AN OVERVIEW OF BHEL

BHEL is the largest engineering and manufacturing enterprise in India in the

energy/infrastructure sector today. BHEL was established more than 40 years ago when its
first plant was set up in Bhopal ushering in the indigenous Heavy Electrical Equipment
industry in India, a dream that has been more than realized with a well-recognized track
record of performance.
BHEL caters to core sectors of the Indian Economy viz., Power Generation & transmission,
Industry, Transportation, Telecommunication, Renewable Energy, Defense, etc. The wide
network of BHEL’s 17 manufacturing divisions, four Power Sector regional centers, over 100
project sites, eight service centers and 18 regional offices, enables the company to promptly
serve its customers and provide them with suitable products, systems and services-
efficiently and at competitive prices. BHEL has already attained ISO 9000 certification for
quality management, ISO 27000 for Information Technology and ISO 14001 certification for
environment management.

POWER GENERATION:
Power generation sector comprises thermal, gas, hydro, and nuclear power plant business.

TELECOMMUNICATION:
BHEL also caters to Telecommunication Sector by way of small, medium and large switching
systems.
TRANSMISSION AND DISTRIBUTION (T&D):
BHEL offers wide-ranging products and systems for T&D applications. Products
manufactured include: power transformers, instrument transformers, dry type
transformers, series &shunt reactors, capacitor banks, vacuum &SF6 circuit breakers, gas-
insulated switchgears and insulators.
INDUSTRIES:
BHEL is a major contributor of equipment and systems to industries, cement, sugar,
fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and other process
industries. The range of systems & equipment supplied includes: captive power plants, co-
generation plants, DG power plants, industrial steam turbines, industrial boilers and
auxiliaries, waste heat recovery boilers, gas turbines, heat exchangers and pressure vessels,
centrifugal compressors, electrical machines, pumps, valves, seamless steel tubes,
electrostatic precipitators, fabric filters, reactors, fluidized bed combustion boilers, chemical
recovery boilers and process controls.
TRANSPORTATION:
BHEL is involved in the development, design, engineering, marketing, production,
installation, and maintenance and after-sales service of rolling stock and traction
propulsions systems. BHEL manufactures electric locomotives up to 5000 HP, diesel electric
locomotives from 350 HP to 3100 HP, both for mainline and shunting duty applications. It
also produces rolling stock for special applications viz. overhead equipment cars, special
well wagons, and Rail-cum road vehicle.
RENEWABLE ENERGY :
Technologies that can be offered by BHEL for exploiting non-conventional and renewable
sources of energy include: wind electric generators, solar photovoltaic systems, solar
heating systems, solar lanterns and battery-powered road vehicles.
OIL AND GAS :
BHEL’s products range includes Deep Drilling Oil Rigs, Mobile Rigs, Work Over Rigs, Well
Heads and X-Mas Trees, Choke and Kill Manifolds, Full Bore Gate Valves, Mudline
Suspension System, Casing Support system Sub-Sea Well
Heads, Block valves, Seamless pipes, Motors, Compressor, Heat Exchangers etc.
INTERNATIONAL OPERATIONS :
BHEL is one of the largest exporters of engineering products & services from India, ranking
among the major power plant equipment suppliers in the world.

VISION, MISSION
 VISION, MISSION AND VALUES
VISION :
A global engineering enterprise providing solutions for a better tomorrow.

MISSION:
Providing sustainable business solutions in the fields of Energy, Industry & Infrastructure.

VALUES:

GOVERNANCE: We are stewards of our shareholders investments and we take that

responsibility very seriously. We are accountable and responsible for delivering superior
results that make a difference in the lives of the people we touch.

RESPECT: We value the unique contribution of each individual. We believe in

respect for human dignity and we respect the need to preserve the environment around us.

EXCELLENCE: We are committed to deliver and demonstrate excellence in whatever

we do.

LOYALTY: We are loyal to our customers, to our company and to each other.

ENTEGRITY: We work with highest ethical standards and demonstrate a behavior

that is honest, decent and fair. We are dedicated to the highest levels of personal and
institutional integrity.

