Professional Documents
Culture Documents
5 Final Internship Report
5 Final Internship Report
CHAPTER-1
COMPANY PROFILE
BHEL manufactures over 180 products under 30 major products groups and
caters to core sector of the Indian economy viz., Power Generation and
transmission, industry, Transportation, Telecommunication, Renewable Energy
etc. 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 company is striving to give shape to its aspiration and fulfill the expectations of the country
to become global player.
The greatest strength of BHEL is its highly skilled and committed 47,525 employees. 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 400kv (AC & DC).
BHEL LOGO
.
Fig. 1.1 BHEL LOGO
Embarking upon the 50th Golden Year of its journey of engineering excellence, BHEL is an
integrated power plant equipment manufacturer and one of the largest engineering and
manufacturing company of its kind in India engaged in the design, engineering, manufacture,
construction, testing, commissioning and servicing of a wide range of the products and services
for the core sector of the economy, viz. Power, Transmission, Industry, Transportation
(Railway), Renewable Energy, Oil & Gas and Defense with over 180 products offering to meet
the needs of these sectors. Establishment of BHEL in 1964 was a breakthrough for upsurge in
India’s Heavy Electrical Equipment industry. Consistent performance in a highly competitive
environment enabled BHEL attain the coveted ‘Maharatna’ status in 2013. BHEL as a part of
Pt. Jawaharlal Nehru’s vision was bestowed with the onus to make the country self-reliant in
manufacturing of heavy electrical equipment. This dream has been more than realized and the
contribution in nation building endeavor is going to continue likewise. Today, with 20,000
MW per annum capacity for power plant equipment manufacturing, BHEL’s mammoth size
of operation is evident from its widespread network of 17 Manufacturing Units, 2 Repair Units,
4 Regional Offices, 8 service centers, 8 overseas offices, 6 joint venture, 15 Regional arketing
Centers and current project execution at more than 150 project site across India and abroad.
The total installed capacity based of BHEL supplied equipment -138 GW in India speaks
volumes about the contribution made by BHEL to Indian power sector. BHEL’s 57% share in
India’s total installed capacity and 65% share in the country’s total generation from thermal
utility sets (coal based) as of March 31,2014 stand testimony to his. The company has been
earning profits continuously since 1971-72 and paying dividends since 1976-77 which is a
reflection of company’s commendable performance throughout.
BHEL has faced challenges with aplomb throughout all the phases of its illustrious journey.
Right from its incorporation in a protected market to facing the pressure of a liberalized
economy and the current slowdown in the economic environment, BHEL has evolved with
transforming its strategies from product manufacturing to market orientation; business
excellence through portfolio restricting ushering in the realm of sustained growth through
diversification.
BHEL’s greatest strength is its highly skilled and committed workforce of more than 47,000
employees who have been the cornerstone of BHEL’s successful journey. Further, the concept
of sustainable development is inculcated in the DNA of BHEL which is evident from its
mission statement- “providing sustainable business solution in the fields of energy, industry
and infrastructure.” BHEL is also engaging with the society pursuing initiatives aimed at
community Development, Health & Hygiene, Education, and Environment Protection,
Disaster Management and Talent Up gradation / skill development.
Power Sector
BHEL is one of the few companies’ in the world having capability of manufacturer entire range
of power plant equipment and has proven turnkey abilities for executing power projects from
concept-to-commissioning. The Power Sector comprises Thermal, Gas, Hydro and Nuclear
power plants.
Supplies steam turbine, generator, boilers and its auxiliaries up to 800 MW including sets of
600/700/800 MW based on supercritical technology Has facility to make thermal set up
to 1000 MW unit size Supplies hydro turbine and generators up to 250 MW Manufacturers
220/235/540/550/700 MW nuclear turbine generator set Has proven expertise in plant
performance improvement through Renovation, Modernization and Uprating of variety of
power plant equipment Special knowhow of residual life assessment health diagnostics and
life extension of plants Supplied thermal sets have consistently exceeded national average
efficiency parameters.
BHEL Hyderabad
Heavy Power Equipment Plant (HPEP), Hyderabad is one of the major manufacturing units of
BHEL. It was established in 1965 with the objective to design, manufacture and supply small
size (12MW to 110 MW) steam turbine generator sets.With a modest beginning, BHEL
Hyderabad has been growing steadily and today it caters to diversified customer needs with a
product mix of gas turbines, steam turbines, compressors, generators, oil field equipment and
other power plant equipment such as pumps, pulverizers and heat exchangers etc.
In the year 2011-12, a separate unit 'Project Engineering & Systems Division' (PE&SD) was
formed at Hyderabad with the mandate to provide end-to-end solutions to customers in
industrial and international business segments. To effectively address customer needs, PE&SD
caters to supply of balance of plant equipment and system engineering for the in house products
of BHEL Hyderabad.
