HEAVY ELECTRICAL EQUIPMENT PLANT, HARIDWAR

R&D AND ENGINEERING

BHEL ’s technological and engineering expertise are geared to offer state Design Software Tools
of the art technology and solutions for future growth and customer PTC Creo (ProE) / Siemens UGNX
needs. Over 2.8% of turnover is earmarked for R&D. HEEP has a strong  3D full featured solid modelling
engineering base with highly experienced engineers, spanning the
functions of proposal, performance and product engineering, project ROTAL-MADYN
management and field services. Our designs adhere to international Rotor Dynamics
ANSYS (FEA Software)
standards and codes like ASME, HTRI, YUBA, TEAMA etc.
 Linear/ non-linear structural
analysis
CSIR recognized Research & Product Development (RPD) groups work at
 Steady-state / transient
units for dedicated R&D of each of our products. Our customers turn to Thermal Analysis/ Creep-
BHEL for our industrial and scientific expertise to enhance capabilities of Fatigue interaction
an existing product and improve process efficiencies. Our Corporate R&D ADAMS (Automated Dynamic
Division at Hyderabad facilitates through several Centres of Excellence Analysis of Mechanical Systems)
 Kinematics and Dynamic
dedicated to various technological areas like Intelligent Machines and
analysis for real-time forces and
Robotics, Machine Dynamics, Nano-technology, UHV Laboratory, motion study
Simulators, Computational Fluid Dynamics, Surface Engineering, MAXWELL
Permanent Magnet Machines, Power Electronics, IGBT & Controller  Electromagnetic design of
Technology, Control and Instrumentation, Advanced Fabrication Generator
Technology, Welding Research Institute, Ceramic Technological Institute PDMS
 3D Development of piping lay-
etc. to name a few, for basic as well as applied research.
out
OTHERS: Coulomb / HYPERMESH /
Mathcad/ AXSTREAM/ CAESAR II/
SPECIAL ACTIVITIES
NETOMAC
 Residual Life Assessment (RLA) including life consumption of
component in creep and fatigue Under the National Mission, BHEL is
 Rotor Dynamics Analysis developing 800 MW Advanced
 3D Design and Development Ultra- Supercritical (AUSC)
technology. AUSC employs
 3D Finite Element Analysis
enhanced main steam parameters
 CFD-CAE tool for investigation of flow and heat transfer aspects for to the next level of 310 ata / 710°C
optimization of steam flow section design and above with an intent to
increase Thermal Power Plant
efficiency and reduce emissions.
MACHINING FACILITIES
Modern and up to date machining facilities have always ranked high on the priorities of BHEL Haridwar.
The plant is equipped with state of the art modern CNC and Heavy Duty machines for machining
complicated shapes and con-tours to a high degree of precision. These facilities are supported by material
handling facilities for large sized and heavy components, material testing and inspection facilities which
ensure quality product manufacturing. Highly skilled manpower having diverse experience in
manufacturing technology, cutting tools and CAM based CNC programming is also a great asset to the
plant’s machining capability.

The machining facilities include the following state of the art machines, in addition to other
conventional/standard facilities:
1. CNC HORIZONTAL BORING MACHINES – 17 Nos.:
Spindle Diameter up to 200 mm
Table Size up to 5000 mm x 5000 mm
Spindle Power up to 100 kw
2. CNC VERTICAL BORING MACHINES – 16 Nos.:
Table Diameter up to 7500 mm
Turning Height up to 7000 mm
Weight Capacity up to 200 tonnes
3. CNC LATHES – 20 Nos.:
Swing Over Carriage up to 3500 mm
Center Distance up to 19000 mm
4. CNC GANTRY MILLING MACHINES – 2 Nos.:
Table Size 12000 mm x 4000 mm
Maximum Job Height 3500 mm
5. CNC HORIZONTAL MACHINING CENTERS – 18 Nos.:
Table Size up to 1000 mm x 1000 mm
6. CNC VERTICAL MACHINING CENTERS – 6 Nos.:
Table Size up to 800 mm x 300 mm
7. CNC MULTI SPINDLE DRILLING MACHINES – 2 Nos.:
No. of Vertical Spindles up to 6
Table Size 10000 mm x 5500 mm
8. CNC 5-AXIS MILLING MACHINES – 27 Nos.:
For Machining of Turbine Blades & Turbo-Generator Cooling Blades of length up to 1000 mm
FABRICATION FACILITIES AND WELDING TECHNOLOGY
The world class fabrication facility at BHEL Haridwar is equipped with heavy rolling machines, Plasma
cutting machines, Horizontal Boring machines, Vertical Boring machines, Horizontal/Vertical Deep hole
drilling ma-chine, Heat Treatment Furnaces with testing facilities. BHEL Haridwar has developed around
400 welding procedures for different materials covering thickness up to 250 mm which adhere to
international codes and standards.

