ACKNOWLEDGEMENT

It is my proud privilege to express deep sense of gratitude, regards and appreciation to my guide Mr. S.K. Jain Dy. Manager (M.M. Hydro) for his invaluable guidance, deep rooted interest, inspiration and continuous encouragement through out my vocational training which helped me to learn about the companys working and to complete my training. I am also thankful 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

TABLE OF CONTENTS
INTRODUCTION TO BHEL............................................................... 4 VISIONS, MISSIONS, & VALUES OF BHEL.......................................7 BHEL AN OVERVIEW......................................................................... 8 HUMAN RESOURCE MANAGEMENT........................................ 13 PRODUCTS........................................................................................ 16 INTERNATIONAL OPERATIONS................................................ 20 FUTURE PLANS................................................................................. 22 BHEL SWOT ANALYSIS............................................................24 HYDRO TURBINES.....................................................................28 PELTON WHEEL( TURBINE)........................................................28 FRANCIS TURBINE.....................................................................31 KAPLAN TURBINE.....................................................................34 BUTTERFLY VALVES.....................................................................36 HEAT EXCHANGER.....................................................................39 STEAM TURBINES.....................................................................42
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HYDRO GENERATORS.....................................................................44 TECH. SPECIFICATIONS OF 210 MW STEAM TURBINE.......45 FACILITIES AT BHEL BHOPAL FOR COIL INSULATIONS........47 PHOSPHATING AND POWDER COATING ..................49 Bibliography................................................................................. 51

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.
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4.

Supplied traction electrics and AC/DC locos to power over 12000 km railway network.

5. Supplied over one million valves to power plants. BHELS 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. BHELS 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 customers 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.

GAS BHEL is the only company to manufacture large sized gas based power plant equipment comprising turbines up to 200 MW. HYDRO BHEL engineers and manufactures has built francis, pelton and Kaplan type turbine, pump turbines and minor-micro hydro plants with matching generators for different head discharge combination. The maximum size of hydro equipment already built and installed is 265 MW. TRANSMISSION BHEL supply a wide range of transmission products and systems up to 400 KV. These include high voltage power and distribution transformers, instrument transformers, dry type transformers, SF 6 switching gears cape electric citers etc for economic transmission of bulk power over long distances. High voltage direct current (HVDC) technology is now available. R & D projects for the development of equipment for 800 KV class are progressing a pace resistance high alumina ceramic line material of power, steel cement and mining industries as well as a wide range of industrial ceramics.

VISION, MISSION & VALUES OF BHEL AT A GLANCE

VISION A world class engineering enterprise committed to enhancing stakeholders value. MISSION To be an Indian multinational engineering enterprise providing total business solutions through quality products, systems and services in the field of energy, industry, transportation, infrastructure and other potential area. VALUES : Zeal to excel and zest for change. : Integrity and fairness in all matters.
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: Respect for dignity and potential of individuals. : Strict adherence commitment. : Ensure speed of response. : Foster learning, creativity and teamwork. : Loyalty and pride in the company.

BHARAT HEAVY ELECTRICALS LIMITED AN OVERVIEW

Bharat heavy Electrical Limited. (BHEL), a company with majority share holding by the government of its kind in India and is among the 12 leading equipment manufacturers in the world. 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. BHEL is organized along three Business Sectors, viz, Power, Industry and International Operations. The main activities of Business Sector are marketing, Project Engineering, Erection, Commissioning and service after sales. The product Range of BHEL encompasses power generating equipment, electrical and thermos mechanical equipment for industrial applications, electrical traction equipment and urban transport systems. The company has a workforce of 44,000 including technicians, skilled workers and about 9,000 qualified engineers. BHEL today has 13 manufacturing plants and host of service divisions and around 200 projects sites. 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$1.25 billion during the year 1992-1993.

POWER
BHEL has commissioned more than 800 Nos. utility and industrial sets totaling to over 50,000 MW equivalent generating capacity. BHELs share in utility generating capacity was approximately 64% of the installed capacity in India in March 1993. Presently, BHEL has capacity to supply power equipment equivalent to 7000 MW per year.
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(A) Thermal Generation: The unit sizes of utility stations in India range from 30 MW to 500 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. The technology for manufacture of turbo generators comes from a comprehensive technical calibration agreement with Scienes AG of Germany. BHEL manufactures steam generator as per technology of M/S ABB Combustion Engineering of the USA. This technology has been acquired through 20 years of collaboration/license agreement. Both these collaboration covered unit ratings up to 1000 MW. Operating in an environment of high technology and severe competition as BHEL does, the company has perform to stay abreast with the technology leaders in the world. 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. BHEL has a well chalked out programmed to assimilate, adapt and modify such acquired technology to suit differing economic, developmental, geographic & climatic requirement. The company has also a full-fledged Research and Development Division which undertake fundamental and applied research in power and related fields. Research; 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, Solar and Wind Power have already resulted in commercial ventures. (B) Hydro Generation: BHEL has supplied Hydro Sets upto 165 MW rating and 200 MW sets are under manufacture, BHEL has facilities to manufacture and install sets of even higher rating as per specific customer requirements. 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. So far, BHEL has commissioned mire than 200 Hydro Sets of various types and capacities tattling to about 12000 MW.
(C)

