Introduction

Heavy Engineering Corporation Limited is situated at Ranchi, the capital of the

Jharkhand, in eastern part of India, and also has its manufacturing facilities located
there. A well-suited location nearing to customer sites and proximity to the ports for
import items is an added advantage for its cost-effectiveness.

HEC is one of the leading suppliers of technical equipment in India for steel, railways,
mining, power, defense, space research, nuclear and strategic sectors. With its inception
on 31st December 1958, the company has been one of the ambitious industrial projects
of independent India. To increase the steel producing capability of the country to
support infrastructure development, HEC was set up to indigenously manufacture and
supply steel plant equipment and machines. With over 50 years of experience, HEC has
proved its forte in equipment design, engineering & manufacturing and development of
unique processes. The government of India based enterprise has served its clients with
utmost commitment and has functioned not only as a supplier, but also as a partner to
them. HEC has definitely managed to be the most preferred supplier of its clients.

With the seamless integration of its facilities, HEC is one of the largest integrated
engineering complexes. Sprawling in an area of around 2100,000 sq. m, HEC has
equipments and facilities from steel melting, casting, forging, fabrication, machining,
assembly and testing. It has its own in-house research and product development wing to
deliver products suiting customers specifications and requirements.

Founded primarily to facilitate manufacture of steel plant equipment indigenously,

HEC has made immense contribution in setting-up, expansion and modernization of
steel plants and other industries in India. Its diverse skill and technical knowledge
enables HEC to provide comprehensive solutions to its customers. HEC provides
complete and cost-effective solutions to the customers advantage. In due course, HEC
has diversified to different sectors and made commendable contributions towards
manufacture and supply of import-substitute products. Bestowed with the onus of
making the country self-reliant for heavy engineering equipment and services, HEC
continues to contribute in the nation-building endeavor. The huge infrastructure, unique
manufacturing facilities, advanced technical skills, highly motivated team and valuable
support from its suppliers form the basis for HECs customers years of trust.

The company has three manufacturing units and one project execution unit.

Foundry Forge Plant (FFP)

FFP provides casting and forging for the other two plants, that is, Heavy Machine
Building Plant and Heavy Machines Tools Plant. In addition FFP also supplies
heavy castings and forging to other customers. It has an annual production
capacity of 44,000 tonnes. With a plant area of 13,16,930 sq. m and
accommodating 76,000 tonnes of installed machinery, it is the largest foundry
and forging complex in India and one of the largest of its kind in the world.
Heavy Machine Building Plant (HMBP)
The plant is spread over a total area of 5,70,000 sq. m and a floor area of nearly
2,00,000 sq. m, well equipped with sophisticated machine tools and handling
equipment to undertake manufacture of heavy machinery and equipment of top
quality. It is engaged in design and manufacture of equipment and components
for Steel Plants, Mining, Mineral Processing, Crushers, Material Handling,
Cranes, Power, Cement, Aluminum, Space Research, and Nuclear Power etc. It
has an installed capacity of 40,000 tonnes of equipment and structures.
Heavy Machine Tools Plant (HMTP)
It is the most modern and sophisticated of its kind in the country, which produces
machine tools in heavier ranges. The plant covers an area of 2,13,500 sq. m. It
designs and manufactures medium and heavy duty CNC and conventional
Machine Tools for railways, Defense, Ordnance Factories, HAL, Space and other
strategic sectors. This division executes turnkey projects from concept to
commissioning of bulk material handling, steel plant projects, coal washeries,
cement plants and other sectors.

Foundry Forge Plant (FFP)

Power Supply Division (PSD)
It is the main power supply unit of all the three units of HEC. Two lines of three-phase
supply are fed from Jharkhand State Electricity Board (JSEB). All the power supply
related issues and operations are carried out in this department. It is the most vital and
necessary part of the whole HEC as without power there would be no work. It receives
132 KV supply from JSEB. There is 132 KV Switching Yard in building 26. Then the
transformation takes place to various voltage levels via different substations. Backed by
a dedicated, committed and experienced team, the division executes various operations
within this unit.

