bhel report final

7/28/2019 Bhel Report Final

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ACKNOWLEDGEMENT

It is my proud privilege to express deep sense of gratitude,

regards and appreciation to my guide Mr. S.K. Jain Dy.

Manager (M.M. Hydro) for his invaluable guidance, deeprooted interest, inspiration and continuous encouragement

through out my vocational training which helped me to

learn about the companys working and to complete my

training.

I am also thankful toMr. G.K. Srinivasa and Mr. Nisar

Haidarfor their guidance through out the period. I alsowant to extend my heart felt thanks to Mr. Sahib Singh

((HRDC Department),Mr. Tushar Yadav(Turbine

Manufacturing Division),Mr. Anand(Coils and insulation

department),Mr. R.K. Ojha(Steam Turbine manufacturing),

Mr. Rao (Hydro Lab) for their continuous support and

inspiration.

Finally, I am grateful to those who have directly or

indirectly helped me during the training.

AADITYA MISHRA

MECHANICAL ENGINEERING (2011-2015)

MAULANA AZAD NATIONAL INSTITUTE

OF TECHNOLOGY, BHOPAL


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TABLE OF CONTENTS

INTRODUCTION TO BHEL............................................................... 4

VISIONS, MISSIONS, & VALUES OF BHEL.......................................7

BHEL AN OVERVIEW......................................................................... 8

HUMAN RESOURCE MANAGEMENT........................................ 13

PRODUCTS........................................................................................ 16

INTERNATIONAL OPERATIONS................................................ 20

FUTURE PLANS................................................................................. 22

BHEL SWOT ANALYSIS............................................................24

HYDRO TURBINES.....................................................................28

PELTON WHEEL( TURBINE)........................................................28

FRANCIS TURBINE.....................................................................31

KAPLAN TURBINE.....................................................................34

BUTTERFLY VALVES.....................................................................36

HEAT EXCHANGER.....................................................................39

STEAM TURBINES.....................................................................42


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HYDRO GENERATORS.....................................................................44

TECH. SPECIFICATIONS OF 210 MW STEAM TURBINE.......45

FACILITIES AT BHEL BHOPAL FOR COILINSULATIONS........47

PHOSPHATING AND POWDER COATING ..................49

Bibliography................................................................................. 51


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INTRODUCTION TO BHEL

BHEL is the largest engineering and manufacturing enterprise in India inthe energy related/infrastructure sector today. BHEL was established more

than 40 years ago ushering in the indigenous heavy electrical industry inIndia, a dream that have been more than realized with a well recognizedtrack record of performance. It has been earning profiles continuouslysince 1971-72 and paying dividends since 1976-77.

BHEL manufactures over 180 products under 30 major product groups andcaters to core sectors of the Indian economy viz., power generation andtransmission, industry, transport, telecommunication, renewable energyetc.

The wide network of BHEL, 14 manufacturing divisions, four powersector reginiol centers over 100 project sites.it services its customers andprovides them with suitable product, system and services efficiently and atcompetitive prices.

THE QUALITY AND RELIABILITY OF ITS PRODUCTS DUE TOEMPHASIS ON DESIGN, engineering and manufacturing to internationalstandards by acquiring and adapting some of the best technologies from

leading companies in the world, together with technologies developed inits own R& D centers.

BHEL has acquired certification to quality management system ISO9001:2000 environmental management system ISO 14001 andoccupational health and safety management system OHSAS 18001 and hasalso adopted the concepts of total quality management.

BHEL HAS:-

1. Installed equipment for over 1, 15,356 MW of power generation forutilities, captive and industrial users.

2. Supplied over 2, 25,000 MW transformer capacities and sustainedequipment operating in transmission and distribution network up to 400KC-AC and DC.

3. Supplied over 25,000 motors with drive control system to power

projects,petrochemicals, refiners, steel, aluminum fertilizer, cement plants etc.


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4. Supplied traction electrics and AC/DC locos to power over 12000 kmrailwaynetwork.

5. Supplied over one million valves to power plants.

BHELS operations are organized around three business sectors, namelypower industry including transmission, transportation, telecommunicationand renewable energy and overseas business .this enables BHEL to have astrong customer orientation to be sensitive to his needs and respondquickly to the changes in the market.

BHELS vision is to become a world class engineering enterprise,committed to enhance stakeholder value. The company is striving to giveshape to its aspirations and fulfill the expectations as a MAHARATNAcompany since February 2013.

The greatest strength of BHEL is highly skilled and committed 44,000employees. Every employee is given equal opportunity to develop himselfand improve his position. Continuous training and retraining, careerplanning, a positive work culture and participative style of managementhave endeared development of a committed and motivated work forceleading to enhanced productivity and higher levels of quality.

BHEL manufactures a wide range of products and systems for thermalnuclear gas and hydro based power plant to meet the customersrequirement for power generation, transmission and utilization. Theproducts that BHEL manufacture are described below.

THERMAL

BHEL manufactures steam turbine generators and boilers with matchingauxiliaries up to 500 MW.

NUCLEAR

In this field BHEL manufactures steam turbines and generators and shieldsand heat exchange for 235 MW projects.


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GAS

BHEL is the only company to manufacture large sized gas based power

plant equipment comprising turbines up to 200 MW.

HYDRO

BHEL engineers and manufactures has built francis, pelton and Kaplan

type turbine, pump turbines and minor-micro hydro plants with matching

generators for different head discharge combination. The maximum size of

hydro equipment already built and installed is 265 MW.

TRANSMISSION

BHEL supply a wide range of transmission products and systems up to

400 KV. These include high voltage power and distribution transformers,

instrument transformers, dry type transformers, SF 6 switching gears cape

electric citers etc for economic transmission of bulk power over long

distances. High voltage direct current (HVDC) technology is now

available. R & D projects for the development of equipment for 800 KV

class are progressing a pace resistance high alumina ceramic line material

of power, steel cement and mining industries as well as a wide range of

industrial ceramics.


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VISION, MISSION & VALUES OF BHEL AT A

GLANCE

VISION

A world class engineering enterprise committed to

enhancing stakeholders value.

MISSION

To be an Indian multinational engineering enterprise providing totalbusiness solutions through quality products, systems and services in the

field of energy, industry, transportation, infrastructure and other potential

area.

VALUES

: Zeal to excel and zest for change.

: Integrity and fairness in all matters.


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: Respect for dignity and potential of individuals.

: Strict adherence commitment.

: Ensure speed of response.

: Foster learning, creativity and teamwork. : Loyalty and pride in the

company.

BHARAT HEAVY ELECTRICALS LIMITED AN

OVERVIEW

Bharat heavy Electrical Limited. (BHEL), a company with majority shareholding by the government of its kind in India and is among the 12 leadingequipment manufacturers in the world. The company was set up in theyear 1956 with a view to reach self-sufficiency in Power and Industrialproducts vital for the industrialization of India.

BHEL is organized along three Business Sectors, viz, Power, Industry andInternational Operations. The main activities of Business Sector are

marketing, Project Engineering, Erection, Commissioning and serviceafter sales. The product Range of BHEL encompasses power generatingequipment, electrical and thermos mechanical equipment for industrialapplications, electrical traction equipment and urban transport systems.

The company has a workforce of 44,000 including technicians, skilledworkers and about 9,000 qualified engineers. BHEL today has 13manufacturing plants and host of service divisions and around 200 projectssites. BHEL major manufacturing divisions have already received

accreditation to ISO 9001/9002 BHEL has enjoyed an impressive growthrecord since its inception and registered a turnover of approximatelyus$1.25 billion during the year 1992-1993.

POWER

BHEL has commissioned more than 800 Nos. utility and industrial setstotaling to over 50,000 MW equivalent generating capacity. BHELs share

in utility generating capacity was approximately 64% of the installedcapacity inIndia in March 1993. Presently, BHEL has capacity to supplypower equipment equivalent to 7000 MW per year.


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(A) Thermal Generation:The unit sizes of utility stations in India range from 30 MW to 500 MWBHEL has so for being responsible for over 2000 of these installationsaccounting for over 40000 MW of installed generating capacity (utility)which include sets up to 500 MW capacity. The technology formanufacture of turbo generators comes from a comprehensive technicalcalibration agreement with Scienes AG of Germany. BHEL manufacturessteam generator as per technology of M/S ABB Combustion Engineeringof the USA. This technology has been acquired through 20 years ofcollaboration/license agreement. Both these collaboration covered unitratings up to 1000 MW.

