Sindhusha Bhel Report

Project Report on BHEL (HPVP)
M/S BHARAT HEAVY

ELECTRICALS LIMITED
HEAVY PLATES AND
VESSELS PLANT-
VISAKHAPATNAM
SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENTS UNDER DIPLOMA

TRAINEE FOR THE AWARD OF
DEPARTMENT OF ELECTRONICS COMMUNICATION AND ENGINEERING
SUBMITTED BY
S. SINDHUSHA (20349-EC-045)
DADI INSTITUTE
OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF ELECTRONICS COMMUNICATION AND ENGINEERING
DADI INSTITUTE OF ENGINEERING AND TECHNOLOGY
DIPLOMA IN ELECTRONICS COMMUNICATION AND ENGINEERING
DADI INSTITUTE OF ENGINEERING AND TECHNOLOGY, ANAKAPALLI

1.
GOVERNMENT POLYTECHNIC COLLEGE FOR WOMEN, BHEEMUNIPATNAM.

M/s BHARAT HEAVY
ELECTRICALS LIMITED
HEAVY PLATES &
VESSELS PLANT,
VISAKHAPATNAM
CERTIFICATE
This is to certify that bearing
20349-EC-045
DADI INSTITUTE OF ENGINEERING AND TECHNOLOGY,ANAKAPALLI. We have
undergone industrial training for six months at M/S BHARAT HEAVY ELECTRICALS LIMITED,
HEAVY PLATES AND VESSELS PLANT- VISAKHAPATNAM. During the training period from
____________________ 2022 to ____________________ 2023 as a part of my 6 th semester of
Diploma in COMPUTER ENGINEERING.
During the above-mentioned period his/her conduct and performance were found to be
……………………………
KRUSHNA PRASADA MISHRA
2.

DGM (HR-HRDC)
BHEL –HPVP VISAKHAPATNAM
M/s BHARAT HEAVY

ELECTRICALS LIMITED
HEAVY PLATES & VESSELS
PLANT,
VISAKHAPATNAM
CERTIFICATE
This is to certify that SIYADRI SINDHUSHA bearing PIN NO: 20349-EC-045 of DADI
INSTITUTE OF ENGINEERING AND TECHNOLOGY, ANAKAPLLI . He
has undergone industrial training for six months at M/S BHARAT HEAVY ELECTRICALS
LIMITED, HEAVY PLATES AND VESSELS PLANT-VISAKHAPATNAM. During the
training period from ____________2022 to_____________2023 as a part of my 6 th semester of
Diploma in Computer Engineering.
STUDENT NAME PIN NO:
SIYADRI SINDHUSHA 20349-EC-045
3.

During the above-mentioned period his/her conduct and performance were
found to be …………………………
POORNAPRIYA
DR. CH. NARSHIMHA
HEAD OF THE ECE DEPARTMENT

PRINCIPAL
DADI INSTTITUTE OF ENGINEERING AND
DADI INSTITUTE OF ENGINEERING AND
TECHNOLOGY, ANAKAPALLI
TECHNOLOGY, ANAKAPLLI
ACKNOWLE
DGEMENT
I acknowledge with profound gratitude, the management of M/S BHARAT

HEAVY ELECTRICALS LIMITED, HEAVY PLATES &VESSELS
PLANT, VISAKHAPATNAM for providing me the opportunity in getting
industrial training in their esteemed organization, I am greatly indebted to the
State Board of Technical Education and Training (SBTET), Vijayawada, AP.
I gratefully acknowledge the aid and facilities provided by Sri. K.P. MISHRA
(DGM/HR-HRDC) throughout the course of our project work.
I thankfully acknowledge with intense gratitude to our

Principal Dr.CH. NARSHIMHA,
POORNAPRIYA, HEAD OF THE DEPARTMENT (DECE)
and our respected training in charge NALINI and other faculty members of DADI
INSTITUTE OF ENGINEERING AND TECHNOLOGY,ANAKAPALLI for giving this opportunity
for successful completion of industrial training.
4.

On conclusion, I will remember my experiences in this industrial training and

utilize this experience to prove our ability and work for pride of the organization
in all respect whenever we get an opportunity.
UNDER THE ESTIMATED GUIDANCE OF
P NAGESWARAO
Dept Sr.
MANAGER
(DEPUTE. ELECTRONICS DEPARTMENT(WE-EM))
INTRODUCTION
TO
5.

BHEL
(HPVP)
Bharat Heavy Electricals Limited (BHEL) owned and founded by the Government of India,
is Engineering and Manufacturing Company based in New Delhi, India. Established in 1964,
BHEL is India’s largest power generation equipment manufacturer. It was granted the prestigious
Maharathna (big gem) status in 2013 by Govt. of India for its outstanding track record and vast
scale of operations.
HPVP (Heavy Plates and Vessels Plant) is the 17 th manufacturing unit of BHEL (Bharat
Heavy Electricals Limited). Prior to merger it was known as BHPV (Bharat Heavy Plates and
6.

