PRODUCT PROFILE

BHEL Hyderabad has supplied a variety of Heat Exchangers in large numbers for diversified applications. A
are Steam Surface Condensors, Air Evacuation System, Feed Water Heaters, Deaerators Inter-Stage Gas Coo
Heat Exchangers, Air cooled Heat Exchangers, L.P.G Bullets. These are rendering good service in a number
Plants, Fertilizer, petroleum, Petrochemical, Steel and other Industrial Plants

CAPABILITIES
ENGINEERING CAPABILITIES

BHEL's Engineering capabilities are borne out of the fact that it meets the exacting benchmarks of internatio
collaborators & customers.
Thermal design is based on:
Heat Exchange Institute (HEI) Standards
Tubular Exchange Manufacturers Association (TEMA) Standards HTRI & HTFS programs
Collaborators programs
Programs developed in-house.

The design is checked for reliable performance at various off design conditions. The customers therefore
optimum design.

Mechanical design and manufacturing is based on:

Heat Exchange Institute (HEI) Standards.
Tubular Exchanger Manufacturers
Association (TEMA) Standards. ASME Sec VIII Div 1 & 2
BS 5500
AD Merkblatter
Collaborators programs
Programs developed in-house
The design is checked for vibration-free & reliable performance at critical off design conditions.
The design takes care of load transients.
BHEL's Corporate R & D extends necessary technical support on case to case basis in areas such as:
i) Thermo-hydraulic analysis

ii) Structural analysis

iii) Selection of suitable materials
iv) Design/testing of specialized items such as spray valves, finned tubes, etc.
v) Vibration, transient analysis
vi) Failure analysis, etc.
STEAM SURFACE CONDENSERS

Surface Condensers for Steam Turbines upto 154 MW in utilities, combined cycle power plants, industr
process plants have been supplied. Surface condensers for cooling water chemistry varying from the softes
most
corrosive
brackish
water
can
be
give
Condensers with Admiralty Brass, Aluminum Brass, Copper-Nickel 90-10&70-30, Carbon Steel and Stainle
with
Ferrous
and
Non-Ferrous
tube
sheets
have
been
su
BHEL has the expertise on different linings for water boxes including metallic overlay, rubber/FRP, corro
lining
and
even
cladded
Some of the salient features are:
Optimised tube layout for minimum pressure drop
Hotwell deaeration
Designed for 100% HP/LP by pass operation
All welded construction
Axial condensers
AIR EVACUATION SYSTEMS

Matching air evacuation systems namely Steam Jet Air Ejectors or Vacuum Pumps for the Surface Conde
supplied by BHEL as part of the condensing system package. While the SJAE are designed, manufactured
BHEL
Hyderabad,
the
vacuum
pumps
are
bought
out
from
repute
The Ejectors are of two-stage design complete with their inter and after condensers and a high capacity qui
starting ejector with silencers. Ejectors for both horizontal and vertical mounting have been supplied.
FEED WATER HEATERS

The product range covers both low and high pressure Feed Water Heaters for utility sets upto 500 MW ratin
industrial applications. Some of the salient feature are:

Overlay of tube sheets for H P Heaters with material compatible with tube material

Split flow De-Superheating zone

Double shroud Drain Cooling zone

Expansion ring in pass partition plate

Self sealing man way

All welded construction

The Heaters are designed for vibration free and reliable performance at critical off design conditions s
condition, operation of heater with lower heater out of service etc. The design takes care of loa
BHEL has supplied single bank Heaters for 500 MW rating thus qualifying to make heaters upto 1000
bank). BHEL has also supplied Duplex L P Heaters (combination of LPH- 1& 2 in one shell) and mounted
dome for 2 x 130 MW Jindal Tractebel Power Co. Ltd.
DEAERATORS

As the name suggests, Deaerator is meant to remove mechanically the dissolved oxygen and other non-cond
from the feed water going to boiler.

BHEL is one of the few organisations in the world which has designed, manufactured and supplied all the
Deaerators, namely.
i.

Tray type

ii.

Spray type

iii.

Spray-cum-Tray type and

iv.

Spray-cum-Tray-cum-Reboiling type

Field tests have given us dissolved oxygen content of less than 7 ppb (0.005 cc/lt).
All types of Deaerators are suitable for variable pressure operation.
INTER STAGE GAS COOLERS

The Gas Coolers handle a variety of gases normally encountered in the fertilizer & Petrochemical Plants.
Air, Ammonia, Synthesis gas, Carbon-di-oxide [ wet & dry], Nitrogen, Freon, Hydrocarbons, and Raw
hazardous and corrosive). Exchangers with gas on shell side have been supplied to those customers who hav
preference. Heat Exchangers with no tube in window design for very low gas pressure drops have been give
PROCESS HEAT EXCHANGERS

Process Heat Exchangers handling a variety of fluids both an shell side and tube side for various a
refineries, petrochemical plants have been supplied to both BHEL's own design and to customers'/consultan
BARGE MOUNTED LPG BULLETS

Barge mounted LPG Bullets for transporting LPG from ships on the high seas to in-land storage facilit
supplied. All activities were done as per Lloyd's Rules under Lloyd's Inspection.
STORAGE AND MOUNDED LPG BULLETS

Storage and Mounded type Bullets for storage of LPG have been supplied on a turnkey basis. BHEL's shop
the welding procedures are approved by the Chief Controller of Explosives [CCOE], Nagpur, the statutory a
AIR COOLED HEAT EXCHANGERS
Air Cooled Heat Exchangers for applications such as Cooling Water Modules, Air Blast Oil Coolers and
coolers are supplied by BHEL.
Air is used to cool the process fluid where water, the conventional coolant, is scarce.

