PROJECT – FABRICATION BLOCK-3

BHEL HARIDWAR

SUBMITTED TO:- SUBMITTED BY:-

SHANTI PRAKASH RAMAKANT VASHISTHA,

B.Tech (ME) 3 rd yr

ROLL NO. 1808528

HARYANA ENGINEERING COLLEGE, MACHANICAL DEPARTMENT

 CONTENT

1: Introduction to B.H.E.L 1-16.

 General
 Power Generation
 Power Transmission & Distribution
 Industries
 Transportation
 Telecommunication
 Renewable Energy
 International Operators
 Technology Up gradation AND Research & Development
 Human Resource Development Centre
 Health, Safety & Environment Management
1.11.1 Environment Policy

1.11.2 Occupational Health & Safety Policy

 Participation in the “Global Compact” of the United Nations

 Principle of Global Compact
1..1 Human Rights
1..2 Labour Standards
1..3 Environment
 Activity Profile
 Summary of B.H.E.L’s Contribution to Various Core Sectors
 Manufacturing Division’s
 Board of Directors

Heavy Electrical Equipment Plant (HEEP)

 2.1 General
 2.2 Establishment & Development Stages
 2.3 Investment
 2.4 Climate & Geographical
 2.5 Communication & Transportation
 2.6 Power & Water Supply System
 2.7 Fire Protection
 2.8 Manpower
 2.9 Township & Peripheral Infrastructure
 2.10 Product Profile
 2.11 Facility & Infrastructure
 2.12 Human Resources Development Centre
 2.13 Pollution Control Research Institute
 2.14 Aviation Product
 2.15 Medical Linac Project
 2.16 Central Plant Stores

1. FABRICATION BLOCK – 2
 3.1 Major Assemblies Made In Block-2
 3.2 Manufacturing Facilities
 3.2.1 Preperation ,BAY – 1
 3.2.2 Non-Destructing Testing Laboratory
 3.2.3 X-Ray Radiography
 3.2.4 Gamma Radiograph
 3.2.5 Sections In Bay-3
 3.2.6 Sections In Bay-4
 3.3 Manufacturing Process

2. Conclusion

3. Reference
 ACKNOWLEDGEMENT

To achieve something or to achieve one’s goal one has to put in a

lot of effort and time. To achieve this and to see that the time and
effort doesn’t goes useless he has to work in the right path at the right
time. The mantra of success totally lies on this objective and everyone
put his utmost best to taste the success. At certain point it may
disappoint but in the last it gives the encouraging results. In this
process one takes help of all the encouraging and helping people.

I would like to express our deep sense of gratitude towards our

project guide Mr.B.D.Sharma ( DGM), BHEL HARIDWAR For keeping a
friendly behavior during the discussion of project. He not only provided
us with the valuable information needed in our project but also guided
us in each and every respect. Without his valuable contribution in this
project we would have never been able to complete it in time.

Finally we are also much grateful to HRDC Deptt. & Subordinators for
giving us a chance to get OJT-III training.

1
 Introduction to B.H.E.L

1.1 GENERAL

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 centers, over
150 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 has already attained ISO 9000 certification for quality
management, and ISO 14001 certification for environment management.
1.2 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
units 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 Kaplan 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 updating of a power plant equipment besides specialized know
how of residual life assessment, health diagnostics and life extension of plants.
1.3 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.
1.4 INDUSTRIES

BHEL is a major contributor of equipment and systems to industries. Cement, sugar, fertilizer,
refineries, petrochemicals, 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 (Flexible AC
Transmission System) projects is under execution.

The range of system & equipment supplied includes: captive power plants, co-
generation plants DG power plants, industrial steam turbines, industrial boilers and auxiliaries.
Water 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.
1.5 TRANSPORTATION

BHEL is involved in the development design, engineering, marketing, production, installation,

and 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.

1.6 TELECOMMUNICATION

BHEL also caters to Telecommunication sector by way of small, medium and large switching
systems.

1.7 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.
1.8 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 Organizations 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.
1.9 TECHNOLOGY UPGRADATION AND RESEARCH & DEVELOPMENT

To remain competitive and meet customers' expectations, BHEL lays great emphasis on the
continuous up gradation 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 commercialization.

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.
1.10 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.

1.11 HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT

BHEL, as an integral part of business performance and in its endeavor 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:

1.11.1 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 is this field.
1.11.2 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.
1.12 PARTICIPATION IN THE "GLOBAL COMPACT" OF THE UNITED
NATIONS

The "Global Compact" is a partnership between the United Nations, the business community,
international labor 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:

1.13 PRINCIPLES OF THE "GLOBAL COMPACT"

1.13.1 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.

1.13.2 Labor 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.
1.13.3 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.
 CONCLUSION

Here, in the end, where I would like to conclude my whole report with
some short sign. I must say that, to rise in the field of Mechanical
Engineering, one must have the good knowledge of all the
manufacturing processes. The most important thing is to study the
drawings and make the route sheet, planning, shop floor management
of the consequent operations. And in that way I prefer myself to get
training at B.H.E.L, Haridwar. Because B.H.E.L is growing in the field of
Manufacturing and is a very big manufacturing unit so it’s very good to
learn at this place the mechanical and the strategies of management
too.
In this report, you will find some very refined data, which is
referenced from a number of books and manuals and websites. This is
just an effort to make my report more efficient.

REFRENCES
1. Fluid Mechanics by D.S Kumar.

2. Fluid Mechanics by R.K Bansal.

3. Fluid Mechanics by R.K Rajput.

4. Thermal Engineering by R.K Rajput.

5. Thermal Engineering by B.L Ballaney.

6. Reference data Available in Block-2.