ACKNOWLEDGEMENTIt 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, deep rooted interest, inspiration and continuous encouragement through out my vocational training which helped me to learn about the company’s working and to complete my training. I am also thankful to Mr. G.K. Srinivasa and Mr. Nisar Haidar for their guidance through out the period. I also want 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 1 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 2 HYDRO GENERATORS.....................................................................44 TECH. SPECIFICATIONS OF 210 MW STEAM TURBINE.......45 FACILITIES AT BHEL BHOPAL FOR COIL INSULATIONS........47 PHOSPHATING AND POWDER COATING ..................49 Bibliography................................................................................. 51 3 INTRODUCTION TO BHEL BHEL is the largest engineering and manufacturing enterprise in India in the energy related/infrastructure sector today. BHEL was established more than 40 years ago ushering in the indigenous heavy electrical industry in India, a dream that have been more than realized with a well recognized track record of performance. It has been earning profiles continuously since 1971-72 and paying dividends since 1976-77. BHEL manufactures over 180 products under 30 major product groups and caters to core sectors of the Indian economy viz., power generation and transmission, industry, transport, telecommunication, renewable energy etc. The wide network of BHEL, 14 manufacturing divisions, four power sector reginiol centers over 100 project sites.it services its customers and provides them with suitable product, system and services efficiently and at competitive prices. THE QUALITY AND RELIABILITY OF ITS PRODUCTS DUE TO EMPHASIS ON DESIGN, engineering and manufacturing to international standards by acquiring and adapting some of the best technologies from leading companies in the world, together with technologies developed in its own R& D centers. BHEL has acquired certification to quality management system ISO 9001:2000 environmental management system ISO 14001 and occupational health and safety management system OHSAS 18001 and has also adopted the concepts of total quality management. BHEL HAS:1. Installed equipment for over 1, 15,356 MW of power generation for utilities, captive and industrial users. 2. Supplied over 2, 25,000 MW transformer capacities and sustained equipment operating in transmission and distribution network up to 400 KC-AC and DC. 3. Supplied over 25,000 motors with drive control system to power projects, petrochemicals, refiners, steel, aluminum fertilizer, cement plants etc. 4 4. Supplied traction electrics and AC/DC locos to power over 12000 km railway network. 5. Supplied over one million valves to power plants. BHEL’S operations are organized around three business sectors, namely power industry including transmission, transportation, telecommunication and renewable energy and overseas business .this enables BHEL to have a strong customer orientation to be sensitive to his needs and respond quickly to the changes in the market. BHEL’S vision is to become a world class engineering enterprise, committed to enhance stakeholder value. The company is striving to give shape to its aspirations and fulfill the expectations as a ‘MAHARATNA’ company since February 2013. The greatest strength of BHEL is highly skilled and committed 44,000 employees. Every employee is given equal opportunity to develop himself and improve his position. Continuous training and retraining, career planning, a positive work culture and participative style of management have endeared development of a committed and motivated work force leading to enhanced productivity and higher levels of quality. BHEL manufactures a wide range of products and systems for thermal nuclear gas and hydro based power plant to meet the customer’s requirement for power generation, transmission and utilization. The products that BHEL manufacture are described below. THERMAL BHEL manufactures steam turbine generators and boilers with matching auxiliaries up to 500 MW. NUCLEAR In this field BHEL manufactures steam turbines and generators and shields and heat exchange for 235 MW projects. 5 steel cement and mining industries as well as a wide range of industrial ceramics. pelton and Kaplan type turbine. The maximum size of hydro equipment already built and installed is 265 MW. HYDRO BHEL engineers and manufactures has built francis. 6 . SF 6 switching gears cape electric citers etc for economic transmission of bulk power over long distances.GAS BHEL is the only company to manufacture large sized gas based power plant equipment comprising turbines up to 200 MW. instrument transformers. These include high voltage power and distribution transformers. TRANSMISSION BHEL supply a wide range of transmission products and systems up to 400 KV. R & D projects for the development of equipment for 800 KV class are progressing a pace resistance high alumina ceramic line material of power. dry type transformers. High voltage direct current (HVDC) technology is now available. pump turbines and minor-micro hydro plants with matching generators for different head discharge combination. MISSION To be an Indian multinational engineering enterprise providing total business solutions through quality products. transportation.VISION. infrastructure and other potential area. : Integrity and fairness in all matters. industry. systems and services in the field of energy. MISSION & VALUES OF BHEL AT A GLANCE VISION A world class engineering enterprise committed to enhancing stakeholders value. VALUES : Zeal to excel and zest for change. 7 . BHEL is organized along three Business Sectors. Commissioning and service after sales. 8 . Presently. utility and industrial sets totaling to over 50. The product Range of BHEL encompasses power generating equipment.000 MW equivalent generating capacity. : Strict adherence commitment. Industry and International Operations. BHEL’s share in utility generating capacity was approximately 64% of the installed capacity in India in March 1993. : Loyalty and pride in the company. (BHEL). The main activities of Business Sector are marketing.000 qualified engineers. The company was set up in the year 1956 with a view to reach self-sufficiency in Power and Industrial products vital for the industrialization of India. Erection.000 including technicians.25 billion during the year 1992-1993. BHEL major manufacturing divisions have already received accreditation to ISO 9001/9002 BHEL has enjoyed an impressive growth record since its inception and registered a turnover of approximately us$1. skilled workers and about 9. : Ensure speed of response. viz. creativity and teamwork. BHEL has capacity to supply power equipment equivalent to 7000 MW per year. Power.: Respect for dignity and potential of individuals. a company with majority share holding by the government of its kind in India and is among the 12 leading equipment manufacturers in the world. : Foster learning. The company has a workforce of 44. electrical traction equipment and urban transport systems. POWER BHEL has commissioned more than 800 Nos. electrical and thermos mechanical equipment for industrial applications. BHEL today has 13 manufacturing plants and host of service divisions and around 200 projects sites. Project Engineering. BHARAT HEAVY ELECTRICALS LIMITED AN OVERVIEW Bharat heavy Electrical Limited. the company has perform to stay abreast with the technology leaders in the world. BHEL has commissioned mire than 200 Hydro Sets of various types and capacities tattling to about 12000 MW. Research. Operating in an environment of high technology and severe competition as BHEL does. Solar and Wind Power have already resulted in commercial ventures. Both these collaboration covered unit ratings up to 1000 MW. geographic & climatic requirement. another two 9 . The company has also a full-fledged Research and Development Division which undertake fundamental and applied research in power and related fields. It is in recognition of such imperatives that BHEL has technology tie-ups around the world for a variety of power station auxiliaries as well.