COMMITMENT: We set high performance standards for ourselves as individuals and

our teams. We respect our commitments in a timely manner.

INNOVATION: We constantly support development of newer technologies, products,

improved processes, better services and management practices.

TEAM WORK: We work together as a team to provide best solutions & services to our
customers. Through quality relationships with all stakeholders we deliver value to our
customers.
 BHARAT HEAVY ELECTRICALS LIMITED JHANSI (UNIT)

A BRIEF INTRODUCTION
By the end of 5th five-year plan, it was envisaged by the planning commission that the
demand for power transformer would rise in the coming years. Anticipating the country’s
requirement BHEL decided to set up a new plant, which would manufacture power and
other types of transformers in addition to the capacity available in BHEL Bhopal. The Bhopal
plant was engaged in manufacturing transformers of large ratings and Jhansi unit would
concentrate on power transformer up-to 50 MVA, 132 KV class and other transformers like
Instrument Transformer s, Traction transformers for railway etc.

This unit of Jhansi was established around 14 km from the city on the N.H. No 26 on Jhansi
Lalitpur road. It is called second-generation plant of BHEL set up in 1974 at an estimated
cost of Rs 16.22 crores inclusive of Rs 2.1 crores for township. Its foundation was laid by late
Mrs. Indira Gandhi the prime minister on 9 th Jan. 1974. The commercial production of the
unit began in 1976-77 with an output of Rs 53 lacs since then there has been no looking
back for BHEL Jhansi.

The plant of BHEL is equipped with most modern manufacturing processing and testing
facilities for the manufacture of power, special transformer and instrument transformer,
Diesel shunting locomotives and AC/DC locomotives. The layout of the plant is well
streamlined to enable smooth material flow from the raw material stages to the finished
goods. All the feeder bays have been laid perpendicular to the main assembly bay and in
each feeder bay raw material smoothly gets converted to subassemblies, which after
inspection are sent to main assembly bay.
The raw material that are produced for manufacture are used only after thorough material
testing in the testing lab and with strict quality checks at various stages of productions. This
unit of BHEL is basically engaged in the production and manufacturing of various types of
transformers and capacities with the growing competition in the transformer section, in
1985-86 it under took the re-powering of DESL, but it took the complete year for the
manufacturing to begin. In 1987-88, BHEL has progressed a step further in under taking the
production of AC locomotives, and subsequently it manufacturing AC/DC locomotives also.
SECTIONS OF BHEL JHANSI UNIT

BHEL has many departments, while production and Administrative departments are
separate.

Broadly speaking BHEL, Jhansi has two production categories.

 Transformer

 Loco

PRODUCT PROFILE OF BHEL JHANSI UNIT

1. Power transformer up to 400 KV class 250 MVA.

2. Special transformer up to 180 KV.
3. ESP transformer 95 KV, 1400 mA.
4. Freight Loco transformer 3900 to 5400 KVA & 7475 KVA
5. ACEMU transformer up to 1000 KVA (1-phase).
1385 KVA (3 phase).
6. Dry type transformer up to 6300 KVA 33 KV class
7. Instrument transformer VT & CT up to 220 KV class.
8. Diesel electric locomotives up to 2600 HP.
9. AC/DC locomotives 5000 HP.
10. Over Head Equipment cum Test Car
11. Well wagon 200 tone.
12.Rail cum road vehicle
13. Dynamic track stabilizer
14. Ballast Cleaning machine
15. Utility Vehicle
 ROTAION REPORT
Main aim behind the rotation of various departments is that one can understand the
working of each and every department and to see that how people (workers, middle level
executive, top officials) work.