Nuclear Generation: Indias first wholly indigenous Atomic Power plant at Kalapakkam near Madras is equipped with two sets of power generation equipment of rating 235 MW each supplied by BHEL. Subsequently, another two
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sets of similar rating have been commissioned successfully at Narora. BHEL is now manufacturing sets of 500 MW rating for nuclear power stations. (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. BHEL has collaboration agreements with two leaders of has turbines technology in the world namely general electric, USA and Siemens AG, Germany. The agreement with GE, USA covers rating from 4.6 MW (ISO). The Siemens agreement covers unit rating from 130 MW to 200 MW. So far BHEL has supplied more than 33 nos. Has a turbine. All these turbines have been supplied from our Hyderabad plant based on general electric, USA technology. BHEL has bagged orders for two gas turbine based projects in Malaysia, commissioning schedule of 6- 10 months. The first project has already been commissioning in 6 months time. While the gas turbines of GE/USA design are supplied from Hyderabad plant. With the plants (i.e. Hyderabad and Hard war) are fully equipped with state of manufacturing and testing facilities. BHEL is fully equipped to supply waste heat recovery boilers from their Tiruchirapalli plant. BHEL have an ongoing collaboration agreement with M/S Henry volt, USA for the Waste Heat Recovery Boilers. BHEL is supplying WHRSGS foe 6X30 MW gas turbines for Delhi electric supply undertaking, and 817 MW Dadri Project of national thermal power corporation limited besides those for other power stations. (E) Transmission: In addition to equipment for generating of power, BHEL supplies a variety of equipment for transmission and utilization of power. The company has also undertaken a number of turnkey sub-station contracts for voltage rating up to 400 kv class. Keeping with the KM long HVDC (High voltage direct current) transmission line project line for reliable and efficient transmission of bulk power. BHEL has in house capability to supply most of the equipment like power transformer current transformer, voltage transformers switches, insulators etc., and also possesses in house modern testing facilities.
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Billions of BHEL manufactured insulators of various ratings upto 160 KN are satisfactory service in many countries namely Turkey, Egypt, Malaysia, Iran, Iraq, USA Libya, Tanzania Dubai and course India. (F) Industry: The industry Sector of BHEL offers diverse items such as Transformers, Switcher, Rectifiers, Insulators, Capacitors, Control Gear, Valves Compressors, Pumps, Piping, Motors, Industrial turbines oilrigs and semiconductor devices to meet the varying needs of industry. (G) Transportation: For over quarter of a century, BHEL has been supplying drives and control for traction equipment mainly to the Indian Railway, which is the third largest Railway network in the world. Today, 65% of the rolling stock in Indian contains electric of BHEL make such as traction motors, traction generators/alternators, and transformers. 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.C. Locos. The urban transportation problem demands different solutions and BHELs contribution extends to underground tube, 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. With over 500 engineers and supporting staff, 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. b) Constructions Management: BHEL has a full-fledged construction management division to undertake erection work. This division well organized with over 500 experienced engineers,1000 technicians and 1300 skilled workers besides construction equipment valued at over 40 million US Dollars.
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c) Service After sales: BHEL extends its supply and construction scope with service such as commissioning field engineering performance monitoring trouble shooting operation and maintenance. Renovation modernization and rehabilitation works of aged power stations are also undertaken. BHEL has a separate spare group response for insuring ready availability of essential spares to Power stations. d) Projects Management: The project management division of BHEL coordinates th4 entire range of BHEL activities in relation to thermal power plant project and is responsible to the purchasing organization for compliance of the specifications. Entrusted with the overall coordination of the project the division initiates, directs coordinates, 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. BHEL offers a wide spectrum of products and services for core sectors like power transmission industry, transportation, oil & gas telecommunication etc, deseeds supply of non-conventional energy systems. It has also embarked it to other areas including defense & aviation.

