INTRODUCTION:

BHEL was established more than 50 years ago when its first plant was setup in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India. Adream which has been more than realized with a well recognized track record of performance it has been earning profits continuously since 1971-72 and achieved aturnover of Rs 2,658 crore for the year 2007-08, showing a growth of 17 per cent over the previous year. Bharat Heavy Electricals Limited is countrys Navratna company andhas earned its place among very prestigious national and international companies. It finds place among the top class companies of the world for manufacture of electricalequipments.BHEL caters to core sectors of the Indian Economy viz., Power Generation's &Transmission, Industry, Transportation, Telecommunication, Renewable Energy,Defense, etc. BHEL has already attained ISO 9000 certification for quality management,and ISO 14001 certification for environment management and OHSAS 18001certification for Occupational Health and Safety Management Systems. The Companytoday enjoys national and international presence featuring in the Fortune International-500 and is ranked among the top 10 companies in the world, manufacturing power generation equipment. BHEL is the only PSU among the 12 Indian companies to figurein Forbes Asia Fabulous 50 list.Probably the most significant aspect of BHELs growth has been itsdiversification .The constant reorientation of the organization to meet the varied needs intime with a philosophy that has led to total development of a total capability fromconcepts to commissioning not only in the field of energy but also in industry andtransportation.In the world power scene BHEL ranks among the top ten manufacturers of power plant equipments not only in spectrum of products and services offered, it is right on top.BHELs technological excellence and turnkey capabilities have won it worldwiderecognition. Over 40 countries in world over have placed orders with BHEL coveringindividual equipment to complete power stations on turnkey basis.

BHEL A Brief Profile: BHEL is the largest engineering and manufacturing enterprise in India in theenergy related infrastructure sector today. The wide network of BHEL's 14manufacturing division, four power Sector regional centers, over 150 project sites, eight service centers and 18 regional offices, enables the Company to promptly serve itscustomers and provide them with suitable products, systems and services efficientlyand at competitive prices. While the company contributes more then 75% of the nationalgrid, interestingly a share of 45% comes from its single unit. And this is none other thenBHEL-Hardwar. BHEL has: Installed equipment for over 90,000MW of power generation for utilities captive and industrial users. Supplied over 2, 25,000 MVA transformer capacity and other equipment operating in transmission and distribution network up to400 kV (AC & DC). Supplied over 25,000 motors with drive control systems to power projects, petrochemicals, refineries, steel, aluminum, fertilizers,cement plants etc. Supplied Traction electrics and AC/DC locos to power over 12,000kms railway network. Supplied over one million valves to power plants and other industries. BHEL An Overview: BHEL today is the largest Engineering Enterprise of its kind in India withexcellent track record of performance, making profits continuously since 1971-72.BHEL's vision is to become a world-class engineering enterprise, committed toenhancing stakeholder value. The company is striving to give shape to its aspirations andfulfill the expectations of the country to become a global player.

BHEL business operations cater to core sectors of Indian Economy like: Power Industry Transportation Transmission Defenses etc 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 inhis career. Continuous training and retraining, career planning, a positive work cultureand participative style of management all these have engendered development of acommitted and motivated workforce setting new benchmarks in terms of productivity,quality and responsiveness. POWER SECTOR : Power generation sector comprises thermal, gas, hydro and nuclear power plant business .BHEL supplied utility sets accounts to 87,646 MW 65% of the total installedcapacity of 1,38,175 MW in the country , as against nil in 1969 -70.As part of Indias largest Solar Power-based Island Electrification Project in India, Bharat Heavy Electricals Limited (BHEL) has successfully commissioned two Grid-InteractiveSolar Power Plants of 100 KW each in Lakshadweep.With this, the company has commissioned a total of eleven Solar Power Plants in theLakshadweep islands, adding over 1 MW of Solar Power to the power generatingcapacity of the coral islands in the Arabian Sea. BHEL has proven turnkey capabilities for executing power projects fromconcept to commissioning and manufactures boilers, thermal turbine generator sets and auxiliaries up to 500MW. It possesses the technology and capability to procure thermal power generationup to 1000MW. Co- generation and combined cycle plants have also been introduced.

