training report on bhel

7/29/2019 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

62

training report on bhel

Documents