A PPT ON TRAINING DONE AT

BHEL HARIDWAR
SUBMITTED TO :
PROF. CHETAN
SELWAL

SUBMITTED BY:
DIVYA RATHORE
13ECESO4
B.TECH
7th SEM

WHAT IS BHEL ?
BHEL stands for Bharat Heavy Electricals

Limited.
It is one of the most important PSUs of our
country.
It manufactures a wide range of electrical
equipment like generators, motors, exciters
and other power plant accessories.

BHEL business operations cater to core

sectors of the Indian Economy like:

Power
Industry
Transportation
Transmission
Defence

MANUFACTURING DIVISIONS
OF
BHEL
Heavy Electrical Plant, Piplani, Bhopal
Electrical Machines Repair Plant (EMRP),

Mumbai
Transformer Plant P.O. BHEL, Jhansi
Heavy Electrical Equipment Plant Ranipur,
Haridwar
Central Foundry Forge Plant Ranipur, Haridwar
Heavy Equipment Repair Plant, Varanasi
Insulator Plant, Jagdishpur, Distt. Sultanpur

Heavy Power Equipment Plant,

Ramachandra Puram,Hyderabad
High Pressure Boiler Plant & Seamless
Steel Tube Plant,Tiruchirappalli
Boiler Auxiliaries Plant, Indira Gandhi
Industrial Complex, Ranipet
Industrial Valves Plant, Goindwal
Electronics Division, Bangalore
Component Fabrication Plant, Rudrapur
Piping Centre, Chennai
Regional Operations Division, New Delhi

BHEL HARIDWAR
It is divided in 2 units i.e. Heavy Electrical

Equipment Plant (HEEP) and Central Foundry

Forge Plant (CFFP).
We did our training at HEEP plant.
HEEP plant is divided into 8 blocks.
Turbo generators are manufactured at HEEP
plant.
Each block manufactures different
components of a turbo generator.

BHEL HEEP PLANT,

HARIDWAR

VARIOUS BLOCKS AT
HEEP
1) Block 1
In block 1 mainly stator, rotor shaft and
exciter are manufactured and assembled for
LSTG (Large Size Turbo Generators).

2) Block 2
In block two large size fabricated
assemblies/components for power equipment
are manufactured & assembled.

3) Block 3
In block -3 steam turbines, gas turbines and
turbines blade are manufactured and
assembled.
4) Block 4
In block -4 winding for turbo generator,
insulating components for turbo generator
are manufactured & assembled.
5) Block 5
In block -5 fabricated parts of steam turbine
are manufactured & assembled.

6) Block 6
In block -6 fabricated oil tanks, hollow guide
blades, rings, stator frames, rotor spiders are
manufactured & assembled.

7) Block 7
In block -7 all types of dies including stamping
dies, stamping for generators & motors are
manufactured & assembled.

8) Block 8
In block -8 LP heaters, ejectors, steam coolers,
oil coolers, ACG coolers, oil tanks are
manufactured & assembled.

INTRODUCTION
CNC Computer Numerical Control
A CNC system receives numerical data,

interpret the data and then control the action

accordingly by an on-board computer system
at the machine tool.
CNC machine is an outstanding contribution
to the manufacturing industries.
It has made possible the automation of the
machining process with flexibility.

How the CNC machines look like

?

Element of CNC
Machines
A CNC machine consist of following 6 major

elements:
i.
ii.
iii.
iv.
v.
vi.

Input Device
Machine Control Unit
Machine Tool
Driving System
Feedback Devices
Display Unit

Block diagram of CNC machines

Technology used
.The CNC systems are constructed with a NC unit

integrated with a PLC :

1. The NC controls the spindle movement and
the speeds and feeds in machining. It calculates
the traversing path of the axes as defined by
the inputs.
2. The PLC controls the peripheral actuating
elements of the machine such as solenoids,
relay coils, etc.
Working together, the NC and PLC enable the
machine tool to operate automatically.

How CNC works?

Controlled by G and M codes.

These are number values and co-ordinates.
Each number or code is assigned to a particular
operation

Common format of a
block

Application of
CNC
1. Machining e.g. milling, drilling, turning,
2.
3.
4.
5.
6.
7.

boring, grinding, laser cutting

Gear shaping
Press working
Welding
Tube bending
Assembly
Coordinate measuring machine.