(A) Thermal Generation: The unit sizes of utility stations in India range from 30 MW to 500 MW BHEL has so for being responsible for over 2000 of these installations accounting for over 40000 MW of installed generating capacity (utility) which include sets up to 500 MW capacity. BHEL has facilities to manufacture and install sets of even higher rating as per specific customer requirements. adapt and modify such acquired technology to suit differing economic. is being carried out on non-conventional energy sources as well. Several of these efforts such as those in the areas of fluidized Bed Combustion. (B) Hydro Generation: BHEL has supplied Hydro Sets upto 165 MW rating and 200 MW sets are under manufacture. Subsequently. (C) Nuclear Generation: India’s first wholly indigenous Atomic Power plant at Kalapakkam near Madras is equipped with two sets of power generation equipment of rating 235 MW each supplied by BHEL. It also supplies turbines for low head mini and micro hydro stations to meet the needs of rural and backward areas located in the remote corners of the country. BHEL manufactures steam generator as per technology of M/S ABB Combustion Engineering of the USA. The technology for manufacture of turbo generators comes from a comprehensive technical calibration agreement with Scienes AG of Germany. This technology has been acquired through 20 years of collaboration/license agreement. developmental. So far. BHEL has a well chalked out programmed to assimilate. USA for the Waste Heat Recovery Boilers. 10 . voltage transformers switches.. The Siemens agreement covers unit rating from 130 MW to 200 MW. While the gas turbines of GE/USA design are supplied from Hyderabad plant.e. BHEL has bagged orders for two gas turbine based projects in Malaysia. BHEL supplies a variety of equipment for transmission and utilization of power. (E) Transmission: In addition to equipment for generating of power. BHEL is supplying WHRSGS foe 6X30 MW gas turbines for Delhi electric supply undertaking. (D)Gas Turbines based generators plants: Today BHEL is fully equipped to supply simple/confined cycle/cozen plants with various frame sizes of gas turbines of unit rating upto 200 MW. The company has also undertaken a number of turnkey sub-station contracts for voltage rating up to 400 kv class.10 months. USA and Siemens AG. The agreement with GE. BHEL has collaboration agreements with two leaders of has turbines technology in the world namely general electric. Germany.sets of similar rating have been commissioned successfully at Narora. USA covers rating from 4. commissioning schedule of 6. BHEL is now manufacturing sets of 500 MW rating for nuclear power stations. The first project has already been commissioning in 6 months time. BHEL have an ongoing collaboration agreement with M/S Henry volt. USA technology. BHEL has in house capability to supply most of the equipment like power transformer current transformer. Hyderabad and Hard war) are fully equipped with state of manufacturing and testing facilities. With the plants (i. Has a turbine. BHEL is fully equipped to supply waste heat recovery boilers from their Tiruchirapalli plant. and also possesses in house modern testing facilities. All these turbines have been supplied from our Hyderabad plant based on general electric. and 817 MW Dadri Project of national thermal power corporation limited besides those for other power stations. So far BHEL has supplied more than 33 nos.6 MW (ISO). insulators etc. Keeping with the KM long HVDC (High voltage direct current) transmission line project line for reliable and efficient transmission of bulk power. Rectifiers.C. (G) Transportation: For over quarter of a century. Today. Malaysia.Billions of BHEL manufactured insulators of various ratings upto 160 KN are satisfactory service in many countries namely Turkey. Switcher.1000 technicians and 1300 skilled workers besides construction equipment valued at over 40 million US Dollars. traction generators/alternators. With over 500 engineers and supporting staff. Capacitors. The company has lately moved from the position of supplier of electrics only to supplier of complete locomotives -both diesels electric as well as A. Control Gear. 65% of the rolling stock in Indian contains electric of BHEL make such as traction motors. This division well organized with over 500 experienced engineers. and transformers. this division offers specialized service in different technical disciplines and undertakes engineering works relating to optimization of cycle configuration selections of parameters and design of suitable system for power stations with a total MW capacity of 30000 and is currently involved in several turnkey project including stations having 500 MW unit size. Egypt. Insulators. 11 . USA Libya. Industrial turbines oilrig’s and semiconductor devices to meet the varying needs of industry. Motors. which is the third largest Railway network in the world. Piping. The urban transportation problem demands different solutions and BHEL’s contribution extends to underground tube. Tanzania Dubai and course India. (F) Industry: The industry Sector of BHEL offers diverse items such as Transformers. Iran. b) Constructions Management: BHEL has a full-fledged construction management division to undertake erection work. Valves Compressors. Locos. Pumps. Iraq. light rail and battery powered road vehicles (H) Services (a) Project Engineering: The total engineering for thermal power stations is undertaken by a core group project engineering management. BHEL has been supplying drives and control for traction equipment mainly to the Indian Railway. HUMAN RESOURCE MANAGEMENT 1. supervises and control all activities that are necessary for the performance of the project right from the conception stage until the contractual obligations are fully discharged. 2002. 12 . Thrust to develop and nurture the participative culture in the Company continued during the current year also. directs coordinates. oil & gas telecommunication etc. The elections of the Unions through secret ballot at various Manufacturing and Service Divisions for representation at the apex level Joint Committee were held in July. deseeds supply of non-conventional energy systems. Renovation modernization and rehabilitation works of aged power stations are also undertaken. transportation. d) Projects Management: The project management division of BHEL coordinates th4 entire range of BHEL activities in relation to thermal power plant project and is responsible to the purchasing organization for compliance of the specifications. Subsequently. BHEL has a separate spare group response for insuring ready availability of essential spares to Power stations.c) Service After sales: BHEL extends its supply and construction scope with service such as commissioning field engineering performance monitoring trouble shooting operation and maintenance. It has also embarked it to other areas including defense & aviation. a seminar for the orientation of new members of the reconstituted Joint Committee and familiarization with the issues related to the Company was held at Hyderabad for 2 days in October. BHEL offers a wide spectrum of products and services for core sectors like power transmission industry. Joint Committee for BHEL was reconstituted. Entrusted with the overall coordination of the project the division initiates. 