HUMAN RESOURCE MANAGEMENT

1. Industrial Relations The Industrial Relations at various Units and service divisions of the Company were harmonious and cordial during the year under report. Thrust to develop and nurture the participative culture in the Company continued during the current year also. 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, 2002. Accordingly, Joint Committee for BHEL was reconstituted. Subsequently, 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, 2002.
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A two days' workshop was also conducted in November, 2002 for Supervisors and Executives on Enhancing Organizational Effectiveness. 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 apex level bipartite forum viz. 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. 2. BHEL Excel Awards Inspired by the ideal of 'Yoga Karmasu Kaushalam', the Board of Directors of BHEL in its 320th meeting held on 30th October, 2000, took a historic step by approving BHEL Excel Awards Scheme to institutionalise the culture of Excellence in BHEL. The first such awards were presented for 2000-01 on 13th January, 2002. The objective of the scheme is to recognise, reward and place on record any direct or indirect outstanding and exemplary contribution by the employee towards growth and profitability of the company. The scheme stipulates the following nine categories of awards, each valuing up to Rs. 50,000 in case of an individual, and up to Rs. 5 lakh in the event of a group/team winning the award. 1. BHEL Utkrishthta Puraskar 2. BHEL Gunvatta Puraskar 3. BHEL Tatparta Puraskar 4. BHEL Utpadakta Puraskar 5. BHEL Utkrishtha Takniki Lekh Puraskar 6. BHEL Anusandhan Puraskar 7. BHEL Srijanatmakta Puraskar 8. BHEL Grahak Santushti Puraskar 9. BHEL Paryavaran/Samaj Seva/Sanskriti/Khel Puraskar While the first eight awards are for the company employees only, the ninth award covers spouses and dependent children of the employees also. The Scheme also stipulates Swasth Karamchari Samman which are given to employees in appreciation of good health. 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.
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The 106 nominations, received from various units/ divisions for the year 2001-02 were scrutinized and short listed by a Screening Committee. The short listed entries were evaluated by the Jury constituted by CMD. 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. Their outstanding contribution is hailed as a significant milestone in BHEL's journey towards excellence. 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. 3. Awards won by BHEL Units and Employees SCOPE Award for Excellence and Outstanding Contribution to the Public Sector Management - Individual Category. Shri K.G.Ramachandran, Chairman and Managing Director, has won the coveted SCOPE Award for Excellence and Outstanding Contribution to the Public Sector Management, for the year 2001-02, in his individual capacity for his outstanding contribution to Public Sector management. The award carries a cash amount of Rupees One Lakh and a Golden Plaque. "Achiever of the Year Award" by CHEMTECH Foundation Shri K.G.Ramachandran, Chairman and Managing Director, has been awarded the "Achiever of the Year Award" by CHEMTECH Foundation, in recognition of his contribution to industry, under the category of Power Plant and Machinery Industry. He was unanimously selected by the awards committee, comprising some of the most prominent industrialists of the country. Prime Minister's Shram Awards Prestigious "Prime Minister's Shram Awards" instituted by Ministry of Labour namely Shram Bhushan, Shram Vir and Shram Shri have been won by four BHEL employees for the year 2002. This is the highest number of awards won by BHEL since the inception of the awards in 1985. Vishwakarma Rashtriya Puraskars Six Vishwakarma Rashtriya Puraskars, for the year 2000 were won by 19 employees of BHEL. The award is instituted by Ministry of Labour. National Safety Awards Four BHEL Units, i.e. Tiruchy, Hyderabad, Electronics Division - Bangalore and Electro porcelains Division Bangalore, won National Safety Awards for the year 2000. The award is instituted by Ministry of Labour. "Excellence in Energy Management"CII Awards HEEP-Haridwar Unit has been awarded a certificate in the category of an "Energy Efficient Unit", along with other companies, in the competition held in December, 2002 at Chennai by CII.
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INSSAN Awards Hyderabad Unit has won the first prize for Excellence in Suggestion Scheme, Best Suggestor Award and two Best Slogan Awards in the INSSAN National Convention for the year 2002. These awards are instituted by the Indian National Suggestion Scheme Association (INSSAN). Those details of the awards won by Hyderabad Unit are: a) Excellence in Suggestion Scheme b) Best Suggestor Award c) Best Slogan Award (Hindi) d) Best Slogan Award (English) 4. Human Resource Development During 2002-03, 40466 participants were exposed to different training programs in our various training Centers at Units as well as at apex level in NOIDA. Besides, 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. Also, 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. 5. Activities of the company for welfare and Advancement of Scheduled Castes (SCs) And Scheduled Tribes (STs) The company has been following the Presidential Directives and guidelines issued by the Government of India from time to time regarding reservation for SCs and STs in letter and spirit. During the year, the various Community Development activities focused on Socio- Economic development of SCs and STs have been carried out by BHEL in the 56 villages adopted by it. Representation of SC/ST employees the representation of SC/ST employees in total manpower was 18.13% and 3.73% for SCs and STs respectively as on 1/1/2003

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PRODUCTS
Industrial fans Power generation & Transmission Sam less Steal tubes Steam Turbine-Generation Sets & Auxiliaries Fabric Filter Boiler and Boiler Auxiliaries AC/DC Motors, Variable Speed Once through Boilers AC Drives Nuclear Power Generation Equipment Electronic Control Gear & 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, AC,AC/DC Locomotives Bag Filter Diesel- Electric Shunting Locomotives
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Valves Tractions Motors Pump Electric Trolley buses electric Machines AC Electric Multiple Units Piping System Drives & Control for Metro system Power, Distribution 7 Instrument Transformers - Battery Operated Passenger Vans Reactors Oil Rigs & Oil Field Equipments Synchronous Condensers Digital Switching System Switchgear Rural Automatic Exchange Control Gear 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

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A dynamic 67000 Strong team embodies the BHEL philosophy of professional excellence with corporate headquarters in New Delhi: BHEL is Indias ambassador to the world with export presence in more than 50 countries. BHEL has a consistent tract of growth performance & profitability.

INTERNATIONAL OPERATIONS
BHEL has over this year established its references in around 60 countries of the world ranging from United States in the west to New Zealand in the East. These References Encompass almost the entire product range of BHEL covering turnkey power project of thermal hydro and gas based type substation project, rehabilitation project, based a wide variety of project, like transformers, insulators, switchgears, heat exchanger, casting and forging, valves well-head equipment etc. Apart from over 1110 MW of boiler capacity contributed in Malaysia and execution of four prestigious power project in Oman, some of the other major successes achieved by the company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Egypt. Technology Up gradation and Research & Development to remain competitive and meet customers expectations, BHEL lays great Emphasis on the continuous up gradation of product and related technologies and development of new project works. The company has upgraded its product to contemporary levels through continuous in- house effort as well as through acquisition of new technology from leading engineering origination of the world. The Corporate R&D Division at Hyderabad, spread over a 140 acre complex leads BHEL research efforts in the number of areas of importance to BHELs product range research and product development center at each of the manufacturing division play a complementary role. BHELs investment in R7D is among the largest past several state-pf-the art product developed in housing 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 produced developed in housing:
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low-Nox oil gas burner, circulating fluidized bed combustion boilers high efficiency Pillion hydro-turbines, petroleum depot automation system, 36KV gas insulated sub stations, etc. The company also transferred a few technologies developed in-housing to other Indian companies for commercialization. Some of on going developed & demonstration project include: Smart wall blowing system for cleaning boiler soot deposit , and micro- controller based governor for diesel- Electro-locomotives . The company also engaged in research in futuristic areas, such as application of super conducting materials in power generation and industry, and fuel cells for distributed environment friendly power generation.