FABRICATION SHOP:
Fabrication is nothing but production. It comprises of three bays i.e. Bay0, Bay1, Bay2
BAY-0:
It is a sub part of Fabrication. It is the preparation shop while the other two bays form the
assembly shop. This section has the following machines:
 Planner machine – To reduce thickness
 Shearing machine
 CNC / ANC Flame Cutting machine – To cut Complicated shaft items using Oxy-
Acetylene flame
 Bending machine
 Rolling machine
 Flattening machine
 Drilling machine
 Nibbling machine
 Pantograph flame cutting machine
BAY-1:
It is also a sub part of Fabrication. It is an assembly shop where different parts of tank
come from bay 0. Here welding processes are used for assembly, after which a rough
surface is obtained Grinder operating at 1200 rpm is used to eliminate the roughness.
BAY-2:
It is also a sub part of Fabrication It is an assembly shop dealing with making different
objects mentioned below.
1-Tank assembly 5-cross feed assembly
2-Tank cover assembly 6-core clamp assembly
3-End Frame assembly 7-pin and pad assembly
4-foot assembly

Before assembly, short blasting (firing of small materials i.e., acid pickling) is done on
different parts of jobs to clean the surface before painting.

NON-DESTRUCTIVE TEST:
1 Ultrasonic test to detect the welding fault on the CRO at the fault place high
amplitude waves are obtained.
2. Die Penetration test Red solution is put at the welding and then cleaned. After
sometime white solution is mixed. Appearance of a red spot indicates a fault at the
welding.
3. Magnetic crack detection Magnetic field is created and then iron powder is put at
the welding. Sticking of the iron powder in the welding indicated a fault.
4. X-Ray Test It is same as human testing and the fault is seen in X-ray film.

BAY-3:
Here are basically three sections in the bay:
 Machine section
 Copper section
 Tooling section

BAY 4:
It is the winding section.
There are four types of coil fixed in a transformer, they are:
1. Low voltage coil (LV)
2. High voltage coil (HV)
3. Tertiary coil
4. Tap coil
The type of winding depends upon job requirement. Also, the width and thickness of the
conductors are designed particulars and are decided by design department. Conductors
used for winding is in the form of very long strips wound on a spool, the conductor is
covered by cellulose paper for insulation.
For winding first mold of diameter equal to inner diameter of required coil is made. The
specification of coil is given in drawing. The diameter of mold is adjustable as its body is
made up of wooden sections that interlock with each other. This interlocking can be
increased or decreased to adjust the inner diameter of coil.

The molds are of following types

1. Belly types
2. Link types
3. Cone type

BAY-5:
It is core and punch section. The lamination used in power, dry, ESP transformer etc. for
making core is cut in this section.
CRGO (cold rolled grain oriented) silicon steel is used for lamination, which is imported in
India from Japan, U.K. Germany. It is available in 0.27 and 0.28mm thick sheets, 1mt wide
and measured in Kg. The sheets are coated with very thin layer of insulating material
called “carlites”.
For the purpose of cutting and punching the core three machines are installed in shop

BAY-6:
Single-phase traction transformer for AC locomotives is assembled in this section. This
Freight locomotive transformers are used where there is frequent change in speed. In this
bay core winding and all the assembly and testing of traction transformer is done.

Three-phase transformers for ACEMU are also manufactured in this section. The supply
lines for this transformer are of 25 KV and power of the transformer is 6500 KVA. The tap
changer of rectifier transformer is also assembled in this bay. Rectified transformer is used
in big furnace like the thermal power stations / plants (TPP).

BAY-7:
 1. This is the insulation shop. Various types of insulations are
2. AWWW - All Wood Water Washed press paper.
3. The paper is 0.2-0.5mm thick cellulose paper and is wound on the
conductors for insulation.
4. PRE-COMPRESSED BOARD: This is widely used for general insulation & separation
of conductors in the forms of blocks.
5. PRESS BOARD: This is used for separation of coils e.g. L.V. from H.V. It is up to 38
mm thick.
6. UDEL (Un dignified Electrical Laminated) wood or Perm wood
7. This is special type of plywood made for insulation purposes.
8. FIBRE GLASS: This is a resin material and is used in fire prone areas.
9. BAKELLITE
10. GASKET- It is used for protection against leakage.
11. SILICON RUBBER SHEET- It is used for dry type transformer.

