CII Hyd Pulveriser Presentation 26.10.10

ORGANISATION
Executive Director
R.Krishnan
General Manager
(Pulv.M&S,F&P & CW)
K.Nivedan
Pulv.Engg. , Tech., BDG & CES Pulveriser Operation

J.G.Kulkarni /AGM M.Veerapratap/ AGM
Pulverisers Commercial Pulveriser Purchase

Ch.V.S.S.S. Sarma / AGM S.Shankar/ Sr. DGM
HUMAN RESOURCES
AREA EXECUTIVES SUPERVISORS ARTISANS & TOTAL

OTHERS
ENGG. & TECH. 14 3 6 23
COMMERCIAL 11 6 6 23
PLANNING 8 10 11 29
PRODUCTION 23 43 211 277
MATERIALS 10 6 2 18
MANAGEMENT
TOTAL 66 68 236 370
PULVERISERS
Pulverisers are employed to

pulverize the pre crushed raw coal to
the required fineness before it is
admitted into the boiler furnace for
combustion in Coal-fired Thermal
Power Station.
हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

BHEL’s JOURNEY 1960’s TO 2010 FOR PULVERISERS
• IN THE 60’s BHEL DESIGNED, MANUFACTURED AND SUPPLIED BALL MILLS WITH
INDIRECT FIRING SYSTEM.
• IN THE 70’s BHEL ENTERED INTO COLLABORATION WITH M/s COMBUSTION

ENGINEERING-USA FOR BOWL MILLS WITH DIRECT FIRING SYSTEM.
• IN THE 80’s BHEL ENTERED INTO COLLABORATION WITH M/s STEIN INDUSTRIE-
FRANCE FOR BALL TUBE MILLS.
• IN EARLY 2000s, BHEL ADOPTED THE MILLS TO SUIT INDIAN COAL CONDITION
AND DEVELOPED BHEL 280 BOWL MILLS AND INTRODUCED PLANETARY
GEARBOX IN PLACE OF MILL BASES WITH WORM GEAR DRIVE.
• IN THE YEAR 2005 BHEL ENTERED INTO COLLABORATION WITH M/s ALSTOM
USA FOR HIGHER CAPACITY BOWL MILLS SUITABLE FOR 660/ 800/ 1000 MW
SUPER-CRITICAL UNITS.
RANGE OF PULVERISERS
• MEDIUM SPEED – BOWL MILLS.
XRP 623 (18 TPH) TO BHEL280 MILL (91 TPH)

HP 1103 (87.1 TPH) AND HP 1203 (121 TPH)
• LOW SPEED – BALL TUBE MILLS.
BBD 3448 (35 TPH), BBD 4760 (90 TPH),

BBD 4772 (110 TPH)
PRESENT MANUFACTURING RANGE OF PULVERISER
I. BOWL MILL
MILL SIZE BASE CAPACITY
•XRP – 623 18.4 TPH
•XRP – 703 26.4 TPH
•XRP – 803 39.8 TPH
•XRP – 883 51.1 TPH
•XRP – 903 54.1 TPH
•XRP - 1003 68.1 TPH
•XRP - 1043 72.0 TPH
•HP - 1103 87.1 TPH
•BHEL – 280 91.0 TPH
•HP - 1203 121 TPH
CLASSIFIER
RAW COAL CHUTE
ASSY.
MILL BODY
GIRTH GEAR
LINERS
GRINDING MEDIA SCREW

CONVEYOR
MAIN REDUCER
AUXILLARY
REDUCER
PRESENT MANUFACTURING RANGE OF PULVERISERS
II. BALL TUBE MILL
MILL SIZE BASE CAPACITY

•BBD 3448 30.5 TPH
•BBD 4760 79.0 TPH
•BBD 4772 110.0 TPH
GRINDING PROCESS IN THE BOWL MILL
P.F. TO BOILER
RAW COAL
HEAVY
PARTICLES CLASSIFIER
P.F.+AIR
HOT AIR GRINDING ZONE
DRYING & GRINDING
REJECTS
NUMBER OF MILLS REQUIRED FOR
500 MW UNIT :
TUBE MILLS BBD- 4772 5 NOS
BOWL MILLS XRP-1003 10 NOS
BOWL MILLS BHEL- 280 8 NOS

NUMBER OF MILLS REQUIRED FOR
SUPER CRITICAL UNITS :
660 MW HP-1103 7-9 NOS
800 MW HP-1103 8-10 NOS

HP -1203 6-9 NOS
1000 MW HP- 1203 8-10 NOS

HP -1303 7-9 NOS
PEOPLE
STRATEGY
PARTNERSHIP &
RESOURCES
PULVERISER S
TRAINING
• Team consisting of Engineering, Technology,
Production and Quality Engineers visited M/s.
ALSTOM, USA for training in manufacturing of
Pulverisers for 660 and 800 MW project.
* Team consisting of Engineering, Production, Quality
and Testing Engineers visited M/s. FLENDER,
GERMANY for training in manufacturing of
Planetary Gear Boxes for 500 and 660 MW
projects.

