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A. BHEL – AN OVERVIEW
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 when its first plant
was setup in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India
a dream which has been more than realized with a well recognized track record of
performance it has been earning profits continuously since 1971-72 and achieved a sales
turnover of Rs. 6347 crore with a pre-tax profit of Rs. 294 crore in 2000-01.
BHEL caters to core sectors of the Indian Economy viz., Power Generation's &
Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense,
etc. The wide network of BHEL's 14 manufacturing division, four power Sector regional
centres, over 150 project sites, eight service centres and 18 regional offices, enables the
Company to promptly serve its customers and provide them with suitable products, systems
and services – efficiently and at competitive prices. BHEL has already attained ISO 9000
certification for quality management, and ISO 14001 certification for environment
management.
POWER GENERATION
Power generation sector comprises thermal, gas, hydro and nuclear power plant
business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the
total installed capacity of 99,146 MW in the country, as against nil till 1969-70.
BHEL has proven turnkey capabilities for executing power projects from
concept to commissioning, it possesses the technology and capability to produce thermal sets
with super critical parameters up to 1000 MW unit rating and gas turbine generator sets of up
to 240 MW unit rating. Co-generation and combined-cycle plants have been introduced to
achieve higher plant efficiencies. to make efficient use of the high-ash-content coal available
in India, BHEL supplies circulating fluidized bed combustion boilers to both thermal and
combined cycle power plants.
The company manufactures 235 MW nuclear turbine generator sets and has commenced
production of 500 MW nuclear turbine generator sets.
Custom made hydro sets of Francis, Pelton and Kapian types for different head discharge
combination are also engineering and manufactured by BHEL.
In all, orders for more than 700 utility sets of thermal, hydro, gas and nuclear have been
placed on the Company as on date. The power plant equipment manufactured by BHEL is
based on contemporary technology comparable to the best in the world and is also
internationally competitive.
The Company has proven expertise in Plant Performance Improvement through renovation
modernisation and uprating of a variety of power plant equipment besides specialised know
how of residual life assessment, health diagnostics and life extension of plants.
POWER TRANSMISSION & DISTRIBUTION (T & D)
BHEL offer wide-ranging products and systems for T & D applications. Products
manufactured include power transformers, instrument transformers, dry type transformers,
series – and stunt reactor, capacitor tanks, vacuum – and SF circuit breakers gas insulated
switch gears and insulators.
A strong engineering base enables the Company to undertake turnkey delivery of electric
substances up to 400 kV level series compensation systems (for increasing power transfer
capacity of transmission lines and improving system stability and voltage regulation), shunt
compensation systems (for power factor and voltage improvement) and HVDC systems (for
economic transfer of bulk power). BHEL has indigenously developed the state-of-the-art
controlled shunt reactor (for reactive power management on long transmission lines).
Presently a 400 kV Facts (Flexible AC Transmission System) project under execution.
INDUSTRIES
BHEL is a major contributor of equipment and systems to industries. Cement, sugar,
fertilizer, refineries, petrochemcials, paper, oil and gas, metallurgical and other process
industries lines and improving system stability and voltage regulation, shunt compensation
systems (for power factor and voltage improvement) and HVDC systems (for economic
transfer of bulk power) BHEL has indigenously developed the state-of-the-art controlled
shunt reactor (for reactive power management on long transmission lines). Presently a 400
kV FACTS (Felxible AC Transmission System) projects is under execution.
INDUSTRIES
BHEL is a major contributor of equipment and systems to industries, cement, sugar, fertilizer,
refinances, petrochemicals, paper, oil and gas, metallurgical and other process industries. The
range of system & equipment supplied includes: captive power plants, co-generation plants
DG power plants, industrial steam turbines, industrial boilers and auxiliaries. Wate heat
recovery boilers, gas turbines, heat exchangers and pressure vessels, centrifugal compressors,
electrical machines, pumps, valves, seamless steel tubes, electrostatic precipitators, fabric
filters, reactors, fluidized bed combustion boilers, chemical recovery boilers and process
controls.
The Company is a major producer of large-size thruster devices. It also supplies digital
distributed control systems for process industries, and control & instrumentation systems for
power plant and industrial applications. BHEL is the only company in India with the
capability to make simulators for power plants, defense and other applications.
The Company has commenced manufacture of large desalination plants to help augment the
supply of drinking water to people.
TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production,
installation, maintenance and after-sales service of Rolling Stock and traction propulsion
systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000
HP, diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting
duly applications. BHEL is also producing rolling stock for special applications viz.,
overhead equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides traction
propulsion systems for in-house use, BHEL manufactures traction propulsion systems for
other rolling stock producers of electric locomotives, diesel-electric locomotives, electrical
multiple units and metro cars. The electric and diesel traction equipment on India Railways
are largely powered by electrical propulsion systems produced by BHEL. The company also
undertakes retooling and overhauling of rolling stock in the area of urban transportation
systems. BHEL is geared up to turnkey execution of electric trolley bus systems, light rail
systems etc. BHEL is also diversifying in the area of port handing equipment and pipelines
transportation system.
TELECOMMUNICATION
BHEL also caters to Telecommunication sector by way of small, medium and large switching
systems.
RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional and renewable
sources of energy include wind electric generators, solar photovoltaic systems, solar lanterns
and battery-powered road vehicles. The Company has taken up R&D efforts for development
of multi-junction amorphous silicon solar cells and fuel based systems.
INTERNATIONAL OPERATIONS
BHEL has, over the years, established its references in around 60 countries of the world,
ranging for the United States in the West to New Zealand in the Far East. These references
encompass almost the entire product range of BHEL, covering turnkey power projects of
thermal, hydro and gas-based types, substation projects, rehabilitation projects, besides a
wide variety of products, like transformers, insulators, switchgears, heat exchangers, castings
and forgings, valves, well-head equipment, centrifugal compressors, photo-voltaic equipment
etc. Apart from over 1110MW of boiler capacity contributed in Malaysia, and execution of
four prestigious power projects in Oman, Some of the other major successes achieved by the
Company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt,
Bangladesh, Azerbaijan, Sri Lanka, Iraq etc.
The Company has been successful in meeting demanding customer's requirements in terms of
complexity of the works as well as technological, quality and other requirements viz extended
warrantees, associated O&M, financing packages etc. BHEL has proved its capability to
undertake projects on fast-track basis. The company has been successful in meeting varying
needs of the industry, be it captive power plants, utility power generation or for the oil sector
requirements. Executing of Overseas projects has also provided BHEL the experience of
working with world-renowned Consulting Organisations and inspection Agencies.
In addition to demonstrated capability to undertake turnkey projects on its own, BHEL
possesses the requisite flexibility to interface and complement with International companies
for large projects by supplying complementary equipment and meeting their production needs
for intermediate as well as finished products.
The success in the area of rehabilitation and life extension of power projects has established
BHEL as a comparable alternative to the original equipment manufactures (OEMs) for such
plants.
TECHNOLOGY UPGRADATION AND RESEARCH & DEVELOPMENT
To remain competitive and meet customers' expectations, BHEL lays great emphasis on the
continuous upgradation of products and related technologies, and development of new
products. The Company has upgraded its products to contemporary levels through continuous
in house efforts as well as through acquisition of new technologies from leading engineering
organizations of the world.
The Corporate R&D Division at Hyderabad, spread over a 140 acre complex, leads BHEL's
research efforts in a number of areas of importance to BHEL's product range. Research and
product development centers at each of the manufacturing divisions play a complementary
role.
BHEL's Investment in R&D is amongst the largest in the corporate sector in India. Products
developed in-house during the last five years contributed about 8.6% to the revenues in 2000-
2001.
BHEL has introduced, in the recent past, several state-of-the-art products developed in-house:
low-NQx oil / gas burners, circulating fluidized bed combustion boilers, high-efficiency
Pelton hydro turbines, petroleum depot automation systems, 36 kV gas-insulated sub-stations,
etc. The Company has also transferred a few technologies developed in-house to other Indian
companies for commercialisation.
Some of the on-going development & demonstration projects include: Smant wall blowing
system for cleaning boiler soot deposits, and micro-controller based governor for diesel-
electric locomotives. The company is also engaged in research in futuristic areas, such as
application of super conducting materials in power generations and industry, and fuel cells
for distributed, environment-friendly power generation.
HUMAN RESOURCE DEVELOPMENT INSTITUTE
The most prized asset of BHEL is its employees. The Human Resource Development
Institute and other HRD centers of the Company help in not only keeping their skills updated
and finely honed but also in adding new skills, whenever required. Continuous training and
retraining, positive, a positive work culture and participative style of management, have
engendered development of a committed and motivated work force leading to enhanced
productivity and higher levels of quality.
HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT
BHEL, as an integral part of business performance and in its endeavour of becoming a world-
class organization and sharing the growing global concern on issues related to Environment.
Occupational Health and Safety, is committed to protecting Environment in and around its
own establishment, and to providing safe and healthy working environment to all its
employees.
For fulfilling these obligations, Corporate Policies have been formulated as:
ENVIRONMENTAL POLICY
Compliance with applicable Environmental Legislation/Regulation;
Continual Improvement in Environment Management Systems to protect our natural
environment and Control Pollution;
Promotion of activities for conservation of resources by Environmental Management;
Enhancement of Environmental awareness amongst employees, customers and
suppliers. BHEL will also assist and co-operate with the concerned Government
Agencies and Regulatory Bodies engaged in environmental activities, offering the
Company's capabilities are this field.
OCCUPATIONAL HEALTH AND SAFETY POLICY
Compliance with applicable Legislation and Regulations;
Setting objectives and targets to eliminate/control/minimize risks due to Occupational
and Safety Hazards;
Appropriate structured training of employees on Occupational Health and Safety
(OH&S) aspects;
Formulation and maintenance of OH&S Management programmes for continual
improvement;
Periodic review of OH&S Management System to ensure its continuing suitability,
adequacy and effectiveness;
Communication of OH&S Policy to all employees and interested parties.
The major units of BHEL have already acquired ISO 14001 Environmental Management
System Certification, and other units are in advanced stages of acquiring the same. Action
plan has been prepared to acquire OHSAS 18001 Occupational Health and Safety
Management System certification for all BHEL units.
In pursuit of these Policy requirements, BHEL will continuously strive to improve work
particles in the light of advances made in technology and new understandings in
Occupational Health, Safety and Environmental Science.
PARTICIPATION IN THE "GLOBAL COMPACT" OF THE UNITED NATIONS
The "Global Compact" is a partnership between the United Nations, the business community,
international labour and NGOs. It provides a forum for them to work together and improve
corporate practices through co-operation rather than confrontation.
BHEL has joined the "Global Compact" of United Nations and has committed to support it
and the set of core values enshrined in its nine principles:
PRINCIPLES OF THE "GLOBAL COMPACT"
HUMAN RIGHTS
1. Business should support and respect the protection of internationally proclaimed
human rights; and
2. Make sure they are not complicit in human rights abuses.
Labour Standards
3. Business should uphold the freedom of association and the effective recognition of the
right to collective bargaining;
4. The elimination of all form of forces and compulsory labour.
5. The effective abolition of child labour, and
6. Eliminate discrimination.
Environment
7. Businesses should support a precautionary approach to environmental challenges;
8. Undertake initiatives to promote greater environmental responsibility and
9. Encourage the development and diffusion of environmentally friendly technologies.
By joining the "Global Compact", BHEL would get a unique opportunity of networking with
corporate and sharing experience relating to social responsibility on global basis.
