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B.Tech (EN)
SRMSCET
BAREILLY(U.P.)
CERTIFICATE
Akhilesh Kumar
Engineer(WEX)
Bharat Heavy
Electricals Limited
Jagdishpur,
Sultanpur (U.P.)
CONTENT
1. Introduction to BHEL
BHEL manufactures over 180 products under 30 major product groups and
caters to core sector of the Indian economy viz., Power Generation and
transmission, Industry, Transportation, Telecommunication, Renewable Energy
etc. The wide network of BHEL’s 14 manufacturing divisions, 4 power sector
regional centers, over 100 project sites, 8 service centers and 18 regional offices,
enables the company to promptly serve its customers and provide them with
suitable products, system and services- efficiently and at competitive prices. The
high level of quality and 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 word,
together with technologies developed in its own R&D centers. Strategic plan
2012 for ensuring a sustainable profitable growth for the company has been
drawn up to enable the company’s turnover to grow from US $ 4 billion to 10
billion by 2011-12. The plan focuses on the capacity and capability enhancement
that will leverage the company’s effort in its core area of power, supported by
industry, transportation, transmission, exports and spares and services
businesses.
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 44,500
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 participate style of management – all these have engendered
development of a committed and motivated workforce setting new benchmarks in
terms of productivity, quality and responsiveness.
BHEL has Installed equipment for over 90,000 MW of power generation -- for
Utilities, Captive and Industrial users. Supplied over 2,25,000 MVA transformer
capacity and other equipment operating in Transmission & Distribution network
up to 400 kV (AC & DC).
Supplied over 25,000 Motors with Drive Control System to Power projects,
Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants etc.
Supplied Traction electric and AC/DC locos to power over 12,000 kms Railway
network. Supplied over one million Valves to Power Plants and other Industries.
PRODUCT RANGE:- .
DISC INSULATORS:
Products: Porcelain Insulators for 300 KN, HVAC, 160 KN HVDC, Post and
Pin, Fog and Anti Fog varieties for transmission lines. Insulators for
33 KV & 11 KV. 420 KN disc insulators has been developed and will
be the product of next year. Hollow bushings are the main new
product of Insulator plant.
CERALIN BENDS
2. Production:
(a) Slip House: In slip - house the raw material are loaded per composition into
"ball-mills". In ball -mills 'river -pebble' are put as grinding -media. When ball
-mill is operated the grinding media and raw material produced the file paste
called 'slip'. This slip is the input for the 'filter- presses to produce the 'cake'. This
cake is output of slip -house and serves as input for manufacturing /Jiggering.
produced by slip -house. The cake are fed into 'pug-mill', which under vacuum
length (as per product), called pugs. These pugs are fed into Jiggering machines,
which at first go impart initial shape of insulator shells. The secondary or final die
gives the final shape shell. These green stage shells are dried in CD (chain-
dryer). After drying these shells are taken out of modes and send for finishing.
(c) Finishing &TD: - The unfinished shells are finished on MCBL (Multi Purpose
Vertical Lathe Machine). These finished articles are loaded onto racks fed into
"Tunnel -Dryer" or MDC. The output of the dryer is totally dried insulator or shell.
(d) Glazing: - The dried insulator shells are finished for minute tracks serration
the accepted articles are glazed on glazing machines with required thickness of
glaze.
(e) Kiln: - It works on oxidation - reduction process. The glazed articles are
loaded into refractory wagons and put into firing. Through OTK (oil tunnel kiln).
upon the product composition. The fired and loaded shell are inspected for the
(f) Assembly & Testing: - The accepted fired shells .are tested for their
mechanical strength for loading hydraulically .The hydraulic accepted shells are
tested for thermal shock endurance .The O.K. shells are spread with 'Bituminous
Paint' on the head and the recess portion accommodate MCI (malleable cast
iron) cap/pin. The painted shells are assembled and cured insulators are put
and put under destructive test .The tested accepted insulator are packed and
(g) E&D (Engg. and Development): - This department provides the required
and other equipment of power plant are subjected to heavy temperature and
erosion due to abrasive materiel .To avoid this untimely failure of the component
lining of abrasive resistance materiel like high Alumina ceramic product is done.
At IP, Jagdishpur, components are lined with the ceramic product to avoid the
erosion.
Production Flow Chart for Ceralin:
Loading / Firing
Metallic Casings
Assembly / Lining
Finished Product
Dispatch
Main functions of the WEX department:
- Daily break down report is fed in wex server (Break down 08-09)
and is analyzed.
2. Preventive Maintenance
In the plant there are many critical machines. To upkeep these machineries
maintenance department does Preventive Maintenance. The frequency of Preventive
Maintenance activities is fixed by Maintenance department and scheduling of
maintenance is done in co-operation with user departments, so that failures /
breakdowns can be minimized.
3. Calibration:
5. Condition Monitoring:
6. Retrofitting:
7. Purchase Indenting:
8. Subcontracting of Works:
The Works Engineering & Services department carries out the activity of
indenting, evaluation of offers, assisting in procurement, inspection / testing and
co-coordinating the installation activity of the new equipment / plant. The
installation of the equipment including erection & commissioning of the
equipment / plant may be carried out by the supplier of equipment as a
part of the purchase contract or through sub-vendors / sub-contractors. On
successful completion of the installation activity the “COMMISSIONING
REPORT” for the equipment is issued.