Two lines named 8C and 9C are fed as supply to the whole unit. At a time, power is
drawn from any one of the two supplies. If there is any fault in one of the supplies or
due to any other reason that supply is not acceptable then another supply line can be
used and the division can operate. Both the lines follow the same layout and are
connected to bus bars AB. Further from this bus bar the supply is carried out further for
other uses.

The line from the feeder is first carried through a Lightning Arrestor (LA), which
basically acts as a safety measure to avoid any major accident or faults. The capacity of
LA is 120 KV but as it is connected in star connection so this voltage acts as phase
voltage and therefore its line voltage is 207.84 KV. This means if there is a supply
exceeding this limit then the LA will cease it and the excess supply will go into the line,
which is earthed into the ground. Further this line is earthed and a switch is supplied
there. This is done with the main purpose of maintenance and service. If there is a
breakdown in the plant and one needs to shut down the supply then the main supply
cannot be closed. For this reason the main supply is directly earthed into the ground and
then there is no current flow in the line. So the service man can now easily carry out the
maintenance and other service related work.

This line is also known as EHT (Electrical High Tension) Line. This is further
connected to a pair of isolators, which acts as a switch for both the lines. The supply
that is desired to be used is closed with the help of isolators and the other one is kept
open. This supply is further connected to a Potential Transformer of 132KV/110V and a
Current Transformer of 200/5/5A. Both these transformers come under the category of
instrument transformer or measuring transformer. The main purpose of these
transformers is to measure and analyze the behavior and nature of current flowing in. It
regularly monitors and keeps a check that the required value of supply is been
delivered.

These supply lines are then connected to Minimum Oil Circuit Breaker (MOCB) which
acts as a breaker for the supply. It is named so because the end terminals of the breaker
and supply produce a great spark when touched with each other as the voltage is very
high, that is, around 132KV. To prevent any damages or shock through spark the
moving end and the fixed end of the breaker are immersed in oil. The oil used is
specific in its viscosity and index. For such heavy machinery and high supply, heavyduty breakers are used which hands cannot operate manually. To move such a heavy
load an air press system and a DC supply is used. With the help of air pressure it is easy
to move the moving end of the breaker. With the air press system it becomes easy to
operate the breaker but there may be plants that dont use air press system. For this
reason it is necessary to use a DC supply. The main purpose of using this supply is that
it provides a constant supply of current, which doesnt, produces a spark by high
fluctuations. This supply ensures safety and prevents any damages. The supply lines are
further connected to the bus bars from which the supply is carried out to various other
places. The capacity of this bus bar is 132 KV 3000 MVA. The first supply from the
bus bar is connected to bus coupler, which acts as a safety device to prevent overvoltage or any other faults. Further the supply is carried out to other regions using
transformers of different ratings.

The listing of transformers and other machinery is given below.

No. of transformers
Bldg. 26 3*31.5 MVA
1*1.5 MVA
2*400 KVA

Bldg. 27 2*8 MVA

2*630 MVA

Bldg. 28 2*8 MVA

Bldg. 29 2*8 MVA

Bldg. 30 2*10 MVA

CPP - 1*600 KVA

Power House 1*400 KVA

Auto Transformers for Turbo-compressors

TK 20 01
TK 10 02
Reactors (external)

30 Ton 01(Demag)
10 Ton 02
Induction Furnaces
3 Ton 1*1300 KVA
5 Ton 1*3200 KVA

Protection against 132 KV yard

a)
b)
c)
d)

Protective relay acting overcurrent/Earth fault.

Loss of AC 220 V.
Non-parallel acting of poles of circuit breaker.
Tripping of PCCB in 100 V circuit AC.
Protection against 33 KV
a) Protective relay acting overcurrent/Earth fault.
b) Loss of AC 220 V.
c) Tripping of PCCB in100 V circuit AC.
d) Breakdown in air press system in cell or shop.

