INDUSTRIAL

VISIT
REPORT TO
BHARAT
HEAVY
ELECTRICALS
LIMITED
(BHEL)
Submitted By:-

PREFACE
Practical knowledge means the visualization of the knowledge,
which we reading our books. For this, we perform experiments and get
observations. Practical knowledge is very important in every field. One
must be familiar with the problems related to that field so that he may
solve them and become a successful person.
Aft.er setting the proper goal in life, an engineer has to enter in
professional career. According to this, he has to serve an industry,
which may be public or private sector or self-owned. To perform
efficient work in the field, one must be well aware of the practical
knowledge as well as theoretical knowledge.
The purpose of industrial visit is to apply theoretical concepts to
the practical field. In this visit we have learnt many interesting concepts
such as functioning of hydraulic turbines, generation of electricity,
management of electricity, management of industry etc.

ACKNOWLEDGEMENT

First its our bounded duty to thank the almighty for his gracious
blessings and for enabling us to finish this report with successful
training at NALGONDA HYDRO POWERPLANT.
I take this opportunity to express my profound gratitude and deep
regards to my guide MR MOHD ABDULLAH for his exemplary guidance,
monitoring and constant encouragement throughout the course of this
thesis.
I express my sincere thanks and gratitude to NALGONDA
POWERPLANT authorities for aVisit to industrial plant helps provide a
practical experience of what we study in classrooms and through the text
books. They help make us understand how people in an organizational
setting actually work together as a team and together coordinate towards
achievement of organizational objectives. Through this project, I provide
my report on the industrial visit to Hyderabad situated plant of. This visit
was a part of industry interface program where the students got a practical
view of organization and its working. The objective of this study was to
impart knowledge in the field of Electrical And Electronics Engineering by
the way of industrial exposure. The methodology adopted for the study
comprised of visit to the plant premises and observing. A question
and answer round was also arranged where the queries were answered.
2

Information available on the websites of BHEL was also used .Although the
study is limited by various constraints of time, space (visit being limited to
plant premises) and individual differences etc, yet it has been an immense
learning experience for students.
BHEL was established in 1964. Heavy Electrical (India) Ltd was merged with
BHEL in 1974. In 1982, it entered into power equipments, to reduce its
dependence on the power sector. It developed the capability to produce a
variety of electrical, electronic and mechanical equipments for all sectors,
including transmission, transportation, oil and gas and other allied
industries. In 1991, it was converted into a public limited company. By the
end of 1996, the company had handed over 100 Electric Locomotives to
Indian Railway and installed 250 Hydro-sets across India.
BHEL's operations are organized around three business sectors, namely
Power, Industry- including Transmission, Transportation,
Telecommunication & Renewable Energy and Overseas Business. This
enables BHEL to have a strong customer orientation, to be sensitive to his
needs and respond quickly to the changes in the market.
BHEL's vision is to become a world-class engineering enterprise, committed
to enhancing stakeholder value. The company is striving to give shape to its
aspirations and fulfill the expectations of the country to become a global
player. The greatest strength of BHEL is its highly skilled and committed
42,600employees. 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 participative style of
management all these have engineered development of a committed and
motivated workforce setting new benchmarks in terms of productivity,
quality and responsiveness. BHEL has taken India from a near total
dependence on imports to complete self-reliance in this vital area of
power plant equipment. BHEL has supplied 97% of the power generating
equipment that was commissioned in India during 1979-80. BHEL has
already supplied generating equipment to
various utilities produce annually; equipment capable of
g e n e r a t i n g 600 0 MW. This will grow further to e nable BHEL to
3

meet all of
Indias projecte d power equi pment require ments, a s well as siz
eable por tion of export targets. Probably the most significant aspect
of BHELs growth has been its diversification. The constant
reorientation of the organization to meet the varied needs in time with
time a philosophy that has led to the development of a total capability
from concept to commissioning not only in the field of energy but also in
industry and transportation. In the world power scene, BHEL ranks
among the top ten manufacturers of power plant equipment and in terms of
the spectrum of products and services offered, it is right on top.