Manufacturing facilities at SHEL Hyderabad are on par with the best in the world with 120
CNC machining canters, 125-ton vacuum balancing tunnel, Cerro-bond technology for steam
turbine precision blade forgings, 5 axis milling for 3D impellers etc. SHEL Hyderabad has also
established CIM (Computer Integrated Machining). 3000 networked PCs provide enhanced
operational efficiency ERP/SAP systems have been implemented to smoothen the information
flow and effective management of business processes. SHEL Hyderabad has a host of
instrumentation laboratories and sophisticated quality control facilities. SHEL is equipped with
ISO 9001, ISO 14001, OHSAS 18001, ASME U & U2 stamp and API certification for oil rigs
which is a testimony of sound and consistent quality and safety practices at SHEL. Customer
training is provided for all products to customers in order to have safe and maintenance free
operation of products at site. SHEL is qualified by Fluor-USA, CS&I-USA and Saipem-ltaly
for supply of critical process equipment to refineries and power plants.
BHEL always strives to exceed customer expectations and has sophisticated engineering
capabilities, manufacturing, testing facilities with a network of high-end engineering work-
stations to cater to the specific needs of the products. SHEL Hyderabad customer profile is a
virtual who's-who of the Indian industry with all sectors catered to by SHEL. We have also
forayed into the export market by supply of products and equipment from SHEL Hyderabad
for power stations and process industry.
PRODUCT
BHEL manufactures a wide range of Power Plant equipment and also caters to the industry
sector.
Fig. a Fig. b
Fig. c Fig. d
Fig. e Fig. f
Fig. g
Fig. 2(a-g) Some Products of BHEL Hyderabad
TASK PERFORMED
GAS TURBINE
BHEL manufactures a complete line of Heavy Duty Industrial Gas turbines for all utility and
Industry applications. They are installed in Refineries, Petrochemical plants, Gas compression
stations, and Power generation plants in India and abroad. BHEL has long-standing experience
in manufacturing Gas turbines dating back to 1986 when a Collaboration agreement was
established with GE (U.S.A.) to complement the existing portfolio of products. A proven
combination of sound design and quality assurance techniques places these gas turbines among
the world's most reliable machines. Basic models produced by BHEL cover the 25,000 to
290,000 kW power range. Extensive research and development, advanced design procedures,
modern manufacturing technology and on-site experience are behind the success achieved by
BHEL gas turbines. BHEL has already installed over 190 gas turbines with cumulative fired
hours of over 13 million. Apart from India, BHEL machines are working in Bangladesh, China,
Iraq, Malaysia, Oman, Saudi Arabia, Srilanka and Kazakhstan.
AREAS OF APPLICATION
These gas turbines are fuel-flexible, and can operate on Natural gas, Liquefied Natural gas
(LNG), Distillate and treated Residual oil in a variety of applications including:
Technical Characteristics
FEATURES:
• Capability to fire wide range of gaseous fuels (Natural gas, Refinery gas, Low BTU
gases) and Liquid fuels (Distillate, Naphtha, Kerosene, LCO, Residual heavy fuels like
Furnace oil, LSHS, crude).
• Low exhaust emission levels upto 15ppm of NOx with DLN combustors
• Suitable for Simple cycle, Combined cycle and Cogeneration cycles applications.
• Suitable base load, peak load, cyclic load applications.
• Horizontally split casing for easy maintenance
• Models below 100 MW are suitable for both 50 Hz and 60 Hz application.
• Suitable for outdoor / indoor installation
• Ideally suited for IGCC application.
• Packaged designs, Shop tested & tuned suitable for shorter Erection and
commissioning periods.
• World's largest experience on Naphtha fired machines.
Working Principal
Fresh air enters the compressor at ambient temperature where its pressure and
temperature are increased. The high pressure air enters the combustion chamber
where the fuel is burned at constant pressure. The high temperature (and
pressure) gas enters the turbine where it expands to ambient pressure and
produces work.
Features:
Brayton Cycle
Brayton cycle is the ideal cycle for gas-turbine engines in which the working fluid undergoes
a closed loop. That is the combustion and exhaust processes are modelled by constant-pressure
heat addition and rejection, respectively.
Fig. 3.3 T-s and P-v diagrams for ideal Brayton cycle.
INLET
COMPRESSOR
COMPRESSOR DISCHARGE (COMBUSTION CHAMBERS)
DISTANCE PEICE
TURBINE
EXHAUST FRAME
EXHAUST DIFFUSER
AIR INLET- Filters and directs the air into to the compressor.
COMPRESSOR- Axial flow. Draws air in and compresses it to a higher
pressure and temperature. consist of rotor assembly, stator casing, rotating
and stationary blades.