2002. Accordingly. Industrial Relations The Industrial Relations at various Units and service divisions of the Company were harmonious and cordial during the year under report. The Samman is at the unit level for employees who do not claim any medical reimbursement for self and also do not avail any leave on account of sickness in the previous financial year. The first such awards were presented for 2000-01 on 13th January. each valuing up to Rs. 1.A two days' workshop was also conducted in November. BHEL Srijanatmakta Puraskar 8. BHEL Excel Awards Inspired by the ideal of 'Yoga Karmasu Kaushalam'. BHEL Paryavaran/Samaj Seva/Sanskriti/Khel Puraskar While the first eight awards are for the company employees only. The Scheme also stipulates Swasth Karamchari Samman which are given to employees in appreciation of good health. the Board of Directors of BHEL in its 320th meeting held on 30th October.000 in case of an individual. The scheme stipulates the following nine categories of awards. reward and place on record any direct or indirect outstanding and exemplary contribution by the employee towards growth and profitability of the company. BHEL Utkrishtha Takniki Lekh Puraskar 6. BHEL Anusandhan Puraskar 7. took a historic step by approving BHEL Excel Awards Scheme to institutionalise the culture of Excellence in BHEL. 2002 for Supervisors and Executives on Enhancing Organizational Effectiveness. BHEL Tatparta Puraskar 4. Joint Committee for BHEL held 3 meetings while the Plant and Shop Councils held 51 and 236 meetings respectively during the year at various Units of the Company. BHEL Gunvatta Puraskar 3. BHEL Utkrishthta Puraskar 2. 2002. BHEL Grahak Santushti Puraskar 9. BHEL Utpadakta Puraskar 5. The objective of the scheme is to recognise. 2000. 50. 2. 13 . 5 lakh in the event of a group/team winning the award. The objective of the workshop was to bring about better understanding and appreciation of the issues being faced both by the Company and the employees. the ninth award covers spouses and dependent children of the employees also. The apex level bipartite forum viz. and up to Rs. The awards have been announced in 8 categories to a total of 50 employees/family members and 2 token awards in 25 recognition of individual skills. "Achiever of the Year Award" by CHEMTECH Foundation Shri K. 14 .G. i. 3. 2002 at Chennai by CII. Shram Vir and Shram Shri have been won by four BHEL employees for the year 2002.Bangalore and Electro porcelains Division Bangalore. in recognition of his contribution to industry. comprising some of the most prominent industrialists of the country. for the year 2000 were won by 19 employees of BHEL. Prime Minister's Shram Awards Prestigious "Prime Minister's Shram Awards" instituted by Ministry of Labour namely Shram Bhushan. The award carries a cash amount of Rupees One Lakh and a Golden Plaque. has been awarded the "Achiever of the Year Award" by CHEMTECH Foundation. This is the highest number of awards won by BHEL since the inception of the awards in 1985.Individual Category. Hyderabad. received from various units/ divisions for the year 2001-02 were scrutinized and short listed by a Screening Committee. Electronics Division . Shri K. The short listed entries were evaluated by the Jury constituted by CMD.Ramachandran. Chairman and Managing Director. in the competition held in December. National Safety Awards Four BHEL Units. Awards won by BHEL Units and Employees SCOPE Award for Excellence and Outstanding Contribution to the Public Sector Management . has won the coveted SCOPE Award for Excellence and Outstanding Contribution to the Public Sector Management. won National Safety Awards for the year 2000.The 106 nominations. for the year 2001-02. A word of appreciation to all those who participated and shown the zeal to excel. The journey of excellence will go on unabated with ever increasing vigour. along with other companies.Ramachandran.e. in his individual capacity for his outstanding contribution to Public Sector management. Vishwakarma Rashtriya Puraskars Six Vishwakarma Rashtriya Puraskars. Chairman and Managing Director.G. under the category of Power Plant and Machinery Industry. "Excellence in Energy Management"CII Awards HEEP-Haridwar Unit has been awarded a certificate in the category of an "Energy Efficient Unit". Their outstanding contribution is hailed as a significant milestone in BHEL's journey towards excellence. Tiruchy. He was unanimously selected by the awards committee. The award is instituted by Ministry of Labour. The award is instituted by Ministry of Labour. 5. Those details of the awards won by Hyderabad Unit are: a) Excellence in Suggestion Scheme b) Best Suggestor Award c) Best Slogan Award (Hindi) d) Best Slogan Award (English) 4. Best Suggestor Award and two Best Slogan Awards in the INSSAN National Convention for the year 2002. Activities of the company for welfare and Advancement of Scheduled Castes (SCs) And Scheduled Tribes (STs) The company has been following the Presidential Directives and guidelines issued by the Government of India from time to time regarding reservation for SCs and STs in letter and spirit. Representation of SC/ST employees the representation of SC/ST employees in total manpower was 18. Also. Besides.73% for SCs and STs respectively as on 1/1/2003 15 . During the year. 40466 participants were exposed to different training programs in our various training Centers at Units as well as at apex level in NOIDA. the various Community Development activities focused on Socio. towards our ongoing efforts for higher customer satisfaction. around 1100 customers' personnel were provided training inputs on our products at Training Centers in the Units.INSSAN Awards Hyderabad Unit has won the first prize for Excellence in Suggestion Scheme. These awards are instituted by the Indian National Suggestion Scheme Association (INSSAN). 3700 Act Apprentices and 1300 Technician Apprentices were also provided with training at our Units. as part of fulfillment of our social obligation towards the society.13% and 3.Economic development of SCs and STs have been carried out by BHEL in the 56 villages adopted by it. Human Resource Development During 2002-03. AC. Variable Speed Once through Boilers AC Drives 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 Thirstier Equipment Waste Heat Recovery Boilers Power Devices Heat Exchangers Energy Meters Condensers Transformer Bowl Mills and Tube Mills Gravimetric Feeders Insulators Regenerative Air Pre-Heaters Capacitors Electrostatic Precipitators Broad Gauge.Electric Shunting Locomotives 16 .AC/DC Locomotives Bag Filter Diesel.PRODUCTS Industrial fans Power generation & Transmission Sam less Steal tubes Steam Turbine-Generation Sets & Auxiliaries Fabric Filter Boiler and Boiler Auxiliaries AC/DC Motors. Valves Tractions Motors Pump Electric Trolley buses electric Machines AC Electric Multiple Units Piping System Drives & Control for Metro system Power.Battery Operated Passenger Vans Reactors Oil Rigs & Oil Field Equipments Synchronous Condensers Digital Switching System Switchgear Rural Automatic Exchange Control Gear Simulators Distributed Digital Control for Power station Wind Electric generators Bus Ducts Solar powered Water Pumps Porcelain Insulators Photo Voltaic System Ceralins Defense Equipments/Oil/Gas Reverse Osmosis Desalination plant/ Telecommunication /Renewable Energy System Turbine Generator Sets 17 . Distribution 7 Instrument Transformers . Cyprus. spread over a 140 acre complex leads BHEL research efforts in the number of areas of importance to BHEL’s product range research and product development center at each of the manufacturing division play a complementary role. Egypt. The Corporate R&D Division at Hyderabad. BHEL has a consistent tract of growth performance & profitability. Apart from over 1110 MW of boiler capacity contributed in Malaysia and execution of four prestigious power project in Oman. 