ACTIVITY PROFILE
PRODUCTS - Industrial Fans
Power Generation & Transmission - Seamless steel Tubes
- Steam Turbine-Generator Sets &
Auxiliaries
- Fabric Filters
- Boiler and Boiler Auxiliaries - AC DC Motors, Variable speed
- Once-through Boilers - AC Drive
- Nuclear Power Generation Equipment - Electronic Control Gear &
Automation
- Hydro Turbine-Generator Sets & Auxiliaries - Equipment
- Mini/Micro Hydro Generator Sets - DDC for Process Industry
- Gas Turbine-Generator Sets - Thruster Equipment
- Waste Heat Recovery Boilers - Power Devices
- Heat Exchangers - Energy Meters
- Condensers - Transformer
- Bowi Mills and Tube Mills - Switch gear
- Gravimetric Feeders - Insulator
- Regenerative Air Pre-Heaters - Capacitors
- Electrostatic Precipitators - Broad Gauge AC, AC/DC Loco
motives
- Bag Filters - Diesel-Electric Shunting
Locomotives
- Valves - Traction Motors & Control
Equipment
- Pumps - Electric Trolley Buses
- Electrical Machines - AC/DC Electric Multiple Units
- Piping Systems - Drives and Controls for Metro
Systems
- Power, Distribution & Instrument Transformers - Battery-Operated Passengers
Vans
- Reactors - X-Mas Trees and Well Heads
- Synchronous Condensers - Cathodic Protection Equipment
- Switchgear - Digital Switching Systems
- Control gear - Rural Automatic Exchange
- Distributed Digital Control for Power
Stations
- Simulators
- Bus Ducts - Wind Electric Generators
- Rectifiers - Solar Powered Water Pumps
- Porcelain Insulators - Solar Water Heating Systems
- Ceralin - Photo Votaic Systems
- Defense Equipment
INDUSTRIES/TRANSPORTATION/OIL &
GAS/
- Reverse Osmoses Desalination
Plants
TELECOMMUNICATION/RENEWABLE
ENERGY
SYSTEMS & SERVICES
- Steam Turbine-Generator Sets - Turkey Utility Power Stations/
EPC
- Gas Turbine-Generator Sets - Contracts
- Diesel Engine-Based Generators - Captive Power Plants
- Industrial Steam Generators - Co-generation Systems
- Heat Recovery Steam Generators - Combined Cycle Power Plants
- Fluidised Bed Combustion Boilers - Modernisation & Renovation of
Power
- Drive Turbine Stations and FLA Studies
- Manne Turbines - Switch yards and Substations
- Industrial Heat Exchangers - HVDC Transmission Systems
- Centrifugal Compressor - Shorts sines condensation
Systems
- Industrial Valves - Power system analysis
- Reactors - Electron comissionly and
operation
- Columns - Consultancy services
- Pressure Vessels - Consultancy Services
- Pumps
SUMMARY OF BHEL'S CONTRIBUTION
TO VARIOUS CORE SECTORS
Power Generation
THERMAL RATING (MW) NO. OF SETS
TOTAL CAPACITY (MW)
500 30 15000250 9 2250210/200 138 28570120/125/130 20 2420195 1 195110 38 4180100 6 60070/67.5 6 41060 14 84030 5 150TOTAL (THERMAL)
267 54615
GAS FRAME SIZE/SCOPE
NO. OF SETS
TOTAL CAPACITY (MW)
9 5 7306 17 5805 13 3093 6 48V 94.2 2 2866FA 3 207STG 24 1190GEN 4 87TOTAL (GAS) 74 3437
NUCLEAR RATING (MW) NO. OF SETS
TOTAL CAPACITY (MW)
500 2 1000220 10 2200TOTAL (NUCLEAR)
12 3200
TOTAL (THERMAL+GAS+NUCLEAR) 353 61252
HYDRO 402 18735GRAND TOTAL 755 79987
SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS CORE SECTORS
POWER TRANSMISSION & DISTRIBUTION
In the T&D sector, BHEL is both a leading equipment-manufacturer and a system-integrator.
BHEL-manufactured T&D products have a proven track record in India and abroad.
In the area of T&D systems, BHEL provides turnkey solutions to utilities. Substations and
shunt compensation installations set up by BHEL are in operation all over the country. EHV
level series compensation schemes have been installed in KSEB, MSEB, SMPSEB and
POWERGRID networks. Complete HVDC systems can be delivered by BHEL. The
technology for state-of-the-art Flexible AC Transmission Systems (FACTS) is being
developed.
INDUSTRIES
Since inception in 1982, the Industry Sector business has grown at an impressive rate and,
today, contributes significantly of BHEL's turnover.
BHEL, today, supplies all major equipment for the industries: AC/DC machines, alternators,
centrifugal compressors, special reactor column, heat exchangers, pressure vessels, gas
turbine based captive co-generation and combined-cycle power plants, DG power plants,
steam turbines and turbo-generators, complete range of steam generators for process
industries, diesel engine-based power plants, solar water heating systems, photovoltaic
systems, electrostatic precipitators, fabric filters, etc.
The industries which BHEL serves include: Steel, Aluminium, Fertiliser, Refinery,
Petrochemicals, Chemicals, Automobiles, Cement, Sugar, Paper, Mining, Textile etc.
TRANSPORTATION
In the transportation filed, product range covers: AC locomotives, AC/DC dual-voltage
locomotives, diesel-electric shunting locomotives, traction motors and transformers, traction
elections and controls for AC, DC and dual voltage EMUs, diesel-electric multiple units,
diesel power car and diesel –electric locomotives, battery-powered vehicles.
A high percentage of the trains operated by Indian Railways are equipped with traction
equipment and controls manufactured and supplied by BHEL.
B. HEEP: AN OVER VIEW
Over the years, Bharat Heavy Electricals Limited has emerged as world class Engineering
and Industrial giant, the best of its kind in entire South East Asia. Its business profile cuts
across various sectors of Engineering/Power utilities and Industry. The Company today
enjoys national and international presence featuring in the "Fortune International-500" and is
ranked among the top 12 companies in the world, manufacturing power generation
equipment. BHEL has now 14 Manufacturing Divisions, 8 Service Centres and 4 Power
Sectors Regional Centres besides a large number of project sites spread over India and
abroad.
The Company is embarking upon an ambitions growth path through clear vision, mission and
committed values to sustain and augment its image as a world class enterprise.
VISION
World-class, innovative, competitive and profitable engineering enterprise providing total
business solutions.
MISSION
The leading Indian engineering enterprise providing quality products systems and services in
the fields of energy, transportation, infrastructure and other potential areas.
VALUES
Meeting commitments made to external and internal customers.
Foster learning creativity and speed of response.
Respect for dignity and potential of individuals.
Loyality and pride in the company.
Team playing.
Zeal to excel.
Integrity and fairness in all matters.
HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)
At Hardwar, against the picturesque background of Shivalik Hills, 2 important manufacturing
units of BHEL are located viz. Heavy Electrical Equipment Plant (HEEP) & Central Foundry
Forge Plant (CFFP). The hum of the construction machinery woke up Shivalik Hills during
early 60s and sowed the seeds of one of the greatest symbol of Indo Soviet Collaboration –
Heavy Electrical Equipment Plant of BHEL. Following is the brief profile of Heavy
Electrical Equipment Plant:-
1. ESTABLISHMENT AND DEVELOPMENT STAGES:
* Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the area
of Scientific, Technical and Industrial Cooperation.
* DPR – prepared in 1963-64, construction started from October '63.
* Initial production of Electric started from January, 1967.
* Major construction / erection / commissioning completed by 1971-72 as per original
DPR scope.
* Stamping Unit added later during 1968 to 1972.
* Annual Manufacturing capacity for Thermal sets was expanded from 1500 MW to
3500 MW under LSTG. Project during 1979-85 (Sets upto 500 MW, extensible to
1000/1300 MW unit sizes with marginal addition in facilities with the collaboration of
M/s KWU-Siemens, Germany.
* Motor manufacturing technology updated with Siemens collaboration during 1984-87.
* Facilities being modernized continually through Replacements / Reconditioning-
Retrofitting, Technological / operational balancing.
2. INVESTMENTS:
* Gross Block as on 31.3.95 is Rs. 355.63 Crores (Plant and Machinery – Rs. 285.32
Crores).
* Net Block as on 31.3.95 is Rs. 113.81 Crores (Plant & Machinery – Rs. 76.21 Crores).
3. CLIMATIC AND GEOGRAPHICAL:
* Hardwar is in extreme weather zone of the Western Uttar Pradesh of India and
temperature varies from 2oC in Winter (December to January) to 45oC in Summer
(April-June); Relative humidity 20% during dry season to 95-96% during rainy
season.
* Longitude 78o3' East, Latitude 29 o55'5" North.
* Height above Mean Sea Level = 275 metres.
* Situated within 60 to 100 KMs of Foot-hills of the Central Himalayan Ranges;
Ganges flows down within 7 KMs from the Factory area.
* HEEP is located around 7 KMs on the Western side of Hardwar city.
4. COMMUNICATION & TRANSPORTATION:
* Telegraphic Code – "BHARAT TELEC, HARDWAR"
* TLX Lines: 05909-206 / 207
* Telephones: P&T / STD – (0133) 427350-59, 423050-423954
FAX: (0091) (133) 426462 / 425069 / 426082 / 426254
* Direct Board gauge train lines to Calcutta (Howrah), Delhi, Bombay, Lucknow,
Dehradun and other major cities; Railway Siding for goods traffic connected to
Hardwar Railway Station.
5. POWER & WATER SUPPLY SYSTEM:
- 40 MVA sanctioned Electric Power connection from UP Grid (132 KV / 11KV /
6.6 KV) (Connected load – around 185 MVA)
- 26 deep submersible Tube Wells with O.H. Tanks for water supply.
- A 12 MW captive thermal power station is located in the factory premises.
6. FIRE PROTECTION:
- Managed by CISF with around 40 personnel and a host of latest fire fighting
equipment and fire tenders.
7. MANPOWER:
Total strength is 9904 as on 31.3.96 which includes around 3000 qualified Engineers
and Technicians (including substantial number of Post graduates), 5200 skilled
artisans and the rest in other categories.
8. TOWNSHIP AND PERIPHERAL INFRASTRUCTURES:
* A large modern township for employees and allied personnel with social and welfare
amenities.
* Medical: - Main Hospital (200 beds) 1
- Dispensaries in various 9
townships sectors
- Occupational health center 1
* Educational: No. of Schools (including 19
Intermediate levels)
Science Degree College 1
* Residential: Around 6780 quarters.
* Other amenities:
- Good Road network
- Shopping Centres
- Central Stadium
- Community Centres
- A Club
- Police Stations
- CISF – Complex for over 500 CISF personnel.
- Convention Hall (a Most modern Air Conditioned Auditorium with 1500 seating
capacity).
- Parks.