Operating in an environment of high technology and severe competition as

BHEL does, the company has perform to stay abreast with the technologyleaders in the world. It is in recognition of such imperatives that BHEL hastechnology tie-ups around the world for a variety of power stationauxiliaries as well.

BHEL has a well chalked out programmed to assimilate, adapt and modifysuch acquired technology to suit differing economic, developmental,geographic & climatic requirement. The company has also a full-fledged

Research and Development Division which undertake fundamental andapplied research in power and related fields. Research; is being carried outon non-conventional energy sources as well. Several of these efforts suchas those in the areas of fluidized Bed Combustion, Solar and Wind Powerhave already resulted in commercial ventures.

(B)Hydro Generation:BHEL has supplied Hydro Sets upto 165 MW rating and 200 MW setsare under manufacture, BHEL has facilities to manufacture and install

sets of even higher rating as per specific customer requirements. It alsosupplies turbines for low head mini and micro hydro stations to meetthe needs of rural and backward areas located in the remote corners ofthe country. So far, BHEL has commissioned mire than 200 HydroSets of various types and capacities tattling to about 12000 MW.

(C) Nuclear Generation:Indias first wholly indigenous Atomic Power plant at Kalapakkam

near Madras is equipped with two sets of power generation equipmentof rating 235 MW each supplied by BHEL. Subsequently, another two


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sets of similar rating have been commissioned successfully at Narora.BHEL is now manufacturing sets of 500 MW rating for nuclear powerstations.

(D)Gas Turbines based generators plants:

Today BHEL is fully equipped to supply simple/confined cycle/cozenplants with various frame sizes of gas turbines of unit rating upto 200MW. BHEL has collaboration agreements with two leaders of has turbinestechnology in the world namely general electric, USA and Siemens AG,Germany. The agreement with GE, USA covers rating from 4.6 MW(ISO). The Siemens agreement covers unit rating from 130 MW to 200MW. So far BHEL has supplied more than 33 nos. Has a turbine. All these

turbines have been supplied from our Hyderabad plant based on generalelectric, USA technology. BHEL has bagged orders for two gas turbinebased projects in Malaysia, commissioning schedule of 6- 10 months. Thefirst project has already been commissioning in 6 months time. While thegas turbines of GE/USA design are supplied from Hyderabad plant. Withthe plants (i.e. Hyderabad and Hard war) are fully equipped with state ofmanufacturing and testing facilities.

BHEL is fully equipped to supply waste heat recovery boilers from their

Tiruchirapalli plant. BHEL have an ongoing collaboration agreement withM/S Henry volt, USA for the Waste Heat Recovery Boilers.

BHEL is supplying WHRSGS foe 6X30 MW gas turbines for Delhielectric supply undertaking, and 817 MW Dadri Project of nationalthermal power corporation limited besides those for other power stations.

(E) Transmission:

In addition to equipment for generating of power, BHEL supplies a varietyof

equipment for transmission and utilization of power. The company hasalso undertaken a number of turnkey sub-station contracts for voltagerating up to 400 kv class. Keeping with the KM long HVDC (High voltagedirect current) transmission line project line for reliable and efficienttransmission of bulk power. BHEL has in house capability to supply mostof the equipment like power transformer current transformer, voltage

transformers switches, insulators etc., and also possesses in house moderntesting facilities.


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Billions of BHEL manufactured insulators of various ratings upto 160 KNare satisfactory service in many countries namely Turkey, Egypt,Malaysia, Iran, Iraq, USA Libya, Tanzania Dubai and course India.

(F) Industry:

The industry Sector of BHEL offers diverse items such as Transformers,Switcher, Rectifiers, Insulators, Capacitors, Control Gear, ValvesCompressors, Pumps, Piping, Motors, Industrial turbines oilrigs and

semiconductor devices to meet the varying needs of industry.

(G) Transportation:For over quarter of a century, BHEL has been supplying drives and controlfor traction equipment mainly to the Indian Railway, which is the third

largest Railway network in the world. Today, 65% of the rolling stock inIndian contains electric of BHEL make such as traction motors, tractiongenerators/alternators, and transformers. The company has lately movedfrom the position of supplier of electrics only to supplier of completelocomotives -both diesels electric as well as A.C. Locos.

The urban transportation problem demands different solutions andBHELs contribution extends to underground tube, light rail and batterypowered road vehicles

(H) Services

(a) Project Engineering:

The total engineering for thermal power stations is undertaken by a coregroup project engineering management. With over 500 engineers andsupporting staff, this division offers specialized service in differenttechnical disciplines and undertakes engineering works relating to

optimization of cycle configuration selections of parameters and design ofsuitable system for power stations with a total MW capacity of 30000 andis currently involved in several turnkey project including stations having500 MW unit size.

b) Constructions Management:

BHEL has a full-fledged construction management division to undertakeerection work. This division well organized with over 500 experiencedengineers,1000 technicians and 1300 skilled workers besides constructionequipment valued at over 40 million US Dollars.


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c) Service After sales:BHEL extends its supply and construction scope with service such as

commissioning field engineering performance monitoring trouble shootingoperation and maintenance. Renovation modernization and rehabilitation

works of aged power stations are also undertaken. BHEL has a separatespare group response for insuring ready availability of essential spares toPower stations.

d) Projects Management:The project management division of BHEL coordinates th4 entire range of

BHEL activities in relation to thermal power plant project and isresponsible to the purchasing organization for compliance of thespecifications. Entrusted with the overall coordination of the project thedivision initiates, directs coordinates, supervises and control all activitiesthat are necessary for the performance of the project right from theconception stage until the contractual obligations are fully discharged.

BHEL offers a wide spectrum of products and services for core sectorslike power transmission industry, transportation, oil & gastelecommunication etc, deseeds supply of non-conventional energy

systems. It has also embarked it to other areas including defense &aviation.

HUMAN RESOURCE MANAGEMENT

1. Industrial Relations

The Industrial Relations at various Units and service divisions of theCompany were harmonious and cordial during the year under report.Thrust to develop and nurture the participative culture in the Companycontinued during the current year also. The elections of the Unionsthrough secret ballot at various Manufacturing and Service Divisions forrepresentation at the apex level Joint Committee were held in July, 2002.Accordingly, Joint Committee for BHEL was reconstituted. Subsequently,

a seminar for the orientation of new members of the reconstituted JointCommittee and familiarization with the issues related to the Company washeld at Hyderabad for 2 days in October, 2002.


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A two days' workshop was also conducted in November, 2002 forSupervisors and Executives on Enhancing Organizational Effectiveness.The objective of the workshop was to bring about better understanding andappreciation of the issues being faced both by the Company and theemployees.

The apex level bipartite forum viz. Joint Committee for BHEL held 3meetings while the Plant and Shop Councils held 51 and 236 meetingsrespectively during the year at various Units of the Company.

2. BHEL Excel Awards

Inspired by the ideal of 'Yoga Karmasu Kaushalam', the Board ofDirectors of BHEL in its 320th meeting held on 30th October, 2000, took ahistoric step by approving BHEL Excel Awards Scheme to institutionalisethe culture of Excellence in BHEL. The first such awards were presentedfor 2000-01 on 13th January, 2002. The objective of the scheme is torecognise, reward and place on record any direct or indirect outstandingand exemplary contribution by the employee towards growth andprofitability of the company. The scheme stipulates the following ninecategories of awards, each valuing up to Rs. 50,000 in case of anindividual, and up to Rs. 5 lakh in the event of a group/team winning the

award.

1. BHEL Utkrishthta Puraskar2. BHEL Gunvatta Puraskar3. BHEL Tatparta Puraskar4. BHEL Utpadakta Puraskar5. BHEL Utkrishtha Takniki Lekh Puraskar 6. BHEL AnusandhanPuraskar

7. BHEL Srijanatmakta Puraskar8. BHEL Grahak Santushti Puraskar9. BHEL Paryavaran/Samaj Seva/Sanskriti/Khel PuraskarWhile the first eight awards are for the company employees only, the ninthaward covers spouses and dependent children of the employees also.The Scheme also stipulates Swasth Karamchari Samman which are givento employees in appreciation of good health. The Samman is at the unitlevel for employees who do not claim any medical reimbursement for selfand also do not avail any leave on account of sickness in the previousfinancial year.