PULVERISER S
TRAINING
• IN HOUSE TRAINING IN HRD FOR UP
GRADATION OF SKILLS.
• NEW ENGINEER TRAINEE IS SENT TO SITE

ALONG WITH EXPERIENCED ENGINEER
FOR ON JOB TRAINING AND PRODUCT
FAMILIARIZATION.

PULVERISER S
STRATEGY
• IN HOUSE DEVELOPMENT OF NEW
PRODUCT
- DEVELOPMENT OF BHEL 280 MILL.
• COLLABORATION FOR HIGHER SIZE MILL
TO MEET MARKET REQUIREMENT
-ENTERED INTO COLLABORATION WITH
M/s. ALSTOM, USA FOR MILLS OF SUPER
CRITICAL BOILER.

DEVELOPMENTS
IN
NEW PRODUCT
DEVELOPMENT
PULVERISER S
BHEL 280 MILL
XRP 1003/903/883 WITH

PLANETARY GEARBOX
BOWL MILLS FOR STEEL PLANT

FOR PULVERISED FUEL
INJECTION TO BLAST FURNACE

PULVERISER
MODIFICATIONS DONE TO S MEET THE
TENDER AT DESIGN STAGE
• BOWL MILLS:
• TO IMPROVE THE PERFORMANCE OF GRINDING ELEMENTS WITH

HIGH ABRASIVE INDIAN COAL, DEVELOPED CENTRIFUGALLY
CAST SUPER Ni-HARD MATERIAL FOR ROLLS & SEGMENTS.
• IN 90’S Hi-CHROMIUM INSERT TYPE GRINDING ROLLS WITH

MATCHING BULL RING SEGMENTS WERE INTRODUCED. THIS HAS
IMPROVED THE GRINDING ELEMENTS LIFE TO 6000-7000 HRS AND
ALSO THERE IS NO COLLAR FORMATION.
• FURTHER, SINTERED CARBIDE ROLLS ARE DEVELOPED ALONG

WITH THE VENDOR.
• WITH THIS, THE OUT PUT OF THE MILL IS ALMOST UNIFORM

THROUGH OUT THE LIFE OF THE GRINDING ELEMENTS.

PULVERISER S
MODIFICATIONS DONE AT
DESIGN STAGE
• BOWL MILLS:
• TALL TOP CLASSIFIER PROVIDED FOR BETTER

CLASSIFICATION.
• BEARING LESS SPRING ASSEMBLY
INTRODUCED TO MINIMISE MAINTENANCE.
• INVERTED CONE PROVIDED FOR REDUCING 50
MESH RETENSION.
• SEAL AIR CONNECTION PROVISION IS MADE
ON BOTH SIDES OF TRUNNION SHAFT FOR
AVOIDING COAL CONTAMINATION.

PULVERISER S
DEVELOPMENT FOR HSE

CONSIDERATIONS

PULVERISER S
PLANETARY GEAR BOX
• Compact design and is placed independent of mill
foundation.
• Gears are made of hardened special steel material. Hence

give long trouble free operation.
• Easy to replace. Hence, the gear box can be taken out to

work shop for any maintenance (clean area).
• Less down time of the mill for maintenance of Gearbox.
• Less Lube oil requirement (from 3000 ltr to 1100 lr/Mill-

65% saving)
• Weight Reduced from 60 Tons to 33 Tons

MILL DRIVE ASSEMBLY (WORM
& WORM GEAR TYPE).
• The gear box is very bulky and the grey iron casting
is complicated and heavy.
• Maintenance of Internals has to be carried out in
situ, thus resulting in long shut down of mill and to
be carried out in dusty atmosphere.
• Gearbox oil quantity requirement is high.
• The efficiency is low.
EFFICIENCY OF GEAR DRIVE
• Mill drive assembly with worm gear set has efficiency of

90%.
• Planetary gear box has efficiency of 95%.