9. HEEP PRODUCT PROFILE:
* THERMAL AND NUCLEAR SETS
(Turbines, Generators, Condensers and Auxiliaries of unit capacity upto 1000 MW)
* HYDRO SETS INCLUDING SPHERICAL AND DISC VALVES
(Kaplan, Francis, Pelton and reversible Turbines of all sizes and matching generators
and auxiliaries maximum runner dia – 6600 mm)
* ELECTRICAL MACHINES:
(For various industrial applications, pump drives & power station auxiliaries, Unit
capacity upto 20000 KW AC / DC)
* CONTROL PANELS
(For Thermal / Hydro sets and Industrial Drives)
* LARGE SIZE GAS TURBINES
(Unit Rating: 60-200 MW)
* LIGHT AIRCRAFT
* DEFENSE PRODUCTS
10. HEEP: FACILITIES AND INFRASTRUCTURE
Modernisation and regular upgradation / up gradation of facilities and other
infrastructure is a continuous endeavour at HEEP, BHEL. After initial setting up of the plant
during the year 1964-72, in collaboration with the Soviet Union, the plant facilities and
infrastructures have since been continuously upgraded under various investment projects viz,
Stamping Unit Project, LSTG Project, Motor Project, Governing Components Project, TG
Facilities Modernisation, TG Facilities Augmentation, Quality Facilities Augmentation, EDP
projects, Gas Turbine Project, Facilities have also been added and establishments have been
created for new projects in Defense and Aviation Project. Additionally, R &D facilities have
also been created under Generators Research Institute, Pollution Control Research Institute,
HTL modernization and other such schemes.
Today the Plant has unique manufacturing and testing facilities, computerized
numerically controlled machine-tools, Blade shop, heavy duty lathes, milling machines,
boring machines, machining centers and many more. The Over Speed Vacuum Balancing
Tunnel created for rotors upto 1300 MW (32T, 6.9 M – dia bladed rotor, 6 rpm upto 4500
rpm) is one of the 8 of its kind in the entire world.
The total spectrum of sophisticated, unique and other facilities at HEEP, Hardwar are
the state-of-the-art in manufacturing processes and can be utilized for a variety of products'
manufacture.
TURBINE AND AUXILIARY BLOCK-III
1.0 GENERAL
1.1 Block-III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and Turbines
Blades. Special Toolings for all products are also manufactured in the Tool Room
located in the same block. Equipment layout plan is a per Drawing appended in
Section III. Details of facilities are given in Section II.
1.2 The Block consists of four Bays, namely, Bay-I and II of size 36x378 metres and
36x400 metres respectively and Bay-III and IV of size 24x402 metres and 24x381
metres respectively. The Block is equipped with the facilities of EOT Cranes,
compressed air, Steam, Overspeed Balancing Tunnel, indicating stands for steam
turbine, rotors, one Test stand for testing 210 MW steam turbines Russian Design, one
Test Stand for Hydro Turbine Guide Apparatus and two separate Test Stands for the
testing of Governing Assemblies of Steam and Hydro Turbines.
1.3 All the parts are conserved, painted and packed before dispatch.
2.0 MANUFACTURING FACILITIES
2.1 HYDRO TURBINES
For manufacturing of Hydro Turbines, Bay-I has the following sections:
(a) Circular Components Machining Section – This section is equipped with a number
of large/ heavy size Horizontal and Vertical Boring Machines, Drilling Machines,
Centre Lathes, Marking Table and Assembly Bed. The major components machined
in this section are Spiral Casing with Stay Ring, Spherical and Disc Valve bodies and
Rotors.
(b) Runner and Servo Motor Housing Machining Section – This section is equipped
with NC/CNC and conventional machines comprising Heavy and Medium size
vertical and Horizontal Boring Machines, Centre Lathes, Grinding machines and
Drilling Machines, Marking Table, Assembly Bed, Assembly Stands for Steam
Turbine and Gas Turbine assemblies and Wooden Platform for overturning heavy
components. Hydro Turbine Runners, Servomotors, cylinders, Labyrinth Ring,
Regulating Ring, Stay Ring, Turbine Cover, Lower Ring, Kaplan Turbine Runner
Body and Blades are machined here.
(c) Guide Vanes and Shaft Machining Section – This section is equipped with Heavy
duty Lathe machines upto 16 metres bed, CNC turning machines, Horizontal Boring
Machine, Heavy planer, Deep Drilling Machine, Boring Machines, marking Table,
Marking Machines and Assembly Beds. Turbine shafts, Guide Vanes, Journals and
Rotors of Spherical and Disc Valves are machined here. Rotors of Steam Turbines are
also machined in this section.
(d) Assembly Section – In this section, assembly and testing of Guide Apparatus, Disc
Valve, Spherical Valves, Servo motor shaft and combined Boring of coupling holes
are done.
(e) Preservation and Packing Section – Final preservation and packing of all the Hydro
Turbine components / assemblies is done here.
(f) Small components Machining Section – This is equipped with Planetary Grinding
Machine, Cylindrical Grinding Machines, small size Lathes, Planers, Vertical and
Horizontal Boring Machines. Small components like Bushes, Levers, Flanges etc. and
governing assemblies and machines here.
(g) Governing Elements Assembly and Test Stand Section – This section is equipped
with facilities like oil Pumping Unit, Pressure Receiver, Servomotors etc. for
assembly and Testing of Governing Elements.
2.2 STEAM TURBINES
The facilities and parts manufactured in the various sections of Steam Turbine
manufacture are as follows:
(a) Turbine casing Machining Section – It is equipped with large size Planer, Drilling,
Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines
etc. Fabrication works like casings, Pedestals etc. are received from Fabrication
Block-II.
(b) Rotor Machining Section – It is equipped with large size machining tools like
Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree
Groove Milling Machine etc. Some rotor forgings are imported from Russia and
Germany and some are indigenously manufactured at CFFP, BHEL, Hardwar.
(c) Rotor Assembly Section – This is equipped with Indicating Stand, Small size
Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and
Discs. Machined Rotor, Discs and Blades are assembled here. Balancing and over
speeding of Rotor is done on the dynamic balancing machine.
(d) Turbine casing Assembly Section – Machined casings are assembled and
hydraulically tested by Reciprocating Pumps at two times the operating pressure.
(e) Test Station - Test station for testing of 210 MW USSR Steam Turbine at no load is
equipped with condensers, Ejector, Oil Pumps, Oil containers Steam Connections etc,
required for testing. Overspeed testing is done for emergency Governor. Assembly
Test Stands for different modules of Siemens design are equipped with accessory
devices.
(f) Painting Preservation and Packing Section – All the parts are painted, preserved
and packed here for final dispatch.
(g) Bearings and Miscellaneous Parts Machining Section – This section is equipped
with small and medium size basic machine tools, e.g., lathes, Milling M/c, Horizontal
Borer, Vertical Borer, drilling M/c etc. for manufacture of bearings and other
miscellaneous parts of turbine.
(h) Sealing and Diaphragm Machining Section – It is equipped with medium size
Vertical Boring, Horizontal Boring, Planning, Drilling Machines etc. wherein castings
of sealing Housings, Liner housings, Forgings of Rotor Discs, castings and fabricated
Diaphragms and components are machined. It is also equipped with CNC machining
center.
Precision Horizontal Boring, Plano-Milling machines etc, are for manufacture of
Governing Casting, Servo Casings and other medium parts of governing and Main
Turbine assemblies.
(i) Governing Machining Section – This section is equipped with medium size and
small size lathes, medium CNC lathe, Milling, Grinding, Drilling, Slotting and
Honing Machines. Governing assembly parts are machined here.
(j) Diaphragm and Governing Assembly Section – It is equipped with deflection
testing equipment for Diaphragms, Dynamic Balancing Machine for balancing
Impeller of Centrifugal Oil Pumps and small fittings and assembly equipment.
Governing test stand is equipped with the facilities like Oil Pumping Unit, Pressure
Receiver, Servomotor, overspeed testing of Emergency Governor etc.
(k) Light machine shop – In addition to normal conventional machine tools it is
equipped with CNC Lathes, CNC Milling, CNC Vertical Boring, Precision Milling,
planetary grinding machines etc. for manufacture of small and medium precision
components of governing and other turbine parts.
2.3 GAS TURBINE
All the components of Gas Turbine are machined and assembled using the facilities
available for manufacturing of steam and hydro turbines except the following
facilities which are procured exclusively for the manufacturing of Gas Turbine and
are installed in the areas specified for gas turbine manufacturing.
a) Hydraulic Lifting Platform
This facility is used for assembly and disassembly of G.T. Rotor. This is a
hydraulically operated platform which travels upto 10 M height to facilitate access to
different stages of Rotor. This is installed in Bay-I assembly area.
b) CNC Creep Feed Grinding M/c.
This is installed in Gas Turbine machining area Bay-II Extn. This M/c grinds the
hearth serration on rotor disc faces. Hirth serrations are radial grooves teeth on both
the faces of rotor discs. Torque is transmitted trough these serrations, which are very
accurately ground.
c) External Broaching Machine
This machine is installed in GT machining area and is used to make groove on the
outer dia of rotor discs for the fitting of moving blades on the discs.
d) CNC Facing Lathe
This machine is installed in GT machining area and is used basically for facing rotor
disc but can turn other components also.
e) CNC Turning Lathe
This machine is installed in Bay-I Heavy Machine Shop and is used to turn Tie Rods
of Gas Turbine, which have very high length / diameter ratio. Tie-Rod is a very long
bolt (length approx. 10 meter & dia 350-mm) which is used to assembly and holds the
gas turbine rotor discs to form a composite turbine rotor.
f) Wax Melting Equipment
This is low temp. electric furnace installed in Gas Turbine blading area in Bay-II. It is
used to mix and melt Wax and Colaphonium, which is required to arrest the blade
movement during the blade tip machining of stator blade rings.
g) Gas Turbine Test Bed
This test bed is installed near the Gas Turbine Machining area in Bay-II. This facility
is used to finally assemble the gas turbine. Combustion chambers are not assembled
here, which are assembled with main assembly at the site.
h) Combustion Chamber Assembly Platform
This facility is a 3 Tier Platform installed in Bay-I assembly area and is used for
assembly of Combustion Chambers of Gas Turbine.
3.0 MANUFACTURING PROCESS
3.1 HYDRO TURBINES
The major processes involved in various Hydro Turbine Sections are as follows:
- Marking and checking of blanks – manual as well as with special marking M/c.
- Machining on Horizontal Boring, Vertical Boring, Lathes etc. as the case may be
on CNC /Conventional Machines.
- Intermediate assembly operation is carried out on the respective assembly beds
provided.
- Then the assembly is machined as per requirement.
- The sub-assemblies are further assembled for hydraulic/functional testing.
Hydraulic testing is done using a power driven triple piston horizontal hydraulic
pump, which can generate a pressure of 200 Kg/Cm2. It can also be carried out
using a power pack.
- On Governing elements / assembly and test stand, the components / sub-
assemblies / assemblies are tested up to a hydraulic pressure of 200 Kg / c m2
using the piston pump. Oil testing upto 40 Kg / c m2 is carried out with oil
pumping unit, which is permanently installed on this bed.
3.2 STEAM TURBINE
Processes carried out in various sections of steam turbine manufacture are based on
the following main phases.
(a) Machine section – Castings, Forgings, welded structures and other blanks are
delivered to this section. The manufacturing process is based on the use of high
efficiency carbide tipped tools, high speed and high feed machining techniques with
maximum utilization of machine – tool capacity and quick acting jigs and fixtures.