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The 106 nominations, received from various units/ divisions for the year2001-02 were scrutinized and short listed by a Screening Committee. Theshort listed entries were evaluated by the Jury constituted by CMD. Theawards have been announced in 8 categories to a total of 50employees/family members and 2 token awards in 25 recognition ofindividual skills. Their outstanding contribution is hailed as a significantmilestone in BHEL's journey towards excellence. A word of appreciationto all those who participated and shown the zeal to excel. The journey ofexcellence will go on unabated with ever increasing vigour.

3. Awards won by BHEL Units and Employees

SCOPE Award for Excellence and Outstanding Contribution to the Public

Sector Management - Individual Category. Shri K.G.Ramachandran,Chairman and Managing Director, has won the coveted SCOPE Award forExcellence and Outstanding Contribution to the Public SectorManagement, for the year 2001-02, in his individual capacity for hisoutstanding contribution to Public Sector management. The award carriesa cash amount of Rupees One Lakh and a Golden Plaque.

"Achiever of the Year Award" by CHEMTECH Foundation ShriK.G.Ramachandran, Chairman and Managing Director, has been awarded

the "Achiever of the Year Award" by CHEMTECH Foundation, inrecognition of his contribution to industry, under the category of PowerPlant and Machinery Industry. He was unanimously selected by the awardscommittee, comprising some of the most prominent industrialists of thecountry. Prime Minister's Shram Awards Prestigious "Prime Minister'sShram Awards" instituted by Ministry of Labour namely Shram Bhushan,Shram Vir and Shram Shri have been won by four BHEL employees forthe year 2002. This is the highest number of awards won by BHEL since

the inception of the awards in 1985. Vishwakarma Rashtriya Puraskars SixVishwakarma Rashtriya Puraskars, for the year 2000 were won by 19employees of BHEL. The award is instituted by Ministry of Labour.National Safety Awards Four BHEL Units, i.e. Tiruchy, Hyderabad,Electronics Division - Bangalore and Electro porcelains Division -Bangalore, won National Safety Awards for the year 2000. The award isinstituted by Ministry of Labour. "Excellence in Energy Management"-CII Awards HEEP-Haridwar Unit has been awarded a certificate in the

category of an "Energy Efficient Unit", along with other companies, in thecompetition held in December, 2002 at Chennai by CII.


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INSSAN Awards

Hyderabad Unit has won the first prize for Excellence in SuggestionScheme, Best Suggestor Award and two Best Slogan Awards in theINSSAN National Convention for the year 2002. These awards are

instituted by the Indian National Suggestion Scheme Association(INSSAN). Those details of the awards won by Hyderabad Unit are:

a) Excellence in Suggestion Scheme b) Best Suggestor Awardc) Best Slogan Award (Hindi)d) Best Slogan Award (English)

4. Human Resource Development

During 2002-03, 40466 participants were exposed to different trainingprograms in our various training Centers at Units as well as at apex levelin NOIDA. Besides, 3700 Act Apprentices and 1300 TechnicianApprentices were also provided with training at our Units, as part offulfillment of our social obligation towards the society.

Also, towards our ongoing efforts for higher customer satisfaction, around1100 customers' personnel were provided training inputs on our products

at Training Centers in the Units.

5. Activities of the company for welfare and Advancement of

Scheduled Castes (SCs) And Scheduled Tribes (STs)

The company has been following the Presidential Directives andguidelines issued by the Government of India from time to time regardingreservation for SCs and STs in letter and spirit. During the year, thevarious Community Development activities focused on Socio- Economic

development of SCs and STs have been carried out by BHEL in the 56villages adopted by it. Representation of SC/ST employees therepresentation of SC/ST employees in total manpower was 18.13% and3.73% for SCs and STs respectively as on 1/1/2003


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PRODUCTS

Industrial fans Power generation & Transmission

Sam less Steal tubes

Steam Turbine-Generation Sets & Auxiliaries

Fabric Filter

Boiler and Boiler Auxiliaries

AC/DC Motors, Variable Speed

Once through Boilers

AC Drives

Nuclear Power Generation Equipment

Electronic Control Gear & AutomationHydro turbine-Generator Sets & Auxiliaries

Equipment

Mini/Micro hydro Generator Sets

DDC for Process Industry

Gas Turbine-Generator Sets

Thirstier Equipment

Waste Heat Recovery BoilersPower Devices

Heat Exchangers

Energy Meters

Condensers

Transformer

Bowl Mills and Tube Mills

Gravimetric Feeders

Insulators

Regenerative Air Pre-Heaters

Capacitors

Electrostatic Precipitators

Broad Gauge, AC,AC/DC Locomotives

Bag Filter

Diesel- Electric Shunting Locomotives


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Valves

Tractions Motors

Pump

Electric Trolley buses

electric Machines

AC Electric Multiple Units

Piping System

Drives & Control for Metro system

Power, Distribution 7 Instrument Transformers - Battery Operated

Passenger Vans

Reactors

Oil Rigs & Oil Field Equipments

Synchronous Condensers

Digital Switching System

Switchgear

Rural Automatic Exchange

Control Gear

SimulatorsDistributed Digital Control for Power station

Wind Electric generators

Bus Ducts

Solar powered Water Pumps

Porcelain Insulators

Photo Voltaic System

CeralinsDefense Equipments/Oil/Gas

Reverse Osmosis Desalination plant/ Telecommunication /Renewable

Energy

System Turbine

Generator Sets


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A dynamic 67000 Strong team embodies the BHEL philosophy ofprofessional excellence with corporate headquarters in New Delhi: BHELis Indias ambassador to the world with export presence in more than 50countries.

BHEL has a consistent tract of growth performance & profitability.

INTERNATIONAL OPERATIONS

BHEL has over this year established its references in around 60 countries

of the world ranging from United States in the west to New Zealand in theEast. These References Encompass almost the entire product range ofBHEL covering turnkey power project of thermal hydro and gas basedtype substation project, rehabilitation project, based a wide variety ofproject, like transformers, insulators, switchgears, heat exchanger, castingand forging, valves well-head equipment etc. Apart from over 1110 MWof boiler capacity contributed in Malaysia and execution of fourprestigious power project in Oman, some of the other major successesachieved by the company have been in Australia, Saudi Arabia, Libya,Greece, Cyprus, Egypt.

Technology Up gradation and Research & Development to remaincompetitive and meet customers expectations, BHEL lays great Emphasis

on the continuous up gradation of product and related technologies anddevelopment of new project works. The company has upgraded its productto contemporary levels through continuous in- house effort as well asthrough acquisition of new technology from leading engineering

origination of the world.

The Corporate R&D Division at Hyderabad, spread over a 140 acrecomplex leads BHEL research efforts in the number of areas of importanceto BHELs product range research and product development center at each

of the manufacturing division play a complementary role.

BHELs investment in R7D is among the largest past several state-pf-theart product developed in housing during the last five years contributed

about 8.6% to the revenues in 2000-2001 BHEL has introduced in therecent past several stateoftheart produced developed inhousing:


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low-Nox oil gas burner, circulating fluidized bed combustion boilers highefficiency Pillion hydro-turbines, petroleum depot automation system,36KV gasinsulated sub stations, etc. The company also transferred a fewtechnologies developed in-housing to other Indian companies forcommercialization.

Some of on going developed & demonstration project include: Smart wallblowing system for cleaning boiler soot deposit , and micro- controllerbased governor for diesel- Electro-locomotives . The company alsoengaged in research in futuristic areas, such as application of superconducting materials in power generation and industry, and fuel cells fordistributed environmentfriendly power generation.

HUMAN RESOURCE DEVELOPMENT INSTITUTE

The most praised asset of BHEL is its employers. The Human ResourceDevelopment Institution and other HRD centers of the company help innot only keeping their skills updated and finally honed but also in addingnew skills, whenever required Continuous training and retraining, a

positive work culture and Participative style of management, haveengendered developed of a committed and motivated workforce, leadingthe enhanced productivity and higher levels of Quality.

MANAGEMENT HEALTH SAFETY AND

ENVIRONMENT

BHEL is the integral part of business performance and in its endeavor of

becoming a word class origination and shearing the growing globalconcern on issue related to environment in and around its ownestablishment, and to provide safe and healthy working environment to allits employers.

For fulfilling these obligations, Corroborate Policies have been formulatedas;

Environmental Policy:

Compliance with applicable Environmental Legislation/ Regulation;


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Continual improvement in Environmental Management System toprotect ournatural environment and Control Pollution;

Promotion of activities for conservation of resources by Environmental

Management

Enhancement of Environment awareness among employees, custom &suppliers

BHEL will also assist and cooperate with the concerned governmentalAgencies and Regulatory Bodies engaged in environmental activities,offering the companys capabilities in this field.