Some of the products BHEL manufactures are

Gas turbines
Steam turbines
4

Compressors
Turbo generators
Heat exchangers
Pumps

Practical knowledge means the visualization of the knowledge,

which we reading our books. For this, we perform experiments and get
observations. Practical knowledge is very important in every field. One
must be familiar with the problems related to that field so that he may
solve them and become a successful person.
Aft.er setting the proper goal in life, an engineer has to enter in
professional career. According to this, he has to serve an industry,
which may be public or private sector or self-owned. To perform
efficient work in the field, one must be well aware of the practical
knowledge as well as theoretical knowledge.
The purpose of industrial visit is to apply theoretical concepts to
the practical field. In this visit we have learnt many interesting concepts
such as functioning of hydraulic turbines, generation of electricity,
management of electricity, management of industry etc.

First its our bounded duty to thank the almighty for his gracious

llowing me to undergo the training in this prestigious

organization. I will always remain indebted to them for their constant
interest and excellent guidance in my training work, moreover for
providing me with an opportunity to work and gain experience.
We take this opportunity to extend our heartiest thanks to our
beloved Head of the department of Engineering Mr M.P SONI, for
giving us complete freedom to carry out this training at NALGONDA to
gain experience.

Introduction
Visit to industrial plant helps provide a practical experience of what we
study in classrooms and through the text books. They help make us
understand how people in an organizational setting actually work together
as a team and together coordinate towards achievement of organizational
objectives. Through this project, I provide my report on the industrial visit to
Hyderabad situated plant of. This visit was a part of industry interface
program where the students got a practical view of organization and its
working. The objective of this study was to impart knowledge in the field of
Electrical And Electronics Engineering by the way of industrial exposure.
The methodology adopted for the study comprised of visit to the
plant premises and observing. A question and answer round was also
6

arranged where the queries were answered. Information available on

the websites of BHEL was also used .Although the study is limited by various
constraints of time, space (visit being limited to plant premises) and
individual differences etc, yet it has been an immense learning experience
for students.

COMPANY PROFILE
BHEL was established in 1964. Heavy Electrical (India) Ltd was merged with
BHEL in 1974. In 1982, it entered into power equipments, to reduce its
dependence on the power sector. It developed the capability to produce a
variety of electrical, electronic and mechanical equipments for all sectors,
including transmission, transportation, oil and gas and other allied
industries. In 1991, it was converted into a public limited company. By the
end of 1996, the company had handed over 100 Electric Locomotives to
Indian Railway and installed 250 Hydro-sets across India.
7

BHEL's operations are organized around three business sectors, namely

Power, Industry- including Transmission, Transportation,
Telecommunication & Renewable Energy and Overseas Business. This
enables BHEL to have a strong customer orientation, to be sensitive to his
needs and respond quickly to the changes in the market.
BHEL's vision is to become a world-class engineering enterprise, committed
to enhancing stakeholder value. The company is striving to give shape to its
aspirations and fulfill the expectations of the country to become a global
player. The greatest strength of BHEL is its highly skilled and committed
42,600employees. 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 participative style of
management all these have engineered development of a committed and
motivated workforce setting new benchmarks in terms of productivity,
quality and responsiveness. BHEL has taken India from a near total
dependence on imports to complete self-reliance in this vital area of
power plant equipment. BHEL has supplied 97% of the power generating
equipment that was commissioned in India during 1979-80. BHEL has
already supplied generating equipment to
various utilities produce annually; equipment capable of
g e n e r a t i n g 600 0 MW. This will grow further to e nable BHEL to
meet all of
Indias projecte d power equi pment require ments, a s well as siz
eable por tion of export targets. Probably the most significant aspect
of BHELs growth has been its diversification. The constant
reorientation of the organization to meet the varied needs in time with
time a philosophy that has led to the development of a total capability
from concept to commissioning not only in the field of energy but also in
industry and transportation. In the world power scene, BHEL ranks
among the top ten manufacturers of power plant equipment and in terms of
the spectrum of products and services offered, it is right on top.