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 the East. BHEL’s investment in R7D is among the largest past several state-pf-the art product developed in housing during the last five years contributed about 8. Technology Up gradation and Research & Development to remain competitive and meet customer’s expectations. These References Encompass almost the entire product range of BHEL covering turnkey power project of thermal hydro and gas based type substation project. insulators. based a wide variety of project. switchgears.6% to the revenues in 2000-2001 BHEL has introduced in the recent past several state –of –the –art produced developed in –housing: 18 .A dynamic 67000 Strong team embodies the BHEL philosophy of professional excellence with corporate headquarters in New Delhi: BHEL is India’s ambassador to the world with export presence in more than 50 countries. Libya. heat exchanger. Saudi Arabia. BHEL lays great Emphasis on the continuous up gradation of product and related technologies and development of new project works. Greece. valves well-head equipment etc.house effort as well as through acquisition of new technology from leading engineering origination of the world. rehabilitation project. some of the other major successes achieved by the company have been in Australia. like transformers. The company has upgraded its product to contemporary levels through continuous in. casting and forging. and micro. Environmental Policy: Compliance with applicable Environmental Legislation/ Regulation. circulating fluidized bed combustion boilers high efficiency Pillion hydro-turbines. Corroborate Policies have been formulated as. The company also engaged in research in futuristic areas. such as application of super conducting materials in power generation and industry.low-Nox oil gas burner. The Human Resource Development Institution and other HRD centers of the company help in not only keeping their skills updated and finally honed but also in adding new skills. HUMAN RESOURCE DEVELOPMENT INSTITUTE The most praised asset of BHEL is its employers. and fuel cells for distributed environment –friendly power generation. leading the 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 global concern on issue related to environment in and around its own establishment. whenever required Continuous training and retraining.controller based governor for diesel. For fulfilling these obligations. Some of on going developed & demonstration project include: Smart wall blowing system for cleaning boiler soot deposit . a positive work culture and Participative style of management. 36KV gas –insulated sub stations. 19 . etc. petroleum depot automation system. have engendered developed of a committed and motivated workforce. and to provide safe and healthy working environment to all its employers. The company also transferred a few technologies developed in-housing to other Indian companies for commercialization.Electro-locomotives . It provided a forum of them to work together and Improve corporate practices through co-operation 20 . Occupational Health and Safety policy: Compliance with applicable Legislations and Regulations. Formulation and maintenance of OH&S Management Programs for continual improvement. offering the company’s capabilities in this field. Product review of OH&S Management system to ensure it continuing suitable adequacy and effectiveness. Promotion of activities for conservation of resources by Environmental Management Enhancement of Environment awareness among employees. and other units are in advanced stages of acquiring the same. Action plan has been prepared to acquire OHSAS 18001Occupational Health and Safety Management systems certification for all BHEL units. Participation in the “Global Compact” of the United Nat the “Global Compact” is a partnership between the United Nations. The major units of BHEL have already acquired ISO14001. Setting objectives and targets to eliminate/ control /minimize risks due to Occupational safety Hazards. international labour and NGOs. Communications of OH&S Polices to its all employees and interested parties. the business Community. custom & suppliers BHEL will also assist and cooperate with the concerned governmental Agencies and Regulatory Bodies engaged in environmental activities.Continual improvement in Environmental Management System to protect our natural environment and Control Pollution.Environmental management system certification. BHEL would get a unique opportunity of networking with corporate and sharing experiences related to social responsibility on Global basis. The elimination of all forms of forces and compulsory labors.Compact” of United Nations and has committed to support it and the set of core value ensured its nine principles. Eliminate discrimination. Business should support a precautionary to environmental changes. The effective abolition of child labor 6. 7. Encourage the development and diffusion of environmentally friendly techniques by joining the “Global Compact” . Business should support and respect the protection of internationally proclaimed Human rights 2. FUTURE PLANS As a part of forward integration strategy the company plans to enter into the power distribution business. 21 . 4. Make sure that they are not complicit in human rights abuse. BHEL has announced that it will launch a B2B portal. switchgears etc. Lab our standards 3. Business should uphold the freedom of association and the effective Recognition of the rights to collective bargaining. “PRINCIPLES OF THE “GLOBAL COMPACT” HUMAN RIGHTS 1. As per the company announcement it could take them four to six month to announce the location of its new business. 8. 9. Undertake initiatives to promote grater environmentally responsibility. The company is planning towards becoming an application service provider. The company already manufactures product required by the distribution systems like transformers. 5. keeping in mind its core competency-power systems. and for pollution control-bag filter technology. Bharat Heavy Electricals Limited (BHEL) . loco refurbishment. BHEL would also put additional emphasis on spares and service business for hydro and thermal plants.25mm lines.SWOT Analysis examines the company’s key business structure and operations. funded by Japan Bank for international cooperation. BHEL is planning to enter new business in integrated gasification combined cycle system. In the power sector.The company will continue to focus on project management reducing cycle time and cost control. equity participation and limited financial syndication. coal washeries and LRT systems. gas-insulated switcher. and provides summary analysis of its key revenue lines and strategy. In its existing businesses of transportation.SWOT Analysis Bharat Heavy Electricals Limited (BHEL) . It is equipping it self with the new type of once-through design boiler technology. HVDC insulators and electronic meters. BHEL is pursuing opportunities in EMU coaches. The electronics division has frayed into traction business and received a large order from Dot for switching equipment for 0. New products are expected to contribute 46% of its total turnover. The company will continue to focus on product development in order to foster its growth strategy.SWOT Analysis company profile is the essential source for top-level company data and information. Bharat Heavy Electricals (BHEL) is an India-based engineering and 22 . transmission and industry. history and products. The electro porcelains division is now manufacturing HVDC disk insulator and its catalytic converter has also passed the entire test. BHEL is introducing a number of new products like 3-phase traction electric and advance class gas turbines in the Indian market. The Industrial System Group has bagged orders from BWSSB for water pumping stations (Cauvery Stage IV). Bharat Heavy Electricals Limited (BHEL) . the company plans to obtain a part of the business generated by independent power producers through a combination of approaches including consortium route. BHEL is headquartered in New Delhi.3 million (approximately $1. The operating profit of the company was INR48.Provides all the crucial information on Bharat Heavy Electricals Limited (BHEL) required for business and competitor intelligence needs . business description.