Major Facilities in Fabrication Shop: Materials Handled:

1. Hot Wire Narrow Gap TIG welding Machine: Horizontal Span: • Titanium
9M; Turn table Dia: 3.5 M ; Weight : 60 Tons • Aluminium
• Nickel based alloys (Inconel)
2. Weld Overlaying Facility: Technology for Weld Overlay on • Carbon steel
Journal Area of IP Turbine Rotor and HP Turbine Rotor; Dia of • Alloy steels like 0.5 Mo, 1Cr-0.5 Mo, P-11
Rotor: 1000 MM-2000 MM & P-22 (Cr-Mo, Cr-Mo-V)
• Special grade SS like 304L, 316L & 317L,
3. GROOVE STELLITE MACHINE: X-axis & Y-axis Travel -5M; Turn P911 & P91
Table dia – 2 M (extendable up to 5 M); Capacity: 20 Tons • Quenched and tempered steel
• Austenitic stainless steels
4. 1.8 MW BOGIE HEARTH FURNANCE: 100 TON; LxWxH:
• Copper-based alloys, Aluminium bronze,
12x8x6M
brass
5. 3-ROLL BENDING MACHINE: Maximum Bending capacity - 60 • Clad steels with Titanium
mm(Tk.) x 3000 mm (Width); Roller length: 9000 mm

6. CNC BRAKE PRESS: Bending capacity - 25 mm (Tk.) x 3000 mm

(Width); Capacity - 340 MT; Adjustable ‘V’ Die (3000 mm long)

7. 4-ROLL BENDING MACHINE

8. 1000T HYDRAULIC PRESS: Working Pressure: 250 kg/cm2

9. CNC FLAME & PLASMA CUTTING MACHINES: Cutting capacity

– Up to 300 mm Tk. for CS; 100 mm Tk. for SS

OTHER MANUFACTURING FACILITIES

BHEL Haridwar is equipped with advanced equipment to ensure production of Turbines, Electrical
Machines like Turbo Generator, Exciters, Permanent Magnet Generators, AC Motors etc. at its facilities.
We are equipped with Coil and Insulation manufacturing shop, Moulding Shop, Vacuum Impregnation
Plant, Brazing Facility, Balancing Facility, testing facility for large size turbo-generators, auxiliaries for TG
etc.
DEFENCE & AEROSPACE FACILITIES
BHEL Haridwar has an excellent facility to manufacture Defence equipment. BHEL takes pride to
manufacture 76/62 Super Rapid Gun Mounting (SRGM) for Indian Navy in collaboration with Leonardo
Defence Systems (formerly M/s OTO Melara), Italy. SRGM being light weight and servo controlled offers
rapid fire naval gun with high-performance and flexibility in air-defence and anti-surface role, particularly
in anti-air role.

Key Capabilities in Defence Production

1. Expertise in fabrication of Aluminium Alloys, Special grade Alloy steel, Bronze, Copper and Dissimilar
Materials

2. Excellent precision machining facility for complex and intricate pro-file in components made of
Titanium alloy, Aluminium alloy, Special Grade Alloy Steel, Bronze within close tolerances

3. Capability for surface protection treatments such as Alodyne, Phosphatising, Zinco-Nickel Plating,
Decorative Chrome, Passivation and special treatments i.e. Hard Chrome & Bronze spray

4. In-house capability for manufacturing and testing of Hydraulic Sub-systems

5. Highly skilled manpower for execution of assembly, testing mechanical and electrical, integration, fault
analysis independently.
POLLUTION CONTROL RESEARCH INSTITUTE, HARIDWAR
Pollution Control Research Institute (PCRI), “OHSAS & ISO 9001 Certified Institute” was set up by the
Department of Heavy Industry (Government of India), through Bharat Heavy Electricals Limited (BHEL),
under United Nations Development Programme (UNDP) at Hardwar.