PRODUCTS:
Some of the products BHEL manufactures are

Gas turbines
Steam turbines
Compressors
Turbo generators
Heat exchangers
Pumps
9

Gas Turbines:
BHEL - the largest Gas Turbine manufacturer in India, with the state-ofart facilities in all areas of Gas Turbine manufacture provide complete
engineering in-house for meeting specific customer requirement. With
over 100 machines and cumulative fired hours of over four million hours,
BHEL has supplied gas turbines for variety of applications in India and
abroad. BHEL also has the world's largest experience of firing highly
volatile naphtha fuel on heavy duty gas turbines.
BHEL is one of the few business associates of M/s. GE, USA and under its
comprehensive Technical Collaboration Agreement from 1986, (license
to manufacture rotors and hot gas path components) offers complete
power plant engineering solutions. BHEL also manufactures Gas Turbine
under its ongoing Technical Collaboration Agreement with M/s Siemens,
Germany. Some specific features:
1. Capability to fire a wide range of gaseous and liquid fuels and a mix of
such fuels ranging from clean fuels like Natural Gas, Distillate Oil,
Naphtha, LNG to heavy fuels like LSHS, crudes, blends, etc. Fuel
economy over a wide range of ambient temperatures and loads.
2. Facilities like Black start, fast start and emergency start.
3. Suitable for power generation and mechanical drive application.
Models below 100 MW suitable for 50 Hz and 60 Hz.
4. All matching equipment like generators, compressors, etc.
manufactured in-house. Design of combustion systems as per
international emission norms. Machines designed as per major
international codes like API, etc.
5. Suitable for IGCC applications.
6. Suitable for indoor or outdoor locations.
7. Use of water or steam injection for abatement of NOX emissions and
power augmentation.
BHEL equipped with precision and sophisticated machine - tools like
10

CNC Broaching Machine, 5-Axis Milling Machine and over speed

Vacuum Balancing Tunnel offers Conversion, Modification and Upgradation services - through joint venture with GE for all existing Gas
turbines. Services are also offered for all Field support, Retrofits and
repairs, inspections and Technical Consultancy on "Operation &
Maintenance of Gas Turbine Based Power Plants". A gas turbine, also
called a combustion turbine, is a type of internal combustion engine. It
has an upstream rotating compressor coupled to a downstream turbine,
and a combustion chamber in-between. The basic operation of the gas
turbine is similar to that of the steam power plant except that air is used
instead of water. Fresh atmospheric air flows through a compressor that
brings it to higher pressure. Energyis then added by spraying fuel into
the air and igniting it so the combustion generates a high-temperature
flow. This high-temperature high-pressure gas enters a turbine, where it
expands down to theexhaust pressure, producing a shaft work output in
the process. The turbine shaft work is used to drive the compressor and
other devices such as an electric generator that may be coupled to the
shaft. The energy that is not used for shaft work comes out in
the exhaust gases, so these have either a high temperature or a high
velocity. The purpose of the gas turbine determines the design so that
the most desirable energy form is maximized. Gas turbines are used to
power aircraft, trains, ships, electrical generators, or even tanks.

PRINCIPLE OF OPERATION:
In an ideal gas turbine, gases undergo three thermodynamic processes:
an isentropic compression, an isobaric (constant pressure) combustion
and an isentropic expansion. Together, these make up the Brayton cycle.
11