(b) Assembly Section – Casings and governing assemblies are hydraulically tested for
leakage on special test Bed. Assembled unit of governing and steam distribution
systems is tested on Governing Test Bed. General Assembly and testing of Steam
Turbine is carried out on the main Test Bed in Bay-II.
(c) Painting, Preservation and Packing – After testing the turbine, it is disassembled
and inspected. Then the parts are painted, conserved and packed for final dispatch.
3.3 GAS TURBINE
The major processes involved in manufacturing Gas Turbine in various sections of
Bk-III are as follows:
a) Machining
Castings, Forgings, welded structures and other blanks are received from concerned
agencies in the respective sections. These are machined keeping in view optimum
utilization of machine tools and toolings. Special jigs and fixtures are made available
to facilitate accurate and faster machining. Proper regime and tool grades have been
established to machine the materials like inconel, which have poor machinablity.
b) Main Assembly
Final assembly is done on test bed. Parts are assembled to make sub-assemblies.
These sub-assemblies are again machined as per technological and design
requirements and are made ready for final assembly. After assembly and insulation
assembled Gas Turbine is sent to site.
c) Rotor Assembly
The rotor is assembled on Hydraulic Lifting Platform and sent to main assembly,
where after checking clearances, it is sent for machining. After balancing, turbine side
of rotor is disassembled, inner casing is fitted and rotor reassembled. This work is also
carried out on Hydraulic Lifting Platform. Finally rotor is sent for assembly on test
bed.
d) Combustion Chamber Assembly
This assembly is carried out on 3 tier platform installed for this purpose in Bay-I
assembly. After machining of all components, ceramic tiles are fitted in flame tube.
Burner and piping etc. is fitted in dome and combustion chamber is finally assembled.
It is directly sent to site after insulation.
B.
BLADE SHOP
1. Introduction:
Major part of Turbine Blade Machining Shop is located in Bay-IV of Block-III. In
this shop various types of Steam Turbine and Gas Turbine Compressor blades are
machined from bar stock, drawn profile, precision and envelope forgings. It is a batch
production shop comprising of various kinds of CNC Machines and Machining
Centers, besides various special purpose and general purpose machines. The layout of
equipments is as per technological sequence of the manufacturing process. Blade shop
implements various On Line Quality Control Techniques through Run Charts and
Control charts. This shop is divided into four distinct areas. Details of facilities are
given in various schedules of Section-II.
2. Manufacturing Facilities:
i) Plain Milling Section
It prepares accurate reference surfaces on the blade blanks by milling and
grinding operation. It also manufactures the brazed type blades by induction
brazing of drawn profile and suitably machined spacers. This section carries
out banking by Band Saws, rhomboid grinding on Duplex grinding machines
and thickness grinding on Surface grinders.
ii) Copy Milling Section
The Semi blanks prepared from plain milling section are further machined by
copy Milling Machines / CNC machines (CNC Heller and BSK – Bed type
Klopp, BFH / BEK Knee type Machines) for concave and convex aero-
dynamic profile forms, (HTC-600, BFK Machines) for expansion angles,
Compound taper grinding of radial plane is carried out by Surface grinders. It
comprises of T-root machining centers for machining of T-root.
iii) LP Section
This area deals with all types of free standing and forged blades for steam
Turbine Compressor. The freestanding blades are cerrobend casted in boxes to
hold the blade with respect to the profile. These blades roots are subsequently
machined on NTH, MPA-80A and T30 Machining Centers. There is a five
station 360o circular copy milling machine for machining the profile of
envelope forged blades / stocks for Steam Turbine and Gas Turbine Blades. It
also has 3D copy Milling and CNC Machines with digitizing features for Tip-
thinning, Fitted milling. The inlet edge of the last stage of Low pressure
Turbine Moving blades are hardened on a Special Purpose Flame Hardening
equipment.
iv) Polishing Section
Blade Contours are ground and polished to achieve the desired surface finish
and other aerofoil requirements.
There are also other small sections e.g. Fitting Section, Tool and Cutter
Grinding, Toolings Repair Section in Blade Shop.
v) Inspection Device
- 3 D Coordinate Measuring Machines for taper and rhomboid checking.
- Moment weighing Equipment
- Real time Frequency analyzer for checking frequency of free standing blades.
- Contour plotter for plotting of blade profile with various magnifications.
- Fir- tree root inspection device.
- Magna spray crack detection equipment.
vi) Miscellaneous
There are other important facilities e.g. High rack storage system for fixtures.
Compactor system storage for finish blades. Jib cranes and EOT cranes for
material handling. The semi finished batch of blades are kept in special boxes
for inter-operation movements. An AGV (Automated Guided Vehicle) is also
located in LP Section of Blade Shop for better material movement.
3.0 MANUFACTURING PROCESS
The manufacturing process of turbine blades primarily depends on the type of blade
e.g. Bar type, Brazed type, Free standing (Forged type), Gas Turbine Compressor
blades. The bar type and brazed type blades are also known as drum stage glades. The
manufacturing technology of each of these blades along with recommended machine
tools / equipment is furnished below.
3.1 BAR TYPE BLADES
PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED
i. Blanking of area material Circular saw/band saw
ii. Sizing to rectangular shape Hor. Milling Machine
iii. Thickness grinding Surface grinder
iv. Rhomboid milling Duplex milling machine
v. Rhomboid grinding Duplex grinding machine
vi. Milling perpendicularity on both ends Hor. Milling machine
vii. Milling radius on surround Hor. Copy milling m/c
viii. Finish milling of convex and
concave profile
Hor. Copy milling / CNC
Hor. Milling machine
ix. Milling expansion faces of convex
And concave sides at root and shroud
Hor. Copy milling m/c/
CNC milling m/c
x. Root slot/root chamfer and
Radit at root and shround
Milling
2 spindle T-root roughing, m/c and
root radius copy milling m/c, T-root
machining center
xi. Taper grinding Surface grinder
xii. Grinding and polishing of profile
And expansion faces
Abrasive belt polishing m/c
xiii. Final Rounding, chamfering etc. Manual fitting.
3.2 BRAZED TYPE BLADES
PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED
i. Cutting of drawn profile & spacer blank Hor. Milling machine
ii. Sizing to rectangular shape Hor. Milling machine
iii. Thickness grinding Surface grinder
iv. Rough and finish milling of internal
profile of spacer
Hor. Milling machine
v. Cutting-off spacer Abrasive cutting
vi. Brazing of drawn profile and spacer Right frequency inducting brazing
installation
vii. Milling of width Duplex milling machine
viii. Pin rough and Root slot Vert. Milling m/c
ix. External profile rough and finish
machining
Hor. Milling machine
x. Pin turning Pin turning lathe
xi. Grinding and polishing Abrasive belt polishing m/c
xii. Debarring and rounding Manual fitting
3.3 FREE STANDING BLADES
PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED
i. Grinding of ref. Belts Abrasive belt polishing
ii. Milling of inlet & outlet edge 3D Vert. Copy milling m/c
iii. Center hole drilling CNC machining Centre
iv. Encapsulating with cerrobend alloy Cerrobend casting equip.
v. Remelting of cerrobend alloy Fir-tree root machining center
vi. Remelting of cerrobend alloy Cerrobend casting equip.
vii. Machining of fillets Vertical 3D copy milling machine
viii. Grinding and polishing Abrasive belt polishing
ix. Cutting-off blade tip Abrasive cutting machine
x. Inlet edge hardening Frame hardening equipments. (if required)
xi. Blade tip rounding Vert. 3-D dcopy milling m/c
xii. Tip thinning (if reqd.) -do-
3.3 GAS TURBINE BLADES
PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED
i. Cerrobend casting Cerrobend casting equip.
ii. Root machining Hor. Machining center
iii. Remelting of cerrobend alloy Cerrobend casting equip.
iv. Profile checking Vert. Stand
v. Length cutting Circular saw/hor. Milling m/c
vi. Tenon Hor. Milling m/c
vii. Grinding and polishing of fillet Abrasive belt polishing m/c
A.
QUALITY CONTROL FACILITIES
As in BHEL Customer Focus is of prime significance, Quality Control Function assumes
vital role. Quality Control facilities get priority in investment planning. The Group is
equipped with the state-of-the-art testing, measuring and analytic facilities. This chapter
covers Facilities existing in various sections under Quality Management Deptt.
1.0 FACILITIES IN QUALITY CONTROL – TURBINE BLOCK
Each Quality Control Station is equipped with conventional measuring instruments as
well as sophisticated testing machine to suit the inspection requirements of the related
area. Some of the important facilities are:-
i) CNC 3D Coordinate Measuring Machine – a fully computer controlled
modern machine for automatic inspection of complex or precision components
of size upto 2000x1200x1000 mm. The important features of this machine are
high-speed computer, versatile software, universal probe head for scanning,
digitization and plotting of known and unknown curves etc.
ii) 2-D Coordinate Measuring Microscope – Used for highly accurate and
precise measurements of small and intricate components of the turbine. The
machine is equipped with multiple feature digital readouts of resolution
0.0001 mm, a separate light generator connected through fiber cables for
better accuracy, optical templates for various inspection purposes etc.
iii) Vibration Measuring Equipments – Three no. of vibration measuring
equipments are available for checking of blade frequency at various stages.
iv) Portable hardness testers it is being used for checking of hardness of
plane hardened- Nitrided and stellited components. It can measure upto a
range of HV 999.
v) MPI Machine – This is used for carrying out magnetic particle test for crack
detection on finished blades.
vi) Surface Finish Measuring Equipment – This is used for checking the
surface finish of machined components. Can measure in R, Rz and Ra.
vii) Hardness Testers of different configurations
* SAROJ (VICKER CUM BRINELL) HV to BH 5 to 250 KG
* SAROJ B-3000 (BRINELL) BH 250 to 3000 Kg
* USSR (ROCKWELL) HRC 150 Kg
* USSR (BRINELL) BH 250 to 3000 Kg
* SAROJ (ROCKWELL CUM BRINELL) HRC/HB 60 to 250 Kg
* SAROJ (ROCKWELL) HRC 60 to 150 Kg
B.
HYDRO TURBINE LABORATORY
1. INTRODUCTION
Hydro Turbine Laboratory at HEEP, Hardwar was set up in late '60s. It comprises of
three Test Beds with electronic Instrumentation Laboratory for test bed
operation/maintenance and for carrying out Site Investigations. It has a modest
Workshop to manufacture hydro turbine models. Till December '95 about 160 number
of tests have successfully been performed in the Laboratory which include
Contractual as well as Developmental tests on Hydro Turbine Models, Calibration of
Hydraulic Valves, Nozzles and Flow Measuring Devices for 210 MW Thermal Sets.
Besides performing the main function of design/ development of hydraulic passages
of hydro turbines, design of models, their manufacture and testing, the Laboratory has
also been engaged in Field Test Studies at various Hydro Power Sites for conducting
Index Tests, Head Loss Measurement, Uprating Studies and attending to various Site
Problems.
2. DESIGN:
3. MANUFACTURING:
4. TESTING:
5. TESTING CAPABILITIES:
- Runaway speed tests of reaction and impulse turbine.
- Determination of MW output of prototype turbine under specified operating
conditions.
6.4 INSTRUMENTATION LABORATORY
The Instrumentation Laboratory is equipped with the most modern instrumentation for
carrying out accurate measurements during testing in the Laboratory as well as during
field testing. The major facilities are:
- Ultrasonic Flowmeter for field tests.
