comply with the following mechanical properties
at room temperature.
0.2% : 600 N/MM2 Min
Tensile strength : 800 950 N/mm2
% Elongation on 5.65 S0 : 15 min.
% reduction in area : 50 min. *
Impact (mean of 3.1S0 V sample): 20 J min.
Hardness (HB-30) : 280
* The smallest value shall be at least 14 J.
12.2 Tensile test shall be carried out in accordance with IS : 1608 or
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equivalent international standard.
12.3 Impact test shall be carried out on 3 ISO-V samples in accordance
with IS : 1757 or equivalent international standard only one test
value out of three, can be below the specified value ; but in no case it
should be below 2/3rd of the minimum specified value; but in no
case it should be below 2/3rd of the minimum specified impact
value.
12.4 Hardness test (Brinell) shall be carried out according to IS : 1500 or
equivalent international standard.
13. NON DESTRUCTIVE TEST : Following NDT shall be carried out.
13.1 UT of the prematerial combined with 100% magnetic partial testing
of all bars in delivery condition.
13.2 Complete UT of all bars in delivery condition.
13.2.1 In case of testing as per 14(a) U.T. shall be carried out as per HW
0850 192 (SEP 1923) test class D3 and MPI of all bars except of face
areas. In case of testing as per 14(b) UT shall be carried out as per
HW 0850 192 (SEP 1923) test class D2.
13.2.2 Mix up test (verification test) of all bars.
13.2.3 Visual inspection of all bars
13.2.4 Acceptance Criteria
a) Magnetic Particle Test : When MT is
carried out as per clause 14.1.
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Surface defects with expected depth > 1 mm are unacceptable.
Indication > 5 mm are unacceptable.
Defect indication observed during MT, can be removed by grinding
(dressing up) but with in 1mm depth.
b) Ultrasonic Test : Quality class 2b with
following modification that individual indication > 2mm EFB (KSR)
and back wall losses > 3dB are unacceptable.
X2 CrMoV1 21
B. 600 N/MM2 minimum 0.2% Proof stress Heat resistant steel bars
for steam turbine blades
1. General : Hot rolled and forged bars of steel grades X22
CrMoV1 21.
2. Application : Bars are required for machining of guide and
moving blades for steam turbines.
3. Dimension & Tolerance :
"b" width across flates
mm
Allowable deviation
on "b" mm
"s" thickness
mm
Allowable devi.
on 'S' mm
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Up to 35 & Over 35 1.5 Up to 20 &
Over 20
+1
Upto 75 + 2 Upto 40 + 2
Over 75 + 3 Over 40 + 3
4. Chemical Composition :
Element % min. % max.
Carbon 0.18 0.24
Silicon 0.10 0.50
Manganese 0.30 0.80
Chromium 11.00 12.50
Malybeonum 0.80 1.20
Vanadium 0.25 0.35
Nickel 0.30 0.80
Sulphur -- 0.020
Phosphorous -- 0.030
5. MECHANICAL PROPERTIES :
0.2 % proof stress : 600 N/mm2 min.
Tensile Strength : 800-950 N/MM2
% Elongation : 14 Min.
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% Reduction in area : 40% Min.
Notch Impact Value : 27 J * Min.
* Average of 3 IS0 V Samples.
C. 600 N/MM2 0.2% PROOF STRESS FORGED BLADES
1. General : This specification governs the quality of guide and
moving blades forged from steel grade X 20 or 13.
2. Application : The blades are used for steam turbines.
3. Condition of Delivery: The forged blades shall be supplied in heat treated
forged blade shall be supplied with center holes
made in accordance with respective technical
requirements or ordering drawing.
4. Dimensions & Tolerance: The dimension and tolerances shall be as per
ordering drawing accompanying the order.
5. Manufacture : The steel shall be manufactured in the blade
electrical furnace and for subsequently refined to
ensure turbine blade quality. The forgings shall be
made as envelope forging or precision forging,
subsequently machine / grinder to achieve the
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ordering drawing dimensions and surface finish.
6. Heat Treatment :
6.1. The forging shall be heat treated to get desired mechanical properties.
6.2. The tempering temperature shall not be below 6500 C. The minimum
residual are to be aimed through sufficient duration of the tempering
treatment and the slow cooling rate from the tempering temperature.
6.3. The blades are to be straightened after heat treatment, each
straightening operation is to be followed by a stress relieving
temperature and in no case below 6100C followed by slow cooling.