HUMAN RESOURCE DEVELOPMENT INSTITUTE

The most praised asset of BHEL is its employers. 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, whenever required Continuous training and retraining, a positive work culture and Participative style of management, have engendered developed of a committed and motivated workforce, 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, and to provide safe and healthy working environment to all its employers. For fulfilling these obligations, Corroborate Policies have been formulated as; Environmental Policy: Compliance with applicable Environmental Legislation/ Regulation;
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Continual improvement in Environmental Management System to protect our natural environment and Control Pollution; Promotion of activities for conservation of resources by Environmental Management Enhancement of Environment awareness among employees, custom & suppliers BHEL will also assist and cooperate with the concerned governmental Agencies and Regulatory Bodies engaged in environmental activities, offering the companys capabilities in this field. Occupational Health and Safety policy: Compliance with applicable Legislations and Regulations; Setting objectives and targets to eliminate/ control /minimize risks due to Occupational safety Hazards; Formulation and maintenance of OH&S Management Programs for continual improvement. Product review of OH&S Management system to ensure it continuing suitable adequacy and effectiveness; Communications of OH&S Polices to its all employees and interested parties. The major units of BHEL have already acquired ISO14001.Environmental management system certification, 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 business Community, international labour and NGOs. It provided a forum of them to work together and Improve corporate practices through co-operation
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Compact of United Nations and has committed to support it and the set of core value ensured its nine principles.

PRINCIPLES OF THE GLOBAL COMPACT HUMAN

RIGHTS 1. Business should support and respect the protection of internationally proclaimed Human rights 2. Make sure that they are not complicit in human rights abuse. Lab our standards 3. Business should uphold the freedom of association and the effective Recognition of the rights to collective bargaining. 4. The elimination of all forms of forces and compulsory labors. 5. The effective abolition of child labor 6. Eliminate discrimination. 7. Business should support a precautionary to environmental changes. 8. Undertake initiatives to promote grater environmentally responsibility. 9. Encourage the development and diffusion of environmentally friendly techniques by joining the Global Compact , BHEL would get a unique opportunity of networking with corporate and sharing experiences related to social responsibility on Global basis.

FUTURE PLANS
As a part of forward integration strategy the company plans to enter into the power distribution business. The company already manufactures product required by the distribution systems like transformers, switchgears etc. BHEL has announced that it will launch a B2B portal, keeping in mind its core competency-power systems. As per the company announcement it could take them four to six month to announce the location of its new business. The company is planning towards becoming an application service provider.

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The company will continue to focus on project management reducing cycle time and cost control. In the power sector, the company plans to obtain a part of the business generated by independent power producers through a combination of approaches including consortium route, equity participation and limited financial syndication. BHEL would also put additional emphasis on spares and service business for hydro and thermal plants. BHEL is introducing a number of new products like 3-phase traction electric and advance class gas turbines in the Indian market. It is equipping it self with the new type of once-through design boiler technology, and for pollution control-bag filter technology. BHEL is planning to enter new business in integrated gasification combined cycle system, coal washeries and LRT systems. In its existing businesses of transportation, transmission and industry. BHEL is pursuing opportunities in EMU coaches, loco refurbishment, gas-insulated switcher, HVDC insulators and electronic meters. The company will continue to focus on product development in order to foster its growth strategy. New products are expected to contribute 46% of its total turnover. The electronics division has frayed into traction business and received a large order from Dot for switching equipment for 0.25mm lines. The Industrial System Group has bagged orders from BWSSB for water pumping stations (Cauvery Stage IV), funded by Japan Bank for international cooperation. The electro porcelains division is now manufacturing HVDC disk insulator and its catalytic converter has also passed the entire test. Bharat Heavy Electricals Limited (BHEL) - SWOT Analysis

Bharat Heavy Electricals Limited (BHEL) - SWOT Analysis company profile is the essential source for top-level company data and information. Bharat Heavy Electricals Limited (BHEL) - SWOT Analysis examines the companys key business structure and operations, history and products, and provides summary analysis of its key revenue lines and strategy. Bharat Heavy Electricals (BHEL) is an India-based engineering and
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manufacturing company that develops electrical and power equipment in energy related and infrastructure sector. It manufactures over 180 products under 30 major product groups and caters to sectors including power generation and transmission, transportation, and renewable energy, among others. The company operates in India. BHEL is headquartered in New Delhi, India and employs over 45,200 people. The company recorded revenues of INR264,914 million (approximately $5,780.4 million) during the financial year ended March 2009 (FY2009). The operating profit of the company was INR48,731.3 million (approximately $1,063.3 million) during FY2009. Scope of the Report - Provides all the crucial information on Bharat Heavy Electricals Limited (BHEL) required for business and competitor intelligence needs - Contains a study of the major internal and external factors affecting Bharat Heavy Electricals Limited (BHEL) in the form of a SWOT analysis as well as a breakdown and examination of leading product revenue streams of Bharat Heavy Electricals Limited (BHEL) -Data is supplemented with details on Bharat Heavy Electricals Limited (BHEL) history, key executives, business description, locations and subsidiaries as well as a list of products and services and the latest available statement from Bharat Heavy Electricals Limited (BHEL) Reasons to Purchase - Support sales activities by understanding your customers businesses better - Qualify prospective partners and suppliers - Keep fully up to date on your competitors business structure, strategy and prospects - Obtain the most up to date company information available

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SWOT ANALYSIS
STRENGTHS
The company has 180 products under 30 major product groups that cater to the needs of the core sector like power, industry,transmission, defense, telecommunication and oil business BHELs ability to acquire modern technology and make it suitable to Indian conditions has been an exceptional strength of the company Quality Cost Competitiveness After sales services Research and development Global Presence Relatively stable industrial relationship Access to contemporary technologies with the support from renowned collaborators. Sound engineering base and ability to assimilate Ability to set up power plants on turnkey basis, complete know- how for manufacture of entire equipment is available with the company. Ability to manufacture or procure to supply spares. Fully equipped to take capital maintenance and servicing of the power plants. Largest source of domestic business leading to major presence and influence in the market.
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Ability to successfully overhaul and renovate power stations equipment of different international companies. Low labour cost.