Occupational Health and Safety policy:

Compliance with applicable Legislations and Regulations;

Setting objectives and targets to eliminate/ control /minimize risks dueto Occupational safety Hazards;

Formulation and maintenance of OH&S Management Programs for

continual improvement.Product review of OH&S Management system to ensure it continuing

suitable adequacy and effectiveness;

Communications of OH&S Polices to its all employees and interestedparties.

The major units of BHEL have already acquired ISO14001.Environmentalmanagement system certification, and other units are in advanced stages ofacquiring the same. Action plan has been prepared to acquire OHSAS18001Occupational Health and Safety Management systems certificationfor all BHEL units.

Participation in the Global Compact of the United Nat the Global

Compact is a partnership between the United Nations, the businessCommunity, international labour and NGOs. It provided a forum of them

to work together and Improve corporate practices through co-operation


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Compact of United Nations and has committed to support it and the set of

core value ensured its nine principles.

PRINCIPLES OF THE GLOBAL COMPACT HUMANRIGHTS

1. Business should support and respect the protection of internationallyproclaimed Human rights

2. Make sure that they are not complicit in human rights abuse. Lab ourstandards

3. Business should uphold the freedom of association and the effectiveRecognition of the rights to collective bargaining.

4. The elimination of all forms of forces and compulsory labors.5. The effective abolition of child labor6. Eliminate discrimination.7. Business should support a precautionary to environmental changes.8. Undertake initiatives to promote grater environmentally responsibility.

9. Encourage the development and diffusion of environmentally friendlytechniques by joining the Global Compact , BHEL would get a unique

opportunity of networking with corporate and sharing experiences relatedto social responsibility on Global basis.

FUTURE PLANS

As a part of forward integration strategy the company plans to enter into

the power distribution business. The company already manufacturesproduct required by the distribution systems like transformers, switchgearsetc.

BHEL has announced that it will launch a B2B portal, keeping in mind itscore competency-power systems. As per the company announcement itcould take them four to six month to announce the location of its newbusiness. The company is planning towards becoming an applicationservice provider.


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The company will continue to focus on project management reducingcycle time and cost control. In the power sector, the company plans toobtain a part of the business generated by independent power producersthrough a combination of approaches including consortium route, equityparticipation and limited financial syndication. BHEL would also putadditional emphasis on spares and service business for hydro and thermalplants. BHEL is introducing a number of new products like 3-phasetraction electric and advance class gas turbines in the Indian market.

It is equipping it self with the new type of once-through design boilertechnology, and for pollution control-bag filter technology. BHEL isplanning to enter new business in integrated gasification combined cyclesystem, coal washeries and LRT systems. In its existing businesses of

transportation, transmission and industry. BHEL is pursuing opportunitiesin EMU coaches, loco refurbishment, gas-insulated switcher, HVDCinsulators and electronic meters.

The company will continue to focus on product development in order tofoster its growth strategy. New products are expected to contribute 46% ofits total turnover. The electronics division has frayed into traction businessand received a large order from Dot for switching equipment for 0.25mm

lines. The Industrial System Group has bagged orders from BWSSB forwater pumping stations (Cauvery Stage IV), funded by Japan Bank forinternational cooperation. The electro porcelains division is nowmanufacturing HVDC disk insulator and its catalytic converter has alsopassed the entire test.

Bharat Heavy Electricals Limited (BHEL) - SWOT Analysis

Bharat Heavy Electricals Limited (BHEL) - SWOT Analysis company

profile is the essential source for top-level company data and information.

Bharat Heavy Electricals Limited (BHEL) - SWOT Analysis examines the

companys key business structure and operations, history and products,

and provides summary analysis of its key revenue lines and strategy.

Bharat Heavy Electricals (BHEL) is an India-based engineering and


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manufacturing company that develops electrical and power equipment in

energy related and infrastructure sector. It manufactures over 180 products

under 30 major product groups and caters to sectors including power

generation and transmission, transportation, and renewable energy, among

others. The company operates in India. BHEL is headquartered in NewDelhi, India and employs over 45,200 people. The company recorded

revenues of INR264,914 million (approximately $5,780.4 million) during

the financial year ended March 2009 (FY2009). The operating profit of the

company was INR48,731.3 million (approximately $1,063.3 million)

during FY2009.

Scope of the Report

- Provides all the crucial information on Bharat Heavy Electricals Limited

(BHEL) required for business and competitor intelligence needs

- Contains a study of the major internal and external factors affecting

Bharat Heavy Electricals Limited (BHEL) in the form of a SWOT analysis

as well as a breakdown and examination of leading product revenue

streams of Bharat Heavy Electricals Limited (BHEL)-Data is supplemented with details on Bharat Heavy Electricals Limited

(BHEL) history, key executives, business description, locations and

subsidiaries as well as a list of products and services and the latest

available statement from Bharat Heavy Electricals Limited (BHEL)

Reasons to Purchase

- Support sales activities by understanding your customers businesses

better

- Qualify prospective partners and suppliers

- Keep fully up to date on your competitors business structure, strategy

and prospects

- Obtain the most up to date company information available


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SWOT ANALYSIS

STRENGTHS

The company has 180 products under 30 major product groups that cater

to the needs of the core sector like power, industry,transmission, defense,

telecommunication and oil business

BHELs ability to acquire modern technology and make it suitable to

Indian conditions has been an exceptional strength of the company

Quality

Cost Competitiveness

After sales services

Research and development

Global Presence

Relatively stable industrial relationshipAccess to contemporary technologies with the support from renowned

collaborators.

Sound engineering base and ability to assimilate

Ability to set up power plants on turnkey basis, complete know- how for

manufacture of entire equipment is available with the company.

Ability to manufacture or procure to supply spares.

Fully equipped to take capital maintenance and servicing of the power

plants.

Largest source of domestic business leading to major presence and

influence in the

market.


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Ability to successfully overhaul and renovate power stations equipment of

different

international companies.

Low labour cost.

WEAKNESSES

The company offers very stringent credit facilities to the customers and

this is a weakness when compared to in the face of rising competition

The company is vertically integrated, which could have been avoided by

outsourcing its components for power generation and transmission. Thiscould have reduced the cost.

Larger delivery cycles in comparison with international suppliers of

similar equipment.

Inability to provide suppliers credit, soft loans and financing of power

projects.

Due to poor financial position of state electricity boards, which are the

major customers

of BHEL in India, liquidity position of BHEL is not satisfactory.

Being a public sector company BHEL is suffering from sub optimality of

control due to:

1. Displacement of social objectives by political objectives, which may

lead to

redundant costs and also rising costs.2. Direct political intervention in managerial decision over an arm length

relationship that would restrict governments task of setting appropriate

managerial incentive structure.

3. Private goals that lead to budget growth and employment growth.

4. Internal inefficiencies in bureaucratic activity


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OPPORTUNITIES

The power sector reforms are expected to pick up in the near future in

India, which would directly benefit BHEL.

The business of modernization and renovation of power plants is expectedto grow in India.

The disinvestment plans of the government would bring in new resources

and experience into the company

Joint venture with Siemens in the name of POWERPLANT

PERFORMANCE IMPROVEMENT LTD.(PPIL), is a major strength for

the company. This tie up will be beneficial as there is a lot of scope forbusiness.

Demand for power and hence plant equipment is expected to grow.

Private sector power plants to offer expanded market as utilities suffers

resource crunch.

Ageing power plants would give rise to more spares and servicesbusiness.

Life expansion program for old power stations.

Easy processing of joint ventures/ collaboration/import/ acquisition of

new technology.

Financial and operational autonomy for profit making public sectorenterprises. To make the public sector more efficient government has

decided to grant enhanced autonomy and delegation of powers to the profit

making public sector enterprises


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THREATS

The global trend of consolidation has already resulted in a fall in turnover

of the company and this will prove to be a major threat in the years to

come as wellUnsatisfactory financial performances

Increased competition both national and international

Multilateral agencies reluctant to lend to power sector because of

poor financial management of S.E.Bs

More concessions to private sector and not to government ownedutilities like NTPC or S.E.Bs, so future power projects would be

opened up in private sector

Level playing ground not available, foreign companies spending

much more on business promotion tactics


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HYDRO TURBINESA leading engineering enterprise which supplies all types of equipment for hydropower generation.