Vessels Limited). BHPV was established as a public sector undertaking under the Department of
Heavy Industry, Government of India. It has been catering to the specialized equipment & plants
required for oil refineries, fertilizer plants, steel plants, defense sector etc. It is the only unit of
BHEL situated at port.
Today, BHEL is the backbone of the Indian’s process industries for
 Steel or Fertilizer
 Chemicals or Refineries
 Petrochemicals
 Gas processing systems
 Boiler plant & Equipment
 Nuclear/Defense/Space
BHEL plays a leading role with a range of products comparable to the best in the world, manufacture
to its own designing or to the specific designing of the customer consultants.
This range of equipment is manufactured in collaboration with some of the world’s leading process
equipment manufacturers.
BHEL is engaged in the design, engineering, manufacturing, construction, testing, commissioning
and servicing of a wide range of products, systems and services for the core sectors of the economy, viz.
power, transmission, industry, transportation, renewable energy, oil & gas defense.
It has a network of 17 manufacturing units,2 repair units, 4 regional offices, overseas offices, 15
regional centers, 8 overseas offices,7 joint venture, and infrastructure allowing it to execute more than
150 projects at sites across India and abroad. The company has established the capability to deliver
20,000 Mw per annum of power equipment to address the growing demand for power equipment to
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address the growing demand for power generation equipment. BHEL’s global references are spread
across over 76 countries across all the six continents of the world.
Major Manufacturing Facilities:
1. High Pressure Boiler Plant (HPBP) – Tiruchirappalli
2. Heavy Electrical Plant (HEP) – Bhopal
3. Heavy Electrical Equipment Plant (HEEP) – Haridwar
4. Heavy Power Equipment Plant (HPEP) – Hyderabad
5. Boiler Auxiliaries Plant (BAP) – Ranipet
6. Transformer Plant (TP) – Jhansi
7. Electronics Division (EDN) – Bangalore
Other Manufacturing Facilities:
1. Electronics System Division (ESD) - Bangalore:
Simulators, Telecommunication systems and other advanced Microprocessor Based Control System .
2. Electro-Porcelains Division (EPD) - Bangalore:
Insulators, Bushings and Ceramic Liners.
3. Industrial Valves Plants (IVP) – Goindwal:
Industrial Valves and Fabrication.
4. Central Foundry Forge Plant (CFFP) - Haridwar:
Heavy Castings and Forgings.
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5. Component Fabrication Plant (CFP) – Rudrapur:
Solar cells, Solar Lanterns, Chargers and Solar Clocks.
6. Seamless Steel Tube Plant (SSTP) – Tiruchirapalli:
Seamless Steel Tube, Spiral Fin Welded Tubes.
7. Insulators Plant (IP) – Jagadishpur:
Insulators and Bushings.
8. Power plant Piping Unit (PPPU) – Thirumayam
9. Heavy Plates and Vessels Plant (HPVP) – Visakhapatnam:
Industrial boiler, Fin tubes, Multilayer vessels, Trays, Hydrocracker reactor, Fired Heater, Waste heat
recovery steam generators, Evaporators, Air cooled heat exchanger, deaerators, Process waste heat
boilers.
10. Centralized Stamping Unit & Fabrication Plant (CSU & FP) - Jagadishpur
11. Heavy Equipment Repair Plant (HERP) - Varanasi
12. Electrical Machine Repair Plant (EMRP) – Mumbai
Besides the above, the Company has a Number of offices across the country for Sales, Engineering,
Project management, Logistics and R&D.
Awards and Recognitions:
 BHEL is the 7th largest power equipment manufacturer in the world.
 BHEL wins many Excellence Award for the year 2006 - 07 for highest growth rate in market
Capitalization.
 In the year 2011, it was ranked ninth most innovative company in the world by US business
magazine Forbes.
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 BHEL is also placed at 4th place in Forbes Asia’s Fabulous 50 List of 2010.
 The company won the prestigious ‘Golden Peacock Award for Occupational Health & Safety
2011’ for significant achievements in the field of Occupational Health & Safety.
 The company bagged PSE Excellence Award 2014 for R&D and Technology Development.
 BHEL wins India Pride Award 2015-16 for Excellence in Heavy Industry
 BHEL received two awards in CII-ITC Sustainability Awards 2012 from the
President of India.
 CBIP Award 2018 for ‘Best Power Equipment Manufacturing Organization’.
PRODUCTS
 Fin Tubes
 Industrial Boilers
 Fired Heaters
 Deaerators
 Cryogenic Storage Tanks
 Cryogenic Transportation Tanks
 Gaseous Storage Tank
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 De-salter Plants
 Sulphur Recovery Unit
 Vacuum Ejector Systems
 Storage Spheres
Spheres Refinery
Transportation package Cryogenic tanks Gaseous storage vessels
Customers of our BHEL – HPVP
HPCL GAIL
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RFCL YADADRI, Kothagudem
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LAYOUT OF BHEL:
LAYOUT DETAILS:
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1 Administration Building 21 Welding technology office