Protection against 6.6 KV

a)
b)
c)
d)
e)

Protective relay acting overcurrent/Earth fault.

Loss of AC 220 V.
Fault in T-23
Breakdown in air press system in cell.
Earth leakage 6.6 KV system.

Energy Consumption Pattern in FFP and HEC

A. FFP

85%

HMBP

13%

HMTP

1.5%

B. In FFP
1. Melting Furnace

33%

2. Compressor House

30%

3. 03 Shop

09%

4. Gas Plant

06%

5. Oxygen Plant

04%

6. Other areas

18%

As per IE rules, the voltage regulation in India should be 12.5%. Considering

132 KV supply the 12.5% of this supply is 16.5 KV. This means that the voltage
regulation should be in between 148.5 KV and 115.5 KV. If the voltage is not in
this range then the supply will not be the rated supply and it should be informed
to the feeding substation, as the unrated voltage will cause damage.
JSEB Tariff
1. Unit Charge

Rs. 5.40 per KWh

2. MD Charge

Rs. 235 per KVA

Maximum Demand (MD)

It is the maximum MVA reading in a month recorded every day in every half an
hour duration i.e. out of 1440 (2*24*30) readings in a month, the maximum
value is taken as MD.

Flexibility and Limitation on MD

1. Maximum is 10% higher than the CD of 19 MVA i.e. 19.8 MVA. If it crosses
19.8 MVA in any month, we have to pay the MD charge on this MVA for the
rest of the year.
2. Minimum is 75% of CD of 18 MVA i.e. 13.5 MVA.

Instrumentation

This division deals with the various kinds of instruments and devices used in FFP
in order to measure or control the values of parameters. It offers a wide range of
instruments for the working purpose of the plant. The maintenance and repairing

of faulty instruments and panels is done in this department. It is one of the most
important divisions in FFP as it serves as very helpful department in proper
functioning and manufacturing done in the plant.

The major shops that are governed by this department are listed below.

A. 02 Shop
This shop controls the melting and forging part of the whole plant. Sand has a
very important part in this process as it provides the base for melting and forging
the metal into required shape and quantity.

The Shop is divided into three sections:

1) Sand Reclamation
The fresh sand is fed into the primary attrition, which sieves out the major
particles present in the sand and makes it easy to transport. This sand is then
carried out to the bucket elevator, which takes the sand to the rotary valve, which
spins the sand and separates any foreign element present in the sand. By this
method a fine consistency of sand is obtained. Further is sand is carried out to the
secondary attrition which sieves the sand for further filtration and makes it more
fine and pure. This is done using FD fan, which blows out the lighter particles
out of the sand. The blown out dust is collected in a dust collector. The sand
becomes hot after going through the secondary attrition, hence cooling classifier

is used to cool it down. Further the useful sand is carried out to the Pneumatic
Transporter using a compressor from which the sand is stored in silos of different
capacities. Now this sand can be used whenever required.

2) Molding Site
The mold for the required metal is prepared in this site. A large box of metal is
taken according to the desired mold. The required metal piece is needed as a
sample to make the mold. This metal piece is placed inside the box. The box is
then filled evenly with the sand and then sealed with the cover of the box. CO2
gas is supplied inside the chamber and the box is then heated at a very high
temperature. After the completion of heating the box is opened and the desired
mold is ready in the form of hard sand. The metal piece is then separated and the
mold is ready to be used. The consistency and quantity of sand required depends
on the desired mold. Also the supply gas and temperature varies depending on
the metal piece.

