FROM-4.06.2009 TO 19.07.

2009
¤ UNDER THE GUIDANCE OF ¤
SR. ENGINEER
P.S.JANGPANGI
CIM, BLOCK-1

¤ SUBMITTED BY ¤
NITISH JOSHI
EE 3RD YEAR
GURUKUL KANGRI UNIVERSITY (HARIDWAR )
 Subject :- study on the manufacturing process of 500MW TG
stator winding bar

BHEL – An Overview

BHEL is the largest engineering and manufacturing enterprise in India in the energy
related/infrastructure sector today. BHEL has built over the years, a robust domestic market
position by becoming the largest supplier of power plant equipment in India, and any developing
strong market presence in select segments of the industrial sectors and the Railways. BHEL was
established more than 40 year ago, 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. Year of 2007-08 was a significant year for BHEL since it crossed milestones at various
fronts. By achieving turnover of Rs. 21,401 crores BHEL crossed the Rs. 20,000 crores landmark
doubling its turnover in last three years. The company crossed the landmark of installing
cumulative projects of more than 1,00,000 MW across the globe and it has become a 10,000 MW
power plant equipment manufacturing company. Order inflow during 2007-08 was a record high
of Rs. 50,270 crores.

BHEL caters to core sectors of the India economy viz., Power Generation and Transmission,
Industry, Transportation, Renewable Energy, Defence etc. The wide network of BHEL’s 14
manufacturing divisions, 4 power sector regional centers, 8 service centers, 15 regional offices and
a large number of projects sites spread all over India and abroad enables the company to promptly
serve its customer and provide them with suitable products, systems and services- efficiently and
at competitive prices.

BHEL has attained ISO-9001 certification for quality management and all the manufacturing
units/divisions of BHEL have been upgraded to the latest ISO-9001:2000 versions, all the major
units/divisions of BHEL have been awarded ISO-14001 certification for Environmental
Management System and OHSAS-18001 certification for Occupational Health and Safety
Management System. BHEL became the first Public Sector Company in the country to win the
coveted “PRIZE” for its Haridwar unit under the CII Exim Award for business excellence, as per the
globally recognized model of European Foundation for Quality Management. BHEL is the only PSU
among the 12 Indian Companies to figure in “Forbes Asia Fabulous 50” third annual list. It has also
won the “Business Standard Star Public Sector Company Award-2006”. The Company received
MoU Excellence Award for the highest growth rate in market capitalization listed CPSEs for 2006-
07.

Power Generation

Power Generation Sector comprises Thermal, Gas, Hydrogen, Nuclear power plant business. As of
31.03.2008, BHEL supplied sets accounts for 85,811 MW or nearly 64% of the total install capacity
of 1,34,722 MW in the country. Significantly these sets generated an all-time high 456.12 Billion
Units of electricity of projects installed worldwide have crossed 1,00,000 MW.

BHEL has proven turnkey capabilities for executing power projects from concept to
Commissioning. The company has introduced new rating Thermal sets of 270 MW, 525 MW & 600
MW in subcritical range and possesses the technology and capability to produce Thermal sets with
super critical parameters and, advanced-class gas turbine generator sets of up to 300 MW units
rating. Co-generation and combined cycle plants have been introduce to achieve higher plant
efficiencies. To make efficient use of the high-ash-content coal available in India, BHEL also
supplies Circulating Fluidized Bed Combustion (CFBC) boilers for Thermal plants.

The Company manufactures 220/235/500/540 MW nuclear turbine-generator sets. Custom-made

hydro sets of Francis, Pelton and Kaplan types for different head-discharge combinations are also
engineered and manufactured by BHEL.
The company has proven expertise in the Plant Performance Improvement through Renovation,
Modernization and Uprating of a variety of Power plant equipment, besides specialized know-how
of residual life assessment, health diagnostics and life extension of plants. Overall, BHEL built
Thermal sets consistently exceed the national average efficiency parameters and have achieved
the highest-ever Plant Load Factor (PLF) of 80.5% during 2007-08 which is 1.9% high than the
National average. Operating Availability (OA) was also the highest-ever at 86.7%.

BHEL is one of the few companies worldwide, involved in the development of integrated
Gasification Combined Cycle (IGCC) technology which would usher in clean coal technology. BHEL
has set up Asia’s first 6.2 MW IGCC power plant with an indigenously pressurized fluidized bed
gasifier. The company has also signed a MoU with APGENCO for setting up a 125 MW IGCC plant at
Vijayawada.

Industries

BHEL manufactures and supplies major capital equipment and systems like captive power plants,
centrifugal compressors, drive turbines, industrial boilers and auxiliaries, waste heat recovery
boilers, gas turbine, pumps, heat exchanger, electrical machines, valves, heavy castings and
forgings, electrostatic precipitators, ID/FD fans, seamless pipes etc., other than plant utilities.
BHEL has also emerged as a major supplier of controls and instrumentation systems, especially
distributed digital control systems for various power plants and industries.