2 Administration canteen 22 Stores
3 Administration site 23 Steel, Pipe yard
4 Garden 24 Scrap yard
5 Administration site 25 Plant office
6 Two-wheeler parking 26 Bay-1
7 Four-wheeler parking 27 Bay-2
8 HR & TI Dept. 28 Bay-3
9 Plant security gate 29 Bay-4
10 Industrial canteen 30 Bay-5
11 EIL office 31 Bay-6
12 R&D Building 32 Bay-7
13 Engineering Building 33 Bay-8
14 Light Machine shop 34 Central Dispatch Section
15 Oxygen Storage Yard 35 Sand Blasting shop
16 Compressor, Transformer section 36 NDT Cabins, HT furnace

17 SF building 37 Garage
18 Executive canteen 38 Sandblasting shed
19 Quality assurance lab 39 Wood cutting shop
20 Quality assurance lab 40 Plate yard
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VALUES OF BHEL:
 Zeal to Excel and Zest for Change
 Integrity and Fairness in all matters
 Respect for Dignity and Potential of individuals
 Strict Adherence to Commitments
 Ensure Speed of response
 Faster Learning, Creativity and Team-work
 Loyalty and Pride for the company
SWOT ANALYSIS OF THE BHEL:
Strength Weakness
 Wide range of the products with better  Lack of access to new technology
quality  Slow rate of production
 Good reputation with customers  Lack of Manpower
 Skilled workers under a roof
Opportunities Threat
 Improved planning and quality control  Competition with private sector companies
 Can adapt new methods and technology  Less access to resources
 Modernise using computerized machines  Exposure of their technology to the
competitor
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DEPARTMENTS
OF
BHEL
(HPVP)
BHEL having the following departments which plays a crucial role to complete a job
1. Modernization & Captive Investment

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2. Engineering department
3. Projects Management
4. Material Management department
5. Planning and Technology department
6. Industrial Engineering department
7. Production department
8. Quality Control department
9. Welding Technology department
10. Electronic & Instrumentation department
11. Works Engineering department
12. Erection & Commissioning department
13. Research and Development department
14. Outsourcing department
15. Subcontracting machining department
16. Finance department
17. Corporate Planning department
18. Transportation department
19. Commercial department
20. Human Resources department

BHEL is easily pictured by dividing the organization into the following divisions to carry out its
functions
 Finance
 Material Management
 Personnel and Administration
 Engineering and Commercial
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 Quality, Research and Development
 Production and Services
Production and Services include planning, production technology, welding technology, and
production. Production shops are classified as feeder shop and assembly shops. MP, LMS, HMS, press
shops and Nozzle shops will under feeder shops while Valve trays, PV, HE, and CP will come under
assembly shops. BHEL is having a shop floor area of over 56,000 sq. meters. With capacity to handle
unit loads up to 241 meters.
BHEL contribution extends too many industries such as
 Oil Industry
 Steel Industry
 Aluminum Industry
 Paper Industry
Industry leaders like the oil and natural gas commission, Steel Authority of India Ltd, Rastriya Ispat
Nigam, Bharat Aluminum Company, National Aluminum Company, and Hindustan Paper Corporation.
In short, BHEL has earned a massive vote of confidence from the entire spectrum of process plant
The factory is provided with comprehensive and modern manufacturing and testing facilities and suitable
material handling equipment.
 The maximum crane lifting capacity is 120 tones but loads up to 250 tones can be lifted with
improvisation. Maximum Rolling Capacity is 60mm in cold condition and 170mm in hot
condition.
 BHEL has the largest heat treatment furnace in India, the size being 5.5 meters width, 5.5 meters
height and 36.5 meters long.
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 One more furnace of 200 tones capacity and 15 meters. Bogie length has been added. Other
critical equipment available.
 Deep Drawing Hydraulic Press of 1600T capacity and a number of welding rotators of capacity
up to 250tones.
 Single spindle CNC deep hole drilling machine with gun drilling attachment and 2Nos CNC
drilling machines which can employ conventional drills.
 Welding equipment such as Manual arc, submerged arc, TIG, MIG, Plasma including the latest
high productive welding equipment such as twin head submerged arc welding, narrow gap
submerged arc welding and bi-cathode TIG welding, tube fining machine.
 A number of vertical and horizontal boring machines with a maximum capacity of 5mts dia and
200mm spindle dia.
 Different types of Non-destructive testing equipment well equipped physical and chemical
laboratories, Metrology etc.
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FUNCTIONS
OF
DEPARTMENTS
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PERSONNEL & ADMINSTRATION
PERSONNEL – Major Functions
 Recruitment and Selection
Responsible for the recruitment in the factory.
 HRDC (Training and Development)
Trains employees and trainees and apprentices at all levels on current issues, topics of interest
etc. Coordinates and trains engineer trainees in inter and intra unit level.
 Establishment
Maintains history of each employee, the pay details, transfer details and department allocation
details.
 Industrial Relationship
Deals with trade unions and bi partite committee where both management and workers take part
in the committee.
 Public Relations
Keeping good relationship with agencies for smooth function of the organization
ADMINISTRATION
 Receives the outgoing mails from other departments. Arrange for the dispatch of the mails to be
sent, receives the inward mails and distributes them to the concerned departments.\
 Maintains the security arrangement for the factory and township.
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21