- Magnetic Tape Recorder with Waveform Analyzer.
- Microprocessor based Pressure Pulsation Measuring System.
- Microprocessor based Wicket Gate Torque Measuring System.
- Microprocessor based Hydraulic Thrust Measuring system.
7. RESEARCH AND DEVELOPMENT
The continuous inhouse research and development efforts of the Laboratory have
enabled it to establish new measurement methods for carrying out special tests, to
bridge know-how / know-why gaps, to resolve certain site problems and to evolve and
establish better and more efficient designs. The benefits of research and development
activities are passed on to the customers through implementation of new concepts of
existing sites and for future projects.
8. FIELD TESTING
The Laboratory is equipped to perform field efficiency and index tests on prototype
turbines at hydropower sites. Many site problems of hydraulic and mechanical nature
have been successfully solved as a result of extensive filed tests and analysis carried
out by the Laboratory. The Laboratory has successfully carried out uprating studies at
many hydro sites resulting in augmentation of power generating capacity of the units
at no extra or minimum cost. Extensive work has been done by the Laboratory to
tackle the problem of silt erosion of runner blades at several hydro power stations
situated in the Himalayan region.
9. CALIBRATION
The Laboratory is equipped with the required facilities for calibration of load cells,
pressure pulsation transducers, weights, volumetric tanks and torque wrenches.
Calibration of these terms is performed with respect to standards with history
traceable to N.P.L., Delhi.
10. FUTURE PLANS
Upgradation and modernization of Hydro Turbine Laboratory has been planned in the
following areas:
- Renovation of Test Beds to the cater for the requirements of IEC-995.
- Modernisation in the field of instrumentation.
- Addition of instantaneous in-siti calibration facility.
- Incorporation of Computerisation and Data Acquisition System
- Modernisation of Workshop facilities.
C.
HUMAN RESOURCE DEVELOPMENT CENTRE
INTRODUCTION
HRDC Workshop caters to the needs of skill training of various trainees at HRDC.
These trainees include Engineering Trainees & ACT Apprentices amongst others. Any other
type of trainees who are to be given imported training can be given skill training in areas of
machining, turning, fitting, welding, electrical, carpentry & electronics. In a year, about 500
ACT Apprentices are given training on various machines.
VARIOUS SECTIONS OF HRDC WORKSHIP
There are 7 different sections in HRDC Workshop in which facilities exist for
training.
(i) Turning Section – has facilities for practical training of Turner Apprentices &
trainees. There are 18 Lathes, which include HMT lathes H22, LB 17, LM 001,
Russian lathe No. 163, Kirloskar lather D 1 and one CNC Trainmaster T-70 of HMT
make.
(ii) Fitting Section – has facilities for training in the area of fitting e.g. 36 bench vices for
fitting work.
(iii) Machining Section – has 24 milling machines for skill training, 1 shaper, 1 slotter
and 10 grinding machines. A CNC machining center also exists for training in CNC
operations.
(iv) Welding Section – has facilities to give practical training in gas welding and electric
welding. The section has transformer, MG set, rectifier & an electrode oven.
(v) Electrical Section – has facilities for providing practical training in electrician field.
Areas in which practical training is given are laying of house wiring, joints making &
motor winding.
(vi) Carpentry Section – facilities for providing practical training in the field of
carpentry. It has various wood working machines, like surface planer lathe, thickness
planer, circular saw, pedestal grinder & drilling machines.
(vii) Electronics Trade – In this section practical training is given in making circuits &
repair work of TVs, tape recorders, amplifiers etc.
FACILITIES IN MANAGEMENT DEVELOPMENT / TRAINING
Audio visual facilities – Facilities exist for video projection through a video
projection system on a wide screen. Other facilities include a colour TV, a 16 mm
film & sound projector, overhead projectors (5 nos.) for transparencies, slide
projectors (2 nos.), a video camera, video cassette recorders (2nos.), two-in-one tape
recorders (2 nos.), a 35 mm photo camera, a conference system (for 6 persons) and a
number of video tapes & 16 mm films on management, technical and functional areas.
All these facilities are primarily used for facilitating learning at HRDC.
D.
POLLUTION CONTROL RESEARCH INSTITUTE
To provide directional thrust to environmental control / protection activities, a Pollution
Control Research Institute has been set up by BHEL at HEEP, Hardwar with the assistance of
United Nations Development Programme (UNDP).
The main objective of the Institute is to develop technologies for pollution control in the
areas of air, water noise and solid waste to obviate unintended side effects of economic
growth. The Institute is concentrating on research and development activities related to
environment protection against pollution emanating from industries. PCRI provides
consultancy services related to pragmatic approaches / methods to maintain pollution within
permissible limits. The other objectives include development of methods for recovery and
recycling of industrial wastes.
Most modern facilities for monitoring and analysis in the area of air, water, noise and solid
waste are available at the Institute. It has full-fledged computer facilities for prediction and
forecasting pollution impact. It also has workshop and other support services.
The laboratories of Pollution Control Research Institute have been recognized by Ministry of
Environment and Forests, Govt. of India; Department of Science and Technology, Govt. of
India; Madhya Pradesh Pradushan Nivaran Mandal; UP State Pollution control Board; Bihar
State Pollution Control Board; Punjab State Council for Technology; Haryana State Pollution
Control Board; Karanataka State Pollution Control Board.
E.
AVIATION PRODUCTS
MANUFACTURING FACILITIES
1. LIGHT TRAINER AIRCRAFT PROJECT
In 1991, BHEL Entered into Aviation Sector as part of its diversification efforts and
has taken up manufacturing of two-seater light trainer aircraft "SWATI". The aircraft
was designed and developed indigenously by R&D Wing of Directorate General of
Civil Aviation, India. Requisite organizational facilities and services infrastructure
has been developed in Sector X at BHEL, Hardwar.
"SWATI" is a general purpose aircraft powered by 116 HP horizontally opposed
piston engine with fixed pitch propeller and has wide range of applications like flying
training, sports, touring, surveillance, photography, courier & personal use.
2. WORKSHOP & FACILITIES:
2.1 General:
Hangar / Manufacturing Workshop consisting of one bay of size 45x90 mtrs with
expansion provision on eastern side have been developed at Aviation Project Site in
Sector X.
2.2 Manufacturing:
Following major components, sub-assemblies & assemblies are manufactured in
different sections:
- Fuselage
- Landing Gear
- Engine Mount
- Fuel Tank
- Pair of Wings
- Pin, Bush, Axle, Stud, etc.
- Lever, Brackets, Controls, etc.
- Fin, Rudder, Tailplane, Elevator, etc.
2.3 Facilities:
i) Fabrication / Welding Section
Equipped with TIG welding machines, this section is meant for fabrication of
fuselage, engine mount, landing gear and welding of lugs, brackets and other items on
fuselage.
ii) Wing Manufacturing Section
This section is located in WWM shop (Block-VII) of HEEP, as all the required wood
working facilities are available in that Shop.
iii) Machine Shop
The Shop is equipped with medium capacity center lathes, milling machines and
drilling machine. Small components like pins, bush, axle, wing to wing attachment
fitting etc. are routed through this Section.
iv) C.M. Section (Chrome Moly-Steel Section)
Components of CM steel like lugs, brackets, levers, control system etc. are
manufactured in this Section. This section is equipped with fitter tables, vices, hand
shear machine, screw press etc.
v) Alclad Section
All components / sub-assemblies made of Alclad material like Fin, Rudder, Tailplane,
Elevator, Cowling etc. are manufactured in this Section. This Section is equipped with
fitter tables, vices, compressed air, Hand shear machine, Sheet folding machine, 160
T Hydraulic press, 25 T Crank press etc. Fuel tank is manufactured in Sheet Metal
Shop of ACM (Block-IV).
vi) FRP Section
FRP Components like fairing, nose cap upper & lower, drag reduction items etc. are
made in this Section.
vii) Assembly Section
Trial Assembly / Final assembly of components on fuseldge is carried out in this
Section like mounting of fin, rudder, tailplane, engine, fuel tank, controls, instruments
etc.
viii) Test Flying Facilities
To establish performance characteristics of aircraft before delivery to the customer, an
airstrip of size 23M in width and 914 M in length has been developed in Sector IX
near the Project Site.
F.
MEDICAL LINAC PROJECT
Introduction:
Medical Linac, a machine for treatment of Cancer by Radiation Therapy has been taken up
for commercial manufacture at HEEP, Hardwar with know-how from (1) Department of
Electronics (DoE), Govt. of India, (2) SAMEER, Bombay, (3) Central Scientific Instruments
Organisation (CSIO), Chandigarh and (4) Post Graduate Institute of Medical Education &
Research (PGIMER), Chandigarh.
Medial Linac test station equipped with facilities for testing of Medical Linac machines upto
15 MeV (Mega Electronic Volt) has been established at HEEP, Hardwar and first 4MeV
machine jointly manufactured by SAMEER, CSIO, PGIMER and BHEL, Hardwar has been
successfully integrated and tested in newly established test station. Efforts are also afoot to
declare this test-station as National Test House.
Littion USA – make Hydrogen brazing furnace, model 4401 (specifications below) has been
installed near the Medical Linac test station. This shall be used to carry out brazing process of
parts made of Oxygen-free high- conductive (OFHC) copper.
Layout proposed for the Medical Linac block is enclosed. No special facilities have been
established for manufacture of controls for Excavator.
Dedicated equipment like vacuum brazing furnace, double vacuum baking furnace, low –
power test equipment including vector network analyzer etc. required for the manufacture of
complete machine will be added in future.
G.
CENTRAL PLANT STORES
General
Materials from suppliers, sub-contractors, other unitsand ancillaries enter the factory
premises from eastern gate.
Material Receipt
The materials are unloaded at receipt area, identified in the Central Plant Stores and
subsequently shifted to respective custody areas after inspection. In case of heavy materials,
receipt areas are adjacent to custody areas.
Material Issue
All the materials are received by Central Plant Stores and issued to users / manufacturing
blocks. Manufacturing blocks have their own sub-stores to receive material from Central
Plant Stores and further issue it to the shop / sections concerned.
Stores Custodies
The locations, where Central Plant Stores stores various types of material, have been
classified as custody-I, II, III, IV & V.
Custodies & Materials Stores
Custodies and the main categories of materials stored are as below:
BROAD SPECIFICATION OF
MAJOR/IMPORTANT MACHINE TOOLS & MACHINES
A: CNC MACHINE TOOLS
CNC HORIZONTAL BORERS:
1. Item Description : CNC Horz. Borer
Model : RAPID 6C
Supplier : WOTN, GERMANY
CNC Control System : FANUC 12M
Spindle Dia. : 200mm
Table : 4000 x 4000 mm
Max. Load on Table : 100 T
Travers : X=20000, Y=5000, X=1400mm
Ram traverse : W = 1000 mm
Ram size : 400 x 400 mm
Power Rating : 90 KW
Weight of the m/c : 111 T
ATC Capacity : 60 Nos.