.
PLANETARY GEARBOX
Vs
CONVENTIONAL GEARBOX
WITH WORM & WORM GEAR
PULVERISER S
MILL DRIVE & BOWL ASSEMBLY

PULVERISER S
WORM GEAR BOX

PLANETARY GEAR BOX
Low speed table
Tilting pads
Housing
Planetary Stage
Bevel gear stage
Gear coupling
PLANETARY GEAR BOX

R&D DEVELOPMENTS
• BHEL 280 MILL DEVELOPED ALONG
WITH CORPORAET R&D. WITH THIS,
NO. OF MILLS REQUIRED FOR 500 MW
IS REDUCED FROM 10 TO 8.
(SAVINGS OF RS 10 CRORES/UNIT)
• DYNAMIC CLASSIFIER DEVELOPED

FOR XRP 803 ALONG WITH APGENCO,
VIJAYWADA. THIS IMPROVES THE
FINENESS AND PERFORMANCE OF
MILL.
R&D EXPENDITURE &
TIE UP WITH IISc /CPRI
• IN PULVERISERS WE ARE SPENDING
Rs 7.8 Cr ON R&D ACTIVITIES.
• ie 1.2 % OF OUR TURNOVER.
• OUR TURN OVER DUE TO IN HOUSE
DEVELOPMENT PRODUCTS IS Rs. 286 Cr.
• This is about 40 % of the Total Turnover.
• DEVELOPING CERMIC BALLS WITH IISc
TIE UP & YGP MACHINE WITH CPRI
TIE-UP.
PATENTS & COPYRIGHTS
• PATENTED:
I. LOWER STIFFNESS SPRING FOR BOWL MILLS.
II. CERAMIC BALLS FOR TUBE MILLS
III. COLLAR TYPE GRINDING ROLLS
IV. REPLACEBALE SEGMENTS FOR ROLLS
• COPYRIGHT:
I. USER FRIENDLY O&M MANUALS
PRESSURE SPRING DESIGN
• SITE STUDY HAS PROVED THAT PRESSURE SPRINGS WITH LESS
SPRING STIFFNESS & MORE COMPRESSION GIVES BETTER ROLL
WEAR LIFE AND LESS POWER CONSUMPTION THAN SPRINGS
WITH HIGHER STIFFNESS AND LESS COMPRESSION VALUE.
• HENCE, NOW PROCURING SPRINGS WITH 20,000 LBS/INCH

SPRINGS INSTREAD OF 30,000 LBS/IN.
• THERE IS LESS VIBRATION DUE TO HIGHER LIFT OF THE SPRING

UNDER FOREIGN MATERIAL.
• THIS ALSO RESULTED IN LESS COST OF THE SPRINGS DUE TO

SMALLER ROD DIAMETER.
PULVERISER S
THE STIFFNESS OF THE SPRING REDUCED TO HAVE LESS POWER
CONSUMPTION AND LONGER ROLL LIEF

KNOWLEDGE MANAGEMENT AND
AUTOMATION IN ENGG.
• SUCCESSFULLY COMPLETED KNOWLEDGEMENT
MANAGEMENT PROJECT FOR BOWL MILLS.
• PARAMETRIZATION FOR NEW MILL
• ANIMATION OF VARIOUS ASSEMBLIES OF MILL
FOR TRAINING PURPOSE TO NEW ENGINEERS IN
BHEL AND CUSTOMERS AS WELL
• GRAPHIC USER INTERFACE (GUI) DEVELOPED FOR
END USER.
PRESENTATIONS IN SEMINARS
 “PULVERISERS FOR SUPER CRITICAL BOILERS AND
MODIFICATIONS AND IMPROVEMENTS IN O&M
PRACTICES” IN THE INTERNATIONAL O&M CONFERENCE
ANCHORED BY NTPC AT NEW DELHI.
 “PULVERISERS: DEVELOPMENTS AND THE O&M

PRACTICES” AT ENGINEERING STAFF COLLEGE OF INDIA
(ESCI) AT HYDERABAD.
 GUEST LECTURE ON “PULVERISERS” AT NATIONAL

POWER TRAINING INSTITUTE (NPTI) AT BENGALURU.
DTC Program –
Implementation Status
Pulveriser
4TH AUGUST 2008
PULVERIZERS
40
Cost Reduction status .
Pulverizer
193
Cost base
(Rs lakh/ref unit)
XRP1003
Target 25
(Per cent)
Cost Reduction syndicated (IL-3) 19

(Per cent)
Cost Reduction syndicated (IL-3) 36

(Rs Lakh)
Ideas syndicated 27
(Number)
41
. PULVERISER XRP-1003
Cost Cost
Reduction Reduction
Product group Cost base* Target syndicated syndicated
Rs lakh per unit Per cent Per cent Rs lakhs
Mill Drive 61 25 18 11
Separator 49 35 21 10
Journal 46 25 25 12
Air-inlet 15 15 12 2
Tools 10 30 10 1
MDV 6 5 0 0
Others 6 5 0 0
Total 193 25 19 36
19
10 4
5
Level 1 Level 2 Level 3 Total