PLANNING & DEVELOPMENT
The planning and development section provide the framework to identify the company’s objectives
and growth plans. This section formulates guidelines for the functioning of various other sections and
acts as a catalyst towards implantation policies and decisions.
Major functions:
 Performs long range planning (Diversification, collaborations and joint ventures etc)
 Draws long range product and functional plans after interaction with engineering, marketing,
commercial and finance group.
 Identifies new products in line with development in other countries and also suitability to our
line of manufacture and expertise.
 Identifies company needs and suitable technology transfer through collaboration.
 Deals with capital budget and investment planning.
 Analyses the investment requirements of new products, modernization and replacement, new
technologies, expansion of facilities, R&D projects etc.
 Also take care of investment in township, schools, hospital, canteen etc.
 Monitors the production targets fixed during the monthly production review meetings.
 Monitors performance on productivity improvement, capital, R&D expenditure through MIRs
 Monitors the operations, coordinates for product or technical committees.
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MARKETING & PUBLIC RELATIONS

The department of Marketing was established in BAP to give a thrust to marketing efforts for
our products in the industrial and power sector front. It is responsible for all direct orders.
Major functions:
 Conducts market survey and defines market needs in terms of product and process
requirements.
 Organizes seminars or exhibitions and industrial fairs, markets our products in India and
abroad.
 Contacts prospective customers and projects our product range.
 Obtains feedback on market conditions for product improvement and for identifying
new products.
 Receives tenders for jobbing orders
 Review render feasibility and resolves all issues with concerned departments.
 Prepares technical offer with the assistance from engineering.
 Prepares the commercial offer. This involves the pricing of components depending on
the cost of raw materials, bought out items and the various duties and concessions
involved. The commercial offer aims at optimum pricing.
 Negotiates and resolves with customer aspects like technical specification, price and
terms of settlement.
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 Organizes pre-contract review meetings, signs the contract and receives advance
wherever applicable. Delegates the work to various other units.
Communications & Public relations
Functions:
 Arranges for press meet during the 1st week of April
 Responsible for photography inside the factory, organizes corporate
communications
PROJECTS DEPARTMENT
Major functions:
 Communicates customer requirements to the concerned sections regularly
 Takes timely efforts to collect back the dues and cash for the bills invoiced on the
customer
 Expedites with the agencies for the timely completion of critical DUs
 Involves in the preparation and submission of consolidated MIRs on the status of
pending Dues
 Assists commercial in monitoring the status of contracts regarding supply
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In the commercial department, Planning Group and product wise sales group are functioning for the
smooth flow of work.
COMMERCIAL
Once the order is received, the marketing department transfers the responsibility to the
commercial through a Contract Phase Transmittal Note. The Commercial department then takes over
the execution of contracts and acts as an interface between the customer and other sections in the
plant, besides projecting the image of the company to the customers
Major functions
 Prepares commercial plan every year considering customer requirement and
commitment Commercial plan is released at PGMA (Product Group Main Assembly)
level and the design documents are released accordingly
 Communicates the commercial plan to the various agencies for drawing their budgets
 Formulates Revenue Budget of the Unit and area wise budgets based on the commercial
plan
 Issues the work order
Work Order
XXXX XXX X XX XXX
Cust No Dispatch Nature of Product Main
Priority No Supply Group assembly
 Releases PGMA lists
 Generates CSR (Contract Status Report)
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 Ensures the adoption of CSR Monitors weekly and monthly target on production,
dispatch, billing and clearance
 Generates pending lists and exception reports when there is a deviation from the
promised production due dates
 Communicates the erection and commissioning requirements to the various executing
agencies
 Interfaces with customers & aids billing and cash collection
OPERATION PLANNING AND CONTROL
Operation planning and control has four groups namely Planning, Scheduling, Process
planning and expediting.
Major functions:
 Prepares yearly/quartile/monthly plan to meet commercial plan
 Analyses the product Ability
 Receives engineering document, OCP /QP/PRQA /PRQS/HT /WPS / Tools list
 Identifies the tooling requirements and coordinates with Tool engineering
 Maintains of list of qualified processes for welding and towering.
 Informs WTC to develop new welding procedure, Maintains master drawing
 Generates and releases operation process sheet
 Coordinates with computer system and prepares cumulative statement of material
requirement
 Coordinates with Industrial Engineering, Material Planning, Design Engineers and
Quality Control to sort out technical problems, Monitors MSA components , Monitors
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the production status of the jobs, Prepares and validates CNC programs to maintain the
systems
INDUSTRIAL ENGINEERING
Industrial Engineering is a common agency required to co-ordinate with all the
departments. IE is considered as a Tool for management. Industrial Engineering is closely associated
with time & motion study. It is concerned with the design, improvement and installation of
integrated systems on man, materials and equipment drawn upon specialized knowledge .
Major functions:
 Conducts Work Study-Method Study & Work measurement, Performs Resource

planning
 Devises Systems and Procedures, Deals with Budget control, Helps in Productivity
Improvement
 Implements the Suggestion scheme
Work Study
Work Study is a technique, which deals with the problems
 As to how a job is done.