COMBUSTORS- Multiple combustion chambers where fuel and air are
mixed and burned to provide the heat energy to the turbine. directs the
combustion gases to the turbine section
TURBINE- Convert the hot gas kinetic energy into rotational shaft power.
EXHAUST- Directs the high temperature, low pressure, gasses to
atmosphere or to a heat recovery steam generator(HRSG)
AUXILIARY SUPPORT SYSTEM- Controls, lubrication oil,
hydraulics, cooling and sealing air and other required for the operation,
control and protection of the turbine
In a gas turbine engine, the combustor or combustion chamber is fed high pressure air by the
compression system. The combustor then heats this air at constant pressure. After heating, air
passes from the combustor through the nozzle guide vanes to the turbine. In the case of a ramjet
or scramjet engines, the air is directly fed to the nozzle.
The objective of the combustor in a gas turbine is to add energy to the system to power the
turbines, and produce a high velocity gas to exhaust through the nozzle in aircraft applications.
As with any engineering challenge, accomplishing this requires balancing many design
considerations, such as the following:
1. Completely combust the fuel. Otherwise, the engine wastes the unburnt fuel and creates
unwanted emissions of unburnt hydrocarbons, carbon monoxide (CO) and soot.
2. Low pressure loss across the combustor. The turbine which the combustor feeds needs
high pressure flow to operate efficiently.
3. It should be capable of relighting at high altitude in an event of engine flame-out.
4. Uniform exit temperature profile. If there are hot spots in the exit flow, the turbine may
be subjected to thermal stress or other types of damage. Similarly, the temperature
profile within the combustor should avoid hot spots, as those can damage or destroy a
combustor from the inside.
5. Small physical size and weight. Space and weight is at a premium in aircraft
applications, so a well-designed combustor strives to be compact. Non-aircraft
applications, like power generating gas turbines, are not as constrained by this factor.
6. Wide range of operation. Most combustors must be able to operate with a variety of
inlet pressures, temperatures, and mass flows. These factors change with both engine
settings and environmental conditions (I.e., full throttle at low altitude can be very
different from idle throttle at high altitude).
Diffuser: A diverging passage, which reduces the velocity of compressor exit air flow
from Mach 0.3 to Mach 0.05-0.1 in combustion passages with minimum pressure loss.
Cowls: Structures attached to dome which guide flow from diffuser into the combustion
passages with minimum pressure loss.
Dome: Front end of the combustion structure which provides shelter and means Front
end of the combustion structure which provides shelter and means of flame stabilization
(e.g. swirler) for the primary combustion zone.
Liners: Thin metal shells extending from the dome to the turbine nozzle for control of
combustion and dilution air jets and cooling air film The liners control of combustion
and dilution air jets and cooling air film. The liners protect the engine casing and
internal shafts form the hot combustion products.
Casings: Engine structural shells which carry thrust loads. Casings also comprise inner
and outer passage boundaries.
Fuel Injectors: Devices which provide fuel to the primary zone, usually through the
dome.
Igniter: Spark plug located in dome or primary zone.
This type of combustion chamber is used on centrifugal compressor type engines. It has several
cans disposed around the engine. Each can is a complete combustion chamber consisting of its
own air outer with a flame-tube(or burner liner) inside. Compressor delivery air is directed by
ducts to pass into the individual chambers. Each can contain its own fuel nozzle.
The chamber cans are all interconnected. This allows each can to operate at the same pressure
and also allows combustion to propagate around the flame tubes during engine starting. Igniter
plugs are installed on two of the cans approximately at 4 and 5 O’clock positions.
Some axial compressor engines have a single annular combustion chamber. This type of
combustion chamber consists of a single flame tube (i.e. liner), completely annular in form,
which is contained in the annulus of an inner and outer casing. The chamber is open at the front
to the compressor and at the rear to the turbine nozzles.
However, the burner liner on some engines cannot be disassembled without removing the
engine from the aircraft, which is a distinct disadvantage.
A Turbo-annular combustion chamber design is used on many large turbojet and turbofan
engines. Individual burner cans are placed side by side to form a circle of cans inside an annular
space between outer and inner air casings. The cans are essentially individual combustion
chambers with concentric rings of perforated holes to admit air for cooling.
ADVANTAGE DISADVANTAGE
Centrifugal
Axial
Axial-flow compressors have two main elements: a rotor (drum or disc type) and a
stator. These compressors are constructed of several different materials depending
on the load and operating temperature. The drum-type rotor consists of rings that are
flanged to fit one against the other so that the entire assembly can be held together by
through bolts.