Plan No. : 1-227 (Block-I)
2. Item Description : CNC Stub Borer
Model : DW 1800
Supplier : HEYLIGENSTAEDT, GERMANY
CNC Control System : SINUMERIK – 7T
Boring Dai : 625 – 2500 mm
Table : 4000 x 4000 mm
Headstock Travel : 4000 mm
Spindle Speed : 0.5 –90 RPM (in 4 Steps)
Power Rating : 63 KW
Max. Load Capacity : 100 T
Weight of the m/c : 72 T
Plan No. : 27-420 (Block-III)
3. Item Description : CNC Horz. Borer (2 Nos.)
Model : W200 HB –NC
Supplier : SKODA, CZECH
CNC Control System : SINUMERIK 850 M
Spindle Dia. : 200 mm
Traverse : X=12500,
Y=5000,
Z=2000mm
CNC LATHES
4. Items Description : CNC Centre Lathe
Model : D-1800 NYF
Supplier : HOESCH MFD, GERMANY
CNC Control System : SINUMERIK 3T
Centre Distance : 8000 mm
Swing Over Carriage : 1800 mm
Swing Over Bed : 2400 mm
Spindle Speed : 0 – 125 RPM
Power Rating : 92 KW
Weight of the Job : 110 TON
Weight of the m/c : 124 TON
Plan No. : 2-394 (Block-III)
5. Item Description : CNC Centre Lathe
Mode : D-2300 NYFS-1
Supplier : HOESCH MFC, GERMANY
CNC Control System : SINUMERIK 7T
Centre Distance : 18000 mm
Swing Over Carriage : 2300 mm
Swing Over Bed : 2900 mm
Spindle Speed : 5 – 125 RPM
Power Rating : 110 KW
Weight of the job : 320 TON
Weight of the m/c : 216 TON
Plan No. : 2-360 (Block-III)
6. Item Description : CNC Centre Lathe
Model : KV2-1100 CNC
Supplier : RANVENSBURG, GERMANY
CNC Control System : SINUMERIK 820 T
Centre Distance : 12000 mm
Centre Height : 900 mm
Swing Over Carriage : 1100 mm
Swing Over Bed : 1400 mm
Max. Turning Length : 12000 mm
Spindle Speed : 2-600 RPM
Longitudinal Cutting Feed (Z-Axis) : 1-5000 mm / min.
Transfer Cutting Feed (X-Axis) : 1-5000 mm/min.
Main Spindle Drive Motor : 95.5 KW DC
Max. Feed Force – Z/X Axis : 45000 N
No. of Tool carriers : 3
Plan No. : 1-120 (Block-III)
CNC MILLING MACHINES
7. Item Description : CNC Horz. Milling M/c (6 Nos.)
Model : BFH-15
Supplier : BATLIBOI, INDIA
CNC Control System : SINUMERIK 810 M
Table : 1500 x 400 mm
Traverse : X=1170 mm
Y=420 mm
Z=420 mm
Spindle Speed : 45 to 2000 RPM
Power Rating : 11 KW
Max. Load Capacity : 630 Kg
Weight of the m/c : 4200 Kg
Plan No. : 2-449, 2-453, 2-454, 2-459, 2-460 (Block-
IIITBM)
8. Item Description : Universal Milling M/cs (2Nos.)
Model : BFK-15
Supplier : BATLIBOI, INDIA
CNC Control System : SINUMERIK 810 M
Table : 1500 x 400 mm
Traverse : X=1170 mm
Y=420 mm
Z=420 mm
Spindle Speed : 45-2000 RPM
Power Rating : 11 KW
Max. Load Capacity : 630 Kg
Weight of the m/c : 4200 Kg
Plan No. : 2-463, 2-466 (Block-III: TBM)
9. Item Description : CNC Bed Type Milling M/c
Model : FSQ 80 CNC
Supplier : TOSKURIM, CZECH
CNC Control System SINUMERIK 810 M
Table : 3000 x 800 mm
TEE SLOT 28H7
Traverse : X= 3000 mm
Y= 870 mm
Z= 850 mm
Spindle Speed Range : H – 2500 RPM
Spindle Drive Power : 18 KW continuous
22 KW intermittent
Spindle Head Size : 620 x 500 incldg ram
543 x 420 encldg ram
ATC Capacity : 24 Nos.
Table Load : 2500 Kg
Plan No. : 2-484 (Block-III)
CNC MACHINING CENTRES
10. Item Description : SPL. Purpose 6 Station T-Root Machining
Centre (2nos.)
Supplier : MIH, JAPAN
CNC Control System : FANUC 7M
Indexing Table : 1900 mm dia
Indexing Position : 6 Nos.
Plan No. : 2-356, 2-41 (Block-III: TBM)
11. Item Description : SPL Purpose FIR Tree Root M/cing Cenre
Model : NTH 200
Supplier : RIGID, SWITZERLAND
CNC Control System : SINUMERIK 7M
Table : 1400 x 1400 mm
Traverse : X= 1950 mm
Y= 900 mm
Z= 600 mm
Spindle Speed : 30600 RPM
No of Spindle : 4
Power Rating : 22 KW
Plan No. 2-354 (Block-III TBM)
CNC VERTICAL BORERS
12. Item Description : CNC Vertical Borer
Model : TMD – 40 / 50
Supplier : OSAKA MACHINES, JAPAN
CNC Control System : FANUC 6TB, 3TC
Table dia : 4000 mm
Turning dia : 5000 mm
Turning Height : 4200 mm
Spindle Speed : 0.23-30 RPM
No. of Ram : 2
Power Rating : 75 KW
Max. Load Capacity : 70T
Machine Weight : 100 T
Max. Ram Travel (Vertical) : 2200 mm
Plan No. : 2-422 (Block-III)
13. Item Description : CNC Vertical Borer (2 Nos.)
Model : 40 DZ
Supplier : SCHIESS, GERMANY
CNC Control System : SINUMERIK 850 T
Table : 4000 mm
Max. Turning dia : 5000 mm
Max. Turning Height : 4200 mm
Ram size : 300 x 250 mm
Table Speed : 0.63 – 63 RPM
Max. Vertical Travel of Ram : 2200 mm
Power Rating : 71 KW
Table Load Carrying Capacity: 80 T
ATC Capacity : 12 Nos.
Plan No. : 1-235 (Block-I), 2-472 (Block-III)
14. Item Description : CNC Vertical Borer
Model : 32 DS 250
Supplier : SCHIESS, GERMANY
CNC Control System : SINUMERIK 850T
Table : 2500 mm
Table Load Carrying Capacity: 25T
Max. Turning Dia : 3200 mm
Max. Turning Height : 2200 mm
Ram Size : 210 x 250 mm
Max. Travel of Ram : 1400 mm
Table Speed : 0.8 – 160 RPM
Power Rating : 56 KW
ATC Capacity : 12 Nos.
Plan No. : 2-483 (Block-III)
OTHER SPECIAL PURPOSE CNC MACHINES
15. CNC SURFACE BROACHING M/C
Make : Marbaix Lapointe, UK
Model : Champion 32 /10, 300
CNC System : SINUMERIC 850 M
Broaching capacity (pulling force) : 320 KN
Broaching slide stroke : 10.3 mm
Broaching slide width : 1500 mm
Max tool length (continuous /row) : 9650 mm
Broaching Speed (cutting stroke) : 1-25 M/min
Broaching Speed (return stroke) : 60 M/min
Drive power rating : 135 KW
Broaching slide movement : Electro-mechanical
Maximum noise level : < 80 Dbs
Max. dia of the disc (mountable) : 2300 mm
Max. weight of the job : 3000 Kgs
Indexing & rotating tables : 1500 mm, 1000 mm
Indexing accuracy : +/- 3 Arc sec.
Plan No. : 2-485
16. CREEP FEED GRINDING M/C
Make : ELB CHLIFE, GERMANY
Model : ELTAC SFR 200 CNC
CNC System : SINUMERIC 3 GG
Work-piece diameter : 200 – 2000 mm
Work height : 2400 mm
Rotary & indexing table dia. : 2050 mm
Indexing accuracy : +/- 1 ARC SEC
Max. load capacity : 20000 KG
Y-axis (grinding head movement)
Vert. Traverse : 750 mm
Z- axis (grinding head support)
Movement on cross rail)
Horizontal traverse : 2400 mm
Traverse feed rate : 02 – 1200 mm /min
Grinding head main support
Drive motor : 34 KW
Grinding wheel max. Dia. : 500 mm
Max. Width : 100 mm
Bore : 203.2 mm
Surface speed : 16-35 M/Sec.
Plan No. : 2-491
17. BROACH SHARPENING M/C
Make : LANDRIANI, ITALY
CNC System : SELCA
Work-piece diameter : Upto 250 mm
Work Length : 200 mm
Plan No. : 2-487
BROAD SPECIFICATIONS OF
MAJOR / IMPORTANT MACHINE TOOLS & MACHINES
B: NON-CNC MACHINE TOOLS
(1) PRECISION HEAVY DUTY LATHE
Manufacturer: Karamatorsk Heavy Machine Tool Works (USSR); Model KS-1614
Specifications
1. Maximum Swing 2000mm
2. Maximum Diameter of work piece over the Saddle 1500 mm
3. Maximum Distance between Centres 8000mm
4. Diameter of Spindle bore 80 mm
5. Maximum Taper when machining by the method of Combined
Feeds
0.15 mm
6. Maximum Length between Centres when machining by the method
of Combined Freeds
1200 mm
7. Maximum Weight of work piece 20000 kg
8. Maximum Length of Machine over the Saddle 8000 kg
9. Maximum Summary Effort of Cutting 10,000 kg
10. Limit Dimension of Thread Cut:
Thread Pitch Max Length of Thread,
Min Max mm
Metric Threade Pitch (in mm)1 96 6300
British Trhread Pitch (Per inch) 20 3/8 6300
Name of Part Power Displacement in mm
Manual Per Rev. of Dial
One Division
Of Dial
Represent
Rapid
Traverse
M/min
Carriage 2.02
Transverse Slide 1130 1130 8 0.1 mm 1.03
Longitudinal Slide 600 600 6 0.1 mm 0.48
Tool Slide 150 6 0.1 mm -
Rotary Part 90o 5 o 0.5 -
Maximum Displacement of the Tailstock Spindle 260 mm
Maximum Transverse Displacement of the Tailstock 17 mm
Rotating Built –in Centre Available
Power Extraction of the Tailstock Spindle Available
Rapid Traverse of the Tailstock 3.44 M/min
12. Overall Dimension:
Length 13900 mm Width 3845 mm Height 2865 mm
13. Plant No. 2-182 (Block-III)
UNIVERSAL VERTICAL TURNING & BORING MACHINE
Manufacturer : Kolomna Machine Tool Works (USSR)
Model – KY 152
Specifications
1. Maximum Dia. of workpiece accommodated 10000/12500 mm
2. Dia. of central table 8750 mm
3. Maximum travel of vertical Tool Heads from center of table 5250 mm
4. Maximum weight of workpiece accommodated on central table
(a) With table speed limited to n (n 6) r.pm. 200 T
(b) At any speed 100 T
5. Maximum cutting force with different length of tool over-hang (L) from head face
R.H. Head
16000 Kg with L 1500 mm
7500 Kg with L 2000 mm
2000 Kg with L 3000 mm
1200 Kg with L 3700 mm
L.H. Head
12500 Kg with L 1500 mm
7500 Kg with L 2000 mm
2000 Kg with L 3000 mm
1200 Kg with L 3700 mm
6. Rated cutting dia on central table 6300 mm
7. Maximum cutting torque on central table 80000 Kg.M
8. Speed range of central table rotation Minimum = 0.112 r p.m.
Maximum – 11.2 r.p.m.