WEAKNESSES
The company offers very stringent credit facilities to the customers and this is a weakness when compared to in the face of rising competition The company is vertically integrated, which could have been avoided by outsourcing its components for power generation and transmission. This could have reduced the cost. Larger delivery cycles in comparison with international suppliers of similar equipment. Inability to provide suppliers credit, soft loans and financing of power projects. Due to poor financial position of state electricity boards, which are the major customers of BHEL in India, liquidity position of BHEL is not satisfactory. Being a public sector company BHEL is suffering from sub optimality of control due to: 1. Displacement of social objectives by political objectives, which may lead to redundant costs and also rising costs. 2. Direct political intervention in managerial decision over an arm length relationship that would restrict governments task of setting appropriate managerial incentive structure. 3. Private goals that lead to budget growth and employment growth. 4. Internal inefficiencies in bureaucratic activity

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OPPORTUNITIES
The power sector reforms are expected to pick up in the near future in India, which would directly benefit BHEL. The business of modernization and renovation of power plants is expected to grow in India. The disinvestment plans of the government would bring in new resources and experience into the company Joint venture with Siemens in the name of POWERPLANT PERFORMANCE IMPROVEMENT LTD.(PPIL), is a major strength for the company. This tie up will be beneficial as there is a lot of scope for business. Demand for power and hence plant equipment is expected to grow. Private sector power plants to offer expanded market as utilities suffers resource crunch. Ageing power plants would give rise to more spares and services business. Life expansion program for old power stations. Easy processing of joint ventures/ collaboration/import/ acquisition of new technology. Financial and operational autonomy for profit making public sector enterprises. To make the public sector more efficient government has decided to grant enhanced autonomy and delegation of powers to the profit making public sector enterprises

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THREATS
The global trend of consolidation has already resulted in a fall in turnover of the company and this will prove to be a major threat in the years to come as 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.E.Bs, so future power projects would be opened up in private sector Level playing ground not available, foreign companies spending much more on business promotion tactics

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HYDRO TURBINES
A leading engineering enterprise which supplies all types of equipment for hydro power generation. A leading turbine manufacturer offering a wide range of Hydro Turbine, Valves, Governors, Turbine and Station Auxiliary systems, Balance of plants for Hydro Power Station and related Services. Installed manufacturing capacity:2500 MW/annum. Two units manufacturing hydro turbines. In the market for more than three decades. Dedicated shop area of over 100000 sq. meters. Ultramodern model development and testing facilities. Sophisticated CAD/CAM facilities. ISO 9001 Certification. ASME "Q" stamp for fabrication facilities.

PELTON WHEEL (TURBINE)

The Pelton wheel is a tangential flow impulse turbine. It was invented by Lester Allan Pelton in the 1870s. The Pelton wheel extracts energy from the impulse of moving water, as opposed to its weight. The water strikes the bucket along the tangent of the runner. Inlet Energy= KINETIC ENERGY Outlet Energy=ROTATIONAL KINETIC ENERGY OF TURBINE+ KINETIC ENERGY OF WATER Used for HIGH HEADS

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FUNCTION: The water flows along the tangent to the path of the runner. Nozzles direct forceful streams of water against a series of spoon-shaped buckets mounted around the edge of a wheel. As water flows into the bucket, the direction of the water velocity changes to follow the contour of the bucket. When the water-jet contacts the bucket, the water exerts pressure on the bucket and the water is decelerated as it does a "u-turn" and flows out the other side of the bucket at low velocity. In the process, the water's momentum is transferred to the turbine. This "impulse" does work on the turbine. For maximum power and efficiency, the turbine system is designed such that the water-jet velocity is twice the velocity of the bucket. A very small percentage of the water's original kinetic energy will still remain in the water; however, this allows the bucket to be emptied at the same rate it is filled, (see conservation of mass), thus allowing the water flow to continue uninterrupted. Often two buckets are mounted side-by-side, thus splitting the water jet in half (see photo). This balances the side-load forces on the wheel, and helps to ensure smooth, efficient momentum transfer of the fluid jet to the turbine wheel. Because water and most liquids are nearly incompressible, almost all of the available energy is extracted in the first stage of the hydraulic turbine. Therefore, Pelton wheels have only one turbine stage, unlike gas turbines that operate with compressible fluid. MAIN PARTS OF PELTON TURBINE ARE: 1. Nozzle and flow regulating arrangement 2. Runners and buckets 3. Casing 4. Draft Tube

Design rules
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The specific speed of a turbine dictates the turbine's shape in a way that is not related to its size. This allows a new turbine design to be scaled from an existing design of known performance. The specific speed is also the main criterion for matching a specific hydro-electric site with the correct turbine type. (dimensioned parameter), where: = Power (kW) = Water head (m) The formula implies that the Pelton turbine is most suitable for applications with relatively high hydraulic head H, due to the 5/4 exponent being greater than unity, and given the characteristically low specific speed of the Pelton. = 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. This is done with the help of many powerful cloud computing and computer aided analyzing softwares like ANSYS, ICEM, CFX, TURBOGRID etc. 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.