Transportation

Most of the trains in Indian Railways, whether electric or diesel powered, are equipped with
BHEL’s traction propulsion system and controls. The systems supplied are both with conventional
DC drives and state of the art AC drives. India’s first underground metro at Kolkata runs on drives
and controls supplied by BHEL. The company also manufactures complete rolling stoke i.e.,
Mainline 25 kV AC locomotives up to 5000 Hp, EMU coaches and Diesel Electric Shunting
Locomotives from 250 HP to 2600 HP. BHEL also undertakes retrofitting and overhauling of rolling
stock. In the area of urban transportation, BHEL is geared up for turnkey execution of electric
trolley bus systems, light rail systems and metro systems. BHEL is contributing to the supply of
electrics for EMUs for 15000V DC & 25kV AC to Indian Railways. Almost all the EMUs in service are
with electrics manufactured and supplied by BHEL. BHEL has also diversified into the area of track
maintenance machines for Indian Railways.

Renewable Energy

BHEL has manufacturing and supplying a range of Renewable Energy products and systems. It
includes Photo Voltaic modules and systems. BHEL has supplied stand alone Power Plants of
ranging up to 150 KW peak, usually used as Distributed Power Generation plants. The company
has capability to design and execute grid connected MW sized PV plants.
BHEL is actively associated with the development and adoption of Wind Power and Concentrated
Solar Power (CSP) projects in India and abroad.

Oil and Gas

BHEL is supplying onshore drilling equipment viz., draw works , rotary-table, travelling block,
swivel, mast and sub structure, mud systems and rig electrics to ONGC and Oil India Ltd. Well
heads & X-Mass tree valves up to 10,000 psi rating for onshore as well as offshore application are
being supplied to ONGC, Oil India Ltd. and private drilling companies. BHEL has also supplied
Casting Support System, Mudline Suspension System and Block Valves to ONGC for offshore
application. It also has the capability to supply complete onshore drilling rings, super-deep drilling
rings, desert rings, mobile rings, workover rings and sub-sea well heads. Currently, BHEL is
executing orders for refurbishment and up-gradation of onshore Oil Rings from ONGC & Oil India
Ltd.

BHEL has supplied GT driven centrifugal compressor packages to GAIL India Ltd. for their gas
compressor stations for Dahej-Vijaipur gas pipeline project.

Transmission

BHEL supplies a wide range of products and systems for transmission and distribution applications.
The products manufactured by BHEL include power transformers, instrument transformers, dry
type transformers, shunt reactors, capacitors, vacuum and SF6 switchgear, gas insulated
switchgears, ceramic insulators etc. BHEL has developed and commercialized the country’s first
indigenous 36 kV Gas Insulated Substation (GIS) and has also developed 145 kV GIS which has
undergone successful trials at Hyderabad.

For enhancing the power transfer capability and reducing transmission losses in 400 kV lines, BHEL
has indigenously developed and executed a number of fixed series compensation schemes. BHEL
has indigenously developed and commercialized state-of-the-art 400 kV Controlled Shunt Reactor
(CSR) for reactive power management of long transmission lines. With a strong engineering base,
the company undertakes turnkey execution of substation/switchyards up to 400 kV and has the
capability to execute 765 kV projects. High Voltage Direct Current (HVDC) systems have been
executed for economic transmission of bulk power over long distances.

Technology Upgradation, Research & Development

To remain competitive and meet customer’s expectation 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 from leading organization of the world.

The corporate R&D Division at Hyderabad leads BHEL’s research efforts in number of areas of
importance to BHEL’s products range. Research and product development centre at each of
manufacturing divisions pay a complementary role. Centre of Excellence have been set up for
Simulators, Computational Fluid Dynamics, Permanent Magnet Machines, Surface Engineering and
Centre for Intelligent Machines and Robotics (CIMAR). In addition to corporate R&D Division, BHEL
has four specialized institute viz., Welding Research Institute at Tiruchy, Ceramic Technological
Institute at Bangalore, Centre of Electric Traction and Hydro Lab at Bhopal and Pollution Control
Research Institute at Haridwar.

BHEL’s investment in R&D is among the highest in the corporate in India. Products developed in-
house during the last five years contributed 13.80% to the revenues in 2007-08.

BHEL has introduced, in the recent past, several state-of-the-art products viz. 60 MW Bubbling
Fluidized Bed Combustion Boiler for power generation against the maximum size of 40 MW being
supplied so far, 260 MW steam turbine designed to suit combined cycle power plants, Bypass Over
Fire Air (BOFA) for reduction of Nox from coal-based thermal power plant, high-efficiency Francis
and Pelton hydro turbines, new LP turbine variant which can be retrofitted in old Russian (LMW)
210 MW thermal sets, automatic storage & retrieval system (ASRS) for storage and inventory
management system of the Indian Army, solar panels with 5500 watts output consisting of high-
efficiency multi-junctions solar cells, satellite batteries for INSAT 4A, Controlled Shunt Reactor
(CSR) for 400 kV transmission lines, Flexible AC Transmission System (FACTS) STATCOM, Phase
Shifting Transformer (PST), 145 kV Gas Insulated Switchgear (GIS), Micro-controller-based flame
scanner, a more energy efficient single cylinder non-reheat steam turbine for 100-140 MW
applications, IGBT-based 3-phase drive system for 700 HP Diesel Electric Locomotives, technology
for manufacture of 400 kV long rod composite insulators with improved properties by adding nano
materials, performance analysis, diagnostic and optimization (PADO) package for power plants, 91
Ton BHEL Bowl Mill, etc.