 For the efficient use of high ash content coal BHEL supplies circulatingfluidized boiler. BHEL manufacturers 235MW nuclear sets and has also commenced productionof 500MW nuclear turbine generator sets. Custom made hydro sets of Francis, pelton and kepian types for different head dischargecombination are also engineering and manufactured by BHEL.In, all 700 utility sets of thermal, hydro, gas and nuclear have been placed on thecompany as on date. The power plant equipment manufactured by BHEL is based oncontemporary technology comparable to the best in the world and is also internationallycompetitive.The Company has proven expertise in Plant Performance Improvement throughrenovation modernization and up rating of variety of power plant equipment besidesspecialized know how of residual life assessment, health diagnostics and life extension of plants.

POWER TRANSMISSION AND DISTRIBUTION (T&D) --:

BHEL offer wide-ranging products and systems for T & D applications Products.manufactured include power transformers, instrument transformers, dry typetransformers, series and shunt 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 electricsubstances 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 thestate-of-the-art controlled shunt reactor (for reactive power management on longtransmission lines). Presently a 400 kV Facts (Flexible AC Transmission System) projectunder execution.

INDUSTRY SECTOR : BHEL is a major contributor of equipment and system to important industries like Cement Petrochemicals Fertilizers Steel papers Refineries Mining and telecommunication 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 and equipment supplied includes: Captive power plants High speed industrial drive turbines Industrial boilers and auxiliaries Waste heat recovery boilers Gas turbine pump, valves, seamless steel tubes Heat exchangers Process control etc.

The Company is a major producer of large-size thruster devices. It also suppliesdigital distributed control systems for process industries, and control & instrumentationsystems for power plant and industrial applications. BHEL is the only company in Indiawith the capability to make simulators for power plants, defense and other applications. The Company has commenced manufacture of large desalination plants to helpaugment the supply of drinking water to people.

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 locomotivesup to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP, both for mainlineand shunting duly applications. BHEL is also producing rolling stock for specialapplications viz., overhead equipment cars, Special well wagons, Rail-cum-road vehicleetc., Besides traction propulsion systems for inhouse 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 dieseltraction equipment on India Railways are largely powered by electrical propulsionsystems 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 turnkeyexecution of electric trolley bus systems, light rail systems etc. BHEL is also diversifyingin the area of port handing equipment and pipelines transportation systems.

TELECOMMUNICATION--BHEL also caters to telecommunication sector by way of small, medium andlarge switching system.At Hardwar, against the picturesque background of Shivalik Hills,importantmanufacturing units of BHEL are located viz. Heavy Electrical Equ ipment Plant(HEEP) & Central Foundry Forge Plant (CFFP). The hum of the construction machineryworking started under Shivalik Hills during early 60s and sowed the seeds of one of thegreatest symbol of Indo Soviet Collaboration Heavy Electrical Equipment Plant:-Consequent upon the technical collaboration between India and USSR in 1959,BHELs prestigious unit, Heavy Electrical Equipment plant (HEEP), was established inOctober, 1963, at Hardwar. It started manufacturing thermal sets in 1967 and nowthermal sets of 210, 250 and 500 MW, including steam turbines, turbo-generators,condensers and all associated equipments, are being manufactured. This unit is capable of manufacturing thermal sets up to 1000 MW. HEEP-manufactured gas turbines, hydroturbines and generators, etc., are not only successfully generating electrical energy withinand outside the country, but have also achieved a historic record of the best operationalavailability and plant load factor.The Company is embarking upon an ambitions 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 enterprise providing total business solutions. MISSION: The leading Indian engineering enterprise providing quality products systems andservices 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. and profitable engineering

 Loyalty and pride in the company. Team playing Zeal to excel. Integrity and fairness in all matters.

ESTABLISHMENT AND DEVELOPMENT STAGES: Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in thearea of Scientific, Technical and Industrial Cooperation. DRR 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 to3500 MW under LSTG. Project during 1979-85 (Sets up to 500 MW, extensibleto 1000/1300 MW unit sizes with marginal addition in facilities with thecollaboration of M/s KWU-Siemens, Germany. Motor manufacturing technology updated with Siemens collaboration during1984-87. Facilities being modernized continually through Replacements Reconditioning-Retrofitting, Technological / operational balancing. /

POWER & WATER SUPPLY SYSTEM: 40 MVA sanctioned Electric Power connection from UP Grid (132 KV / 11KV /6.6 KV) (Connected load around 185 MVA) 26 deep submersible Tube Wells with O.H. Tanks for water supply. A 12 MW captive thermal power station is located in the factory premises.

