CHAPTER-1
1.1
INTRODUCTION
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
Equipment industry in India – a dream that has been more than realized with a
well-recognized track record of performance. Established in the late 50’s,
Bharat Heavy Electrical Limited (BHEL) is, today, a name to reckon with in the
industrial world. It is the largest engineering and manufacturing enterprise of
its kind in India, and one of the leading international companies in the power
field.
Established in the late 50’s, Bharat Heavy Electrical
Limited (BHEL) is, today, a name to reckon with in the industrial
world.
1.2MANUFACTURING
UNITS OF B.H.E.L
First generation units:
BHOPAL
: Heavy Electrical Plant
HARIDWAR : Heavy Electrical
Equipment Plant
HYDERABAD : Heavy Electrical Equipment Plant
TIRUCHY
: High Pressure Boiler Plant
Second
generation units:
JHANSI
: Transformer and Locomotives Plant
HARIDWAR : Central
Foundry and Forge Plant
TIRUCHY
: Seamless Steel Tube Plant
Units
through actuation and merger:
BANGALORE
: Electronics division and Electro porcelain
division
New manufacture unit:
RANIPAT
: Boiler auxiliaries’ plants
JAGDISHPUR : Insulator plants
RUDRAPUR : Components and
Fabrication Plants
BANGALORE : Industrial system group
BHEL is growing concerns to meet the changing needs of the
nation has taken it beyond power into the total gamut of energy, industrial and
transportation BHEL is able to offer a total services in each of these fields.
Its manufacturing capability is supported R and S division at Hyderabad work
closely with research and development cells at various units and welding
Research institute in Trichy.
BHEL offers
over 180 products and provides systems and services to meet the needs of core
sectors like: Power, Transmission, Industry, Transportation, Non-Conventional
Energy Sources, Oil& Gas Exploration & Telecommunication. With 14
Manufacturing Divisions wide spread Regional Services Network and Project Sites
all over India & abroad and with an export presence in more than 50
countries, BHEL is truly India’s Industrial ambassador to the world. All major
Manufacturing, Erection and Service units of BHEL have been awarded ISO 9000
certification.
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 Equipment industry in India - a dream that has been more than
realized with a well-recognized track record of performance. The company has
been earning profits 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
& Transmission, Industry, Transportation, Telecommunication, Renewable
Energy, etc. The wide network of BHEL's 16 manufacturing divisions(two new
added, CSU&FP), four Power Sector regional centers, over 100 project sites,
eight service centers 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 is the largest engineer and
manufacturing in the field of heavy electrical in India and among the leading
power equipment manufactures in the world. BHEL has presence in core sector
like power, industry, transportation, oil and gas, telecommunication, defense
and non-convectional energy source from “concept of commissioning”. BHEL
products and systems have been exported to over 52 countries worldwide.
BHEL has continuously contributed dividends to the government.
BHEL also received “Excellent” rating for 9 years consequently memorandum of
undertaking targets with Government of India and has conferred the price status
of a “Navarathna Company” another major contribution of BHEL to the nation is
by the way of its involvement in the social development work. Such as adoption
of backward villages, buildings and running of schools, medical centers
providing self-employment facilities for windows, handicapped persons etc.
The
greatest strength of BHEL is its highly skilled and committed 44,500 employees.
Every employee is given an equal opportunity to develop himself and grow in his
career.
Continuous training and retraining, career
planning, a positive work culture and participate style of management – all
these have engendered development of a committed and motivated workforce
setting new benchmarks in terms of productivity, quality and responsiveness.
BHEL has acquired certifications to
Quality Management Systems (ISO 9001), Environmental Management Systems (ISO 14001)
and Occupational Health & Safety Management Systems (OHSAS 18001) and is
also well on its journey towards Total Quality.
It has Installed equipment for over
90,000 MW of power generation -- for Utilities, Captive and Industrial users.
Supplied over 2,25,000 MVA transformer capacity and other equipment operating
in Transmission & Distribution network up to 400 kV (AC & DC).
Supplied over 25,000 Motors with
Drive Control System to Power projects, Petrochemicals, Refineries, Steel, Aluminum,
Fertilizer, Cement plants etc. Supplied Traction electric and AC/DC locos to
power over 12,000 kms Railway network.
Supplied over one million Valves to Power Plants and other
Industries .
1.3 BOILERS AUXILIARY PLANT RANIPET
Boiler
Auxiliaries Plant (BAP), the 13th manufacturing unit of BHEL was set up at Ranipet
in 1980 as a part of the 4000 MW expansion of the High Pressure Boiler Plant,
Trichy. BAP at Ranipet was set up as a spin-off plant for the manufacture of
boiler auxiliaries viz. Electrostatic Precipitators (ESP), Air Pre-Heaters
(APH) and Fans.
Over
the years, the following products are also added to BAP's portfolio: Steel
Chimneys, Gates and Dampers, RO based Desalination (for Industrial and Potable
application), Flue Gas Conditioning Systems (FGC), Flue Gas Desulphurization
Systems (FGD), Wind Electric Generators (WEG) and Missile Launchers for
Defence.
The
Company has been a fore runner in creating history with its State-of-the-art
Design facilities, Research and development capabilities, modernized
manufacturing facilities with sophisticated Metrology laboratory and NDT
facilities to meet the growing demand for Quality power.
The
Company has an extensive outsourcing facility which makes it possible to grow
consistently over the years. The Company nourishes 400 ancillary small-scale
units by off-loading structural fabrication and machining jobs through annual
rate contracts.
The
Company is also an ISO 9001:2000, ISO 14001, ISO 27001 and OHSAS 18001 company,
and has the unique distinction of becoming the first unit of its whole
corporation to upgrade to ISO 9001:2008 Quality Management System.
1.4
THERMAL POWER PLANT:
Main parts of the plant are:
o Coal conveyor
o Stoker
o Pulverizer
o Boiler
o Coal ash
o Air preheater
o Electrostatic precipitator
o Smoke stack
o Turbine
o Condenser
o Transformers
o Cooling towers
o Generator
o High - voltage power lines
1.4.1Coal conveyor :
This is a belt type of arrangement. With this coal is
transported from coal storage place in power plant to the place near by boiler.
1.4.2 Stoker :
The coal which is brought near by boiler has to put in
boiler furnace for combustion. This stoker is a mechanical device for feeding
coal to a furnace.
1.4.3 Pulverizer
:
The coal is put in the boiler after pulverization. For this
pulverizer is used. A pulverizer is a device for grinding coal for combustion
in a furnace in a power plant.
Types of Pulverizer’s
·
Ball and Tube Mill
·
Ring and Ball
1.4.4 Boiler :
Now that pulverized coal is put in boiler furnace. Boiler is
an enclosed vessel in which water is heated and circulated until the water is
turned in to steam at the required pressure.
Coal is burned inside the combustion chamber of boiler. The
products of combustion are nothing but gases. These gases which are at high
temperature vaporize the water inside the boiler to steam. Some times this
steam is further heated in a superheater as higher the steam pressure and
temperature the greater efficiency the engine will have in converting the heat
in steam in to mechanical work. This steam at high pressure and temperature is
used directly as a heating medium, or as the working fluid in a prime mover to
convert thermal energy to mechanical work, which in turn may be converted to
electrical energy. Although other fluids are sometimes used for these purposes,
water is by far the most common because of its economy and suitable
thermodynamic characteristics.
Classification of Boilers
Boilers are classified as