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.063. key executives.780. transportation.Keep fully up to date on your competitors’ business structure. The company operates in India.manufacturing company that develops electrical and power equipment in energy related and infrastructure sector. Scope of the Report .731. India and employs over 45.Obtain the most up to date company information available 23 .4 million) during the financial year ended March 2009 (FY2009). strategy and prospects . It manufactures over 180 products under 30 major product groups and caters to sectors including power generation and transmission.Support sales activities by understanding your customers’ businesses better .3 million) during FY2009.Qualify prospective partners and suppliers .200 people. and renewable energy. The company recorded revenues of INR264.914 million (approximately $5. 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 . among others. •Ability to manufacture or procure to supply spares. •Fully equipped to take capital maintenance and servicing of the power plants.SWOT ANALYSIS STRENGTHS •The company has 180 products under 30 major product groups that cater to the needs of the core sector like power. •Largest source of domestic business leading to major presence and influence in the market. •Sound engineering base and ability to assimilate •Ability to set up power plants on turnkey basis. 24 . defense.how for manufacture of entire equipment is available with the company. industry.transmission. complete know. telecommunication and oil business •BHEL’s 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 relationship •Access to contemporary technologies with the support from renowned collaborators. •Inability to provide supplier’s credit. which are the major customers of BHEL in India. •Low labour cost. •Due to poor financial position of state electricity boards. •Larger delivery cycles in comparison with international suppliers of similar equipment. 3.•Ability to successfully overhaul and renovate power stations equipment of different international companies. This could have reduced the cost. Private goals that lead to budget growth and employment growth. liquidity position of BHEL is not satisfactory. Direct political intervention in managerial decision over an arm length relationship that would restrict government’s task of setting appropriate managerial incentive structure. •Being a public sector company BHEL is suffering from sub optimality of control due to: 1. which could have been avoided by outsourcing its components for power generation and transmission. 2. Internal inefficiencies in bureaucratic activity 25 . 4. Displacement of social objectives by political objectives. which may lead to redundant costs and also rising costs. 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. soft loans and financing of power projects. •Financial and operational autonomy for profit making public sector enterprises.(PPIL). •Life expansion program for old power stations. •The business of modernization and renovation of power plants is expected to grow in India.OPPORTUNITIES •The power sector reforms are expected to pick up in the near future in India. •Ageing power plants would give rise to more spares and services business. 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 26 . This tie up will be beneficial as there is a lot of scope for business. •Easy processing of joint ventures/ collaboration/import/ acquisition of new technology. which would directly benefit BHEL. is a major strength for the company. •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. •Private sector power plants to offer expanded market as utilities suffers resource crunch. •Demand for power and hence plant equipment is expected to grow. 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 well •Unsatisfactory 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 owned utilities like NTPC or S.Bs.E. 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 27 . A leading turbine manufacturer offering a wide range of Hydro Turbine. ASME "Q" stamp for fabrication facilities. •The water strikes the bucket along the tangent of the runner. Sophisticated CAD/CAM facilities.HYDRO TURBINES A leading engineering enterprise which supplies all types of equipment for hydro power generation. Installed manufacturing capacity:2500 MW/annum. Valves. ISO 9001 Certification. Turbine and Station Auxiliary systems. Governors. PELTON WHEEL (TURBINE) The Pelton wheel is a tangential flow impulse turbine. It was invented by Lester Allan Pelton in the 1870s. Balance of plants for Hydro Power Station and related Services. •Inlet Energy= KINETIC ENERGY •Outlet Energy=ROTATIONAL KINETIC ENERGY OF TURBINE+ KINETIC ENERGY OF WATER •Used for HIGH HEADS 28 . Ultramodern model development and testing facilities. In the market for more than three decades. •The Pelton wheel extracts energy from the impulse of moving water. as opposed to its weight. Dedicated shop area of over 100000 sq. Two units manufacturing hydro turbines. meters. thus splitting the water jet in half (see photo). Often two buckets are mounted side-by-side. Runners and buckets 3. This balances the side-load forces on the wheel. the turbine system is designed such that the water-jet velocity is twice the velocity of the bucket. Because water and most liquids are nearly incompressible.FUNCTION: The water flows along the tangent to the path of the runner. Nozzle and flow regulating arrangement 2. efficient momentum transfer of the fluid jet to the turbine wheel. Pelton wheels have only one turbine stage. Casing 4. 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. This "impulse" does work on the turbine. In the process. (see conservation of mass). When the water-jet contacts the bucket. A very small percentage of the water's original kinetic energy will still remain in the water. however. the direction of the water velocity changes to follow the contour of the bucket. unlike gas turbines that operate with compressible fluid. As water flows into the bucket. and helps to ensure smooth. For maximum power and efficiency. MAIN PARTS OF PELTON TURBINE ARE: 1. Therefore. almost all of the available energy is extracted in the first stage of the hydraulic turbine. the water's momentum is transferred to the turbine. Nozzles direct forceful streams of water against a series of spoon-shaped buckets mounted around the edge of a wheel. this allows the bucket to be emptied at the same rate it is filled. Draft Tube Design rules 29 . thus allowing the water flow to continue uninterrupted. ICEM. (dimensioned parameter). Testing not only helps in predicting the efficiency of the prototype but also helps in knowing the changes required to be done in the existing model so as to get maximum efficiency. = rpm DESIGN METHODOLOGY USED IN BHEL BHOPAL The Research and Development block of the Hydro Lab here in BHEL bhopal is dedicated for the development of the most