 How much time a job should take for completion
 The answer for the first question is method study or motion study and for the second is
time study or work measurement.
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Method Study
It is defined as a Systematic invitation of existing and proposed way of doing a job as a means
of developing and implementing easier and effective methods and thereby reducing cost.
Objectives:
 Improving the process and procedure, eliminating wastage of time and labour
 Finding the best way of doing a job, improving the quality of a product
 Devising ways for effective utilization of materials, machinery and workers improving
the design of work place layout
FINANCE
Finance function can be divided into four main areas
 Cash Management
 Accounting
 Financial control
 Financial Policies
Cash Management
It being the first priority task of a finance manager, he should know right quantum, right
source, right time and at the right price to raise to amount. He should know the various sources of
funds and should utilize them at reasonable cost.
Accounting
The accounting department maintains the accounting records for reporting to the Shareholders,
Public and Govt. It maintains a set of accounting books like annual report, Balance sheet and profit
& loss account.

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Ratio Analysis
 This can be treated as a tool to find where the problem lies Cost Accounting
 Job Costing, Raw Material, Components, Lab our (Weekly time collect System)
 Subtracting Expenses related to admin, Common Factory Overheads, Process Costing
Target Costing
 Tolerable Cost = Permissible Price - Acceptable Profit
Payment of duty
 Through Challans, Consolidating all dispatches for a day
 No excess drawl should be there
 They should be remitted before the clearance of the goods.
PURCHASE
PURCHASE IS MOST IMPORTANT FUNCTION IN ANY

ORGANISATION
The department of Purchase is responsible for the selection of sources of supply,
finalization of terms of purchase, placement of purchase orders; follow up, maintenance of smooth
relationships with the suppliers, approval of payment to suppliers and rating of suppliers.
Major functions
 Registers the indents received from MPL & Engineering and sends them to the
corresponding sections.
 Sends the enquiries to suppliers after approval from the concerned persons (according to
delegation of power).
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 Opens the tenders (which may be limited tenders, single tender or open tenders
 The nature of which is decided either by MPL, customers / purchase) on their due dates
either in camera / open. If the value of the tender exceeds 5 lakh rupees, it is opened in
the presence of the Finance man.
 Tenders are technically evaluated by the indentor and recommended to the purchase.
 Places the purchase order on the technically approved offer after the approval according
to DOP & with the concurrence of finance whenever required.
 Performs follow up of material so that it is supplied on time
 Ensures the prompt payment to the supplier.
OBJECTIVES OF PURCHASE:
Objective of procurement activity shall be to Purchase the required materials,
equipment’s and related or associated services at the right time, at an optimum price, consistent with
quality requirements, in a transparent and fair manner line with extant guidelines and government
directives to meet customer commitments.
 Purchase of satisfactory material
 Proper negotiations with suppliers
 Co-ordination with other departments
 Timely deliveries
 Continuous and regular supply
 Minimized wastages
 Quality
 To control the quantity of the material
 Information about new material and processes which can reduce the cost of production
and improve the performance of the product

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The key issues involved in purchase are
1. Time
2. Quantity
3. Quality
4. Place
 This procedure covers the purchase activities of Materials Management Department (MM)
commencing from receipt of Material Indents (MI) till receipt of materials /components in
BHEL-HPVP/ customer sites.
QUALITY
BHEL is committed to Total Quality Management (TQM). The TQM efforts are aimed at
improving quality of products, customer focus, timely delivery, technology, and process up
gradation, on continuous basis.
Major functions
 Develops quality systems and procedures as per the corporate policies and assists
Head/Quality in the preparation/revision, issue and control of quality assurance
manual.
 Conducts enquiry / contact reviews for quality requirements and transmittal of the
same as work instructions where required.
 Organizes vendor evaluations based on Purchase/ MSA request.
 Provides online support for development of vendors / subcontractors.
 Analyses and resolves product non-conformance and monitors corrective / preventive
actions.
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 Organizes quality improvement plants for product technology and process.
 Organizes quality related training and awareness programs for test performers through
P&A and corporate quality Assurances.
 Organizes quality audits and apprising management effectiveness of quality systems .
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PRODUCTION
SHOPS
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MANUFACTURING SHOPS
WORKSHOP:
Workshop is the place where all the actual manufacturing work starting from marking to
dispatch of final product is carried out. BHEL workshop is mainly classified as feeder shop
and production shop.
A) Feeder shop:
Any final product is a assembly of several individual components like nozzles, shells, dish
ends, pipe attachments etc. Thus, the basic individual components of a product are manufactured
in a shop called as feeder shop. The feeder shop is further divided into separate sections or shops
listed below:
L.M.S - Light Machine shop
M.P - Material Preparation
H.M.S - Heavy Machine shop
Press - Bending & welding plates
Nozzles - Pipe preparation & welding
Shells - Rolling & welding operation
B) Production shop:
The individual components or parts that are manufactured in the feeder shop are then moved
for final assembly to the production shop. Thus, in production shop, assembly of the individual
component takes place. The production shop is further classified depending upon the nature of
the product. These shops are divided into 5 types. They are:
P.V - Pressure Vessels