These are finned tube heat exchanger bundles. The process fluid flows through the tubes and air over the tu
by induced/forced draft' is created by means of axial flow fans.

Most commonly used in tubes are G or L type. Tube material is Carbon Steel, Admiralty Brass, Alum
Stainless Steel with Aluminum fins. Fans are of hollow blade Aluminum construction for less weight an
consumption.
The header design can be either plug type or flanged type based on customers'/ customers' preference.
The total unit comprising of finned tube bundles, pumps, motors, piping arrangement with necessary
supplied.

MATERIALS USED

In the various Heat Exchangers and Pressure Vessels, materials such as Corbon Steel, Alloy Steel, Stain
304/304L/316/316L, non-ferrous such as Admiralty Brass, Aluminum Brass, Cu-Ni alloys, Naval Bras
Bronze, Muntz metal are being regularly used. As and when required over-layed/ cladded plates, rubber
components have been successfully used. Special materials such as alloy steels with compositions 1Cr-1/2
and 5Cr-2Mo (P4 and P5 Group) materials have also been employed.

SPECIAL FACILITIES

Apart from good optimised design, correct manufacturing technology and manufacturing facilities have an i
bearing in the ultimate quality, reliability and performance of the equipment. Some of the facilities available

CNC multi spindle deep hole drilling machine of Kolb Germany, for drilling tube plates upto 1100 m

Hydraulic driven expansion machine of Vernon USA for tube-to-tube sheet expansion.

Mueller pipe profile gas cutting machine for pipes upto dia 400 mm

Pipe bending machine of URALMASH Russia. For bending pipes upto dia 219x28 mm thick

CNC multi spindle drilling machine of wadkin UK, for drilling battle plates and tube plates upto 70

Vertical lathe of HOMMA Japan, (6m turning dia)

Orbital Automatic Tig welding machines of ESAB Sweden and A/c Machines USA for tube-to-tube

CNC multi torch flame cutting machine of SUAG German ( 200mm thick)

Plasma arc cutting unit for SS (80 mm thick)

Edge planning machine upto 12m length plates)

4-Roll plate rolling machine for forming thick shells

Heat treatment furnace of 5mx5mx15m

Submerged arc strip-cladding machine of ESAB Swden, for overlaying of tube sheets.

Horizontal boring machine WD 160

Narrow gap welding machine for thick shells

Shot blasting facility of 8m x 8m x 14m Hydrostatic testing facilities unto 1000 Kg/sq. cm (g)

Overhead travelling cranes of 80 tonnes capacity

QUALITY AND RELIABILITY

Quality of the product is of prime importance of BHEL. To ensure this, the Quality s assurance and Contro
report directly to the Chief Executive. They oversee all aspects of quality functions, covering design
production,
materials,
in-process
inspection
and
testin
In addition to our own quality control and quality assurance departments, many of the equipment are made
third party inspection agencies such as PDIL, EIL, Lloyd's. TCE, DAE, NTPC, DOB (AP), TUV,
Customer / contract specific Quality Plans are developed to ensure compliance with specification / standa
stages
viz.,
engineering,
materials
procurement
manufacturing
and
The prime NDT facilities available in-house are:
Radiography (X-ray) equipment - 300 KV 5 mA
Gamma ray equipment - Iridium 192, 50 Curie, Cobalt 60,60 Curie
Ultrasonic flow detectors - 10m depth - 1 to 16 M Hz
Magnetic crack detector - 6000 A HWDC
Digital ultrasonic flaw detector (upto 10m depth)

In recognition of the QA programs and the implementation of systems and practices in all areas of operatio
been awarding the prestigious 'U' Stamp certificate to BHEL Hyderabad since 1984. In June 1998, BH
awarded the ASME 'U2' Stamp certificate also.
SERVICE AFTER SALES

BHEL accords the utmost importance to "Service after Sales". BHEL has an all-India service network
headquarters in the four regions of the country. This is backed by core Field Support Services and Field
"Service groups located in Hyderabad.
TOTAL QUALITY MANAGEMENT
After systematizing its operations and obtaining ISO: 9001 Certification in 1994, BHEL has
move to TQM phase for improving the entire business operations by adopting principles of
"TOTAL QUALITY MANAGEMENT", to provide improved service to all its stake holders viz.,
Customers, Employees, Suppliers, Shareholders and society at large.
The TQM exercise is based on the Self-Assessment Technique as per European Foundation for
Quality Management (EFQM) model and planned to achieve world class status by the year 2001.

PROVEN PERFORMANCE

Starting its first supplies in 1965-66 as on a March 1999, BHEL Hyderabad has sup
940 Feed Water Heaters ( including 67 HP Heaters and 62 LP Heaters for 17 n nos. 500 MW Power Pla
240
Deaerators
(including
16
nos.
for
500
MW
Power
Plants
340
Surface
Condensers
with
matching
Air
Evacuation
535
Heat
Exchangers,
385
Pressure
Heat Exchangers have been exported to Malta, Cyprus, Egypt, Malaysia, Oman, Saudi Arabia, etc.

RENOVATION & MODERNIZATION

With the experience gained over the years, BHEL is now fully geared to rake up refurbishment/power plant
projects in a big way. The scope includes system study, recommendation, engineering, manufacturing, testin
and commissioning of the equipment.
The vast reference list and successful operation of the various Heat Exchangers supplied is a testimony of B
performance.

| Steam Turbine | Compressor |Electrical Machine | Switchgear | Bowl Mills | Heat Exchangers
| Oil Rigs | Gas Turbine | Pumps |

Registered Office : BHEL House, Siri Fort, New Delhi - 110049, India.

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