BAY 8:
It is the instrument transformer and ESP transformer manufacturing section.
INSTRUMENT TRANSFORMER
These are used for measurement. Actual measurement is done by measuring
instruments but these transformers serve the purpose of stepping down the voltage to
protect the measuring instrument. They are used in AC system for measurement of
current voltage and energy and can also be used for measuring power factor, frequency
and for indication of synchronism. They find application in protection of power system and
for the operation of over voltage, over current, earth fault and various other types of
relays.
ESP TRANSFORMER
The Electrostatic Precipitator transformer is used for environmental application. It is used to
filter in a suspended charge particle in the waste gases of an industry. They are of particular
use in thermal power stations and cement industry.
The ESP is a single-phase transformer. It has a primary and secondary. The core is laminated
and is made up of CRGOS. It is a step-up transformer. An AC reactor is connected in series
with primary coil. The output of the transformer must be DC the is obtained by rectifying AC
using a bridge rectifier (bridge rectifier is a combination of several hundred diodes). A radio
frequency choke (RF choke) is connected in series with the DC output for the protection of
the secondary circuit and filter circuit. The output is chosen negative because the particles
are positively charged. The DC output from the secondary is given to a set of plates arrange
one after the others. Impurity particles being positively charged stick to these plates, which
can be jerked off. For this a network of plates has to be setup all across the plant. This is
very costly process in comparison with the transformer cost. A relive vent is also provided to
prevent the transformer from bursting it higher pressure develops, inside it. It is the
weakest point in the transformer body. An oil temperature indicator and the secondary
supply spark detector are also provided.
One side of the transformer output is taken and other side has an ‘marshalling box’ which is
the control box of the transformer.
BAY-9:
In this bay power transformer are assembled. After taking different input from different
bays 0-9 assembly is done Power transformer is used to step and step-down voltages at
generating and sub-stations. There are various ratings –11KV, 22KV, manufactured, they are

1. Generator transformer.
2. System
3. Autotransformer.

A transformer in a process of assemblage is called a job. The design of the transformer is

done by the design dept. & is unique of each job; depends on the requirement of customer.
The design department provides drawing to the assembly shop, which assembles it
accordingly.

The steps involved in assembly are:

1. Core building
2. Core Lifting.
3. Unlacing.
4. replacing and end-frame mounting.
5. High voltage terminal gear and low volt terminal gear mounting
 6. Vapour phasing and oil soaking
7. Final servicing and tanking.
8. Case fitting.

TRANSFORMER COMMERCIAL (TRC):

The objective of the department is interaction with the customers. It brings out tenders and
notices and also responds to them. It is this department that bags contracts of building
transformers. After delivery regarding faults, this department does failures and
maintenance. All such snags are reported to them and they forward the information to the
concerning department.

One of the major tasks of this department is to earn decent profits over all negotiations.
Transformer industry has become very competitive. The company offering the lowest price
gets the contract but this process may continue does the work on very low profits. To avoid
such a situation, a body by the name of India Electrical and Electronics Manufacture
Association (IEEMA) was set up. This association helps to maintain a healthy competitive
atmosphere in the manufacturing of electrical appliances.

TRANSFORMER ENGINEERING (TRE):

The transformer manufactured in BHEL Jhansi range from 10 MVA to 250 MVA and up to
400 KV. The various transformers manufactured in this unit are:
POWER TRANSFORMER
a) Generator transformer
b) System transformer.
c) Auto transformer.