H.E. - Heat Exchangers
C.P. - Cryogenic production
C.S.P.1 - Combustion system products
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C.S.P.2 - Combustion system products
In addition, it has the requisite handling facilities. Bigger equipment’s handled at shops are
220MT and the shop can handle equipment up to 60 meters long height crane under hook is 18
meters.
The basic layout or construction planning of the work shop can be visualized from the below figure.
BHEL covers over a total area of 197 areas out of which 90,000 square meters is covered by
different sectors. The production shops cover an area of 56,000 square meters. Basically the
workshop is constructed in such a way that the L.M.S including CSP-2 are under one roof and
remaining shops under one roof.
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SALIENT FEATURES OF DIFFERENT SHOPS
MATERIAL PREPARATION SHOP (MP)
This shop prepares the materials to feed to the other shops for further processing. It is
equipped with machines suitable for gas cutting, edge preparation, saving, straightening, and
grounding etc., for preparing the raw material to the required shape and size.
Major functions:
 Cuts and prepares the raw material inputs like plates, sheets, coil rounds and rods etc., to
the required size and profile for further fabrication or assembly in the respective
production shops
 Optimizes material usage and minimizes waste and scrap
Machines in Material Preparation Shop:
Once the markings are completed the sheets are sent for cutting as per dimensions.
Depending upon the length, thickness, and path to be followed during cutting the operation is
done on different machines like
1. Flame planning machine
2. Shearing machine
3. Manual gas cutting machine
4. Gas cutting pug machine
5. Edge planning machine
Marking, Cutting and Preparation:
 Raw material shall be marked and cut to size by shearing, machining, saw cutting, flame
or plasma cutting. Flame cut edges shall be cleaned to remove slag.
 Uneven surfaces shall be dressed by grinding
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 The tolerances shall be maintained within +2mm unless otherwise specifies. The
diagonal difference shall be within 3mm
 Stainless steel materials shall be cut using plasma cutting or shearing only
FLAME PLANNING MACHINE
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LIGHT MACHINE SHOP (LMS)
In this shop, all small components machining such as marking holes in tube sheet, drilling and
planning of small items will taken up here. From nozzle to flange welding is done in this shop.
In this feeder shop lathe works, drilling, boring and milling operations are done. Boiler items,
nozzle and flanges are prepared in this shop.
Machinery used in light machine shop:
1. Small and medium lathes - 14
2. Auto threading lathe - 01
3. Radial drilling machines - 09
4. Small horizontal boring machine -01
5. Medium horizontal boring machine -02
6. Heavy lathe - 01
7. Plane drilling machine -01
8. CNC drilling machine - 01
9. CNC deep hole drilling machine -01
10. Cylinder grinding machine - 01
11. Horizontal surface grinder - 01
.
38

HEAVY MACHINE SHOP (HMS)

Machining, drilling and surfacing of the components which are larger than the capacity of
L.M.S will be carried out here. The shop is equipped with one 500mm diameter , one 400mm diameter,
two 250 diameter heavy double column vertical turning and boring machines besides a number of small
machines. Horizontal boring machine is capable of boring to a maximum depth of 2000mm.
Machinery used in heavy machine shop:
1. Radial drilling
2. Universal drilling
3. Single column planning
4. Double column planning
5. Large horizontal boring
6. Medium VTBS
7. Large VTBS
Vertical and horizontal boring machines:
General operations on boring machines are facing, beveling, tapering, enlarging holes etc.
Depending upon the holding capacity boring machines are classified as SK25, SK40, SK50 where
25,40,50 are the maximum diameters of the jobs that can be hold in 1000’s of mm. Horizontal boring
machines are used for facing operation of discharge elbows etc.
HORIZONTAL BORING MACHINE VERTICAL BORING MACHINE
.
39

PRESS SHOP
The dished ends required for vessels are prepared with petal construction in this shop.
Hydraulic presses with maximum capacity of 1600T are used for pressing of dished ends, petals of
storage spheres and various other parts. Maximum diameter of dished ends those can be handled in
single stroke is 80mm up to 120mm thick plates prepared in stages.
Machinery used in press shop:
1. Section bending roll
2. Pneumatic hammer
3. Pipe bending
4. Hydraulic press 250T
7. Bending roll
HYDRAULIC PRESS
.
40