3) Melting Site
This is the most important site as the major forging of the metal takes place
under this division. It consists of various arc furnaces, which operate at
temperature ranging from 1200C to 1800C. Theses furnaces are operated by a
team of highly experienced workers. The raw metal is fed in the form of cast iron
and the furnace is supplied with high value of current. The melting takes place

for few hours and the molten metal is then filled in the molds to get the required
shape of metal. The temperature is monitored and managed using thermocouple.
Thermocouple is a device used to measure temperature. It consists of two wire
legs made from different metals. The wires legs are welded together at one end,
creating a junction. This junction is where the temperature is measured. There are
many types of thermocouples, each with its own unique characteristics in terms
of temperature range, durability, vibration resistance, chemical resistance, and
application compatibility. Type J, K, T & E are Base Metal thermocouples, the
most common type of thermocouples. Type R, S and B thermocouples are
Noble Metal thermocouples, which are used in high temperature applications.
The listing of arc furnaces used is given below.

Electric Arc Furnace

60T, 30T (2 nos), 10T

Induction Furnace

2T and 5T

Vacuum Arc degassing

60T

Vacuum degassing unit

90T

Ladle Furnace

60T

Primary and secondary refinement is carried out under close observation of

expert metallurgists and is supported by a laboratory set-up to continuously
monitor the composition of liquid steel.

B. 03 Shop

This is the forging shop of FFP where shaping and hammering of the metal is
done. With the use of hydraulic press machines of different capacities it is very
easy to forge and press metal piece into the required shape. The metal is piece is
first heated to a very high temperature (around 1500C) and then placed under
the hydraulic press. Depending on the size and elasticity of the metal different
hydraulic press are used. The hot metal is then forged using the press from the
desired side in order to get the required shape.

The listings of different hydraulic press machines are given below.

Hydraulic Press

6000T

2650T
1650T
1000T

Forging Hammers -

3, 1.5T

Die Forgings

The supplies for dispatch includes the following:

Equipment for blast furnace

Coke oven equipment and machines
Continuous casting machines for blooms/slabs
Metallurgical cranes from 25T to 450T capacity

Steel Melting shop equipment including converters

Forged rolls
Hot metal mixers
Sinter plant equipment.
Slag cups

CO2 welding and Plazma welding also take place in this shop.

C. 04 Shop
This shop is also known as the machining shop as various machining and CNC
facilities are provided in this shop. Different types of CNC and Lathe works are
carried out in this shop and many other machinery works are operated. The
special machining facilities are listed below.

Lathe: Swing overbed 4 m, centre to centre 20 m

Vertical turning and boring: Job dia 14 m, weight 250T
Horizontal boring: Spindle dia 200 mm, column travel 20 m
Gear hobbing: Job dia 5 m, 40 mm module

D. 01 Shop
Non-Ferrous Casting takes place in this shop. The non-ferrous metals cannot
be treated in the 02 and 03 Shops. Therefore, these metals are treated here.
The die casting process forces molten metal under high pressure into mold
cavities (which are machined into dies). Most die-castings are made from
nonferrous metals, specifically zinc, copper and aluminum-based alloys.

Electrical Repair Shop

This shop deals with the repairing and maintenance of all the electrical
equipment used in FFP. Ranging from motors to transformers many machines
are repaired here. The motors ranges from 4.5 KW to 200 MW are brought
here and depending on the winding and capacity of the motors they are
repaired.
The most common fault found in the faulty motors is the damaging of the
field winding or the coil. In a very few cases there is a fault in the shaft or
rotor. The faulty winding is then removed and new winding is done using
suitable copper cables. The winding pattern and capacity of the motor is kept
in mind and the winding is done accordingly. After the winding is done the
motor is heated inside a heating chamber so that the winding is held together
and the wires of different coil bundles do not make contact with each other.
The heating is done according to the capacity of the motor and the
temperature & time is managed accordingly. The motor is then taken out from
the heating chamber and then left out to cool. The motor is then tested using
testing equipment, which analyze the machine and gives out a detailed report

of the motor. If the motor matches certain parameters then it is passed and
returned back to the plant to resume its work. If the motor doesnt matches the
minimum required parameters then it is checked for the fault and corrected. In
the same way, transformers are also repaired.
The maximum torque is directly proportional to square of rotor induced emf
at the standstill and inversely proportional to rotor reactance. The maximum
torque is independent of rotor resistance. By varying rotor resistance,
maximum torque can be obtained at any required slip.

