Industrial visit to BHEL, Ranipet

1. Industrial visit to Bharat Heavy Electricals Limited (BHEL),Ranipet
Date: 17/04/2019
Report by: Pritish Tayal (15BME0595)
On 17th
April we visited Bharat Heavy Electricals Limited (BHEL),Ranipet as a part of machine
drawing course under the guidance of our faculty Dr. Arivarasu M. It is a boiler auxiliary plant.In
BHEL BAP we were accompanied by Mr. Pardiyan who is working as a deputy engineer there. He
gave us a plant tour and told us about what all things they manufacture. He also explained us about
manufacturing processes and the machines used in the process.
Boiler Auxiliaries Plant (BAP), the 13th manufacturing unit of BHEL was set up at Ranipet in 1980
as a part of the 4000 MW expansion of the High Pressure Boiler Plant, Trichy. BAP at Ranipet was
set up as a spin-off plant for the manufacture of boiler auxiliaries viz. Electrostatic Precipitators
(ESP), Air Pre-Heaters (APH) and Fans. The total capacity of BAP is 57000 tons/year.
Over the years, the following products are also added to BAP's portfolio: Steel Chimneys, Gates and
Dampers, RO based Desalination (for Industrial and Potable application), Flue Gas Conditioning
Systems (FGC), Flue Gas Desulphurization Systems (FGD), Wind Electric Generators (WEG) and
Missile Launchers for Defence. The Company has an extensive outsourcing facility which makes it
possible to grow consistently over the years. The Company nourishes 400 ancillary small-scale units
by off-loading structural fabrication and machining jobs through annual rate contracts
The Company has been a fore runner in creating history with its State-of-the-art Design facilities,
Research and development capabilities, modernized manufacturing facilities with sophisticated
Metrology laboratory and NDT facilities to meet the growing demand for Quality power. One of the
major projects completed by this plant is for ISRO, they manufactured satellite fuel tank which was
made of titanium with a volume capacity of 260Litres and a mere thickness of 0.5mm. It was an
assembly of 3 subparts manufactured using a mould which were later welded together.

2. Components in a Boiler Auxiliaries
1) Fan
- Axial reaction fans of single stage and double stage for clean air application and dust laden hot gases
applications up to 200°Ϲ, with capacity ranging from 40 to 1300 m3/s and pressure ranging from 400
to 1,500 mm of water column.
- Axial impulse fans both clean air and fuel gas application up to 200°Ϲ, and ranging from 25 to 600
m3/s and pressure up to 300 to 700 mm of water column.
- Single and double-section radial fans (plate aero-foil bladed) for clean air and dust laden hot gases
applications up to 400°Ϲ, with capacity ranging from 4 to 660 m3/s and pressure ranging from 200 to
3000 mm water column.
2) Air-Pre-heaters
- Tubular Air Preheater for industrial and utility boilers.
- Rotary regenerative air-preheaters for boilers and process furnaces.
- Large rotary regenerative air-preheater for utility of capacity up to 800MW.
3) Pulverisers
- Bowl mills of slow and medium speed for coal tired thermal stations with capacity from 18 t/ hour to
110 t/hour catering to 67.5 MW to 800 MW thermal power stations.
4) Electrostatic Precipitators (ESP)
- Electrostatic precipitators of any capacity with outlet emission as low as 17mg/Nm3 (efficiency up
to 99.97%) for utility and industrial applications including Boi mass fired boilers, cement plants, steel
plants, soda recovery boilers etc.
5) Guillotine Gates & Dampers
- Guillotine gates with electric. Pneumatic actuator, Size up to 6m height & 7m width (with split)
100% leak proof with seal air.
6) Soot Blowers
- Long retractable soot boilers (LRSB) for travel up to 12.2m
- Furnace temperature probe (FTP) for travel length 6.9m and 8.3m
- Ash Retractable Non-rotating (LRNR) soot blowers with forward blowing for Air-heater.
7) Valves
- High and Low-pressure turbine Bypass Valves & hydraulic system for utility and industrial
application