ELECTRICAL MACHINES BLOCK (BLOCK-I)INTRODUCTION-- Block-I is designed to manufacturing Turbo Generators, Hydro generators andlarge and medium size AC and DC Electrical machines. The Block consist of 4 bays: Bay-1 (36*482 meters), Bay-2 (36*360 meters) andBay-3 and Bay-4 of size 24 *360 meters each. For handling and transporting thevarious components over-head Crane facilities are available, depending upon the products manufactured in each Bay. There are also a number of self-propelledelectrically-driven transfer trolleys for the inter-bay movement of components/assemblies.

BASIC TRAINING DEPARTMENTS: MACHINE SHOP. T/G ROTOR WINDING. H/G IRON ASSEMBLY. EXCITER. T/G STATOR WINDING. TOTAL IMPREGNATION TECHNIQUE.

 T/G IRON ASSEMBLY. T/G MAIN ASSEMBLY. L.S.T.G ROTOR WINDING. L.S.T.G STATOR WINDING. L.S.T.G MAIN ASSEMBLY. TEST BED. TURBO GENERATOR : Turbo generator or A.C. generators or alternators operates on the fundamental principles of ELECTROMAGNETIC INDUCTION.In them the standard constructionconsists of armature winding mounted on stationary element called stator and fieldwindings on rotating element calledrotor . The stator consists of a cast-iron frame , whichsupports the armature core , having slots on its inner periphery for housing the armatureconductors. The rotor is like a flywheel having alternating north and south poles fixed toits outer rim. The magnetic poles are excited with the help of an exciter mounted on theshaft of alternator itself. Because the field magnets are rotating the current is suppliedthrough two slip rings. As magnetic poles are alternately N and S, they induce an e.m.f and hence current in armature conductors. The frequency of e.m.f depends upon the no.of N and S poles moving past a conductor in 1 second and whose direction is given byFleming s right hand rule. SYNOPSIS OF THE FUNCTION OF T.G: 1. The generator is driven by a prime mover which is steam turbine in this case. 2. The other side of generator is provided by a rotating armature of an exciter which produces A.C. voltage. This is rectified to D.C. by using a rotating diode wheel.

3. The rear end of above exciter armature is mounted by a permanent magnetgenerator rotor. 4. As the above system is put into operation, the PMG produces A.C. voltage. 5. The voltage is rectified by thyristor circuit to D.C. 6. This supply is given to exciter field. This field is also controlled by takingfeedback from main generator terminal voltage, to control exciter field variation by automatic voltage regulator. The rectified DC supply out of exciter is suppliedto turbo generator rotor winding either through brushes or central which will bedirectly connected to turbo generator. This depends on the type of exciter viz. DCcommutator machines or brushes exciter. 7. The main A.C. voltage is finally available at the stator of Turbo Generator. LARGE SIZE TURBO GENERATOR : In these types of generators steam turbine does the function of prime mover whichrotates the rotor of LSTG and the field winding is supplied D.C. by an exciter. Main types of T.G. are:1 2 3 4 5 6 . . . . . . T T T T T T H A H H H H R R D D D F I I I D F F

1 st LETTER = (here-T)= 3-phase turbo generator

2 nd LETTER =(here H or A)=Medium present for generator cooling(H= hydrogen, A or L=air) 3 rd LETTER =type of rotor cooling employedR= radial,F= direct water coolingD= direct axial gas cooling) 4 th LETTER = type of as used for stator winding coolingI= indirect gas coolingD= direct gas coolingF= direct water cooling

COMPONENTS OF T.G. : STATOR 1.Stator frame 2.Stator core 3.Stator winding 4.End covers. ROTOR 1.Rotor shaft 2.Rotor windings 3.Rotor retaining rings BEARINGS COOLING SYSTEM EXCITATION SYSTEM STATOR The generator stator is a tight construction supporting and enclosing stator winding, core and hydrogen cooling medium. Hydrogen is contained within

the frameand circulated by fans mounted at either end of rotor. The generator is driven by a directcoupled steam turbine at the speed of 3000 rpm.The generator is designed for continuous rated output. Temperature detector or other devices installed or connected within the machine, permits the winding core andhydrogen temperature, pressure and purity in machine. STATOR FRAME The stator frame is used for housing armature conductors. It is made of cylindricalsection with two end shields which are gas tight and pressure resistant. The stator frameaccommodates the electrically active parts of stator i.e. the stator core and the stator winding