42
*Based on XRP-1003 Pulveriser
ESTIMATED COST REDUCTION ACCRUAL* – PULVERIZERS
.
Year of No. of
Accrual Project Mills
13
2007 XRP 1003 Expected Cost Reduction
-08 DADRI II 9 0.35
Rs Crore
JSW-THERMAX 2 0.31
XRP 1003
10
BELLARY II 7 1.08 7
FARAKKA 5 0.78
2008 KORBA NTPC 10 1.56
-09 NTPC SIMHADRI 5 0.78
KOTHAGUDEM 7 1.52 6
XRP 1003 0
XRP 883
XRP 883 3
RAICHUR VIII 6 0.19 1
HARDUAGUNJ 12 0.38 BHEL 280 0 1
BUDGE BUDGE 6 0.57
0 1 0
2007-08 2008-09 2009-10
XRP 1003
FARAKKA 7 1.02
DADRI II 5 1.83
2009 MEJIA 10 4.15
-10 NTPC SIMHADRI 5 3.05
BHEL 280
KAPERKHEDA V 8 1.43
BHUSAVAL 16 1.92
43
* Based on work order released
* Accrual assumed when the mill is despatched
BOWL HUB MODIFICATION
OLD BOWL HUB-wt NEW BOWL HUB- wt

8.2 tons 5.2 tons
ANSYS -
ANALYSIS
PULVERISER S
VENDOR/ PARTNERSHIP
FOCUS

PULVERISER S
Journal
Assembly
with Ni-hard
Grinding roll

PULVERISER S
SECTIONAL VIEW OF CARBIDE INSERTS

S G IRON
INSERTS
Made of
Hi-Cr / Sintered
carbide

PULVERISER S
Hi-Cr INSERTS ROLL

PULVERISER S
Grinding rolls in initial wear condition

PULVERISER S
Worn out grinding roll
after 6500 running hours

TABLE /BULL RING SEGMENTS
XRP 1003
PULVERISER S
JOINT IMPROVEMENT ALONG

WITH VENDORS
• Developed insert type grinding rolls and segments
along with M/s. AIA Engg.Ahmedabad for longer
wear life of grinding elements.
• Ceramic tiled inner cones and ceramic balls
developed for longer life and improved performance
(EPD Bangalore).
• Fabricated separator body developed for faster
delivery and defect less components (Fabricators)

AIR INLET HOUSING ASSLY.
Air inlet housing
fabrication and
assembly of
insulation will be
completed by the
Vendor and will be
dispatched as DD.
FOR 2011-12
TOTAL 349
IN-HOUSE 121
OUTSOURCE (DD) 228
NO OF VENDORS 5
INNER CONE BY EPD BANGALORE
The inner cones will be

supplied by EPD
Bangalore and will be
Dispatched Directly
(DD) to site.
Totally outsourced.
SEPARATOR TOP ASSEMBLY
Separator top assemblies
will be procured from
manufacturers having
capabilities of procurement
of the other components as
per our specification. The
finish machined assemblies
will be dispatched directly to
site from the Vendors works.
FOR 2011-12
TOTAL 349
IN-HOUSE 121
OUTSOURCE (DD) 228
NO OF VENDORS 7
SEPARATOR BODY
The Separator bodies

having Casting and
Fabrication will be
procured from established
regular Vendors in finished
machined condition as a DD
item.
FOR 2011-12
TOTAL 349
IN-HOUSE 129
OUTSOURCE (DD) 220
NO OF VENDORS 5
PULVERISER S
CUSTOMER
FOCUS

PULVERISER S
ACTION AGAINST CUSTOMER FEED
BACK.
• Supplied Hi-Chrome Liners and balls to improve the
wear life.
• Girth Gear Greasing system- Bituminus grease
changed to environmental friendly grease.
• Sealing system around PGB improved to avoid dust
leakage.
• External lube oil system provided for longer life of
bearings and gears.

PULVERISER S

PULVERISER S

PULVERISER S
MODIFICATIONS DONE AT
DESIGN STAGE
• BOWL MILLS:
• Ni-HARD LINERS ARE PROVIDED ON WEAR PRONE

PART LIKE JOURNAL HEAD, JOURNAL OPENING
FRAMES, SEPARATOR TOP TO PROTECT THESE
CRITICAL COMPONENTS & TO HAVE LONGER WEAR
LIFE.
• BUTTERFLY TYPE MILL DISCHARGE VALVE
REPLACED WITH FLAP TYPE.
• MDV CASTINGS REPLACED WITH CERAMIC LINED
FABRICATED BODY FOR LONGER LIFE.

