A

REPORT
ON

BHARAT HEAVY
ELECTRICALS LIMITED
HARIDWAR

Submitted to: Submitted by:

Mangesh Jaiswal
Anand Engineering
College, Agra
U.P.
 PREFACE

In the present competitive world market when customer satisfaction is the

prime objective. Quality, price and services are the major areas to conquer.
Initiative, foresight, talent and competency are imperative to manage the
business.

The B.Tech. Course imparts the students the tinge of such virtues and
prepares to take the technical world in their stride. In the midst of the course.
Summer training in some technical organization is arranged for the students:
that is vitally essential. Such training gives practical experience and helps the
students to view the real technology closely, which in turn widely influences
their conceptions and perceptions.
The summer training assumed all the more significance when it is done
in a reputed, last growing and professionally managed world level organization
like BHARAT HAVEY ELECTRICALS LIMITED. I was really fortunate in
getting an opportunity to work with them
The project taken up was to study the Central foundry forge plant.
I feel proud of getting a chance to study the technical system of a world
level company and have learnt a lot about the complicity and legal aspects of
the system.
 HEEP
&
CFFP
BHEL, HARIDWAR
 ACKNOWLEDGEMENT

The preparation of this project report would not have been

possible without the guidance and blessings of several people.
I owe my thanks to Mr. Kapil Dev (Principal of S&T
Training Centre) for this encouragement, expert guidance in
bringing out this project.

Mangesh Jaiswal
 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

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.

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 modernization and up rating of a variety of power plant equipment
besides specialized know how of residual life assessment, health diagnostics and
life extension of plants.

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. Waste 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.

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.

ACTIVITY PROFILE

PRODUCTS - Industrial Fans

Power Generation & Transmission - Seamless steel Tubes
- Steam Turbine-Generator Sets & - Fabric Filters
Auxiliaries
- 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 - Battery-Operated Passengers
Transformers 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 - Simulators
Stations
- 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 - Reverse Osmoses Desalination
 & GAS/ Plants
TELECOMMUNICATION/RENEWABL SYSTEMS & SERVICES
E ENERGY
- 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 - Modernization & 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

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 ambitious 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.
 Loyalty 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 up to 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. 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.

4. 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 up to 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

5. HEEP: FACILITIES AND INFRASTRUCTURE

Modernization and regular up gradation / 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 Modernization, 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 up to 1300 MW (32T, 6.9 M –
dia bladed rotor, 6 rpm up to 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 Tooling’s 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, Over speed 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 up to 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 work 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, Haridwar.

(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. Over speed 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, over speed 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 up to 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 through
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 hold 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/Cm 2.
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 up to 40 Kg / c m 2 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 are 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 tooling’s. 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.
3.2 BRAZED TYPE BLADES

3.3 GAS TURBINE BLADES

A.
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 numbers of tests have successfully been performed
in the Laboratory which includes 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, Up rating 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. 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. 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 trace.

BOARD OF DIRECTORS
K.G. Ramachandran Chairman & Managing Director
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi – 110 049
A.V. Singh Additional Secretary & Financial Advisor
Ministry of Industry. Deptt. of Heavy Industry
Udyog Bhawan, New Delhi – 110 011
Pradeep Kumar Joint Secretary
Ministry of Industry. Deptt of Heavy Industry
Udyog Bhawan, New Delhi – 110 011
Dr. Jamshed J. Irani Managing Director
Tata Iron & Steel Company Limited
Jamshedpur – 831 001
Shekhar Datta Ex-Managing Director & President
Greaves Limited, E/8, Sea Face Park
Bhulabhai Desai Road, Mumbai – 400 001
Ms. Tarjani Vakil Ex-CMD, EXIM Bank of India
A-1, Ishwar Das Mansion, Nana Chowk
 Mumbai – 400 007
J. Jayaraman Ex-CMD, Cochin Refineries Limited
39/4, Ashwin Apartment
C.P. Ramaswamy Road, Chennai – 600 018
K.C. Lahiry Director (Power)
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi – 110 049
K.S. Rao Director (IS&P)
Bharat Heavy Electricals Limited
Integrated Office Complex
Lodhi Road, New Delhi – 110 003
Ishan Shankar Director (Personnel)
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi – 110 049
M.K. Mittal Director (ER&D)
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi – 110 049