ADVANTAGE DISADVANTAGE
Table No. 3.3 advantage and disadvantages of gas turbine engine compressor
Operability Performance
∗ Ground start ∗ Combustion efficiency
∗ Altitude relight ∗ Pressure drop
∗ Lean blow out ∗ Exit temperature
∗ Bleed airflow distribution
Configuration Emissions
∗ Size ∗ Smoke
∗ Weight ∗ Carbon monoxide(CO)
∗ Maintainability ∗ Unburned hydrocarbons
∗ Thermal growth ∗ Oxides of nitrogen(Nox)
∗ Mounting method Durability
∗ Structural integrity
∗ Cyclic life
• Combustor design and development efforts rely very heavily on previous experience.
• Design rules usually involve empirical correlation of data from previous design.
• CFD simulations are also used in conjunction with the empirical correlation.
• Design rules actually used in industry tend to vary from manufacturer to manufacturer.
CHAPTER-4
Reflection
During my work experience at BHEL, I was fortunate enough to have experienced first-hand
and learnt, many different sides of what goes into a project, the general process of how a project
is initially planned, developed and completed; as well as how much work and detail goes into
every stage. Another valuable lesson I have learnt during these 1 month, the many different
types of work an Engineer has to perform, which in turn, have provided me with more insight
into the different types of roles and responsibilities that I could perform, as a Mechanical
Engineer.
Reflecting back to my first day at BHEL, it was one of the most memorable days of my
time at work. After being introduced to everyone, I was handed a task to work on, in which
they had asked me for recommendations to improve certain aspects of the project wherever I
see fit, as well as my opinions on the project as an entirety. They were very open and happy
for me to contribute as much as I wanted to, and were open to any suggestions and ideas. This
instantly made me feel comfortable and definitely made me feel as though I was part of the
team.
During the first week of work completing the task, I was overwhelmed by the work and
the responsibilities that were placed on me, but with the help of my supervisors and the
directors, who have had years of experience in the industry, I felt more confident and supported
as I knew my work would be double checked and any uncertainties were explained. By
observing and learning from them, I managed to pick up tips and learnt different types of skills,
from learning to communicate and deal with other companies, to reading and deciphering many
different types of plans. Working on task for the first few weeks was enjoyable for me as it did
make me use all the techniques I learnt at University in every stream of Mechanical
Engineering that had been taught to us, namely; Dynamics, Structural, Designing and
thermodynamics. I realize this might not be the same everywhere and usually Mechanical
Engineers might focus on one type of stream, but I was happy that I had the opportunity to use
all of my theoretical knowledge and applied them to real‐life situations.
I found that the workplace itself was relatively diverse from what I had observed
working at BHEL. There are surveyors, project supervisors/managers to Mechanical engineers
all working in the one office. This large range of people have different strengths and
qualifications and they work together and organize their work in sync with one another so that
work flows and they are able to complete their work efficiently in order to present it to the
client on time. This in turn, manages to help the workplace become better as team and therefore
creates a good atmosphere in the working environment.
The work that I had to complete varied day‐to‐day depending on what project was about
to begin, or what task was due. Some days were quiet, and during these days I would usually
take a tour of a company and try to learn about different type of machines, such as vertical
lathe, horizontal Boring Machine & Plano Milling Machine(VMM). This helped me learn more
about the company.
There were many days that were busy where a task deadline had to meet or a client
might need something completed urgently, and these days were stressful to the point where
there
were times I did have to stay back with the superiors to learn some of work. This in
some ways reminded me a lot of my late night study sessions at university and how even in the
workplace, it did not change.
Overall, my work experience at BHEL was positive. I was very happy with the amount
of things that I have learned and experienced in the 1 month of being an Engineering Trainee
with the company. I believe that University should keep this aspect of the Engineering course
as it does provide students with the experience needed in order to find a job later on (even if
the experience is over a short amount of time). Also, it can be very beneficial as skilled can be
shown on collage interview which will increase your chance of getting selected. I ended up
learning a lot more than I thought I would be able to in the time span, and my hard work paid
off as they gave a certificate of training. I am so happy, and proud that I have completed my
training for a well-known institute.
CHAPTER-5
CONCLUSION
The project training carried out for 4 weeks has enhanced me with not only the
theoretical knowledge of my engineering career, but also have shown me the practical use of
engineering and its applications around on the site. This first experience for on-site industrial
training was very much needed as this will be at par for all the knowledge and information
gained in return of time and efforts. Getting an opportunity to pursue the training under such a
vibrant company has shown me the afterlife of the professional course and its co-existence
with logical concepts. The company is making rapid progress in the various spheres. Being
from a background of mechanical engineering, nothing else could have been better than being
able to learn and adapt things from the company’s tactics of growing together. Renowned for
best corporate practices and value-based management each of the Department channelizes its
resources in a most efficient and optimum manner. This is reflected in its continuous organic
growth and the leadership position in the sector. The organisational structure and resources are
deployed effectively to earn a reasonable rate of return in its investment.
REFERENCES