3. PRODUCTS OF BHEL BAP
1. AIR PREHEATER
An air preheater (APH) is any device designed to heat air before
another process (for example, combustion in a boiler) with the
primary objective of increasing the thermal efficiency of the process.
They may be used alone or to replace a recuperative heat system or
to replace a steam coil.
2. ELECTROSTATIC PRECIPITATOR
The electrostatic precipitators (ESP) are extensively used in the
thermal power plant or steam power plant for removal of fly ash
from the electric utility boiler emissions. ... Because the presence of
large quantities of the carbon in the gas can adversely affect the
efficiency of the electrostatic precipitator
3. GATES & DAMPERS
In chimney vented residential boilers, both steam and hot water, it is
common for manufacturers to include an electrically operated flue
damper between the boiler and chimney. By closing the flue pipe
between heating cycles, less warm room air was pulled up the
chimney through the flue diverter, allowing them to claim a higher
efficiency.
4. FORCED DRAFT (FD) & INDUCED DRAFT (ID) FANS
Forced Draft Fan. An FD fan draws air from the atmosphere and forces it
into the furnace through a preheater. These fans are located at the inlet of
the boiler to push high pressure fresh air into combustion chamber, where
it mixes with the fuel to produce positive pressure.
Various machinery in BHEL BAP
1) Horizontal Boring machine
2) 360deg universal milling machine
3) CNC drilling machine
4) CNC lathe machine
5) Heavy duty vertical lathe (Double column)

4. Various Departments of BHEL BAP
1) MARKETING
• They Participates in various tenders and get orders from the customers.
• Follows Indirect Marketing
• Business to Business
2) COMMERCIAL
• Initiates the process by making contracts with the customers.
• Plans & execute the operation by releasing the work orders.
• Monitoring & controlling the work.
3) ENGINEERING
• Design the each and every product using softwares.
• Prepare drawings in both 2D & 3D format
• Prepare Bill of Material (BOM) for every product.
4) OPERATION PLANNING & CONTROL
• Verify the Product diagrams & BOM.
• Prepare work schedule based on priority & sequence of operation.
• Create work order no. for every product.
5) MATERIAL PLANNING
• Responsible for availability of material at right time, price, quantity & quality.
• Prepare Indents (Purchase Requirement Slip).
• Calculate Purchase Schedule & EOQ.
6) PURCHASE
• Receive the indents from MPl dept.
• Send an enquiry to all the verified suppliers.
• Evaluates the Quotation send by the suppliers.
• Place the purchase orders.
7) PRODUCTION
• BHEL BAP has 10 production bays.
• When the work order is released, workmen start actual production.
• Shop Engineers guides the workmen using product drawings.
CUSTOMERS & COMPETITORS
CUSTOMERS
• The major customers are National Thermal Power Corporation (NTPC) and State Electricity Board.
• Some Private customers are TATA, Adhani, Jinthal Steels, Reliance, etc.
COMPETITORS
• Larsen & Toubro (L&T)
• Doosan
• Mitsubishi
• IJT
CONCLUSION
It was a very good learning experience for all the students. We had a very fruitful discussion with our
faculty and the resource person. Since, all the students were from mechanical branch we got an
opportunity to see various manufacturing machines and process. This industrial visit gave us an
insight of how a manufacturing plant actually works and what all things have to be kept in mind when
working there.
I observed BHEL considered their employees as most valuable asset and strength for sustained growth
& development. They supported their employees and in return, the employees worked efficiently and
effectively.

5. REFERENCES
1. www.bhel.com/home.php
2. www.economictimes.indiatimes.com/bharat-heavy-electricalsltd/infocompanyhistory/companyid
11831.cms
3. https://en.wikipedia.org/wiki/Bharat_Heavy_Electricals
4. BHEL Annual Report 2013-14 (English) from www.bhel.com