MANUFACTURING UNITS OF B.H.E.L

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