SPECIAL TRANSFORMER
a) Freight loco transformer.
b) ESP transformer.
c) Instrument transformer.
d) Dry type transformer.
STORE:
There are three sections in store:
1. Control Receiving Section
2. Custody Section
3. Scrap Disposal Section

LOCOMOTIVE PRODUCTION (LMP):

There are following products are manufactured at Loco shops
 Alternating Current Locomotive (ac Loco)
 WAG-5H
 AC./D.C. Loco
 WCAM-2P
 WCAM-3
W-broad gauge A-running in AC mode
C-running in DC mode G-hauling goods train
P-hauling passenger train M-hauling passenger
& goods train
 Diesel Electric Locomotive Shunting (DESL)
 350 HP
 700 HP
 Single Power Pack (SPP): One 700 HP m/c is made as a single
Unit. It is a meter gauge locomotive
Twin Power Pack (TPP): 2 350HP m/cs are combined in 1 engine
& can be operated individually or in combination depending on
the load.
 450 HP
 1400 HP
 1150 HP
 1350 HP
 2600 HP
1150 HP and 1350 HP DESL s are non-standard locomotives and are modified
versions of 1400 HP DESL based on requirement of customer.
 Under mention are the new non-conventional products designed and developed
for Indian Railways based on their requirement.
 OHE (Overhead electric) recording and testing cars
 UTV (Utility vehicle)
 RRV (Rail cum road vehicle)
 DETV (Diesel electric tower car)
 BPRV (Battery power road vehicle)
 BCM (Blast cleaning machine)
 200 T Well wagon for BHEL Haridwar
 Metro Rake-Kolkata Metro Railways

LOCOMOTIVE MANUFACTURING (LMM):

This section deals with manufacturing of locomotives. The main parts of the
locomotives are

Under frame: The frame on which a locomotive is built

Super structure: The body of locomotive is called superstructure or Shell
and is made of sheet of Mild steel
DC motor
Alternator
Compressor
Flower
Static Rectifier-MSR
Static Converter-SC
Exchanger
Bogie-The wheel arrangement of a loco is called a bogie. A bogie essentially
contains
1-wheel axle arrangement
2-Suspension
3-Brake rigging
 Traction transformer: It is fixed on under frame and gets supply from an overhead
line by equipment called pantograph. The type of pantograph depends on supply.
This transformer steps down voltage and is fitted with a tap changer. Different taps
are taken from it for operating different equipment. One tap is taken and is
rectified into DC using MSR and is fed to the DC motor.
Railways has two types of power supplies – 25 KV,1 Phase ,50hz AC
-1500 V DC
An AC/DC loco is able to work on both of these supplies. For e.g. WCAM-3.

WORK ENGINEERING & SERVICES (WE&S):

This department looks after the commissioning and maintenance of all the
machinery used in the factory. It also has 3 two-stage air compressors for supplying
compressed air to the various bays.
The department has 03 different divisions:

 Electrical Engineering
 Electronics Engineering
 Mechanical Engineering

TECHNOLOGY:
changes accordingly. This is very important because the products must not get
obsolete in the market otherwise they will be rejected by the customer.

FUNCTIONS: Technology functions can be classified as:

 Processing Sequence - The sequence of process of manufacturing is decided

for timely and economic completion of the job.
 Operation time estimate - It includes incentive scheme management
 Allowed operation time - It includes incentive amount
 Facilities identification - It includes looking for new equipment or plant or
tools to increase productivity
  Special process certification - Special processes are the ones requiring
expertise for example identifying errors, cracks, air bubbles in welding
 Special tools requirement - Special tools are allotted, if possible, when
required else the design has to be reconsidered.
 Productivity projects compilation - It includes the initial analysis of the
problem and their appropriate solution to enhance productivity.
The principle of working is that “IF YOU DO
NOT MAKE THE CHANGES IN YOUR COMPANY, THE CUSTOMER WILL CHANGE
YOU”.

CENTRAL QUALITY SERVICE:

First, we get acquainted with a few terms concerning this department.

QUALITY:
It is the extent to which products and services satisfy the customer needs.

QUALITY ASSURANCE:
All those plants and systematic action necessary to provide adequate confidence that a
product or service will satisfy the given requirement is called quality assurance.

QUALITY CONTROL:
The operational technique and activities that are used to fulfill requirement for quality are
quality control.

QUALITY INSPECTION:
Activities such as measuring, testing, gauging one or more characteristics of a product or
service and comparing these with specified requirement to determine conformity are
termed quality inspection.