PULVERISER S
CERAMIC TILE LINED MDV BODY
THE BODY IS FABRICATED

INSTEAD OF CASTING
PULVERISER S
BHEL 280 MILL

• DEVELOPED BHEL280 MILL. NOW SUCCESSFULLY
RUNNING AT CHANDRAPUR STPS UNIT-6.
- BASE CAPACITY 91.0 TPH. SUITABLE FOR 500 & 660 MW

SIZE UNITS.
- WITH THIS NUMBER OF MILLS IN 500 MW WOULD BE

ONLY 8, THERE BY REDUCING NUMBER OF
AUXILIARIES, BOILER ELEVATIONS
SPECIAL FEATURES OF BHEL280 MILL:

-- STATE OF THE ART PLANETARY GEARBOX.
-- SPLIT TYPE MILLSIDE AIR INLET HOUSING.
-- SINTERED CARBIDE GRINDING ELEMENTS.

PULVERISER S
Bowl Mill

PULVERISER S

PULVERISER S
BHEL 280 MILL INSTALLED AT
CHANDRAPUR STPS UNIT-6C.

Customer Satisfaction Study
14th July 2009

Submitted to: Bharat Heavy Electricals
Limitted Hyderabad
By: The Nielsen Company
Overall Satisfaction Index – By Product Groups
1.2 Commitment Share Netural Vulnerable Share
1 4
7 11
14 14 13 13
13 18 23 28
0.8 10 13 16 18 17
13
12
0.6
0.4 80 78
77 71 70
64 60
0.2 73 71
0
Pulverisers Gas Turbine Compressor Pumps Heat Steam Turbo Gen Switch Gears Oil Rigs
Exchangers Turbine
Base 8 11 3 7 25 20 22 1 5
Above 90 Very Good Satisfaction 70 - 79 Healthy but need to improve satisfaction
80 - 89 Good Satisfaction 60 - 69 Low Satisfaction
69
PULVERISER S
ACHIEVEMENT
OF
PULVERISERS DIVISION

PULVERISER S
Developments of High
capacity mills: BHEL 280
mill (Base capacity 91
TPH) with this number of
mills for 600 MW reduced
from 10 nos. to 8 nos.
Saving Rs. 10.00 Crores
per unit.
Establishment of manufacturing
of planetary gear boxes in the shop
in place of mill base assembly.
Mill base worm shaft weight: 40 Tons
Planetary gear box weight : 12 Tons

PULVERISER S
AWARDS
EXCELLENT AWARD AT CCQC PAR EXCELLENT AWARD AT

HYDERABAD CHAPTER -2008 NCQC, BARODA-2008
INSSAN BEST SUGGESTOR

AWAARD 2008
EXCELLENT AWARD AT
E.D. ROLLOING SHIELD -09
NCQC, BANGLORE-2009

PULVERISER S
INITIATION FOR SHOP EXPANSION
• SHOP CAPACITY ENHANCED TO MEET 15000 MW

PER ANNUM POWER GENERATING CAPACITY
• ADDITION OF 2 NOS. VTL-25
• ADDITION OF OM 70
• ADDITION OF TESTING FACILITY
• ADDITION OF

PULVERISER S
INCREASE IN MARKET DEMAND
YEAR NO. OF MILLS

2007-08 96
2008-09 124
2009-10 145
2010-11 172
2011-12 349
PULVERISER S
Mills Planned For 2010 – 11& 2011 - 12
Type of Mill 2009 - 10 2010 - 11 2011 - 12
PGB Type 125 124 290
Conventional 14 45 59
Type
Ball Mills 6 3 0
Total 145 172 349

PULVERISER S
Mills Planned For 2010 – 11 & 2011 - 12
Type 2009 - 10 (Compl.) 2010 - 11 2011 - 12
XRP - 623 6 6 4
XRP - 803/703 8 39 51
XRP - 663 0 0 4
XRP - 883 7 11 38
XRP - 903 0 30 6
XRP - 943 0 0 48
XRP -1003 110 48 84
XRP - 1043 8 26 57
XRP - 1063 0 0 18
XRP - 1103 0 0 24
HP - 1103 0 9 9
HP - 1203 0 0 6
Ball Mills 6 3 0
Total 145 172 349

PROPOSED ACTION PLAN
* Procurement of partial quantity of

finished assemblies from competent
vendors.
• Dispatching of above assemblies as Direct
Dispatch (DD) items to customers.
• Enlarging vendor base having capabilities
to supply complete assemblies.
(arranging castings, fabrication,
machining, SD items procurement and
then assembling them as per drawings)
PULVERISER S
LOOSE AND SMALL ITEMS
* Allloose Fasteners required for each

type of mill are bunched together and
procured as sub-delivery direct
dispatch from the Vendor to Project
site under one specification.