efficient pelton turbines for future projects. X Mw) 2 X 115 2 X 89 4 X 84 460 440 435 HEAD (m) SPEED(RPM) RUNNER DIAMETER (mm) 4500 3680 3680 Varahi Sharavathy Tilari 250 300 300 30 . due to the 5/4 exponent being greater than unity. and given the characteristically low specific speed of the Pelton. Bhopal has a dedicated HYDRO LAB for testing the models of the turbines to be produced by the manufacturing units. This allows a new turbine design to be scaled from an existing design of known performance. TESTING METHODS: BHEL. where: • = Power (kW) • = Water head (m) The formula implies that the Pelton turbine is most suitable for applications with relatively high hydraulic head H. BHEL BHOPAL PELTON TURBINES PROJECTS PROJECT RATING (No. This is done with the help of many powerful cloud computing and computer aided analyzing softwares like ANSYS. CFX.The specific speed of a turbine dictates the turbine's shape in a way that is not related to its size. This not only helps in increasing the efficiency of the turbines but also helps the company to quote approximate and accurate tenders for future projects so as to earn maximum profit and provide best services. TURBOGRID etc. The specific speed is also the main criterion for matching a specific hydro-electric site with the correct turbine type. •The Francis turbine is a type of water turbine that was developed by James B. Francis in Lowell. Runner Blades:Runner blades are the heart of any turbine as these are the centers where the fluid strikes and the tangential force of the impact causes the shaft of the turbine to rotate and hence electricity is produced. it has numerous openings at regular intervals to allow the working fluid to impound on the blades of the runner. to maintain a constant flow rate despite the fact that numerous openings have been provided for the fluid to gain entry to the blades. In this part one has to be very careful about the blade angles at inlet and outlet as these are the major parameters affecting the power production. 31 . •In modern Francis turbines. Different Parts Of Francis Turbine A francis turbine comprises mainly the following parts: 1)Spiral Casing 2)Guide or Stay Vanes 3)Runner Blades 4)Draft Tube Spiral Casing: The spiral casing around the runner of the turbine is known as volute casing . these openings convert the pressure energy of the fluid into momentum energy just before the fluid impound on the blades. •Thus modern francis turbine is a Mixed flow reaction turbine.FRANCIS TURBINE The Francis turbine is a type of Inward Flow Reaction Turbine having radial discharge at outlet.the cross-sectional area of this casing decreases uniformly along the circumference. All throughout it's length. Guide or Stay Vanes: The primary function of the guide or stay vanes is to convert the pressure energy of the fluid into the momentum energy. Massachusetts. 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. it also serves to direct the flow at design angles to the blade runners. The purpose of providing a draft tube will be better understood if we carefully study the net available head across a reaction turbine.Draft tube: The draft tube is a conduit which connects the runner exit to the tail race where the water is being finally discharged from the turbine. The primary function of the draft tube is to reduce the velocity of the discharged water to minimize the loss of kinetic energy at the outlet. 32 . This permits the turbine to be set above the tail water without any appreciable drop of available head. 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. Theory of Operation The Francis turbine is a type of reaction turbine. who combined automatically adjusted propeller blades with automatically adjusted wicket gates to achieve efficiency over a wide range of flow and water level. •Kaplan turbines are widely used throughout the world for electrical power production. X Mw) 6 X 165 4 X 150 3 X 135 HEAD (m) 320 100 304 SPEED(RP M) 300 166. The lower end of the shaft is made larger which is known as ‘hub’ or ‘boss’. water acts on the spinning cup-shaped runner features. Scroll casing 33 . The turbine's exit tube is shaped to help decelerate the water flow and recover the pressure.quantified by the expression of Degree Of Reaction.7 300 RUNNER DIAMETER (mm) 3730 4550 3850 SPIRAL INLET (mm) 2600 5000 2400 Dehar Ranjit Sagar Ranganadi KAPLAN TURBINE •The Kaplan turbine is a propeller-type water turbine which has adjustable blades. At the exit. MAIN PARTS OF KAPLAN TURBINE ARE: 1. •It was developed in 1913 by the Austrian professor Viktor Kaplan. leaving at low velocity and low swirl with very little kinetic or potential energy left. while the remaining part of the energy is extracted by the volute casing of the turbine. •Inexpensive micro turbines on the Kaplan turbine model are manufactured for individual power production with as little as two feet of head. CUT VIEW OF FRANCIS TURBINE(GUIDE VANES) BHEL BHOPAL FRANCIS TURBINE PROJECTS PROJECT RATING (No. They cover the lowest head hydro sites and are especially suited for high flow conditions. • For axial flow reaction turbine the shaft is vertical. Guide vane mechanism 3. Draft tube 34 . Hub with vanes or the runner of the turbine 4.2. 4 RUNNER DIAMETER (mm) 4700 5650 5182 SPIRAL INLET (mm) 6200 6500 7982 S S Canal UKAI OBRA 35 .4 150 115.8 20. X Mw) 5 X 50 4 X 75 3 X 33 HEAD (m) 36.0 47.BHEL BHOPAL KAPLAN TURBINE PROJECTS PROJECT RATING (No.4 SPEED(RP M) 136. Each component part is available in a variety of materials called “trim features. bubble-tight. causing conveying line inefficiencies. a butterfly valve consists of a circular disc with its pivot axis at right angles to the direction material is flowing. and liquid applications. 3) A disc opening or closing on a standing column of dry material may cause the material to jam / pack. disc. Listed below is a brief introduction to some of these other types. or liquid. The valve is made up of a body. bi-directional shut off. Typically the material is air. butterfly valves provide a reliable. Certain dry materials may also be handled through a butterfly valve. Care must be taken when applying a butterfly valve in semi-abrasive or abrasive dry material applications (this includes slurry applications that contain suspended particles because: 1) A valve disc closing on dry bulk material will create premature wear to the rubber seat. steam. stem. gases and liquids) that are easily displaced by the valve disc as it closes. Simply. Applications As stated earlier. When handling this type of material.g.” Properly combining trim features to address material handled and environment is important in selecting the correct model valve for its intended service. economically priced.BUTTERFLY VALVES A Butterfly Valve is used to control the flow of material through a circular pipe or tube. Butterfly Valves are generally specified for most air. Other Types of Butterfly Valves As a person becomes familiar with butterfly valves. seat. positive shut-off valve for handling materials (e. gas. 2) The obstructed orifice created by the disc may cause bridging of material on the inlet side of the valve. and actuator. They offer an excellent. Inflatable Seated Butterfly Valves 36 . they will undoubtedly discover other types of butterfly valves on the market. steam. gas. 4) Particles of dry material or suspended particles in slurries may become trapped between the disc and seat. Pros: 1) Since the seal is created after the disc closes. A smaller sized actuator costing less money is can be used. 4) The inflatable bladder is subject to damage and abrasion. HEAD (m) 460 440 435 DOOR TYPE Balimela Ranjit Nagar Srisailam LENS LATTICE LATTICE 37 . the bladder is inflated pneumatically. requiring periodic replacement. These controls add cost to the valve. 