A leading turbine manufacturer offering a wide range of Hydro Turbine, Valves,Governors, Turbine and Station Auxiliary systems, Balance of plants for HydroPower Station and related Services.

Installed manufacturing capacity:2500 MW/annum.

Two units manufacturing hydro turbines.

In the market for more than three decades.

Dedicated shop area of over 100000 sq. meters.

Ultramodern model development and testing facilities.

Sophisticated CAD/CAM facilities.

ISO 9001 Certification.

ASME "Q" stamp for fabrication facilities.

PELTON WHEEL (TURBINE)

The Pelton wheel is a tangential flowimpulse turbine. It was invented byLester

Allan Peltonin the 1870s.

The Pelton wheel extracts energy from theimpulseof moving water, as opposed toits weight.

The water strikes the bucket along the tangent of the runner.

Inlet Energy= KINETIC ENERGY

Outlet Energy=ROTATIONAL KINETIC ENERGY OF TURBINE+ KINETIC

ENERGY OF WATER

Used for HIGH HEADS
http://en.wikipedia.org/wiki/Impulse_turbinehttp://en.wikipedia.org/wiki/Impulse_turbinehttp://en.wikipedia.org/wiki/Impulse_turbinehttp://en.wikipedia.org/wiki/Lester_Allan_Peltonhttp://en.wikipedia.org/wiki/Lester_Allan_Peltonhttp://en.wikipedia.org/wiki/Lester_Allan_Peltonhttp://en.wikipedia.org/wiki/Lester_Allan_Peltonhttp://en.wikipedia.org/wiki/Impulse_(physics)http://en.wikipedia.org/wiki/Impulse_(physics)http://en.wikipedia.org/wiki/Impulse_(physics)http://en.wikipedia.org/wiki/Impulse_(physics)http://en.wikipedia.org/wiki/Lester_Allan_Peltonhttp://en.wikipedia.org/wiki/Lester_Allan_Peltonhttp://en.wikipedia.org/wiki/Impulse_turbine


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FUNCTION:

The water flows along the tangent to the path of the runner. Nozzles direct forcefulstreams of water against a series of spoon-shaped buckets mounted around the

edge of a wheel. As water flows into the bucket, the direction of the water velocity

changes to follow the contour of the bucket. When the water-jet contacts the

bucket, the water exerts pressure on the bucket and the water is decelerated as it

does a "u-turn" and flows out the other side of the bucket at low velocity. In the

process, the water's momentum is transferred to the turbine. This "impulse" does

workon the turbine. For maximum power and efficiency, the turbine system is

designed such that the water-jet velocity is twice the velocity of the bucket. A very

small percentage of the water's originalkinetic energywill still remain in the water;

however, this allows the bucket to be emptied at the same rate it is filled, (see

conservation of mass), thus allowing the water flow to continue uninterrupted. Often

two buckets are mounted side-by-side, thus splitting the water jet in half (see

photo). This balances the side-load forces on the wheel, and helps to ensure

smooth, efficient momentum transfer of the fluid jet to the turbine wheel.

Because water and most liquids are nearly incompressible, almost all of theavailable energy is extracted in the first stage of the hydraulic turbine. Therefore,

Pelton wheels have only one turbine stage, unlike gas turbines that operate withcompressible fluid.

MAIN PARTS OF PELTON TURBINE ARE:

1.Nozzle and flow regulating arrangement

2.Runners and buckets

3.Casing

4.Draft Tube

Design rules
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Thespecific speed of a turbine dictates the turbine's shape in a way that is notrelated to its size. This allows a new turbine design to be scaled from an existingdesign of known performance. The specific speed is also the main criterion formatching a specific hydro-electric site with the correct turbine type.

(dimensioned parameter), = rpmwhere:

= Power (kW)

= Water head (m)

The formula implies that the Pelton turbine is most suitable for applications withrelatively high hydraulic head H, due to the 5/4 exponent being greater than unity,and given the characteristically low specific speed of the Pelton.

DESIGN METHODOLOGY USED IN BHEL BHOPALThe Research and Development block of the Hydro Lab here in BHEL bhopal isdedicated for the development of the most efficient pelton turbines for futureprojects. This is done with the help of many powerful cloud computing andcomputer aided analyzing softwares like ANSYS, ICEM, CFX, TURBOGRID etc.

This not only helps in increasing the efficiency of the turbines but also helps thecompany to quote approximate and accurate tenders for future projects so as toearn maximum profit and provide best services.

TESTING METHODS:

BHEL, Bhopal has a dedicated HYDRO LAB for testing the models of the turbinesto be produced by the manufacturing units. Testing not only helps in predicting theefficiency of the prototype but also helps in knowing the changes required to bedone in the existing model so as to get maximum efficiency.

BHEL BHOPAL PELTON TURBINESPROJECTS

PROJECT RATING(No. X Mw)

HEAD(m)

SPEED(RPM) RUNNERDIAMETER

(mm)

Varahi 2 X 115 460 250 4500

Sharavathy 2 X 89 440 300 3680

Tilari 4 X 84 435 300 3680
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FRANCIS TURBINE

The Francis turbine is a type of Inward Flow Reaction Turbine having

radial discharge at outlet.

The Francis turbine is a type ofwater turbinethat was developed byJames B.

FrancisinLowell, Massachusetts.

In modern Francis turbines, the water enters the runner of the turbine in the radial

direction at outlet and leaves in the axial direction at the inlet of the runner.

Thus modern francis turbine is a Mixed flow reaction turbine.

Different Parts Of Francis Turbine

A francis turbine comprises mainly the following parts: 1)Spiral Casing 2)Guide orStay Vanes 3)Runner Blades 4)Draft Tube

Spiral Casing: The spiral casing around the runner of the turbine is known asvolute casing . All throughout it's length, it has numerous openings at regularintervals to allow the working fluid to impound on the blades of the runner. theseopenings convert the pressure energy of the fluid into momentum energy justbefore the fluid impound on the blades. to maintain a constant flow rate despite thefact that numerous openings have been provided for the fluid to gain entry to theblades,the cross-sectional area of this casing decreases uniformly along the

circumference.

Guide or Stay Vanes: The primary function of the guide or stay vanes is to convertthe pressure energy of the fluid into the momentum energy. it also serves to directthe flow at design angles to the blade runners.

Runner Blades:Runner blades are the heart of any turbine as these are thecenters where the fluid strikes and the tangential force of the impact causes theshaft of the turbine to rotate and hence electricity is produced. In this part one hasto be very careful about the blade angles at inlet and outlet as these are the majorparameters affecting the power production.
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Draft tube: The draft tube is a conduit which connects the runner exit to the tailrace where the water is being finally discharged from the turbine. The primaryfunction of the draft tube is to reduce the velocity of the discharged water tominimize the loss of kinetic energy at the outlet. This permits the turbine to be setabove the tail water without any appreciable drop of available head. The purpose ofproviding a draft tube will be better understood if we carefully study the netavailable head across a reaction turbine.

Theory of OperationThe Francis turbine is a type of reaction turbine, a category of turbine in which the

working fluid comes to the turbine under immense pressure and the energy is

extracted by the turbine blades from the working fluid. A part of the energy is given

up by the fluid because of pressure changes occuring in the blades of the turbine,


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quantified by the expression of Degree Of Reaction, while the remaining part of

the energy is extracted by the volute casing of the turbine. At the exit, water acts on

the spinning cup-shaped runner features, leaving at low velocity and low swirl with

very littlekineticorpotential energyleft. The turbine's exit tube is shaped to help

decelerate the water flow and recover the pressure.

CUT VIEW OF FRANCIS TURBINE(GUIDE VANES)

BHEL BHOPAL FRANCIS TURBINE

PROJECTS

PROJECT RATING(No. X Mw)

HEAD(m)

SPEED(RPM)

RUNNERDIAMETER

(mm)

SPIRALINLET (mm)

Dehar 6 X 165 320 300 3730 2600

Ranjit Sagar 4 X 150 100 166.7 4550 5000

Ranganadi 3 X 135 304 300 3850 2400

KAPLAN TURBINEThe Kaplan turbine is a propeller-typewater turbinewhich has adjustable blades.

It was developed in 1913 by the Austrian professorViktor Kaplan, who combined

automatically adjusted propeller blades with automatically adjusted wicket gates toachieve efficiency over a wide range of flow andwater level.

Kaplan turbines are widely used throughout the world for electrical powerproduction. They cover the lowest head hydro sites and are especially suited forhigh flow conditions.