PULVERISER S
LOOSE AND SMALL ITEMS

* Other loose and small fabricated
components are bunched together and
procured from regular subcontract
vendor as DD under one specification.
* With the implementation of above
actions the loose items would be reduced
from 120 to 30 numbers per project.

PULVERISER S
AUGUMENTATION IN SHOP
* To meet the shop capability of manufacturing around 150 mills,
following action plan is proposed.
- The middle bay will be dedicated to assembly of planetary gear
boxes and Journal assembly.
- Two nos. of Semi Gantry cranes of 10 ton capacity to be
installed for handling of small components.
- Gear box testing facility will be increased by installing one
more test bed with required accessories.

PULVERISER S
ADDITION
OF
NEW MACHINES
IN 51 SHOP

PULVERISER S
CNC HOR. BORING MACHINE

(SPINDLE DIA
100 MM)
M/S TOS, CZECH, / Cost Rs. 171 Lakhs
Commissioned on
27/02/2007.
CNC CYL GRINDING MACHINE

(φ 630 X 6000)
M/S GIORIA, ITALY, / Cost Rs. 318
Lakhs Commissioned on
06/07/2007.

PULVERISER S
CNC VER. LATHE ( φ6.0/ φ7 x 4.5 )

M/s
OM Ltd., JAPAN / Cost Rs.1764.0
Lakhs Commissioned on
06/11/2009.
CNC TRAV. COLUMN

DRILLING
M/s WEILER,
CZECH REPUBLIC / Cost.
378951 EU. Commissioned
on 01/10/2009.

PULVERISER S
CNC HOR. BORING MACHINE (SPI. DIA

200 MM) M/s
QIQIHAR, CHINA / Cost $ 3035014 USD
Commissioned on 29/04/2010
CNC VER. LATHE (2.5 M TABLE,

LIVE SPINDLE & C-AXIS)
M/s REM BACAU,
ROMANIA
Cost Rs.731.90 Lakhs /
Commissioning by Dec.2010

PULVERISER S
MACHINES APPROVED UNDER 15,000 MW

CAPACITY ENHANCEMENT
Sl.no. Machine Cost
1) CNC VTL 2.5 M TABLE DIA WITH Rs.731.9 lakhs
LIVE SPINDLE & C-AXIS.

(M/S: REM BACAU, ROMANIA)
2) CNC VTL 2.5 M TABLE DIA Rs. 601.9 lakhs

(M/S: REM BACAU, ROMANIA)
3) CNC GANTRY DRILLING Rs.1189 lakhs

MACHINE WITH MOVABLE
CROSS RAIL. DRILLING
AREA: 5300 X 10000 (M/S: JOBS, ITALY)

PULVERISER S
MACHINES APPROVED UNDER 20,000 MW

CAPACITY ENHANCEMENT
Sl.no. Machine Cost.

1)CNC Vertical Lathe of Rs.1579.96 lakhs
4.0 meters Table
2)CNC Horizontal Boring M/c Rs.554 lakhs
(Spindle Dia 130 mm)
3) 5T Semi Gantry Crane Rs. 27.5 lakhs
4)New Store (18M x 60M) & Rs. 385 lakhs
Electrical and Mechanical works
in the stores.

PULVERISER S
CNC VERTICAL LATHE (2.5 M

TABLE) M/s
REM BACAU, ROMANIA / Cost
Rs.601 Lakhs
Commissioning by Dec.2010
CNC DOUBLE COLUMN

DRILLING M/c
(M/s JOBS, ITALY) / Cost
Rs.1189.0 Lakhs /
Predispatch inspection by Nov
2010

PULVERISER S
CNC VERTICAL LATHE (4.0 M

TABLE DIA)
M/s REM MASINI UNELTE S.R.L,
ROMANIA / Cost Rs.
1579 Lakhs / Delivery By No
v 2011
CNC HOR. BORING MACHINE

(SPI. DIA 130 MM) M/s HMT
Limited, HYDERABAD
Cost Rs.368 Lakhs /
Delivery By Feb 2012

KEY
RESULTS
PULVERISERS FINANCIAL - OVER YEARS
With the abovePULVERISER
arrangements
S
Pulveriser Division
is confident
of meeting the customer schedule
Of supplying
349 mills
in the year
2011-12.
With the abovePULVERISER
arrangements
S
With the strategy and

Proper process plan
Pulveriser received
15 nos. of – 600 MW
orders with their
In-house developed
BHEL 280 mill

PULVERISERS

PULVERISER S
BUSINESS EXCELLENCE PROJECTS 2009-10
Sl.no. Project.
1) Cycle time reduction for PGB Assemblies.