To meet its commitment to clean environment, BHEL has developed design for an IGCC power
plant and has also signed an IGCC plant at Vijayawada.

The company is also engaged in research in futuristic areas like fuel cells for distributed
environment friendly power generation, clean coal technology applications, superconductivity
applications in transformers, generators/motors etc. thin film solar cells and nano technology for
various applications.

Activity Profile

Power Generation & Transmission

 Steam Turbine-Generator Sets & Auxiliaries
 Boilers and Boiler Auxiliaries
 Nuclear Power Generation Equipment
 Hydro Turbine-Generator Sets Auxiliaries
 Mini/Micro hydro Generator Sets
 Advanced-Class Gas Turbine-Generator Sets
 Waste Heat Recovery Boilers
 Heat Exchangers
 Condensers
 Bowl Mills and Tube Mills
 Gravimetric Feeders
 Regenerative Air Pre-Heaters
 Electrostatic Precipitators
 Bag Filters
 Valves
 Pumps
 Electrical Machines
 Piping Systems
 Power Distribution & Instrument Transformers
 Reactors
 Synchronous Condensers
 Switchgears
 Controlgears
 Distributed Digital Controls for power stations
 Bus Ducts
 Rectifiers
 Porcelain Insulators
 Ceralin

Industries/Transportation/Oil & Gas/Renewable Energy

 Steam Turbine-Generator Sets

 Gas Turbine-Generator Sets
 Diesel Engine-Based Generators
 Industrial Steam Generators
 Heat Recovery Heat Generators
 Fluidized Bed Combustion Boilers
 Drive Turbines
 Marine Turbines
 Industrial Heat Exchangers
 Centrifugal Compressor
 Industrial Valves
 Reactors
 Columns
 Pressure Vessels
 Pumps
 Industrial Fans
 Seamless Steam Tubes
 Fabric Filters
 AC/DC Motors, Variable-Speed AC Drives
 Electronic Control Gear & Automation Equipments
 Thyristor Equipment
 Power Devices
 Transformers
 Switchgears
 Insulators
 Capacitors
 Broad Gauge AC, AC/DC Locomotives
 Diesel-Electric Shunting Locomotives
 Traction Motors & Control Equipments
 Electric Trolley Buses
 AC/DC Electric Multiple Units
 Drives and Controls for Metro Systems
 Battery-Operated Passengers Vans
 Oil Rings and Oil Filled Equipments
 X-Mass Trees and Well Heads
 Cathodic Protection Equipments
 Simulators
 Wind Electric Generators
 Stand-alone and Grid-Interactive
 Solar Power Plants
 Solar Water Heating Systems
 Photovoltaic Systems
 Defence Equipments
 Reverse Osmosis Desalination Plants

Systems & Services

 Turnkey Utility Power Stations/EPC Contracts

 Captive Power Plants
 Co-generation Systems
 Combined Cycle Power Plants
 Switchyards and Substations
 HVDC Transmission Systems
 Shunt & Series Compensation Systems
 Flexible AC Transmission systems (FACTS)
 Power System Analysis
 Erection, Commissioning, Operation & Maintenance
 Consultancy Services
 Construction Services
 Material Handling systems
 Software Packages for Utilities

STATOR OF A 500MW TURBO-GENERATOR :

Summary of BHEL’s Contribution to various Core Sectors

Power Generation Sector

Thermal Rating(MW) No. of SETS
490/500/525/600 73
270 4
250 53
210/200/195 152
 120/125/130 30
110 38
100 6
75/70/67.5 7
60 14
30 5
Total (Thermal) 382

Gas Frame Size/Scope No. of SETS

9 18
6 18
5 14
3 6
V 94.2 2
6FA 5
STG 52
Total (Gas) 115

Nuclear Rating (MW) No. of SETS

500 3
220/235 10
Total (Nuclear) 13

Total (Thermal + Gas + 497

Nuclear)
Hydro 485+

BHEL Units –Products-mix & Technology

Unit – Haridwar (HEEP)

Period- Established in 1963

Production Starts- Since 1967

Collaborator (Original)- PROMMASH-EXPORT, USSAR

Product-mix

1) Thermal Sets (210/250/500 MW)

2) Gas Turbine Sets
3) Nuclear Sets (235/500 MW)
4) Hydro Sets
5) AC/DC Motors
6) Apparatus Control Gear
7) Super Rapid Gun Mount (SRGM)

Unit – Haridwar (CFFP)

Period- Established in 1974

Production Starts- Since 1976

Collaborator (Original)- CURESOT LOIRE, FRANCE

Product-mix

1) CI Castings 12000 MT
2) NF casting 250 MT
3) Steel Casting 600 MT
4) Forgings 3250 MT
5) Hot Die Steel