SHELLS SHOP
In this shop, plates are rolled to required size and long seams and circumferential seam
welding will be done. Narrow gap welding is done in this shop. Special narrow gap welding machine
is available in this shop, this can weld up to 350mm thick groove width about 18 to 25 mm.
In this feeder shop, plates are rolled on to shells with the help of plate bending or rolling
machines. The plate bending or rolling machines are classified according to the thickness of the plate
and diameter of the shell. In this feeder shop, C-seam welding and L-seam welding will also be done
after the plates are rolled.
Machinery used in shell shop:
1. Plate edge planning 1200x80mm thick
2. Plate bending rolls 359x3.25mm thick
3. Plate bending rolls 4000x22mm thick
4. Plate bending rolls 3000x75mm thick
5. Submerged arc welding twin head
BENDING OF PLATE
.
41

COMBUSTION SYSTEM PRODUCTS (CSP)
This shop mainly deals with boiler pipe attachments. In boilers or heat exchangers we have
several pipes which used to carry flue gases or liquids. In CSP 1& 2 shop mainly welding of Boiler
panel pipes and welding of nozzles, flanges, pipes etc., are done. Welding equipment such as Manual
Arc , Sub merged Arc, TIG, MIG, Plasma including the latest high productive welding equipment
such as Twin Head submerged arc welding, Narrow Gap submerged arc Welding and Bi- cathode
TIG Welding , Tube Finning Machine are provided.
 C.S.P.1 (Combustion system products)
In this shop different types of pipes are bent in to require shapes which are mainly used in
boilers. Machinery used in Combustion system products:
1. Four torch welding machine 01
2. Panel Bending Machine 01
 C.S.P.2 (Combustion system products)
In this feeder shop, the operation is bending & facing of pipes. Basically, pipe bending
machine is used to bend the pipe through certain angles mostly less than are equal to 90 whereas
section wise rolling machine is used to bend the pipe through 180
.
42

NON-DESTRUCTIVE TESTS (NDT)
Non-Destructive Testing is a wide group of analysis techniques used in science and industry
to evaluate the properties of a material, component or system without causing damage. NDT is
commonly used tool in forensic engineering, aeronautical engineering, mechanical engineering,
electrical engineering, civil engineering etc., Because NDT does not permanently alter the article
being inspected, it is a highly- valuable technique that can save both money and time in product
evaluation, troubleshooting, and research.
Therefore, choosing the right method and technique is an important part of the performance of NDT.
The tests that are carried out in BHEL are:
 Visual inspection test (VT)
 Liquid penetrant test (LPT)
 Magnetic-particle inspection (MT or MPI)
 Radiographic test (RT)
 Ultrasonic test (UT)
RADIOGRAPHY TEST EQUIPMENT
.
43

RESEARCH AND DEVELOPMENT (R&D)
The R&D department was established in BHPV in the year 1975, with the intention of
generating know-how in process equipment design and fabrication technologies and in order to
bridge the gap in existing know-how, to enable BHPV attain self-sufficiency in the field of process
equipment industry.
The R & D department is recognized by the Department of Scientific and Industrial Research
(DSIR) since 1976. R&D is also taking up sponsored research projects for other institutions such as
Aeronautical Development Agency (ADA), Bangalore etc.
The activities of R&D department aim at generating / formulating sufficient information that
can be directly used for the design and fabrication of processes as well as cryogenic equipment and
developing advanced fabrication technologies.
R&D had developed the manufacturing technology for the spherical high-pressure titanium air
bottles for the Prithvi and Trishul missiles. R&D developed many technologies. They are
1. Vacuum brazing technology for aluminum and its alloys & for stainless steel
2. Welding technologies for titanium and its alloys & duplex stainless steel
.
44

SAFETY DEPARTMENT
FUNCTION OF SAFETY MANAGEMENT
 Accident prevention
 Safety education
 Personnel protective equipment
 Safety committee
1. Accident prevention
Accident analysis, investigation, prevention, statistical reports and monitor plant inspection
and job safety analysis
2. Safety education
Courses for all level of employment, periodical publication, safety appreciation course to all
employees
Discussion and implementation of safety matters

SAFETY COMMITEE Safe working environment
SAFETY AWARNESS AND Safety contest

MOTIVATION Motivation towards safety
Accident investigation report

ACCIDENT INVESTIGATION
Prevention of recurrence
Plant inspection report

PLANT SAFETY INSPECTION Safe working environment
Celebrations, lecturers,course materials

SAFETY EDUCATION Awareness on safety
Issue of PPE
PPE
Secondary line eqipment
SAFETY DEPARTMENT – ACTIVITY CHART