9. Travel rate of column assembly 190 mm /minute
10. Plan No. 1-13 (Block-I)
1-24 (Block-III)
BALANCING MACHINE
Manufacturer: SCHENK (West Germany)
Model: Dj 90
Specifications
1. Weight of rotor 10,000 to 80,000
kg
2. Minimum weight without considerable loss of measuring sensitivity,
provided the berings can accommodate such small rotors.
5000 kg
3. Maximum weight for one bearing pedestal 45,000 kg
4. Height of rotor axis above machine bed 1600 mm
5. Rotor diameter (free swing over machine bed) not considering the
funnel
4000 mm
6. Diameter of journal Max. 540 mm
7. Diameter of journal, with special sleeve bearing cups made from
high grade material.
Max. 600 mm
8. Minimum distance between bearings for less than 10 tons rotor 1500 mm
9. Minimum distance between bearings for more than 10 tons rotor 1900 mm
10. Maximum distance between coupling plague and center of the scond
bearing pedestals
13500 mm
11. Rotational Speeds Min. 800 rpm
(a) For rotors from 5 to 10 tons Max. 4000 rpm
Min. 700 rpm
(b) For rotors from 10 to 20 tons Max. 3600 rpm
Min. 600 rpm
(c) For rotors from 20 to 80 tons Max. 3600 rpm
12. Maximum test speed and overspeeds
(a) For rotors upto 50 tons
(b) For rotors upto 50 to 80 tons
4500 rpm
3600 rpm
13. Maximum centrifugal force admissible on each bearing pedestals for
short period of time
50,000 Kg
14. Balancing accuracy to be obtained depending on Selling Weight 0.3 to 3 micron
15. Sensitivity of indication depending on rotor weight, speed and
selling weight
0.1-8 div/micron
16. Accuracy of the angle indication 1 o – 2o
17. Stiffness of bearing pedestals, when mounted on machine bed
(a) With unclamped bearings 1.2 Kg/micron
(0.85 micron/Kg)
(b) With clamped bearing 100 Kg/micron
(0.01 micron
/Kg).
SPECIAL DRILLING & BORING MACHINE
Manufacturer: Machine Tool Works, Ryazan (USSR)
Model: PT 182 H5
SPECIFICATIONS:
1. Swing over bed 800 mm
2. Drilling dia 40-80 mm
3. Boring dia 80-250 mm
4. Swing of job in rest Max
Min
300 mm
110 mm
5. Swing of job in Max. 300
Headstock chuck Min. 110 mm
6. Maximum length of job 3000 mm
7. Maximum weight of job 2000 Kg
8. Number of spindles Headstock
Stemstock
1
1
9. Spindle location Horizontal
10. Distance to spindle axis: From bed wasy
From floor
400 mm
1100 mm
11. Head stock Spindle speed Max
Min.
750 r.p.m.
71. r.p.m.
Number of steps of spindle speed
Spindle braking
24
Available
12. Stemstock Spindle speeds Max.
Min.
730 r.p.m.
123 r.p.m.
Number of steps of spindle speed
Stemstock feed Max.
Min.
6
1680 mm / min
168 mm / min
Number of feed steps Stepless
13. Overall dimensions
Length 13500 mm
Width 2300 mm
Height 1700 mm
Weight 23844 Kg.
14. Plan No 1-105 (Block-
III)
SPECIAL INTERNAL GRINDING MACHINE
Manufacturer: Saratov Machine Binding Works (USSR)
Model : MB 6020 T
SPECIFICATIONS
1. Diameter of ground holes
(a) Maximum
(b) Minimum
320 mm
90 mm
2. Maximum length of grinding (with maximum hole diameter) 560 mm
3. Maximum weight of work 600 Kg
4. Distance from spindle axis to floor level 1100 mm
5. Distance from spindle axis to table
(a) Maximum
(b) Minimum
300 mm
100 mm
6. Cantilever vertical travel
(a) Per one revolution of handwheel 0.133 mm
(b) Speed of rapid vertical traverse (from motor) 190 mm / min.
(c) Per dial graduation 0.01 mm
7. Table working surface dimensions 500 x 1200 mm
8. Table cross-traverse
(a) To operator from intermediate (zero) position 200 mm
(b) From operator from intermediate (zero) position 200 mm
(c) Total 400 mm
(d) For one revolution of hand wheel 0.2 mm
(e) For one dial graduation 0.01 mm
(f) Speed of rapid traverse (from motor) 280 mm / min
UNIVERSAL THREAD GRINDING MACHINE
Manufacturer: Moscow Jig Boring Machine Plant (USSR)
Model: 5822B3
SPECIFICATIONS
1. Maximum diameter of work admitter 160 mm
2. Nominal diameter of thread being ground Min
Max
25 mm
125 mm
3. Thread pitch Min
Max
0.5 mm
6 mm
4. Maximum length of thread being ground,
(a) By single-ribbed wheel 75 mm
(b) By multiple ribbed wheel 55 mm
5. Maximum taper of thread: 1o 47' 24"
or 1:16
6. Table
Maximum longitudinal table traverse,
(a) By hand 425 mm
(b) By power 415 mm
Table rapid withdrawal speed (variable:
maximum
about 1.2
m/min)
7. Taper
(a) Headstock spindle MT 4
(b) Tailstock spindle MT 5
8. Grinding Wheelhead
Maximum cross feed
(a) By hand 125 mm
(b) By power 50 mm
Movement per dial division 0.005 mm
Movement per dial revolution 1 mm
PLANER
Manufacturer: The Yefemov Plant TIAZHSTANKOGIDRO-PRESS (USSR)
Model: 7A288-T
SPECIFICATIONS
1. Max. width of planning 4000 mm
2. Max. height under cross rail 4000 mm
3. Distance between housings 4250 mm
4. Max. travel of slides below cross rail and inside housing
(a) for vertical tool heads 700 mm
(b) for side tool heads 700 mm
5. Max. allowable weight of workpiece 100 T
6. Max. cutting force
Arrangement for mechanizing and automating the machine
40000 Kg.
operation is available
7. Table
Dimension of working surface of table,
(a) Width 3600 mm
(b) Length 12000 mm
Table Stroke, Max. 12000 mm
Min. 3000 mm
Safety devices to stop table after worm
disengaging.
Available.
8. Tool Heads
Number of tool heads (a) Vert. 2
(b) Side 2
Travel of tool heads, mm. V.Tool Side Tool Heads
Heads R.H. L.H.
(i) Max. vertical travel 700 3750 3750
(ii) Max. horizontal travel 5000 700 700
(iii) Travel per turn of hand-wheel lever, (in mm)
Vertical travel 1.14 4.25 4.25
Horizontal travel 0.52 1.14 1.14
(iv) Dial division value
Vertical 0.1 0.2 0.2
Horizontal 0.2 0.1 0.1
(v) Rapid travel
Speed mm
Vertical 1.25 2.5 2.5
Horizontal 2.5 1.25 1.25
9. Cutter Head:
(i) Max. dimension of tool holder Vertical Side
Tool head Tool head
(a) Width 120 mm 120 mm
(b) Height 120 mm 120 mm
(ii) Max. angle of slide Swiveling
(a) To the right 60 o 45o
(b) To the left 60 o 45o
(iii) Dial division value 10 10
(iv) Swiveling of cutter head plate 10 o 10 o
(v) Cutter head automatic lifting during return
stroke of table
Available Available
10. Cross Rail:
Maximum travel 4000 mm
Rapid travel speed Not less than 0.3 M/min
Time of cross rail automatic fixing 20 to 30 sec.
Main drive motor 2 x 130 KW
11. Plan No. 2-189 (Block-III)
BOARD OF DIRECTORS
Ashok K.Puri Chairman & Managing DirectorBharat Heavy Electricals LimitedBHEL House, Siri Fort, New Delhi – 110 049
Naresh Chaturvedi Additional Secretary & Financial AdvisorMinistry of Industry. Deptt. of Heavy IndustryUdyog Bhawan, New Delhi – 110 011
Dlip Raj Singh Chaudhary Joint Secretary
Ministry of Industry. Deptt of Heavy IndustryUdyog Bhawan, New Delhi – 110 011
Dr. Jamshed J. Irani Managing DirectorTata Iron & Steel Company LimitedJamshedpur – 831 001
Shekhar Datta Ex-Managing Director & PresidentGreaves Limited, E/8, Sea Face ParkBhulabhai Desai Road, Mumbai – 400 001
Ms. Tarjani Vakil Ex-CMD, EXIM Bank of IndiaA-1, Ishwar Das Mansion, Nana ChowkMumbai – 400 007
J. Jayaraman Ex-CMD, Cochin Refineries Limited39/4, Ashwin ApartmentC.P. Ramaswamy Road, Chennai – 600 018
K.Ravi. Kumar Director (Power)Bharat Heavy Electricals LimitedBHEL House, Siri Fort, New Delhi – 110 049
A.K.Mathur Director (IS&P)Bharat Heavy Electricals LimitedIntegrated Office ComplexLodhi Road, New Delhi – 110 003
S.K.Jain Director (Personnel)Bharat Heavy Electricals LimitedBHEL House, Siri Fort, New Delhi – 110 049
Ramji Rai Director (ER&D)Bharat Heavy Electricals LimitedBHEL House, Siri Fort, New Delhi – 110 049
MATERIALS SPECIFICATION
X20 – Cr – 13
A. 13% Cr. Stainless Steel Bars (Hardened & Tempered)
1. General : This specification governs the quality of stainless steel
bars of grade X20 – Cr. –13
2. Application : For machining of moving and guide blades of steam
Turbine.
3. Condition of Delivery : Hot rolled / Forged & hardened and tempered. The
bars shall be straight and free from waviness.
4. Complete with standards: There is no Indian standard covering this material.
5. DIMENSIONS & TOLERANCES :
Dimension : Bars shall be supplied to the dimensions specified in
the purchase order unless otherwise specified in the
order. The bars shall be supplied in random length of
3 to 6 meters with a maximum of 10% shorts down to
meter.
Forged bars shall be supplied in length of 1.5 to 3 meters.
Tolerance : The tolerance on cross sectional dimensions shall be
as per table.
5.1. Hot Rolled Bars : Tolerance on hot rolled flat bars shall be as specified
below :
"b" width across flates mm Allowable deviation on
"b" mm
"s" thickness mm Allowable devi. on
'S' mm
Up to 35 + 1.5 Up to 20 +1
b
s
Over 35 and Upto 75 + 2 Over – 20 and
Upto – 40
+ 2
Over 75 + 3 Over 40 + 3
Note : Other tolerances shall be as per DIN 1017. Twisting and bending off the bars shall not
exceed 0.001X length of the bar. Bulging on the sides shall not be more than 0.01 x b
and 0.01 x s respectively.
5.2 Forged Bar : Tolerances on size for forged bars shall be +8% of the
size.
6. MANUFACTURE:
6.1 The steel shall be manufactured in basic electric furnace process and
subsequently vacuum degassed or electric slag refined (ESR). Any other process
of meeting shall be subjected to mutual agreement between supplier & BHEL.
6.2 For manufacture of flat bars, if initial material is other than ignot (e.g. continuous
casting), supplier shall mention it in his quotation for prior approval from
BHEL.