In a practical gas turbine, mechanical energy is irreversibly transformed

into heat when gases are compressed (in either a centrifugal or
axial compressor), due to internal friction and turbulence. Passage
through the combustion chamber, where heat is added and the specific
volume of the gases increases, is accompanied by a slight loss in
pressure. During expansion amidst the stator and rotor blades of the
turbine, irreversible energy transformation once again occurs.
If the device has been designed to power a shaft as with an industrial
generator or a turboprop, the exit pressure will be as close to the entry
pressure as possible. In practice it is necessary that some pressure
remains at the outlet in order to fully expel the exhaust gases. In the case
of a jet engine only enough pressure and energy is extracted from the
flow to drive the compressor and other components. The remaining high
pressure gases are accelerated to provide a jet that can, for example, be
used to propel an aircraft.
As with all cyclic heat engines, higher combustion temperatures can
allow for greaterefficiencies. However, temperatures are limited by
ability of the steel, nickel, ceramic, or other materials that make up the
engine to withstand high temperatures and stresses. To combat this
many turbines feature complex blade cooling systems.
As a general rule, the smaller the engine, the higher the rotation rate of
the shaft(s) must be to maintain tip speed. Blade-tip speed determines
the maximum pressure ratios that can be obtained by the turbine and
the compressor. This, in turn, limits the maximum power and efficiency
that can be obtained by the engine. In order for tip speed to remain
constant, if the diameter of a rotor is reduced by half, the rotational
speed must double. For example, large jet engines operate around 10,000
rpm, while micro turbines spin as fast as 500,000 rpm.[8]
Mechanically, gas turbines can be considerably less complex
than internal combustion piston engines. Simple turbines might have
one moving part: the shaft/compressor/turbine/alternative-rotor
assembly (see image above), not counting the fuel system. However, the
required precision manufacturing for components and temperature
resistant alloys necessary for high efficiency often makes the
construction of a simple turbine more complicated than piston engines.
More sophisticated turbines (such as those found in modern jet engines)
12

may have multiple shafts (spools), hundreds of turbine blades, movable

stator blades, and a vast system of complex piping, combustors and heat
exchangers.
Thrust bearings and journal bearings are a critical part of design.
Traditionally, they have been hydrodynamic oil bearings, or oilcooled ball bearings. These bearings are being surpassed by foil bearings,
which have been successfully used in micro turbines and auxiliary power
units

STEAM TURBINES:
BHEL, Ramachandrapuram has
been playing an active role for
almost four decades in its promise
of "bringing power to the people".
BHEL has responded to
requirements of the nation with a
comprehensive range of products.
This has been achieved by superior
technology Which is supported by
an integrated workforce of skilled
professionals and an accent
on quality, excellence and efficiency. At BHEL Hyderabed, the art of Steam
13

Turbine Building has been perfected over a quarter of a century by the

absorption of leading technologies and building up of experience for catering
to every possible application in the product range.
A steam turbine is a device that extracts thermal energy from
pressurized steam and uses it to do mechanical work on a rotating output
shaft. Its modern manifestation was invented by Sir Charles Parsons in
1884.[1]
Because the turbine generates rotary motion, it is particularly suited to be
used to drive an electrical generator about 90% of all electricity generation
in the United States (1996) is by use of steam turbines.[2] The steam turbine
is a form of heat engine that derives much of its improvement
in thermodynamic efficiency from the use of multiple stages in the
expansion of the steam, which results in a closer approach to the ideal
reversible expansion process.

PRINCIPLE OF OPERATION:
An ideal steam turbine is considered to be an isentropic process, or constant
entropy process, in which the entropy of the steam entering the turbine is
equal to the entropy of the steam leaving the turbine. No steam turbine is
truly isentropic, however, with typical isentropic efficiencies ranging from
2090% based on the application of the turbine. The interior of a turbine
comprises several sets of blades or buckets. One set of stationary blades is
connected to the casing and one set of rotating blades is connected to the
shaft. The sets intermesh with certain minimum clearances, with the size
and configuration of sets varying to efficiently exploit the expansion of steam
at each stage.

14

TURBO GENERATORS:
BHEL presently has manufactured Turbo-Generators of ratings upto 560
MW and is in the process of going upto 660 MW. It has also the capability
to take up the manufacture of ratings upto 1000 MW suitable for thermal
power generation, gas based and combined cycle power generation as-wellas for diverse industrial applications like Paper, Sugar, Cement,
Petrochemical, Fertilizers, Rayon Industries, etc. Based on proven designs
and know-how backed by over three decades of experience and
accreditation of ISO 9001, the Turbo-generator is a product of high-class
workmanship and quality. Adherence to stringent quality-checks at each
stage has helped BHEL to secure prestigious global orders in the recent past
from Malaysia, Malta, Cyprus, Oman, Iraq, Bangladesh, Sri Lanka and Saudi
Arabia.
The successful completion of the various export projects in a record time is
a testimony of BHEL's performance.