Inexpensive micro turbines on the Kaplan turbine model are manufactured forindividual power production with as little as two feet of head.

For axial flow reaction turbine the shaft is vertical. The lower end of the shaft ismade larger which is known as hub or boss.

MAIN PARTS OF KAPLAN TURBINE ARE:

1.Scroll casing
http://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Potential_energyhttp://en.wikipedia.org/wiki/Potential_energyhttp://en.wikipedia.org/wiki/Potential_energyhttp://en.wikipedia.org/wiki/Water_turbinehttp://en.wikipedia.org/wiki/Water_turbinehttp://en.wikipedia.org/wiki/Water_turbinehttp://en.wikipedia.org/wiki/Viktor_Kaplanhttp://en.wikipedia.org/wiki/Viktor_Kaplanhttp://en.wikipedia.org/wiki/Viktor_Kaplanhttp://en.wikipedia.org/wiki/Hydraulic_headhttp://en.wikipedia.org/wiki/Hydraulic_headhttp://en.wikipedia.org/wiki/Hydraulic_headhttp://en.wikipedia.org/wiki/Hydraulic_headhttp://en.wikipedia.org/wiki/Viktor_Kaplanhttp://en.wikipedia.org/wiki/Water_turbinehttp://en.wikipedia.org/wiki/Potential_energyhttp://en.wikipedia.org/wiki/Kinetic_energy


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2.Guide vane mechanism

3.Hub with vanes or the runner of the turbine

4.Draft tube


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BHEL BHOPAL KAPLAN TURBINE

PROJECTSPROJECT RATING

(No. X Mw)HEAD

(m)SPEED(RP

M)RUNNER

DIAMETER(mm)

SPIRALINLET (mm)

S S Canal 5 X 50 36.0 136.4 4700 6200

UKAI 4 X 75 47.8 150 5650 6500

OBRA 3 X 33 20.4 115.4 5182 7982


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BUTTERFLY VALVESA Butterfly Valve is used to control the flow of material through a circular pipe

or tube. Typically the material is air, gas, steam, or liquid. Certain drymaterials may also be handled through a butterfly valve.

Simply, a butterfly valve consists of a circular disc with its pivot axis at rightangles to the direction material is flowing. The valve is made up of a body,seat, disc, stem, and actuator. Each component part is available in a variety ofmaterials called trim features. Properly combining trim features to addressmaterial handled and environment is important in selecting the correct modelvalve for its intended service.

Applications

As stated earlier, Butterfly Valves are generally specified for most air, gas,steam, and liquid applications. They offer an excellent, economically priced,positive shut-off valve for handling materials (e.g. gases and liquids) that areeasily displaced by the valve disc as it closes. When handling this type ofmaterial, butterfly valves provide a reliable, bubble-tight, bi-directional shutoff.

Care must be taken when applying a butterfly valve in semi-abrasive orabrasive dry material applications (this includes slurry applications that containsuspended particles because:1) A valve disc closing on dry bulk material will create premature wear to therubber seat.

2) The obstructed orifice created by the disc may cause bridging of material onthe inlet side of the valve.

3) A disc opening or closing on a standing column of dry material may causethe material to jam / pack.

4) Particles of dry material or suspended particles in slurries may becometrapped between the disc and seat, causing conveying line inefficiencies.

Other Types of Butterfly Valves

As a person becomes familiar with butterfly valves, they will undoubtedlydiscover other types of butterfly valves on the market. Listed below is a briefintroduction to some of these other types.

Inflatable Seated Butterfly Valves


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Inflatable seated butterfly valves utilize an inflatable seat or bladder to createa seal around the disc. Once the disc is brought to the closed position, thebladder is inflated pneumatically.

Pros:1) Since the seal is created after the disc closes, less torque is required to

move the disc into the closed position. A smaller sized actuator costing lessmoney is can be used.

2) Again, because the seal is created after the disc closes, minimal abrasionexists between the disc and the seat.

Cons:1) In addition to the controls needed to verify the position of the disc,additional controls are needed to identify whether the bladder is inflated ornot. These controls add cost to the valve.

2) The bladder may be damaged and not creating a seal, even though controlsidentify that a seal has been established.

3) The valve must be located near an air supply to pneumatically inflate thebladder.

4) The inflatable bladder is subject to damage and abrasion, requiring periodicreplacement.

BHEL BHOPAL BUTTERFLY VALVESPROJECTS

PROJECT VALVE DIAMETER(mm)

MAX. HEAD(m)

DOOR TYPE

Balimela 2 X 115 460 LENS

Ranjit Nagar 2 X 89 440 LATTICE

Srisailam 4 X 84 435 LATTICE


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HEAT EXCHANGERS

Thermal group of BHEL-Bhopal was formulated in year1968 (Initial collaborationwith M/s AEI -U.K. took place in year 1970) and started its production from year

1971 onwards. Subsequently, new collaboration agreement with M/s BALCKEDURR- Germany for Moisture Separator Re-Heater (MSR) took place in 1987.MSR to this new design were manufactured and supplied for 236 MW RAPP 3, 4 &KAIGA 1, 2 and 500 MW TAPP 3&4 Nuclear plants.

BHEL-Bhopal Thermal group products manufactured and supplied all over India todifferent State Electricity Boards and exported to countries like LIBYA, Malaysia,Azerbaizan, Bangladesh, OMAN etc. major customers of thermal equipments areState Electricity Boards and NTPC. Similarly Industrial Heat Exchangers have beensupplied to IFFCO, FEDO, RELIANCE, GAIL, ONGC, IOCL, etc. Production ofsome of the other products like Rubber Expansion Joints, Flash Tanks,Miscellaneous storage tanks and Butterfly valves added in subsequent years.

All the Thermal products are tailor made and customer specific product. andCustomer requirements are continuously captured through pre-tender and posttender discussions, contract review etc. Perception is collected through customersurveys.

Thermal group products are Technology intensive and therefore Technology

development is of strategic importance. Product technology is continuouslyupgraded through in house development projects/ or Technical Collaboration.

Heat Exchanger

Auxiliary Heat Exchangers

Different types of auxiliary heat exchangers are being manufactured at BHEL.Depending upon application these auxiliary Heat Exchangers are named as

.Air Coolers (CACW)

. Oil Coolers (Shell & tube type / Frame and tube type (Single tube & Concentricdouble tube construction) / OFAF), Plug in type. Water Water Cooler (Shell & Tube type). Hydrogen Cooler etc. (Frame and tube type).. Air Cooler CACA ( Duct and tube type)These coolers are accessories to main equipments such as Generator, Turbine,Transformer , Motors, etc. hence special attention is given to make these coolerscompact in design and for trouble free service.

To ensure long life of these coolers materials for different components is decidedcarefully considering its application and water chemistry. Constructionally thesecoolers are very easy to maintain.


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Technical Information/Application

Air coolers, Oil coolers, Water-Water coolers and Hydrogen Coolers act asaccessories to Transformers, turbines, Motors and Generators, etc.

In Generator, Air Coolers are used to cool the generator air which is a closed circuitair of maintained humidity and which in turn cools winding of stator. In turbine, oilcoolers are used to cool bearing oil or the oil which in turn cools the rotating parts.Similarly, Transformer Coolers are used to cool transformer oil by air or water.These coolers play an important role in smooth functioning of the main equipments.CACW type and CACA type air coolers are also used for cooling air, which in turncools motor windings.

Industrial Heat Exchangers

Industrial Heat Exchangers, as the name implies are used in industries dealingin various types of chemicals. In general Heat Exchangers used are of shell andtube type construction. Main components of shell and tube type heat exchangersare tube nest assembly; shell assembly and types of enclosure i.e. end closing.

BHEL is manufacturing different types of shell and tube type heat exchangers forIndustries like Refineries , Petrochemicals and Fertilizers, etc. Since differenttype of chemicals is involved in Industrial Heat Exchangers, material selectionbecomes an important criteria.

BHEL is capable of doing special types of mechanical design apartfrom normal design of shell, tubes , dished ends ,flat covers, backing ring andflanges etc. Special type of mechanical design covers design ofeccentric/concentric types of shell i.e. kettle type construction , reverse flange typedesign, fixed tube sheet with bellows, high pressure enclosures , and doublepipe type heat exchangers.