.
45

CONCLUSION
This Has Been an Effective Training Experience in BHEL-HPVP,

Visakhapatnam With A Great Exposure to Industrial Level Working. We Got an Experience of
working as an asst computer administrator for HR dept.
All Our Anticipated Knowledge Has Been Turned into Reality During Our Course of Training
In BHEL-HPVP, Visakhapatnam. We Are Extremely Thankful to The Human Resource and
Development Centre For Giving Us This Opportunity. We Also Thank the Staff of The BHEL
(HPVP) For Imparting All the Knowledge
References
 BHEL HPVP WIKIPIDEA
 EMPLOYEES OF BHEL
 OLD COMPANY BOOKS FROM BHEL LIBRARY
.
46

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Project Report on BHEL (HPVP)

M/S BHARAT HEAVY

SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENTS UNDER DIPLOMA

DEPARTMENT OF ELECTRONICS COMMUNICATION AND ENGINEERING

DEPARTMENT OF ELECTRONICS COMMUNICATION AND ENGINEERING

DADI INSTITUTE OF ENGINEERING AND TECHNOLOGY

DIPLOMA IN ELECTRONICS COMMUNICATION AND ENGINEERING

DADI INSTITUTE OF ENGINEERING AND TECHNOLOGY, ANAKAPALLI

GOVERNMENT POLYTECHNIC COLLEGE FOR WOMEN, BHEEMUNIPATNAM.

This is to certify that bearing

DADI INSTITUTE OF ENGINEERING AND TECHNOLOGY,ANAKAPALLI. We have

____________________ 2022 to ____________________ 2023 as a part of my 6 th semester of

Diploma in COMPUTER ENGINEERING.

KRUSHNA PRASADA MISHRA

GOVERNMENT POLYTECHNIC COLLEGE FOR WOMEN, BHEEMUNIPATNAM.

BHEL –HPVP VISAKHAPATNAM

M/s BHARAT HEAVY

INSTITUTE OF ENGINEERING AND TECHNOLOGY, ANAKAPLLI . He

LIMITED, HEAVY PLATES AND VESSELS PLANT-VISAKHAPATNAM. During the

training period from ____________2022 to_____________2023 as a part of my 6 th semester of

Diploma in Computer Engineering.

STUDENT NAME PIN NO:

SIYADRI SINDHUSHA 20349-EC-045

GOVERNMENT POLYTECHNIC COLLEGE FOR WOMEN, BHEEMUNIPATNAM.

HEAD OF THE ECE DEPARTMENT

I acknowledge with profound gratitude, the management of M/S BHARAT

I thankfully acknowledge with intense gratitude to our

for successful completion of industrial training.

GOVERNMENT POLYTECHNIC COLLEGE FOR WOMEN, BHEEMUNIPATNAM.

On conclusion, I will remember my experiences in this industrial training and

UNDER THE ESTIMATED GUIDANCE OF

(DEPUTE. ELECTRONICS DEPARTMENT(WE-EM))

GOVERNMENT POLYTECHNIC COLLEGE FOR WOMEN, BHEEMUNIPATNAM.

GOVERNMENT POLYTECHNIC COLLEGE FOR WOMEN, BHEEMUNIPATNAM.

BHEL situated at port.

Today, BHEL is the backbone of the Indian’s process industries for

 Gas processing systems

 Boiler plant & Equipment

to its own designing or to the specific designing of the customer consultants.

BHEL is engaged in the design, engineering, manufacturing, construction, testing, commissioning

GOVERNMENT POLYTECHNIC COLLEGE FOR WOMEN, BHEEMUNIPATNAM.

Major Manufacturing Facilities:

1. High Pressure Boiler Plant (HPBP) – Tiruchirappalli

2. Heavy Electrical Plant (HEP) – Bhopal

3. Heavy Electrical Equipment Plant (HEEP) – Haridwar

4. Heavy Power Equipment Plant (HPEP) – Hyderabad

5. Boiler Auxiliaries Plant (BAP) – Ranipet

6. Transformer Plant (TP) – Jhansi

7. Electronics Division (EDN) – Bangalore

Other Manufacturing Facilities:

1. Electronics System Division (ESD) - Bangalore:

2. Electro-Porcelains Division (EPD) - Bangalore:

Insulators, Bushings and Ceramic Liners.

3. Industrial Valves Plants (IVP) – Goindwal:

Industrial Valves and Fabrication.

4. Central Foundry Forge Plant (CFFP) - Haridwar:

Heavy Castings and Forgings.

GOVERNMENT POLYTECHNIC COLLEGE FOR WOMEN, BHEEMUNIPATNAM.

Solar cells, Solar Lanterns, Chargers and Solar Clocks.

6. Seamless Steel Tube Plant (SSTP) – Tiruchirapalli:

Seamless Steel Tube, Spiral Fin Welded Tubes.

7. Insulators Plant (IP) – Jagadishpur:

Insulators and Bushings.

8. Power plant Piping Unit (PPPU) – Thirumayam

2022 to 2023 as a part of my 6 th semester of

training period from 2022 to_2023 as a part of my 6 th semester of