2) Establishment of test bed facility for KMP 350
3) Establishment of KMP 350 machining of components and
Assembly
Planet carrier, Drive table, Flange bushing etc.
4) Outsourcing of complete assemblies of Sep. body and Air
inlet housing and converting into DDs.
5) Development of BHEL Varanasi for critical machining and
assembly of 623 and 803 components.
6) Fabrication of complete assembly of BHEL 280 Sep. body
and Air inlet housing.
7) Establishment of lubrication system procurement with complete items
including C&I for BHEL 280 mills and HP 1103 mills.

1. CNC HORIZANTAL BORING MACHINE ¢100 mm SPINDLE - COMMISSIONED ON 03.03.07
2. CNC CYLINDRICAL GRINDING MACHINE ¢630 mm x 6000 mm - COMMISSIONED ON 07.07.07
3. NC RORARY TABLE 4M x 4M FOR HORIZANTAL BORING M/C - COMMISSIONED ON 03.09.07
4. CNC INDUCTION HARDENING EQUIPEMNT - COMMISSIONED ON 0 10.10.07
5. GRIT BLASTING EQUIPMENT - COMMISSIONED ON
6. PAINTING & BANKING SYSTEM - COMMISSIONED ON
7. CNC VERTICAL LATHE 6M TABLE / TM SWING / 4.5M HT - ORDERED ON

M/S OM LTD.,
JAPAN
(PO.NO.M206P003
DTD 09.05.2006)
COMMG BY
MARCH 2009
8. CNC TRAVELLING COLUMN (SINGLE COLUMN) DRILLING MACHINE - ORDERED ON M/S
WEILER, CZECH
REPUBLIC
(PO.NO.M207P004
DTD.17.07.2007)
COMMG. BY
MARCH 2009
1. CNC HORIZANTAL BORING MACHINE ¢200 mm SPINDLE - ORDERED ON M/S QIQIHAR, CHINA,
(PO.NO. M207P006 DTD.27.10.2007)
INSPECTION COMPLETED, DEL.BY
31/12/08
2. PORTABLE UNIVERSAL RADIAL DRILLING MACHINE - COMMISSIONING BY FAB 2009
COMMISSIONED ON 27.09.2007
3. BAY EXTENSION (30 M X 168 M) - CIVIL WORKS UNDER PROGRESS
COMPLATING BY JAN.2009
MATERIAL HANDLING FACILITIES :
4. 8OT / 15T EOT CRANE - ITEM RECEIVED COMMISSIOIN BY
JAN.2009
JAN.2009
JAN.2009
7. 4OT CROSS TRANSFER TROLLEYS. 2 NOS - ORDERED ON M/S OVIS, HYD.,
(PO.NO. M207E034 DTD.28.07.2007)
DEL.BY 31/12/07, YET TO RECEIVE.
-
UNDER COMMISSIONING
8. TEST FACILITIES FOR PGB
1. CNC VERTICAL LATHE 2.5M TABLE WITH C-AXIS - PRICE BID OPENED, P.O. TO BE PLACED
& LIVE SPINDLE (EXCLUSIVELY TO MACHINE PLANET ON M/S. REM BACAU, ROMANIA (L1)
CARRIERS OF PGB)
2. CNC VERTICAL LATHE 2.5M TABLE - PRICE BID OPENED, P.O. TO BE PLACED
(FOR MACHINING ROTARY TABLES, PGB HOUSINGS ON M/S. REM BACAU, ROMANIA ( L 1)
AND BOWL HUBS ETC)
3. CNC GANTRY DRILLING MACHINE - TECHNICAL RECOMMENDATIONS

(FOR DRILLING FLANGE HOLES ON SEP BODIES, GIVEN, PRICE BID TO BE OPENED
SEP. TOPS, M.S. HOUSINGS, PGB HOUSINGS,
BOWL HUBS AND TUBE MILL SHELLS)
SCHEME-4 :
ENHANCING THE CAPACITY FROM 172 TO