BHEL is having a vast experience of manufacturing and supply of Heat

Exchangers with Carbon steel , stainless steel, Alloy Steel and Non-ferrous tubesand shell materials. In addition to the type as mentioned earlier , CladdedExchangers also have been supplied by BHEL. Various types of constructionalfeatures as described in TUBULAR EXCHANGER MANUFACTURERSASSOCIATED (TEMA) Standardcan be offered by BHEL.

Feed Water Heaters


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BHEL is manufacturing feed water heaters for power stations of Unit Rating up-to250 MW Thermal Power Project since more than last 25 years. Feed water heaters(both High pressure and Low pressure) are used in feed heating system ofregeneration cycle by heating feed water by steam extracted from suitable stagesof turbine. Over the years design and technological developments took place and atpresent feed heaters with stainless steel tube materials are being used for longerlife expectancy. Both Horizontal and vertical type of heaters are manufactured withhighest standard of engineering to provide reliability in operation. Feed waterheaters are designed as per HEI standard and high pressure heaters comes underpurview of Indian Boiler Regulations. Hence these are designed and manufacturedin strict compliance to applicable code requirements.

Technical Information/Application

- The high pressure & Low pressure feed water heaters are employed to increasethe overall efficiency of the regenerative cycle by heating the feed water by thesteam extracted from suitable stages of the turbine.- The feed water passes through the 'U' tubes and the steam/drain (condensedsteam) passed over the tubes. These heaters are located in feed water heatingcycle and feed water going to boilers is heated with steam extracted from differentstages of turbine resulting in saving of energy and increased efficiency. Feedheaters play a vital role in power plant. The heaters are, therefore, subjected tovery onerous duty and hence the design and manufacture of both type of heaters,i.e. High Pressure heaters and Low pressure feed water heaters complies with thehighest standard of engineering to provide adequate reliability in the operation of

these heaters. Both High pressure & Low pressure feed water heaters come underpurview of Indian Boiler Regulation hence compile with all code requirements.

Moisture Separator Re-heater (MSR)

In Nuclear Turbines the Moisture separator re-heater is a thermo-hydraulic

junction where two-phase (steam/ water) flows interact, while separating the high

energy phases and exchanging heat.


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STEAM TURBINE

A steamturbineis a device that extractsthermal energyfrom pressurizedsteam

and uses it to domechanical workon a rotating output shaft. Its modernmanifestation was invented bySir Charles Parsonsin 1884.

Because the turbine generatesrotary motion, it is particularly suited to be used todrive anelectrical generator

The steam turbine is a form ofheat enginethat derives much of its improvement inthermodynamic efficiencythrough the use of multiple stages in the expansion of thesteam, which results in a closer approach to the most efficientreversible process.

Steam supply and exhaust conditions

These types include condensing, non-condensing, reheat, extraction and induction.
http://en.wikipedia.org/wiki/Turbinehttp://en.wikipedia.org/wiki/Turbinehttp://en.wikipedia.org/wiki/Turbinehttp://en.wikipedia.org/wiki/Thermal_energyhttp://en.wikipedia.org/wiki/Thermal_energyhttp://en.wikipedia.org/wiki/Thermal_energyhttp://en.wikipedia.org/wiki/Steamhttp://en.wikipedia.org/wiki/Steamhttp://en.wikipedia.org/wiki/Steamhttp://en.wikipedia.org/wiki/Work_(physics)http://en.wikipedia.org/wiki/Work_(physics)http://en.wikipedia.org/wiki/Work_(physics)http://en.wikipedia.org/wiki/Charles_Algernon_Parsonshttp://en.wikipedia.org/wiki/Charles_Algernon_Parsonshttp://en.wikipedia.org/wiki/Charles_Algernon_Parsonshttp://en.wikipedia.org/wiki/Rotational_motionhttp://en.wikipedia.org/wiki/Rotational_motionhttp://en.wikipedia.org/wiki/Rotational_motionhttp://en.wikipedia.org/wiki/Electric_generatorhttp://en.wikipedia.org/wiki/Electric_generatorhttp://en.wikipedia.org/wiki/Electric_generatorhttp://en.wikipedia.org/wiki/Heat_enginehttp://en.wikipedia.org/wiki/Heat_enginehttp://en.wikipedia.org/wiki/Heat_enginehttp://en.wikipedia.org/wiki/Thermodynamic_efficiencyhttp://en.wikipedia.org/wiki/Thermodynamic_efficiencyhttp://en.wikipedia.org/wiki/Reversible_process_(thermodynamics)http://en.wikipedia.org/wiki/Reversible_process_(thermodynamics)http://en.wikipedia.org/wiki/Reversible_process_(thermodynamics)http://en.wikipedia.org/wiki/Reversible_process_(thermodynamics)http://en.wikipedia.org/wiki/Thermodynamic_efficiencyhttp://en.wikipedia.org/wiki/Heat_enginehttp://en.wikipedia.org/wiki/Electric_generatorhttp://en.wikipedia.org/wiki/Rotational_motionhttp://en.wikipedia.org/wiki/Charles_Algernon_Parsonshttp://en.wikipedia.org/wiki/Work_(physics)http://en.wikipedia.org/wiki/Steamhttp://en.wikipedia.org/wiki/Thermal_energyhttp://en.wikipedia.org/wiki/Turbine


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Non-condensing or back pressure turbines are most widely used for process steamapplications. The exhaust pressure is controlled by a regulating valve to suit theneeds of the process steam pressure. These are commonly found at refineries,district heating units, pulp and paper plants, anddesalinationfacilities wherelarge amounts of low pressure process steam are available.

REHEAT TURBINESReheat turbines are also used almost exclusively in electrical power plants. In areheat turbine, steam flow exits from a high pressure section of the turbine and isreturned to the boiler where additional superheat is added. The steam then goesback into an intermediate pressure section of the turbine and continues itsexpansion. Using reheat in a cycle increases the work output from the turbine andalso the expansion reaches conclusion before the steam condenses, there byminimizing the erosion of the blades in last rows. In most of the cases, maximumnumber of reheats employed in a cycle is 2 as the cost of superheating the steamnegates the increase in the work output from turbine.

Extracting type turbines are common in all applications. In an extracting typeturbine, steam is released from various stages of the turbine, and used for industrialprocess needs or sent to boilerfeed water heatersto improve overall cycleefficiency. Extraction flows may be controlled with a valve, or left uncontrolled.

Induction turbines introduce low pressure steam at an intermediate stage toproduce additional power.

Casing or shaft arrangements

These arrangements include single casing, tandem compound and crosscompound turbines. Single casing units are the most basic style where a singlecasing and shaft are coupled to a generator. Tandem compound are used wheretwo or more casings are directly coupled together to drive a single generator. Across compound turbine arrangement features two or more shafts not in line drivingtwo or more generators that often operate at different speeds. A cross compound

turbine is typically used for many large applications.

Two-flow rotors
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A two-flow turbine rotor. The steam enters in the middle of the shaft, and exits at each end,balancing the axial force.

The moving steam imparts both a tangential and axial thrust on the turbine shaft,but the axial thrust in a simple turbine is unopposed. To maintain the correct rotorposition and balancing, this force must be counteracted by an opposing force.Eitherthrust bearingscan be used for the shaft bearings, or the rotor can bedesigned so that the steam enters in the middle of the shaft and exits at both ends.The blades in each half face opposite ways, so that the axial forces negate each

other but the tangential forces act together. This design of rotor is called two-flowor double-exhaust. This arrangement is common in low-pressure casings of acompound turbine.

BHEL BHOPAL STEAM TURBINE PROJECTS

Turbines

1) Design, Manufacturing, Erection, Commissioning and Services of :

30 MW, 120 MW Steam Turbines

236 MW Nuclear Turbines.

15000 SHP Marine Turbines

210 MW Steam Turbines.

2) Supply of Spares and Repairs of above Steam Turbines.
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3) R & M and Life assessment studies of BHEL & Non BHEL TG sets.

4) Repair and Supply of Spares of 210 MW and 500 MW KWU Turbines.

5) Repair and supply of Spares for Non BHEL TG Sets.