Advantages of CNC
machine
1. Higher productivity
2. Easier to program
3. Reduced manpower
4. Just in time (JIT) manufacture
5. Improved quality control -Avoids human errors

Challenges
1. Costly setup
2. Skilled operators-finding and training of

NC personnel.
3. Maintenance is difficult

PROGRAMMABLE LOGIC
CONTROL(PLC)
A Programmable Logic Controller (PLC) is a specialized

computing system used for control of industrial machines

and processes.
A PLC is a computer designed to work in an industrial

environment .
It uses a programmable memory to store the instructions

and specific functions that include On/Off control, timing

counting, sequencing, arithmetic and data handling.
PLCs are equipped with special input/output interfaces .

Components of
PLC

Processor.
Memory unit .
Power supply.
I/O Modules.
Programming device

1.Processor
Processor is the central processing unit (CPU)

of the programmable controller, it executes the

various logic and sequencing functions by
operating on the PLC inputs to determine the
appropriate output signals.
The CPU consists of one or more
microprocessors similar to that of PCs and other
data processing equipment but are designed to
facilitate I/O transactions with different ranges
with corresponding clock speed.

 Consists of a microprocessor for

implementing the logic and controlling the

communications among the modulus.
Designed, so the desired circuit can be
entered in relay ladder logic form.
The processor accepts the input data from
various sensing devices, executes the
stored user program and sends appropriate
output commands to control devices

2.Memory
Memory unit is connected to the CPU,

which contains the programs of logic,

sequencing and I/O operations .
It also holds data files associated with

these programs, including I/O stations bits,

counter and timer constants, and other
variable and parameter values.

3. Power supply
A power supply of 120v alternating current(ac)

is typically used to drive the PLC (some units

operate on 240 v ac).
The power supply converts the 120v ac into
direct current (dc) voltages of 5V.
These low voltages are used to operate
equipment that many have much higher voltage
and power ratings than the PLC itself.
The power supply often includes a battery backup
that switches in automatically in the event of an
external power source failure.

Supplies DC power to other modules that

plug into the rack.

In large PLC systems, this power supply
doe not normally supply power to the field
devices.
In small and micro PLC systems , the
power supply is also used to power field
devices.`

4.I/O module
The input/output module provides the connections

to the industrial equipment or process that is not to

be controlled.
Inputs to the controller are signals from limit-switches
, push-buttons, sensors , and other on/off devices.
Outputs from the controller are on/off signals to
operate motors, valves, and other devices required to
actuate the process.
Many PLCs are capable of accepting continuous
signals from analog sensors ad generating signals
suitable for analog actuators

Forms the interface by which

input field devices are

connected to the controller.
The terms field and

real world are used to

distinguish actual external
devices that exist and must be physically
wired into the system.

5. Programming
Device
The PLC is programmed by means of a programming

device. The programming device is usually detachable

from the PLC cabinet so that it can be shared among
different controllers.
Different PLC manufacturers provide different
devices , ranging from simple teach pendant type
devices , similar to those used in robotics, to special
PLC programming keyboards and CRT displays.

PCs and laptops now widely used for programming a

much faster and a PC / laptop are also smaller now.

The software allows users to create ,

edit .document,
programs .

store and trouble shoot

The personal computer communicates with

the plc processor via serial or parallel data

communications link

Hand held programming devices are sometimes used to

program small PLCs.

They are compact, inexpensive and easily to use, but are not

able to display as much logic on screen as a computer

monitor.
Hand-held units are often used on the factory floor for

trouble shooting, modifying programs

programs to multiple machines.

and

transferring

PLC
ADVANTAGES

Less and simple wiring.

Increased Reliability.
More Flexibility/Modular.
Lower Cost .
Faster Response.
Easier to troubleshoot.
Remote control capability.
Communication Capability.
Handles much more complicated systems.

PLC
DISADVANTAGE
There's too much work required in connecting

wires.
It is difficult to find errors.
Skillful workers are required.
Theres difficulty with replacements.
PLC devices are proprietary, which means that
parts and software from one manufacturer
cant easily be used in combination with parts
of another manufacturer, which limits the
design and cost options.

PLC
APPLICATIONS
PLCs are generally used in industries for

controlling heavy machinery and processes

like conveyor system, CNC machines etc.
PLC usage can also be observed in day to
day life.
For eg : automatic washing
machines, cars, video cameras etc.
PLC has its applications in almost every
automatic machine.