TESTING METHODS:
BHEL, Bhopal has a dedicated HYDRO LAB for testing the models of the turbines to be produced by the manufacturing units. 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.

BHEL BHOPAL PELTON TURBINES PROJECTS

PROJECT RATING (No. 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

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FRANCIS TURBINE
The Francis turbine is a type of Inward Flow Reaction Turbine having radial discharge at outlet.
The Francis turbine is a type of water turbine that was developed by James B. Francis in Lowell, Massachusetts. In modern Francis turbines, the water enters the runner of the turbine in the radial direction at outlet and leaves in the axial direction at the inlet of the runner. Thus modern francis turbine is a Mixed flow reaction turbine.

Different Parts Of Francis Turbine

A francis turbine comprises mainly the following parts: 1)Spiral Casing 2)Guide 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 . All throughout it's length, it has numerous openings at regular intervals to allow the working fluid to impound on the blades of the runner. these openings convert the pressure energy of the fluid into momentum energy just before the fluid impound on the blades. to maintain a constant flow rate despite the fact that numerous openings have been provided for the fluid to gain entry to the blades,the cross-sectional area of this casing decreases uniformly along the circumference. Guide or Stay Vanes: The primary function of the guide or stay vanes is to convert the pressure energy of the fluid into the momentum energy. it also serves to direct the flow at design angles to the blade runners. 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. 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.

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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. This permits the turbine to be set above the tail water without any appreciable drop of available head. The purpose of providing a draft tube will be better understood if we carefully study the net available head across a reaction turbine.

Theory of Operation
The Francis turbine is a type of reaction turbine, a category of turbine in which the working fluid comes to the turbine under immense pressure and the energy is extracted by the turbine blades from the working fluid. A part of the energy is given up by the fluid because of pressure changes occuring in the blades of the turbine,

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quantified by the expression of Degree Of Reaction, while the remaining part of the energy is extracted by the volute casing of the turbine. At the exit, water acts on the spinning cup-shaped runner features, leaving at low velocity and low swirl with very little kinetic or potential energy left. The turbine's exit tube is shaped to help decelerate the water flow and recover the pressure.

CUT VIEW OF FRANCIS TURBINE(GUIDE VANES)

BHEL BHOPAL FRANCIS TURBINE PROJECTS

PROJECT RATING (No. X Mw) 6 X 165 4 X 150 3 X 135 HEAD (m) 320 100 304 SPEED(RP M) 300 166.7 300 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. It was developed in 1913 by the Austrian professor Viktor Kaplan, 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. They cover the lowest head hydro sites and are especially suited for high flow conditions. Inexpensive micro turbines on the Kaplan turbine model are manufactured for individual power production with as little as two feet of head. For axial flow reaction turbine the shaft is vertical. The lower end of the shaft is made larger which is known as hub or boss. MAIN PARTS OF KAPLAN TURBINE ARE: 1. Scroll casing
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2. Guide vane mechanism 3. Hub with vanes or the runner of the turbine 4. Draft tube

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BHEL BHOPAL KAPLAN TURBINE PROJECTS

PROJECT RATING (No. X Mw) 5 X 50 4 X 75 3 X 33 HEAD (m) 36.0 47.8 20.4 SPEED(RP M) 136.4 150 115.4 RUNNER DIAMETER (mm) 4700 5650 5182 SPIRAL INLET (mm) 6200 6500 7982

S S Canal UKAI OBRA

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BUTTERFLY VALVES
A Butterfly Valve is used to control the flow of material through a circular pipe or tube. Typically the material is air, gas, steam, or liquid. Certain dry materials may also be handled through a butterfly valve. Simply, a butterfly valve consists of a circular disc with its pivot axis at right angles to the direction material is flowing. The valve is made up of a body, seat, disc, stem, and actuator. Each component part is available in a variety of materials called trim features. Properly combining trim features to address material handled and environment is important in selecting the correct model valve for its intended service. Applications As stated earlier, Butterfly Valves are generally specified for most air, gas, steam, and liquid applications. They offer an excellent, economically priced, positive shut-off valve for handling materials (e.g. gases and liquids) that are easily displaced by the valve disc as it closes. When handling this type of material, butterfly valves provide a reliable, bubble-tight, bi-directional shut off. 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. 2) The obstructed orifice created by the disc may cause bridging of material on the inlet side of the valve. 3) A disc opening or closing on a standing column of dry material may cause the material to jam / pack. 4) Particles of dry material or suspended particles in slurries may become trapped between the disc and seat, causing conveying line inefficiencies. Other Types of Butterfly Valves As a person becomes familiar with butterfly valves, they will undoubtedly discover other types of butterfly valves on the market. Listed below is a brief introduction to some of these other types. Inflatable Seated Butterfly Valves

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Inflatable seated butterfly valves utilize an inflatable seat or bladder to create a seal around the disc. Once the disc is brought to the closed position, the bladder is inflated pneumatically. Pros: 1) Since the seal is created after the disc closes, less torque is required to move the disc into the closed position. A smaller sized actuator costing less money is can be used. 2) Again, because the seal is created after the disc closes, minimal abrasion exists between the disc and the seat. Cons: 1) In addition to the controls needed to verify the position of the disc, additional controls are needed to identify whether the bladder is inflated or not. These controls add cost to the valve. 2) The bladder may be damaged and not creating a seal, even though controls identify that a seal has been established. 3) The valve must be located near an air supply to pneumatically inflate the bladder. 4) The inflatable bladder is subject to damage and abrasion, requiring periodic replacement.