TECHNICAL SPECIFICATION OF 210 MW STEAM TURBINE

SL.NO DESCRIPTION PARAMETER

1 RATEDCAPACITY

210 MW

2 PRESSUREAT STOPVALVE

150 KG/CM2

3 TEMPERATU

RE AT STOPVALVE

535 C

4 MAX. STEAMFLOW AT S.V

641 TONNES /HR

5 REHEAT/NONREHEAT

REHEAT

6 TYPE OFGOVERNING

THROTTLE CONTROL

7 TURBINE

SPEED

3000 RPM


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8 EXHAUSTPRESSURE

76 MM HG.ABS

9 NUMBER OFCYLINDERS

H.P-1,DOUBLE FLOW IP-1,DOUBLE FLOW LP-1

10 NUMBER OF

STAGES

HP-25, IP-20 +20,LP-8+8

11 HEIGHT OFLAST STAGEBLADE

676 MM

12 LASTSTEAGEMEAN DIA

2132 MM

13 SPECIALFEATURE

-DOUBLE SHELL HP WITH BARREL TYPEOUTER SHELL - DOUBLE SHELL DOUBLE FLOW

IP - HYDRAULIC BARRING - ELECTRO-HYDRAULIC GOVERNING

14 WEIGHT OFTURBINE

425 TONNES

15 LENGTH OFTURBINE

14.1 METERS

16 TYPE OFTURBINE REACTION

17 COLLABORATOR

SIEMENS, GERMANY


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HYDRO GENERATORS

FACILITIES AT BHEL BHOPALFabricationfacilities

Special types of welding

- Submerged Arc

- Electro slag

- Narrow Gap

- TIG

3000 T shell bending press

Electronic flame cutting machine

Stress relieving furnace

Shot blasting chamber

NDT test facilities

- Dye penetrant

- Magnetic particle

- Ultrasonic

- Radiographic

Machiningfacilities

Rotating Column Vertical Borer:Max. Job dia 16 mtrs -Ht 4mtrs

Vertical Borer (HOMMA):Max. job dia 9 mtrs - Ht 4mtrsHorizontal Ram Borer:Max. travel Vert. 4.15 mtrs. -Horiz 19mtrsHorizontal Planning Machine:Bed Length 9 mtrs. -Ht 3 mtrs.

Centre Lathe:Max. Job dia 4 mtrs. -Length 15 mtrs


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Blanking/Varnishingfacilities

250T blanking line

1600T hydraulic press

500/300T hydraulic press

Deburring machine

Spot welding machine

Automatic varnishing plant

Coilmanufacturing facilities

Automatic cleaning and cutting machine

Hydraulic coil pulling machine

Hydraulic press for consolidation of stator coils

1000T press for consolidation of field coils

Air conditioned room for taping

Testing Complete assembly of generators

Performance test consisting of- Characteristic curves - Temperature rise efficiency - 3-phasesudden short circuit test

STATOR HYDRO GENERATOR COILS ASSEMBLY AFTER INSULATION


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PHOSPHATE COATING

Phosphate coatings are used onsteelparts forcorrosionresistance,lubricity, oras a foundation for subsequent coatings or painting.[1][2] It serves as aconversion

coatingin which a dilute solution of phosphoric acid and phosphate salts is appliedvia spraying or immersion and chemically reacts with the surface of the part beingcoated to form a layer of insoluble, crystalline phosphates.[3] Phosphate conversioncoatings can also be used on aluminium, zinc, cadmium, silver and tin.

The application of phosphate coatings makes use ofphosphoric acidand takesadvantage of the low solubility of phosphates in medium or high pH solutions. Iron,zinc or manganese phosphate salts are dissolved in a solution of phosphoricacid.[6] When steel or iron parts are placed in the phosphoric acid, a classicacid

andmetalreaction takes place which locally depletes thehydronium(H3O+) ions,raising the pH, and causing the dissolved salt to fall out of solution and beprecipitated on the surface. The acid and metal reaction also createsironphosphatelocally which may also be deposited. In the case of depositingzincphosphateormanganese phosphatethe additional iron phosphate is frequently anundesirable addition to the coating.

The acid and metal reaction also generateshydrogengas in the form of tinybubbles that adhere to the surface of the metal. These prevent the acid fromreaching the metal surface and slows down the reaction. To overcome thissodiumnitriteis frequently added to act as anoxidizing agentthat reacts with the hydrogento form water. This chemistry is known as a nitrate accelerated solution. Hydrogenis prevented from forming a passivating layer on the surface by the oxidant additive.

The following is a typical phosphating procedure:[3]

1. cleaning the surface

2. rinsing

3. surface activation (in some cases)

4. phosphating

5. rinsing

6. neutralizing rinse (optional)7. drying

8. application of supplemental coatings: lubricants, sealers, oil, etc.
http://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Corrosionhttp://en.wikipedia.org/wiki/Corrosionhttp://en.wikipedia.org/wiki/Corrosionhttp://en.wikipedia.org/wiki/Lubricationhttp://en.wikipedia.org/wiki/Lubricationhttp://en.wikipedia.org/wiki/Lubricationhttp://en.wikipedia.org/wiki/Conversion_coatinghttp://en.wikipedia.org/wiki/Conversion_coatinghttp://en.wikipedia.org/wiki/Conversion_coatinghttp://en.wikipedia.org/wiki/Conversion_coatinghttp://en.wikipedia.org/wiki/Phosphoric_acidhttp://en.wikipedia.org/wiki/Phosphoric_acidhttp://en.wikipedia.org/wiki/Phosphoric_acidhttp://en.wikipedia.org/wiki/Acidhttp://en.wikipedia.org/wiki/Acidhttp://en.wikipedia.org/wiki/Acidhttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Hydroniumhttp://en.wikipedia.org/wiki/Hydroniumhttp://en.wikipedia.org/wiki/Hydroniumhttp://en.wikipedia.org/wiki/Iron_phosphatehttp://en.wikipedia.org/wiki/Iron_phosphatehttp://en.wikipedia.org/wiki/Iron_phosphatehttp://en.wikipedia.org/wiki/Iron_phosphatehttp://en.wikipedia.org/wiki/Zinc_phosphatehttp://en.wikipedia.org/wiki/Zinc_phosphatehttp://en.wikipedia.org/wiki/Zinc_phosphatehttp://en.wikipedia.org/wiki/Zinc_phosphatehttp://en.wikipedia.org/w/index.php?title=Manganese_phosphate&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Manganese_phosphate&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Manganese_phosphate&action=edit&redlink=1http://en.wikipedia.org/wiki/Hydrogenhttp://en.wikipedia.org/wiki/Hydrogenhttp://en.wikipedia.org/wiki/Hydrogenhttp://en.wikipedia.org/wiki/Sodium_nitritehttp://en.wikipedia.org/wiki/Sodium_nitritehttp://en.wikipedia.org/wiki/Sodium_nitritehttp://en.wikipedia.org/wiki/Sodium_nitritehttp://en.wikipedia.org/wiki/Oxidizing_agenthttp://en.wikipedia.org/wiki/Oxidizing_agenthttp://en.wikipedia.org/wiki/Oxidizing_agenthttp://en.wikipedia.org/wiki/Oxidizing_agenthttp://en.wikipedia.org/wiki/Sodium_nitritehttp://en.wikipedia.org/wiki/Sodium_nitritehttp://en.wikipedia.org/wiki/Hydrogenhttp://en.wikipedia.org/w/index.php?title=Manganese_phosphate&action=edit&redlink=1http://en.wikipedia.org/wiki/Zinc_phosphatehttp://en.wikipedia.org/wiki/Zinc_phosphatehttp://en.wikipedia.org/wiki/Iron_phosphatehttp://en.wikipedia.org/wiki/Iron_phosphatehttp://en.wikipedia.org/wiki/Hydroniumhttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Acidhttp://en.wikipedia.org/wiki/Phosphoric_acidhttp://en.wikipedia.org/wiki/Conversion_coatinghttp://en.wikipedia.org/wiki/Conversion_coatinghttp://en.wikipedia.org/wiki/Lubricationhttp://en.wikipedia.org/wiki/Corrosionhttp://en.wikipedia.org/wiki/Steel


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PHOSPHATING5-10 MINS

TEMP. 55-90 DEGREE. CELSIUS

DERUSTING8-10 MINS


RINSING10-12 MINS


PICKLING10-12 MINS

TEMP. 60-70 DEGREE. CELSIUSCONC. 50-60 gm/liters

RINSING10-12 MINS


DEGREASING10-42 MINS

TEMP. 70-80 DEGREE. CELSIUSCONC. 75-80 m/liters CAUSTIC SODA


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BIBLIOGRAPHY

1. BHEL Manual

2. www.google.com

3.www.wikipedia.org

4. BHEL Diary 2008

5.www.bhel.com
http://www.google.com/http://www.wikipedia.org/http://www.bhel.com/http://www.bhel.com/http://www.wikipedia.org/http://www.google.com/

bhel report final

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