2) The bladder may be damaged and not creating a seal. additional controls are needed to identify whether the bladder is inflated or not. 3) The valve must be located near an air supply to pneumatically inflate the bladder. Cons: 1) In addition to the controls needed to verify the position of the disc. 2) Again. less torque is required to move the disc into the closed position. Once the disc is brought to the closed position. even though controls identify that a seal has been established. minimal abrasion exists between the disc and the seat. BHEL BHOPAL BUTTERFLY VALVES PROJECTS PROJECT VALVE DIAMETER (mm) 2 X 115 2 X 89 4 X 84 MAX. because the seal is created after the disc closes.Inflatable seated butterfly valves utilize an inflatable seat or bladder to create a seal around the disc. 38 . OMAN etc. etc. IOCL. All the Thermal products are tailor made and customer specific product. Depending upon application these auxiliary Heat Exchangers are named as . Miscellaneous storage tanks and Butterfly valves added in subsequent years. Oil Coolers (Shell & tube type / Frame and tube type (Single tube & Concentric double tube construction) / OFAF). 39 . To ensure long life of these coolers materials for different components is decided carefully considering its application and water chemistry. Production of some of the other products like Rubber Expansion Joints. Azerbaizan. 2 and 500 MW TAPP 3&4 Nuclear plants. Heat Exchanger Auxiliary Heat Exchangers Different types of auxiliary heat exchangers are being manufactured at BHEL. RELIANCE. FEDO. . Bangladesh. took place in year 1970) and started its production from year 1971 onwards. contract review etc. BHEL-Bhopal Thermal group products manufactured and supplied all over India to different State Electricity Boards and exported to countries like LIBYA. and Customer requirements are continuously captured through pre-tender and post tender discussions. Plug in type . etc. MSR to this new design were manufactured and supplied for 236 MW RAPP 3. Air Coolers (CACW) . Constructionally these coolers are very easy to maintain. ONGC.HEAT EXCHANGERS Thermal group of BHEL-Bhopal was formulated in year 1968 (Initial collaboration with M/s AEI -U. Flash Tanks. Air Cooler CACA ( Duct and tube type) These coolers are accessories to main equipment’s such as Generator. Similarly Industrial Heat Exchangers have been supplied to IFFCO. Perception is collected through customer surveys. new collaboration agreement with M/s BALCKE DURR.Germany for Moisture Separator Re-Heater (MSR) took place in 1987.K. Hydrogen Cooler etc. GAIL. hence special attention is given to make these coolers compact in design and for trouble free service. Turbine. 4 & KAIGA 1. Water Water Cooler (Shell & Tube type) . (Frame and tube type). Subsequently. major customers of thermal equipments are State Electricity Boards and NTPC. Transformer . Thermal group products are Technology intensive and therefore Technology development is of strategic importance. Malaysia. Product technology is continuously upgraded through in house development projects/ or Technical Collaboration. Motors. stainless steel. etc. end closing. shell assembly and types of enclosure i.Technical Information/Application Air coolers. Cladded Exchangers also have been supplied by BHEL. BHEL is having a vast experience of manufacturing and supply of Heat Exchangers with Carbon steel . kettle type construction . which in turn cools motor windings. Feed Water Heaters 40 . BHEL is capable of doing special types of mechanical design apart from normal design of shell. Oil coolers. In general Heat Exchangers used are of shell and tube type construction. backing ring and flanges etc. Air Coolers are used to cool the generator air which is a closed circuit air of maintained humidity and which in turn cools winding of stator. Various types of constructional features as described in TUBULAR EXCHANGER MANUFACTURER’S ASSOCIATED (TEMA) Standard can be offered by BHEL. In addition to the type as mentioned earlier . Similarly. Water-Water coolers and Hydrogen Coolers act as accessories to Transformers. BHEL is manufacturing different types of shell and tube type heat exchangers for Industries like Refineries . turbines. Petrochemicals and Fertilizers. tubes .e. material selection becomes an important criteria. dished ends . etc.flat covers.e. CACW type and CACA type air coolers are also used for cooling air. Industrial Heat Exchangers Industrial Heat Exchangers. Alloy Steel and Non-ferrous tubes and shell materials. Special type of mechanical design covers design of eccentric/concentric types of shell i. and double pipe type heat exchangers. Motors and Generators. fixed tube sheet with bellows. as the name implies are used in industries dealing in various types of chemicals. Since different type of chemicals is involved in Industrial Heat Exchangers. Main components of shell and tube type heat exchangers are tube nest assembly. In turbine. Transformer Coolers are used to cool transformer oil by air or water. In Generator. oil coolers are used to cool bearing oil or the oil which in turn cools the rotating parts. high pressure enclosures . reverse flange type design. These coolers play an important role in smooth functioning of the main equipments. . i. Both High pressure & Low pressure feed water heaters come under purview 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. Feed heaters play a vital role in power plant. High Pressure heaters and Low pressure feed water heaters complies with the highest standard of engineering to provide adequate reliability in the operation of these heaters.The feed water passes through the 'U' tubes and the steam/drain (condensed steam) passed over the tubes. while separating the high energy phases and exchanging heat.e. Hence these are designed and manufactured in strict compliance to applicable code requirements. subjected to very onerous duty and hence the design and manufacture of both type of heaters.The high pressure & Low pressure feed water heaters are employed to increase the overall efficiency of the regenerative cycle by heating the feed water by the steam extracted from suitable stages of the turbine. Feed water heaters (both High pressure and Low pressure) are used in feed heating system of regeneration cycle by heating feed water by steam extracted from suitable stages of turbine.BHEL is manufacturing feed water heaters for power stations of Unit Rating up-to 250 MW Thermal Power Project since more than last 25 years. Over the years design and technological developments took place and at present feed heaters with stainless steel tube materials are being used for longer life expectancy. Both Horizontal and vertical type of heaters are manufactured with highest standard of engineering to provide reliability in operation. Technical Information/Application . Feed water heaters are designed as per HEI standard and high pressure heaters comes under purview of Indian Boiler Regulations. therefore. The heaters are. These heaters are located in feed water heating cycle and feed water going to boilers is heated with steam extracted from different stages of turbine resulting in saving of energy and increased efficiency. 41 . it is particularly suited to be used to drive an electrical generator •The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam. extraction and induction.STEAM TURBINE •A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating output shaft. non-condensing. Steam supply and exhaust conditions These types include condensing. reheat. •Because the turbine generates rotary motion. 