BHEL BHOPAL BUTTERFLY VALVES PROJECTS

PROJECT VALVE DIAMETER (mm) 2 X 115 2 X 89 4 X 84 MAX. HEAD (m) 460 440 435 DOOR TYPE Balimela Ranjit Nagar Srisailam LENS LATTICE LATTICE

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HEAT EXCHANGERS
Thermal group of BHEL-Bhopal was formulated in year 1968 (Initial collaboration with M/s AEI -U.K. took place in year 1970) and started its production from year 1971 onwards. Subsequently, new collaboration agreement with M/s BALCKE DURR- Germany for Moisture Separator Re-Heater (MSR) took place in 1987. MSR to this new design were manufactured and supplied for 236 MW RAPP 3, 4 & KAIGA 1, 2 and 500 MW TAPP 3&4 Nuclear plants. BHEL-Bhopal Thermal group products manufactured and supplied all over India to different State Electricity Boards and exported to countries like LIBYA, Malaysia, Azerbaizan, Bangladesh, OMAN etc. major customers of thermal equipments are State Electricity Boards and NTPC. Similarly Industrial Heat Exchangers have been supplied to IFFCO, FEDO, RELIANCE, GAIL, ONGC, IOCL, etc. Production of some of the other products like Rubber Expansion Joints, Flash Tanks, Miscellaneous storage tanks and Butterfly valves added in subsequent years. All the Thermal products are tailor made and customer specific product. and Customer requirements are continuously captured through pre-tender and post tender discussions, contract review etc. Perception is collected through customer surveys. Thermal group products are Technology intensive and therefore Technology development is of strategic importance. Product technology is continuously upgraded through in house development projects/ or Technical Collaboration. Heat Exchanger Auxiliary Heat Exchangers Different types of auxiliary heat exchangers are being manufactured at BHEL. Depending upon application these auxiliary Heat Exchangers are named as . Air Coolers (CACW) . Oil Coolers (Shell & tube type / Frame and tube type (Single tube & Concentric double tube construction) / OFAF), Plug in type . Water Water Cooler (Shell & Tube type) . Hydrogen Cooler etc. (Frame and tube type). . Air Cooler CACA ( Duct and tube type) These coolers are accessories to main equipments such as Generator, Turbine, Transformer , Motors, etc. hence special attention is given to make these coolers compact in design and for trouble free service. To ensure long life of these coolers materials for different components is decided carefully considering its application and water chemistry. Constructionally these coolers are very easy to maintain.
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Technical Information/Application Air coolers, Oil coolers, Water-Water coolers and Hydrogen Coolers act as accessories to Transformers, turbines, Motors and Generators, etc. In Generator, 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. In turbine, oil coolers are used to cool bearing oil or the oil which in turn cools the rotating parts. Similarly, Transformer Coolers are used to cool transformer oil by air or water. These coolers play an important role in smooth functioning of the main equipments. CACW type and CACA type air coolers are also used for cooling air, which in turn cools motor windings. Industrial Heat Exchangers Industrial Heat Exchangers, as the name implies are used in industries dealing in various types of chemicals. In general Heat Exchangers used are of shell and tube type construction. Main components of shell and tube type heat exchangers are tube nest assembly; shell assembly and types of enclosure i.e. end closing. BHEL is manufacturing different types of shell and tube type heat exchangers for Industries like Refineries , Petrochemicals and Fertilizers, etc. Since different type of chemicals is involved in Industrial Heat Exchangers, material selection becomes an important criteria.

BHEL is capable of doing special types of mechanical design apart from normal design of shell, tubes , dished ends ,flat covers, backing ring and flanges etc. Special type of mechanical design covers design of eccentric/concentric types of shell i.e. kettle type construction , reverse flange type design, fixed tube sheet with bellows, high pressure enclosures , and double pipe type heat exchangers. BHEL is having a vast experience of manufacturing and supply of Heat Exchangers with Carbon steel , stainless steel, Alloy Steel and Non-ferrous tubes and shell materials. In addition to the type as mentioned earlier , Cladded Exchangers also have been supplied by BHEL. Various types of constructional features as described in TUBULAR EXCHANGER MANUFACTURERS ASSOCIATED (TEMA) Standard can be offered by BHEL.

Feed Water Heaters

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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. 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. 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. Feed water heaters are designed as per HEI standard and high pressure heaters comes under purview of Indian Boiler Regulations. Hence these are designed and manufactured in strict compliance to applicable code requirements. Technical Information/Application - 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. - The feed water passes through the 'U' tubes and the steam/drain (condensed steam) passed over the tubes. 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. Feed heaters play a vital role in power plant. The heaters are, therefore, subjected to very onerous duty and hence the design and manufacture of both type of heaters, i.e. High Pressure heaters and Low pressure feed water heaters complies with the highest standard of engineering to provide adequate reliability in the operation of these heaters. 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, while separating the high energy phases and exchanging heat.

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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. Its modern manifestation was invented by Sir Charles Parsons in 1884. Because the turbine generates rotary motion, 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, which results in a closer approach to the most efficient reversible process.

Steam supply and exhaust conditions

These types include condensing, non-condensing, reheat, extraction and induction.