This Institute is recognized by Ministry of Environment & Forests, Central Pollution Control Board as
Recognized Environ-mental Laboratory. PCRI is Member of CHD 032 Environmental Protection Sectional
Committee which is part of Bureau of Indian Standards (BIS). National Mission for Clean Ganga (NMCG)
has also nominated Pollution Control Research Institute as Class “A” Ganga Monitoring Centre (GMC) for
carrying out Water Quality monitoring studies on River Ganga.

SERVICES OFFERED
• Environmental Impact Assessment (EIA) Studies MODERN MONITORING AND ANALYTICAL
• Environmental Audit FACILITIES:
• Environmental Monitoring for • Atomic Absorption Spectrophotometer
Regulatory/Mandatory Requirements • Gas Chromatograph
• Water (Effluent/Sewage, Bio-assay Test, Drinking • UV VIS Spectrophotometer
Water) • Flue Gas Analyser
• Air (Stack Emissions, Ambient Air, Work Place) • Bomb calorimeter
• Noise (Ambient Noise, Work Place Noise, Noise • VOC Analyser
Mapping, Equipment Noise) • PM10 & PM2.5 Samplers
• Sludge and Solid Waste Analysis • Multi Gas Analyser for Work Place
• HSE Monitoring (Heat Stress Assessment, Oxygen Monitoring
Level Monitoring, Illumination Studies, Work Zone • Sound Level Meter with Octave Filter
Air Quality, Noise Dose, Bacteriological Monitoring) • Heat Stress Meter
• Environmental Management Consultancy Services • Illumination Meter
• Performance Evaluation of Effluent/Sewage • Noise Dose Meter
Treatment Plants & Air Pollution Control Systems • Bacteriological Air Sampler
and suggestions for improving its treatment • Automatic Bacteriological Colony
efficiency Counter
• On-line Monitoring System
• Development of Environment Laboratories at
Units
• Training on Health, Safety and Environment issues
TESTING AND RESEARCH FACILITIES
BHEL Haridwar’s in-house facilities are equipped to perform mandatory routine, type tests and customer
specified supplementary tests on all our products. Central Plant Laboratory, Metals Research Laboratory
and Generator Research Institute located in the plant premises support the product engineering, quality
control and meeting testing requirements of our products. These labs provide one stop solution for
verifying the quality of raw materials and incoming products. The services offered by our labs are:
Material Testing, Investigational Services, Calibration, Vendor Development and Performance
Enhancement. In addition, all our manufacturing shops have testing facilities.

MAJOR TEST FACILITIES AVAILABLE:

 Fully equipped Non-Destructive Testing (NDT) Laboratory
 3D Coordinate Measuring Machine: Size upto 3 x 2 x 1.6 m
 Laser Tracker
 Helium Leak Testing Facility
 High Voltage Testing Facility

 Dynamic Mechanical Analyser

 Differential Scanning Calorimeter
 Scanning Electron Microscope with Energy Dispersive Micro-analyser
 Optical Metallograph with Image Analyser
 Advanced UTM Machines with strain rate control (Capacity 600KN,250KN,10KN)
 Vacuum Emission Spectrometer
 Universal Length Measuring Machine- HPD3000B
 Thermo-gravimetric Analyzer
 Fourier Transform Infrared Spectrophotometer
 Multi-Channel Modal Analysis System (Bump-test/NFT)
 Laser-based vibration monitoring system
 Sound intensity measurement system
 Heavy Duty Shaker System for endurance testing

QUALITY FIRST
In line with its vision to "Become a global engineering enterprise providing solutions for better
tomorrow", BHEL is com-mitted to deliver best in class products and services. BHEL Haridwar is certified
to various certification in Quality, Safety and Environmental systems to ensure our operations meet the
highest industrial standards.

 ISO 9001:2015 Quality Management System

 ISO 14001:2004 Environmental Management Systems
 OHSAS 18001:2007 Occupational Health & Safety Management Systems
 ISO 50001:2011 Energy Management System