7. Freedom from Defects : Blades shall be free from folds due to forging ;
cracks, tearing and other material defects,
elonganed non-metallic and jusions, seams etc. any
blade blade containing such defects shall be
rejected.
8. Surface finish : The blade shall be supplied in a desoaled and
deburred condition. The surface finish shall comply
with the requirements specified on the drawing. In
the surface is ground prior to blasting the the
surface finish must be anouired in compliance with
the finish specified on the drawing. Grinding may
be performed to a depth not more than H/2 and
ground areas shall be blended over a length of
LP/2. HoweverH Shall not be exceeded.
H : Allowable profile deviation on the pressure side.
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LP : Profile length measured from leading edge to
trailing edge.
9. Chemical Composition : The chemical analysis of the material shall confirm
to the following :
Element % min. % max.
Carbon 0.17 0.22
Silicon 0.10 0.50
Manganese 0.30 0.80
Chromium 12.50 14.00
Nickel 0.30 0.80
Sulphur -- 0.020
Phosphorous -- 0.030
10. Selection of Test Sample : All tests and examination shall be
performed on specimens taken in
accordance with annexure 1 from at least
one blade of each drawing per melts and
heat treatment batch.
11. Mechanical properties :
11.1 The mechanical properties of the blade material shall conform to the
following :
0.2 % proof stress : 600 N/mm2
Tensile Strength : 800-950 N/MM2
% Elongation : 15 Min.
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% Reduction in area : 50 Min.
Impact Value (Average of
3, ISO V Sample) : 20 J Min.
Brinell hardness HB 30 : 280 Max.
11.2 Tensile Test : The tensile test piece shall confirm to the gauge length.
L 5.65 S0 0=
11.3 Impact test shall be carried out on standard test piece as per ISO V notch
according to IS : 1757.
11.4 Hardness Test : The brinell hardness test HB 30 shall be carried out
according to IS : 1500.
12. Non Destructive Test :
12.1 Blade shall only be manufactured from ultrasonically examined rare
material.
12.2 In order to ensure freedom from defects. All blades shall be subjected to
magnetic particle examination prior to shipment.
13. Dimenional Checks for Acceptance :
13.1 The supplier shall check 100% of the forgings w.r.t. to all parameters.
13.2 Dimensions parameters to be checked for acceptance.
Following dimensional parameters of each of the check sections as
specified in ordering drawing shall be inspected after fixing / clamping
the forging in vertical stand to check conformance of profile of
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individual section as well as in relation to each other.
o From tolerance for pressure
side = H
o From tolerance for suction
side = R, max difference R
o From tolerance for Inlet edge
= H
o Twist Tolerance =
( H, R) max.
Profile thickness of each section. = D Max. / D /
D1
Max. profile length of each section.
Root dimensions.
Base dimensions.
Base plate contour.
Axial and tangential shift of profile with respect to root.
Overall length of forging.
Surface finish.
13.3 Procedure for dimensional checks :
Check of inlet edge: The profile of inlet edge shall be checked by
using split profile gauges.
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Check of Profile : All the dimensional parameters mentioned at
(13.2) shall be checked using a vertical measuring stand.
Drilling of BHEL Centre holes
Checking of BHEL Centres.
A.
CLASSIFICATION OF BLADES
L.P. Moving Blade Forged Ist Stage.
L.P. Moving Blade 500 MW Last Stage.
100 MW 25th Stage Impulse Blade.
Compressor blade Sermental coated.
Compressor Blade 'O' stage.
Gas Turbine Compressor Blade.
T-2 Blade.
T-4 Blade.
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3DS Blade.
Brazed Blade
Russian Design Blades.
Z Shroud Blade.
Twisted Blade.
Present Range of Blades.
Future Range of Blades.
MANUFACTURING DIVISIONS
Heavy Electricals Plant, Piplani, Bhopal
Electricals Machines Repair Plant (EMRP), Mumbai
Transformer Plant P.O. BHEL, Jhansi.
Bharat Heavy Electricals Limited :
Heavy Electricals Equipment Plant,
Central Foundary 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.
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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.
Industrial Systems Group.
BANGALORE .
Component Fabrication Plant, Rudrapur.
Piping Centre, Chennai.
Regional Operations Division, New Delhi
CONTENTS
1. Prologe A. BHEL An Overview
B. HEEP An Overview
2. Study on Turbines & Auxiliary Block
3. Study on Material Specification
4. Study On Blade Shop
5. Broad Specification of Major Machines Tools & Machines
(CNC & Non CNC)
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6. Other Areas
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