217 MILLS TO MEET THE REQUIREMENT AS
PER XII PLAN PROJECTION (20,000 Mw)
SUBMITTED FOR CORPORATE APPROVAL.
PROPOSED
INVESTEMENT : Rs.9129 LAKHS
EMPLOYEES PARTICIPATION
• SHOP COUNCIL
•SAFETY COUNCIL
•QUALITY CIRCLES
•SUGGESTION COMMITTEE
•COMMUNICATION MEETINGS BY PRODUCT AND
SECTIONAL HEADS
•WORK CENTRE WORK SHOPS
EMPLOYEES DEVELOPMENT PLAN
• e map- trg. need identification.
•HRD ANNUAL TRG MANUAL

•TECHNICAL ,SKILL ORIENTED, IT BASED TRGS
•MANAGERIAL, BEHAVIOURAL,SUPERVISORY
•YMP,GMP,SMP AND TOP MGMT TRG.
•PRODUCT LEVEL AND FUNCTION LEVEL TRG
COORDINATORS
ROOT CAUSE ANALYSIS (RCA)
 FORTNIGHTLY MEETINGS CONDUCTED IN PULV ENGG. DEPT.
 PRESIDED BY AGM(ENGG.)
 NO. OF MEETINGS HELD SO FAR: 12

 NO. OF QUALITY RELATED ISSUES RESOLVED: 5
 ACTION PLAN DRAWN ON 9 AREAS BASED ON
CUSTOMER FEEDBACK WITH ROOT CAUSE ANALYSIS
AND TARGET DATE FOR IMPLEMENTATION
 REVIEW MADE IN PRODUCT QUALITY MEET

CII Hyd Pulveriser Presentation 26.10.10

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CII Hyd Pulveriser Presentation 26.10.10

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ORGANISATION

Pulv.Engg. , Tech., BDG & CES Pulveriser Operation

Pulverisers Commercial Pulveriser Purchase

AREA EXECUTIVES SUPERVISORS ARTISANS & TOTAL

PRODUCTION 23 43 211 277

Pulverisers are employed to

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

• IN THE 70’s BHEL ENTERED INTO COLLABORATION WITH M/s COMBUSTION

XRP 623 (18 TPH) TO BHEL280 MILL (91 TPH)

• LOW SPEED – BALL TUBE MILLS.

BBD 3448 (35 TPH), BBD 4760 (90 TPH),

GRINDING MEDIA SCREW

II. BALL TUBE MILL

MILL SIZE BASE CAPACITY

TUBE MILLS BBD- 4772 5 NOS

BOWL MILLS XRP-1003 10 NOS

BOWL MILLS BHEL- 280 8 NOS

660 MW HP-1103 7-9 NOS

800 MW HP-1103 8-10 NOS

1000 MW HP- 1203 8-10 NOS

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

• NEW ENGINEER TRAINEE IS SENT TO SITE

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

BHEL 280 MILL

XRP 1003/903/883 WITH

BOWL MILLS FOR STEEL PLANT

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

• TO IMPROVE THE PERFORMANCE OF GRINDING ELEMENTS WITH

• IN 90’S Hi-CHROMIUM INSERT TYPE GRINDING ROLLS WITH

• FURTHER, SINTERED CARBIDE ROLLS ARE DEVELOPED ALONG

• WITH THIS, THE OUT PUT OF THE MILL IS ALMOST UNIFORM

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

• TALL TOP CLASSIFIER PROVIDED FOR BETTER

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

DEVELOPMENT FOR HSE

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

• Gears are made of hardened special steel material. Hence

• Easy to replace. Hence, the gear box can be taken out to

• Less down time of the mill for maintenance of Gearbox.

• Less Lube oil requirement (from 3000 ltr to 1100 lr/Mill-

• Weight Reduced from 60 Tons to 33 Tons

• Mill drive assembly with worm gear set has efficiency of

• Planetary gear box has efficiency of 95%.

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

WORM GEAR BOX

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

Bevel gear stage

PLANETARY GEAR BOX

• DYNAMIC CLASSIFIER DEVELOPED

• HENCE, NOW PROCURING SPRINGS WITH 20,000 LBS/INCH

• THERE IS LESS VIBRATION DUE TO HIGHER LIFT OF THE SPRING

• THIS ALSO RESULTED IN LESS COST OF THE SPRINGS DUE TO

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

 “PULVERISERS: DEVELOPMENTS AND THE O&M

 GUEST LECTURE ON “PULVERISERS” AT NATIONAL

Cost Reduction syndicated (IL-3) 19

Cost Reduction syndicated (IL-3) 36

Level 1 Level 2 Level 3 Total

OLD BOWL HUB-wt NEW BOWL HUB- wt

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)

SECTIONAL VIEW OF CARBIDE INSERTS

हमारी दृष्टि - ग्राहक संतुष्टि (Our Vision - Customer Satisfaction)