42 . which results in a closer approach to the most efficient reversible process. Its modern manifestation was invented by Sir Charles Parsons in 1884. In an extracting type turbine. or left uncontrolled. Extraction flows may be controlled with a valve. Using reheat in a cycle increases the work output from the turbine and also the expansion reaches conclusion before the steam condenses. In a reheat turbine. The exhaust pressure is controlled by a regulating valve to suit the needs of the process steam pressure. Casing or shaft arrangements These arrangements include single casing. Tandem compound are used where two or more casings are directly coupled together to drive a single generator. Single casing units are the most basic style where a single casing and shaft are coupled to a generator. tandem compound and cross compound turbines. These are commonly found at refineries. there by minimizing the erosion of the blades in last rows. REHEAT TURBINES Reheat turbines are also used almost exclusively in electrical power plants. In most of the cases. Induction turbines introduce low pressure steam at an intermediate stage to produce additional power. pulp and paper plants. A cross compound turbine arrangement features two or more shafts not in line driving two or more generators that often operate at different speeds. steam is released from various stages of the turbine. district heating units. steam flow exits from a high pressure section of the turbine and is returned to the boiler where additional superheat is added. The steam then goes back into an intermediate pressure section of the turbine and continues its expansion. Extracting type turbines are common in all applications. maximum number of reheats employed in a cycle is 2 as the cost of superheating the steam negates the increase in the work output from turbine. A cross compound turbine is typically used for many large applications. and used for industrial process needs or sent to boiler feed water heaters to improve overall cycle efficiency.Non-condensing or back pressure turbines are most widely used for process steam applications. and desalination facilities where large amounts of low pressure process steam are available. Two-flow rotors 43 . or the rotor can be designed so that the steam enters in the middle of the shaft and exits at both ends. The blades in each half face opposite ways. To maintain the correct rotor position and balancing. BHEL BHOPAL STEAM TURBINE PROJECTS Turbines 1) Design. 2) Supply of Spares and Repairs of above Steam Turbines. This design of rotor is called two-flow or double-exhaust. so that the axial forces negate each other but the tangential forces act together. but the axial thrust in a simple turbine is unopposed. 15000 SHP Marine Turbines 210 MW Steam Turbines. The moving steam imparts both a tangential and axial thrust on the turbine shaft. 120 MW Steam Turbines 236 MW Nuclear Turbines. This arrangement is common in low-pressure casings of a compound turbine. The steam enters in the middle of the shaft. balancing the axial force. 44 . and exits at each end. Manufacturing.A two-flow turbine rotor. Either thrust bearings can be used for the shaft bearings. Erection. this force must be counteracted by an opposing force. Commissioning and Services of : • • • • 30 MW. TECHNICAL SPECIFICATION OF 210 MW STEAM TURBINE SL.3) R & M and Life assessment studies of BHEL & Non BHEL TG sets.NO DESCRIPTIO N PARAMETER 1 2 3 4 5 6 7 RATED 210 MW CAPACITY PRESSURE 150 KG/CM2 AT STOP VALVE TEMPERATU 535 C RE AT STOP VALVE MAX. STEAM 641 TONNES /HR FLOW AT S.V REHEAT/NON REHEAT REHEAT TYPE OF THROTTLE CONTROL GOVERNING TURBINE 3000 RPM SPEED 45 . 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. P-1.DOUBLE FLOW LP-1 HP-25.HYDRAULIC BARRING .DOUBLE SHELL DOUBLE FLOW IP .ABS H.DOUBLE FLOW IP-1. GERMANY 46 .1 METERS REACTION SIEMENS.LP-8+8 676 MM 2132 MM -DOUBLE SHELL HP WITH BARREL TYPE OUTER SHELL .8 9 10 11 12 13 EXHAUST PRESSURE NUMBER OF CYLINDERS NUMBER OF STAGES HEIGHT OF LAST STAGE BLADE LAST STEAGE MEAN DIA SPECIAL FEATURE 76 MM HG. IP-20 +20.ELECTROHYDRAULIC GOVERNING 14 15 16 17 WEIGHT OF TURBINE LENGTH OF TURBINE TYPE OF TURBINE COLLABORA TOR 425 TONNES 14. -Ht 3 mtrs.Electro slag .Radiographic Machining facilities Rotating Column Vertical Borer :Max.TIG 3000 T shell bending press Electronic flame cutting machine Stress relieving furnace Shot blasting chamber NDT test facilities .HYDRO GENERATORS FACILITIES AT BHEL BHOPAL Fabrication facilities Special types of welding . -Horiz 19mtrs Horizontal Planning Machine:Bed Length 9 mtrs. Job dia 16 mtrs -Ht 4mtrs Vertical Borer (HOMMA) :Max. Centre Lathe:Max.Narrow Gap . job dia 9 mtrs .Dye penetrant .Ultrasonic . -Length 15 mtrs 47 . Job dia 4 mtrs.Ht 4mtrs Horizontal Ram Borer :Max.Magnetic particle .Submerged Arc .15 mtrs. 4. travel Vert. Blanking/Var 250T blanking line nishing 1600T hydraulic press facilities 500/300T hydraulic press Deburring machine Spot welding machine Automatic varnishing plant Coil Automatic cleaning and cutting machine manufacturin Hydraulic coil pulling machine g facilities 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 .3-phase sudden short circuit test STATOR HYDRO GENERATOR COILS ASSEMBLY AFTER INSULATION 48 .Temperature rise efficiency .Characteristic curves . 5. 2. silver and tin. The acid and metal reaction also generates hydrogen gas in the form of tiny bubbles that adhere to the surface of the metal. In the case of depositing zinc phosphate or manganese phosphate the additional iron phosphate is frequently an undesirable addition to the coating. oil. raising the pH.[1][2] It serves as a conversion coating in which a dilute solution of phosphoric acid and phosphate salts is applied via spraying or immersion and chemically reacts with the surface of the part being coated to form a layer of insoluble. This chemistry is known as a nitrate accelerated solution. The application of phosphate coatings makes use of phosphoric acid and takes advantage of the low solubility of phosphates in medium or high pH solutions. Iron. zinc or manganese phosphate salts are dissolved in a solution of phosphoric acid. crystalline phosphates. The acid and metal reaction also creates iron phosphate locally which may also be deposited. cleaning the surface rinsing surface activation (in some cases) phosphating rinsing neutralizing rinse (optional) drying application of supplemental coatings: lubricants. zinc. cadmium. 8. 4. The following is a typical phosphating procedure:[3] 1. and causing the dissolved salt to fall out of solution and be precipitated on the surface.[3] Phosphate conversion coatings can also be used on aluminium. 6. or as a foundation for subsequent coatings or painting. sealers. These prevent the acid from reaching the metal surface and slows down the reaction. To overcome this sodium nitrite is frequently added to act as an oxidizing agent that reacts with the hydrogen to form water. a classic acid and metal reaction takes place which locally depletes the hydronium (H3O+) ions. Hydrogen is prevented from forming a passivating layer on the surface by the oxidant additive. 49 . 3. lubricity.PHOSPHATE COATING Phosphate coatings are used on steel parts for corrosion resistance.[6] When steel or iron parts are placed in the phosphoric acid. 7. etc. 70-80 DEGREE. CELSIUS SURFIX 601 50 .DEGREASING 10-42 MINS TEMP. CELSIUS CONC. CELSIUS FRESH WATER PICKLING 10-12 MINS TEMP. 20-30 DEGREE. 75-80 gm/liters( CAUSTIC SODA) SURFOLINSK-40 RINSING 10-12 MINS TEMP. CELSIUS CONC. 70-80 DEGREE. 60-70 DEGREE. 50-60 gm/liters SULPHURIC ACID(HOT) HYDROCHLORIC ACID (COLD) RINSING 10-12 MINS TEMP. CELSIUS FRESH WATER DERUSTING 8-10 MINS TEMP. 20-30 DEGREE. CELSIUS KEMPICRLE 711 PHOSPHATING 5-10 MINS TEMP. 55-90 DEGREE. BIBLIOGRAPHY 1.www.bhel.com 3.google.wikipedia. BHEL Diary 2008 5. www. BHEL Manual 2.com 51 .www.org 4.