7. HEAT TREATMENT :
7.1 The bars shall be heat treated to get the desired mechanical properties specified
in this specification. The hardening temperature shall be in the range of 980 –
10300C and the tempering temperature shall not be below 6500C As per DIN-
19440.
7.2. Minimum possible residual stress shall be aimed with slow cooling and longer
duration of tempering treatment.
7.3. If the bars require straightening after heat treatment, the bars shall be stress
relieved after straightening operation at 300C below the actual tempering
temperature.
8. FREEDOM FROM DEFECTS:
8.1 The bar shall be free from lamination cracks, scabs, seams, shrinkage porosity,
inclusions and other harmful defects.
8.2 Decarburisation and other material defects shall not exceed the dimensional
tolerances and machining allowances.
9. FINISH:
9.1 The bar surface be smooth, free from laps, rolled in scale etc. Dents roll marks.
Scratches are permitted provided their depth does not exceed half the tolerance
limits specified in table.
9.2 Repair of surface flaws by welding in not permitted
9.3 The edges of bars shall be cut square by swaing or shearing.
10. CHEMICAL COMPOSITION: The chemical composition of material shall be
as follows (table analysis in %)
Element Min. Max.
Carbon 0.17 0.22
Silicon 0.10 0.50
Manganese 0.30 0.80
Chromium 12.50 14.00
Nickel 0.30 0.80
Sulphur -- 0.020
Phosphorus -- 0.030
11. SELECTION OF TEST SAMPLES :
11.1 Chemical analysis shall be reported on each heat basis..
11.2 For Mechanical Test
11.2.1 One tensile & 3 impact test samples shall be selected for mechanical testing
per melt per heat treatment batch basis from lot of size.
11.2.2 The uniform strength of a delivery shall be certified through hardness test. In
case of bars with sectional dimensions more than 120mm, all the bar shall be
tested for hardness. In case of bars with sectional dimension less than or
equal to 120mm hardness shall be checked on 10% of the bars or 10
numbers of bars which ever is higher.
11.2.3 The mechanical and notch impact test is to be done in longitudinal direction
on the hardest and softest bars. Test sample shall be to Km. at 1/3rd below
the surface of the bars.
12. Mechanical Properties:
12.1 The material shall comply with the following mechanical properties at room
temperature.
0.2% : 600 N/MM2 Min
Tensile strength : 800 – 950 N/mm2
% Elongation on 5.65 : 15 min.
% Reduction in area : 50 min. *
Impact (mean of 3.1S0 – V sample) : 20 J min.
Hardness (HB-30) : 280
* The smallest value shall be at least 14 J.
12.2 Tensile test shall be carried out in accordance with IS : 1608 or equivalent
international standard.
12.3 Impact test shall be carried out on 3 ISO-V samples in accordance with IS :
1757 or equivalent international standard only one test value out of three,
can be below the specified value ; but in no case it should be below 2/3rd of
the minimum specified value; but in no case it should be below 2/3rd of the
minimum specified impact value.
12.4 Hardness test (Brinell) shall be carried out according to IS : 1500 or
equivalent international standard.
13. NON DESTRUCTIVE TEST: Following NDT shall be carried out.
13.1 UT of the prematerial combined with 100% magnetic partial testing of all
bars in delivery condition.
13.2 Complete UT of all bars in delivery condition.
13.2.1 In case of testing as per 14(a) U.T. shall be carried out as per HW 0850 192
(SEP 1923) test class D3 and MPI of all bars except of face areas. In case of
testing as per 14(b) UT shall be carried out as per HW 0850 192 (SEP 1923)
test class D2.
13.2.2 Mix up test (verification test) of all bars.
13.2.3 Visual inspection of all bars
13.2.4 Acceptance Criteria
a) Magnetic Particle Test : When MT is carried out as per clause 14.1.
Surface defects with expected depth > 1 mm are unacceptable.
Indication > 5 mm are unacceptable.
Defect indication observed during MT, can be removed by grinding (dressing
up) but with in 1mm depth.
b) Ultrasonic Test : Quality class 2b with following modification that
individual indication > 2mm EFB (KSR) and back wall losses > 3dB are
unacceptable.
X2 – CrMoV1 21
B. 600 N/MM2 minimum 0.2% Proof stress Heat resistant steel bars for steam turbine
blades
1. General : Hot rolled and forged bars of steel grades X22
CrMoV1 21.
2. Application : Bars are required for machining of guide and moving
blades for steam turbines.
3. Dimension & Tolerance :
"b" width across flates mm Allowable deviation on
"b" mm
"s" thickness
mm
Allowable devi.
on 'S' mm
Up to 35 & Over 35 ± 1.5 Up to 20 & +1
s
b
Over 20
Upto 75 + 2 Upto – 40 + 2
Over 75 + 3 Over 40 + 3
4. Chemical Composition:
Element % min. % max.
Carbon 0.18 0.24
Silicon 0.10 0.50
Manganese 0.30 0.80
Chromium 11.00 12.50
Malybeonum 0.80 1.20
Vanadium 0.25 0.35
Nickel 0.30 0.80
Sulphur -- 0.020
Phosphorous -- 0.030
5. MECHANICAL PROPERTIES:
0.2 % proof stress : 600 N/mm2 min.
Tensile Strength : 800-950 N/MM2
% Elongation : 14 Min.
% Reduction in area : 40% Min.
Notch Impact Value : 27 J * Min.
* Average of 3 IS0 – V Samples.
C. 600 N/MM2 0.2% PROOF STRESS FORGED BLADES
1. General : This specification governs the quality of guide and
moving blades forged from steel grade X 20 or 13.
2. Application : The blades are used for steam turbines.
3. Condition of Delivery: The forged blades shall be supplied in heat treated forged
blade shall be supplied with center holes made in
accordance with respective technical requirements or
ordering drawing.
4. Dimensions & Tolerance: The dimension and tolerances shall be as per ordering
drawing accompanying the order.
5. Manufacture : The steel shall be manufactured in the blade electrical
furnace and for subsequently refined to ensure turbine
blade quality. The forgings shall be made as envelope
forging or precision forging, subsequently machine /
grinder to achieve the ordering drawing dimensions and
surface finish.
6. Heat Treatment:
6.1. The forging shall be heat treated to get desired mechanical properties.
6.2. The tempering temperature shall not be below 6500 C. The minimum residual
are to be aimed through sufficient duration of the tempering treatment and the
slow cooling rate from the tempering temperature.
6.3. The blades are to be straightened after heat treatment, each straightening
operation is to be followed by a stress relieving temperature and in no case
below 6100C followed by slow cooling.
7. Freedom from Defects: Blades shall be free from folds due to forging; cracks, tearing
and other material defects, elonganed non-metallic and
jusions, seams etc. any blade blade containing such
defects shall be rejected.
8. Surface finish : The blade shall be supplied in a desoaled and deburred
condition. The surface finish shall comply with the
requirements specified on the drawing. In the surface is
ground prior to blasting the the surface finish must be
anouired in compliance with the finish specified on the
drawing. Grinding may be performed to a depth not
more than H/2 and ground areas shall be blended over a
length of LP/2. However H shall not be exceeded.
H : Allowable profile deviation on the pressure side.
LP : Profile length measured from leading edge to trailing
edge.
9. Chemical Composition: The chemical analysis of the material shall confirm to
the following:
Element % min. % max.
Carbon 0.17 0.22
Silicon 0.10 0.50
Manganese 0.30 0.80
Chromium 12.50 14.00
Nickel 0.30 0.80
Sulphur -- 0.020
Phosphorous -- 0.030
10. Selection of Test Sample: All tests and examination shall be performed on
specimens taken in accordance with annexure 1
from at least one blade of each drawing per
melts and heat treatment batch.
11. Mechanical properties:
11.1 The mechanical properties of the blade material shall conform to the following :
0.2 % proof stress : 600 N/mm2
Tensile Strength : 800-950 N/MM2
% Elongation : 15 Min.
% Reduction in area : 50 Min.
Impact Value (Average of
3, ISO – V Sample) : 20 J Min.
Brinell hardness HB 30 : 280 Max.
11.2 Tensile Test: The tensile test piece shall confirm to the gauge length.
11.3 Impact test shall be carried out on standard test piece as per ISO – V notch
according to IS: 1757.
11.4 Hardness Test: The brinell hardness test HB 30 shall be carried out according to
IS : 1500.
12. Non Destructive Test:
12.1 Blade shall only be manufactured from ultrasonically examined rare material.
12.2 In order to ensure freedom from defects. All blades shall be subjected to magnetic
particle examination prior to shipment.
13. Dimenional Checks for Acceptance:
13.1 The supplier shall check 100% of the forging w.r.t. to all parameters.
13.2 Dimensions parameters to be checked for acceptance.
Following dimensional parameters of each of the check sections as specified in
ordering drawing shall be inspected after fixing / clamping the forging in
vertical stand to check conformance of profile of individual section as well as
in relation to each other.
o From tolerance for pressure side = H
o From tolerance for suction side = R, max differenceR
o From tolerance for Inlet edge = H
o Twist Tolerance = (H, R) max.
Profile thickness of each section. = D Max. / D / D1
Max. profile length of each section.
Root dimensions.
Base dimensions.
Base plate contour.
Axial and tangential shift of profile with respect to root.
Overall length of forging.
Surface finish.
13.3 Procedure for dimensional checks :
Check of inlet edge : The profile of inlet edge shall be checked by using split
profile gauges.
Check of Profile: All the dimensional parameters mentioned at (13.2) shall be
checked using a vertical measuring stand.
Drilling of BHEL Centre holes
Checking of BHEL Centres.
A.
CLASSIFICATION OF BLADES
L.P. Moving Blade Forged Ist Stage.
L.P. Moving Blade 500 MW Last Stage.
100 MW 25th Stage Impulse Blade.
Compressor blade Sermental coated.
Compressor Blade 'O' stage.
Gas Turbine Compressor Blade.
T-2 Blade.
T-4 Blade.
3DS Blade.
Brazed Blade
Russian Design Blades.
Z – Shroud Blade.
Twisted Blade.
Present Range of Blades.
Future Range of Blades.
MANUFACTURING DIVISIONS
Heavy Electricals Plant, Piplani, Bhopal
Electricals Machines Repair Plant (EMRP), Mumbai
Transformer Plant P.O. BHEL, Jhansi.
Bharat Heavy Electricals Limited :
– Heavy Electricals Equipment Plant,
– Central Foundary Forge Plant., Ranipur, Hardwar
Heavy Equipment Repair Plant, Varanasi.
Insulator Plant, Jagdishpur, Distt. Sultanpur.
Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad
High Pressure Boiler Plant & Seamless Steel Tube Plant, Tiruchirappalli.
Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex, Ranipet.
Industrial Valves Plant, Goindwal.
Electronics Division :
– Electronics Systems Division.
– Amorphous Silicon Solar Cell Plant (ASSCP).
– Electroporcelains Division.
– Industrial Systems Group.
BANGALORE.
Component Fabrication Plant, Rudrapur.
Piping Centre, Chennai.
Regional Operations Division, New Delhi
CONTENTS
1. Prologe – A. BHEL – An Overview
B. HEEP – An Overview
2. Study on Turbines & Auxiliary Block
3. Study on Material Specification
4. Study On Blade Shop
5. Broad Specification of Major Machines Tools & Machines
(CNC & Non CNC)
6. Other Areas