15

A turbo generator is the combination of a turbine directly connected to

an electric generator for the generation of electric power. Large steam
powered turbo generators provide the majority of the world's electricity and
are also used by steam poweredturbo-electric ships.
Smaller turbo-generators with gas turbines are often used as auxiliary power
units. For base loads diesel generators are usually preferred, since they offer
better fuel efficiency, but on the other hand diesel generators have a lower
power density and hence, require more space.
The efficiency of larger gas turbine plants can be enhanced by using
a combined cycle, where the hot exhaust gases are used to
generate steam which drives another turbo generator.

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HEAT EXCHANGERS:
BHEL Hyderabad has supplied a variety of Heat Exchangers in large
numbers for diversified applications. Among them are Steam Surface
Condensers, Air Evacuation System, Feed Water Heaters, Desecrators InterStage Gas Coolers, Process Heat Exchangers, Air cooled Heat Exchangers,
L.P.G Bullets. These are rendering good service in a number of Power
Plants, Fertilizer, petroleum, Petrochemical, Steel and other Industrial
Plants.

17

A heat exchanger is a piece of equipment built for efficient heat

transfer from one medium to another. The media may be separated by a
solid wall to prevent mixing or they may be in direct contact.[1] They are
widely used in space heating, refrigeration, air conditioning, power
plants, chemical plants, petrochemical plants, petroleum refineries, natural
gas processing, and sewage treatment. The classic example of a heat
exchanger is found in an internal combustion engine in which a circulating
fluid known as engine coolant flows through radiator coils and air flows past
the coils, which cools the coolant and heats the incoming air.

COMPRESSORS:
BHEL manufactures a complete range of centrifugal compressors for all
major compression applications. They are used in oil & gas production, gas
transportation, refinery and petrochemical industries, fuel gas boosting and
other similar processes. Our licensor GE holds the record for centrifugal
compressor applications having designed and manufactured the first high
pressure compressor for ammonia and urea plants, the most powerful
compressors for offshore applications (over 30,000 HP) and re-injection
compressors with delivery pressures as high as 10,000 psi(700 bar).
18

Specific requirements are met by custom configuring each compressors

using standardized advance technology components proven over a wide
range of process conditions. This approach delivers reliable, high
performance compressors for natural gas, refinery, petrochemical, and
newer applications. Skilled staff of local engineers and technicians provides
on-site technical support for installation, commissioning, overhaul, repair
and maintenance of our equipment. Steam turbine, Gas turbine, Electric
motor and VFD Systems can be provided for driving the compressors.
BHEL can provide complete solution involving Driver, Compressor, Heat
Exchangers, Piping, Electrical and Instrumentation, erection and
commissioning, civil works.

A gas compressor is a mechanical device that increases the pressure of

a gas by reducing its volume. An air compressor is a specific type of gas
compressor.Compressors are similar to pumps: both increase the pressure
on a fluid and both can transport the fluid through a pipe. As gases are
compressible, the compressor also reduces the volume of a gas. Liquids are
relatively incompressible; while some can be compressed, the main action of
a pump is to pressurize and transport liquids.
An air compressor is a device that converts power (usually from an electric
motor, a diesel engine or a gasoline engine) into kinetic energy by
compressing and pressurizing air, which, on command, can be released in
quick bursts.