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

REHEAT TURBINES
Reheat turbines are also used almost exclusively in electrical power plants. In a reheat turbine, 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. Using reheat in a cycle increases the work output from the turbine and also the expansion reaches conclusion before the steam condenses, there by minimizing the erosion of the blades in last rows. In most of the cases, 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. Extracting type turbines are common in all applications. In an extracting type turbine, steam is released from various stages of the turbine, and used for industrial process needs or sent to boiler feed water heaters to improve overall cycle efficiency. Extraction flows may be controlled with a valve, or left uncontrolled. Induction turbines introduce low pressure steam at an intermediate stage to produce additional power.

Casing or shaft arrangements

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

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

The moving steam imparts both a tangential and axial thrust on the turbine shaft, but the axial thrust in a simple turbine is unopposed. To maintain the correct rotor position and balancing, this force must be counteracted by an opposing force. Either thrust bearings can be used for the shaft bearings, 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, so that the axial forces negate each other but the tangential forces act together. This design of rotor is called two-flow or double-exhaust. This arrangement is common in low-pressure casings of a compound turbine.

BHEL BHOPAL STEAM TURBINE PROJECTS

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

30 MW, 120 MW Steam Turbines 236 MW Nuclear Turbines. 15000 SHP Marine Turbines 210 MW Steam Turbines. 2) Supply of Spares and Repairs of above Steam Turbines.

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3) R & M and Life assessment studies of BHEL & Non BHEL TG sets. 4) Repair and Supply of Spares of 210 MW and 500 MW KWU Turbines. 5) Repair and supply of Spares for Non BHEL TG Sets.

TECHNICAL SPECIFICATION OF 210 MW STEAM TURBINE SL.NO DESCRIPTIO N PARAMETER

1 2

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

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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.ABS H.P-1,DOUBLE FLOW IP-1,DOUBLE FLOW LP-1 HP-25, IP-20 +20,LP-8+8 676 MM

2132 MM

-DOUBLE SHELL HP WITH BARREL TYPE OUTER SHELL - DOUBLE SHELL DOUBLE FLOW IP - HYDRAULIC BARRING - ELECTROHYDRAULIC GOVERNING

14 15 16 17

WEIGHT OF TURBINE LENGTH OF TURBINE TYPE OF TURBINE COLLABORA TOR

425 TONNES 14.1 METERS REACTION SIEMENS, GERMANY

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HYDRO GENERATORS
FACILITIES AT BHEL BHOPAL
Fabrication facilities Special types of welding - Submerged Arc - Electro slag - Narrow Gap - TIG 3000 T shell bending press Electronic flame cutting machine Stress relieving furnace Shot blasting chamber NDT test facilities - Dye penetrant - Magnetic particle - Ultrasonic - Radiographic

Machining facilities Rotating Column Vertical Borer :Max. Job dia 16 mtrs -Ht 4mtrs Vertical Borer (HOMMA) :Max. job dia 9 mtrs - Ht 4mtrs Horizontal Ram Borer :Max. travel Vert. 4.15 mtrs. -Horiz 19mtrs Horizontal Planning Machine:Bed Length 9 mtrs. -Ht 3 mtrs. Centre Lathe:Max. Job dia 4 mtrs. -Length 15 mtrs

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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 - Characteristic curves - Temperature rise efficiency - 3-phase sudden short circuit test

STATOR HYDRO GENERATOR COILS ASSEMBLY AFTER INSULATION

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PHOSPHATE COATING
Phosphate coatings are used on steel parts for corrosion resistance, lubricity, or as a foundation for subsequent coatings or painting.[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, crystalline phosphates.[3] Phosphate conversion coatings can also be used on aluminium, zinc, cadmium, silver and tin. 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.[6] When steel or iron parts are placed in the phosphoric acid, a classic acid and metal reaction takes place which locally depletes the hydronium (H3O+) ions, raising the pH, and causing the dissolved salt to fall out of solution and be precipitated on the surface. The acid and metal reaction also creates iron phosphate locally which may also be deposited. In the case of depositing zinc phosphate or manganese phosphate the additional iron phosphate is frequently an undesirable addition to the coating. The acid and metal reaction also generates hydrogen gas in the form of tiny bubbles that adhere to the surface of the metal. 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. This chemistry is known as a nitrate accelerated solution. Hydrogen is prevented from forming a passivating layer on the surface by the oxidant additive. The following is a typical phosphating procedure:[3] 1. 2. 3. 4. 5. 6. 7. 8. cleaning the surface rinsing surface activation (in some cases) phosphating rinsing neutralizing rinse (optional) drying application of supplemental coatings: lubricants, sealers, oil, etc.

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DEGREASING 10-42 MINS TEMP. 70-80 DEGREE. CELSIUS CONC. 75-80 gm/liters( CAUSTIC SODA) SURFOLINSK-40

RINSING 10-12 MINS TEMP. 20-30 DEGREE. CELSIUS FRESH WATER

PICKLING 10-12 MINS TEMP. 60-70 DEGREE. CELSIUS CONC. 50-60 gm/liters SULPHURIC ACID(HOT) HYDROCHLORIC ACID (COLD)

RINSING 10-12 MINS TEMP. 20-30 DEGREE. CELSIUS FRESH WATER

DERUSTING 8-10 MINS TEMP. 70-80 DEGREE. CELSIUS KEMPICRLE 711

PHOSPHATING 5-10 MINS TEMP. 55-90 DEGREE. CELSIUS SURFIX 601

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BIBLIOGRAPHY
1. BHEL Manual 2. www.google.com 3.www.wikipedia.org 4. BHEL Diary 2008 5.www.bhel.com

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