Heavy Machine Building Plant (HMBP)

Power Engineering Department (PED)

The 33 KV supply from PSD, FFP is converted to 11 KV, which is the required
supply input in HMBP. The 11 KV supply is linked to a bus bar from where
supply to HMBP, HMTP and other areas is provided. In HMBP, two supply lines
of 11 KV come from the bus bar. At a time, only one of the two supply lines is
used for the power supply purpose. The other line is kept so that in a case when
one line gets faulty, the other supply line can be used.

This 11 KV supply line is carried out to various other shops in HMBP. These
shops then use this supply line according to the needs of the machines present in
the shop. The listing of a few shops is given below.

A. 010 Shop
This shop mainly comprises of CNC & conventional machine tools. For various
turning and boring operations, high power supply is required. For lathe
operations high torque is required for which high power supply is required. This
11 KV supply is used efficiently in all the machines.
B. 043-044 Shop

This shop consists of double column Plano milling machine, double column
planning machine, radial drilling machine, horizontal boring & milling machine
and roll grinding machine. The supplies are then dispatched to defense and
strategic sectors where the quality parameter should be above average. In order
to deliver an excellent product it is necessary that there should be no compromise
with the input work, which also includes power supply as a vital part of it.
Hence, the power is distributed among all the machines according to the desired
input ratings.

Electrical Design Bureau (EDB)

This division basically deals with the designing and manufacture of various
electrical equipment. All the designing and fabricating work takes place under
this division.

IEC (International Electrotechnical Commission) uses eight duty cycle

designations to describe an electrical motors operating conditions.
In HMBP, four types of duty cycles of motors are designed and manufactured.
According to the customers need the suitable duty cycle motor is supplied.
These motors are namely:

S2 Duty cycle - The motor works at a constant load, but not long enough
to reach temperature equilibrium. The rest periods are long enough for the

motor to reach ambient temperature.

S3 Duty cycle Sequential, identical run and rest cycles with constant
load. Temperature equilibrium is never reached. Starting current has little

effect on temperature rise.

S4 Duty cycle Sequential, identical start, run and rest cycles with
constant load. Temperature equilibrium is not reached, but starting current

affects temperature rise.

S5 Duty cycle Sequential, identical cycles of starting, running at constant
load and running with no load. No rest periods.

The expression for electrical power obtained is given by

Electrical Power (KW) =Mechanical Power (KW) * VFD * CDF/Ambient

Temperature
Here,
CDF Cycle Duty Factor
VFD = 1.18

Non-Conventional Ambient Temperature

CDF

45C

0.95

50C

0.88

55C

0.83

60C

0.75

Now-a-days PLC (Programmable Logic Controllers) drives are used in

controlling and regulating the motor. A common PLC application is the speed
control of AC motors with variable speed drives. The PLC program will
contain the logic to start, stop, and interlock the forward/reverse commands. It
also protects the motor from any fault or damage.

Heavy Machine Tools Plant (HMTP)

Maintenance

All the maintenance and service related tasks are carried out in this division.
Various machinery equipment and tools are manufactured and corrected here.
All kinds of gears, spindles, lathe, drilling machines, cranes, motor parts and
forged rolls are dealt with here. Any mechanical or electrical faults in the
equipment is examined and analyzed here. It involves fixing any sort of
mechanical or electrical device should it become out of order or broken. It
also includes performing routine actions, which keep the device in working
order or prevent trouble from arising.

Maintenance operations can be categorized by whether the product remains

the property of the customer or whether the product is brought by the
reprocessing organization and sold to any customer wishing to make the
purchase. In the former case it may be a backshop operation within a larger
organization or smaller operation.

For material all supply and repair action taken to keep a force in condition
to carry out its mission. There are four types of maintenance in use:
Preventive Maintenance

 Operational Maintenance
Corrective Maintenance
Adaptive Maintenance