19

PUMPS:
BHEL Ramachandrapuram Unit has acquired considerable experience in the
design and manufacture of various important types of pumps required for
the thermal power plants like the Boiler Feed Pump, Boiler Feed Booster
Pump, Condensate Extraction Pump and Cooling Water Pump.
Starting its manufacturing activities in mid sixties, the pumps were designed
and manufactured for 60 MW, 110 MW and 210 MW under technical
20

collaboration with M/s. Sigma Lutin of Czechoslovakia. Over the years,

hundreds of pumps have been manufactured and supplied with this design
and have earned a good reputation for their robust design, trouble-free
operation and reliable service.
In order to meet the requirements of higher efficiency pumps for 210 MW
units and large capacity pumps for 500 MW units, collaboration was entered
in 1980 with M/s. Wier Pumps Limited, U.K., who are acknowledged as one
of the leading manufacturers of pumps in the world. With this, BHEL has
geared itself to meet the market demand of cartridge design pumps with
high efficiency and reliability.
In 2007, BHEL Hyderabad has entered into collaboration with M/s.
Mitshubishi Heavy Industries, Japan to manufacture pumps for super-critical
thermal power plants up to 1000 MW and thus taking a major stride towards
meeting the demands of market with the advanced state-of-the-art supercritical power plant technology.
With this, BHEL has geared itself to meet the market demand of cartridge
design pumps with high efficiency and reliability.

A pump is a device that moves fluids (liquids or gases), or

sometimes slurries, by mechanical action. Pumps can be classified into three
major groups according to the method they use to move the fluid: direct
lift, displacement, and gravity pumps.

21

Pumps operate by some mechanism (typically reciprocating or rotary), and

consumeenergy to perform mechanical work by moving the fluid. Pumps
operate via many energy sources, including manual operation,
electricity, engines, or wind power, come in many sizes, from microscopic
for use in medical applications to large industrial pumps.
Mechanical pumps serve in a wide range of applications such as pumping
water from wells, aquarium filtering, pond filtering and aeration, in the car
industry for water-cooling and fuel injection, in the energy
industry for pumping oil and natural gas or for operating cooling towers. In
the medical industry, pumps are used for biochemical processes in
developing and manufacturing medicine, and as artificial replacements for
body parts, in particular the artificial heart and penile prosthesis.
In biology, many different types of chemical and bio-mechanical pumps
have evolved, and biomimicry is sometimes used in developing new types of
mechanical pumps.

Observations
BHEL is the largest engineering and manufacturing enterprise in India in
the energy-related/infrastructure sector. 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 high level
of quality & reliability of its products is due to the emphasis on design,
engineering and manufacturing to international standards by acquiring and
adapting some of the best technologies from leading companies in the world,
together with technologies developed in its own R&D centres. The greatest
strength of BHEL is its highly skilled and committed 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 participative style of management all these have
engineered development of a committed and motivated workforce setting
new benchmarks in terms of productivity, quality and responsiveness. BHEL
22

has its headquarters at New Delhi. Its operations are spread over 11
manufacturing plants and number of engineering and service divisions
located across the country.

Conclusion
BHEL is one of the largest engineering and
m an u f ac tu r i n g
e n t e r pr i s e s i n I n d i a i n th e i r r e sp e c t i v e f i e l d s. I t i s committed to
customer, quality and excellence, and while doing so, maintain
t h e h i g h e st s tan d ar d s o f e th i c s a n d s oc i e tal r e sp o n s i bi l i ti e s .
I t h a s manpower, proven management, and world-class products. They
both occupy a very significant position in the economy of our country. The
organizations understand the fact that the people are the centre of
the whole system and most of the problems in organization are human
related, as human beings are dynamic and complex. In order to create a
performing organization and to sustain the performance, the human
resources should be
c om p e t e n t a n d e f fi c i e n t an d t h e fou n d a ti on i s t a p pi n g d ow n c
o m pe t e n t workforce and retaining them. At BHEL the workers are not
seen as a liability, but a s a k e y r e s ou r c e w h i c h n e e d s t o b e
23

c ar e fu l l y n u r tu r e d a n d c o n s t an tl y developed. It truly believes

that a "Learning Organization" is essential for survival in the present
era of Liberalization, Privatization and Globalization.
This industrial visit to the plant of BHEL has been an immense learning
experience for all the students.

24