final report - kisan

CENTRALISED STRUCTURAL CATALOGUE MANAGEMENT

IT Solutions & Services

A REPORT

ON

CENTRALISED STRUCTURAL CATALOGUE

MANAGEMENT

BY

E.KISAN 2008A4394G

AT

BHARAT HEAVY ELECTRICALS LIMITED

TIRUCHIRAPALLI

A Practice School – I station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE,

PILANI

(JULY, 2010)



A REPORT

ON

CENTRALISED STRUCTURAL CATALOGUE

MANAGEMENT

BY

E.KISAN 2008A4394G

B.E.(Hons) Mechanical Engg.

Prepared in partial fulfillment of the

Practice School – I course No.

BITS GC221

AT

BHARAT HEAVY ELECTRICALS LIMITED

TIRUCHIRAPALLI

A Practice School – I station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE,

PILANI

(JULY, 2010)



ACKNOWLEDGEMENT

I would like to express my gratitude to Mr. A.V. Krishnan, Executive

Director, BHEL, Tiruchirapalli who has given me this opportunity to do my

practice school in this company.

I wish to thank Mr. K. Chandrasekaran, AGM – HRDC and coordinator

of the PS programme in the organization and Mr. Narayan Doss, Senior

Manager – HRDC who has allowed me to do project work in BHEL.

I would like to express my sincere gratitude to Mr. M. S. Ramesh, SDGM,

ITS&S and Ms. N. Bhagyalakshmi, Dy. Manager, ITS&S for their timely

help and valuable suggestions which has encouraged me during the course

of this project.

I am in debt to express my gratitude to Mr. Tamilsevan.T, Assistant

Engineer II, ITS&S for his constant guidance and help rendered throughout

the course of the project.

Lastly, I would like to thank Dr. P. Srinivasan, PS instructor at BHEL,

who has been a constant moral support and guidance throughout the course

of practice school.



BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

PILANI (RAJASTHAN)

Practice School Division

Station: Bharat Heavy Electricals Ltd. Centre: Tiruchirapalli

Duration: 54 days Date of Start: 24/05/2010

Date of Submission: 15/06/2010

Title: Centralized Structural Catalogue Management

Names of Experts Designation

Tamilselvan T. Asst. Engineer Gr.II

Name of the Student ID No. Discipline

E.kisan 2008A4PS394G B.E.(Hons)MechanicalEngg.

Name of PS Faculty: Dr. P. Srinivasan

Key Words: PDMS, SQL, VISUAL BASIC, CATALOGUE

MANAGEMENT AND ORACLE DATABASE.

Abstract: A brief overview of BHEL, and its various departments. A

detailed description to structural catalogue management software for oracle

database is given.

Signature of Student Signature of PS Faculty

Date: 16/07/2010 Date: 16/07/2010



TABLE OF CONTENTS(PART A)

1. BHEL ……………………………………2

1.1 OVERVIEW………………………….2

2. BHEL:TIRUCHIRAPALLI………………3

2.1 INTRODUCTION……………………3

2.2 PRODUCT PROFILE………………..4

3. SEAMLESS STEEL TUBE PLANT……..8

4. TUBULAR PRODUCTS SHOP…………12

4.1 INTRODUCTION…………………….12

4.2 PRODUCTION……………………….12

4.3 SAFETY………………………………14

5. VALVES DEPARTMENT………………..15

5.1 MANUFACTURING FACILITIES….15

5.2 PRODUCTS…………………………..16

5.3 SERVICES……………………………17

5.4 CUSTOMERS………………………...18

6. CCDP……………………………………...19

6.1 IGCC………………………………….19

7. ITS&S……………………………………..25

7.1 INTRODUCTION…………………….25

7.2 ITS&S WORK PROFILE……………..26

8. WRI………………………………………...28

8.1 INTRODUCTION…………………28

8.2 SERVICES…………………………29

8.3 FACILITIES………………………30

9. PRESS AND DRUM SHOP……………...32



1.BHARAT HEAVY ELECTRICALS LTD (BHEL)

1.1 OVERVIEW

Bharat Heavy Electricals Limited (BHEL) is largest engineering and

manufacturing enterprise in India in the energy related and infrastructure

sectors today. BHEL‘s Vision: BHEL‘s vision is to become a world class

engineering enterprise, committed to enhancing stakeholder value.

BHEL manufactures over 180 products under 30 major groups. BHEL

isequipped with 14 manufacturing divisions, 4 power sector regional

centres, 8 service centres, 18 regional offices and a large number of

project sites. BHEL‘s products meet the international standards and retain

accreditations from world‘s quality certifying firms. In more than 45

years of its existence, BHEL has installed equipment for over 1, 37,000

MW of power generation, for utilities, captive and industrial users. BHEL

supplied over 2, 00,000 MVA transformer capacity and sustained

equipment operating in transmission and distribution network up to 400

kV-AC & DC. Over 25,000 motors with drive control system, more than

900 electrostatic precipitators and one million valves have been supplied

by BHEL to Power projects, petro chemicals, refineries, Aluminium,

Fertilizer, cement and paper plants. BHEL also supplied traction electrics

and AC/DC locos to power over 12,000kms of railway network in India.

The greatest strength of BHEL is its highly

skilledand committed 44,000 employees. Every employee is given an

equal opportunity to develop himself and improve his position.

Continuous training and retraining, career planning, a positive work

culture, participative style of management have engendered development

of a committed and motivated work force leading to enhanced

productivity and higher levels of quality.



2. BHEL:TIRUCHIRAPALLI

2.1 INTRODUCTION

The High Pressure Boiler Plant of the Bharat Heavy Electricals Limited

was setup in 1963 for the manufacture of High Pressure Boilers. The plant

achieved its full annual capacity to design manufacture and supply high

pressure boiler equipmentupto 4000 MW in 1984 with boiler unit ratings

up to 500 MW. BHEL, Tiruchi has over the years seen formidable growth in

capacity, capability, turnover and profitability. Product diversification has

resulted in the development of new products enabling BHEL to absorb modern

technologies. Such innovations result in continuous updation of manufacturing

facilities to serve the customers in a more comprehensive way and for

improving quality and productivity.

BHEL, Tiruchi has added to its High Pressure Boiler Plant (HPBP), a

Seamless Steel Tube Plant (SSTP) at Tiruchirappalli (adjacent to the HPBP), a

Boiler Auxiliaries Plant (BAP) at Ranipet (in the state of Tamil Nadu), a

Piping Centre (PC) at Chennai in Tamil Nadu and an Industrial Valve Plant

(IVP) at Goindwal (in the Northern state of Punjab). HPBP and SSTP are spread

over 2908 acres of land at Tiruchi and BAP over 1256 acres at Ranipet. HPBP

and SSTP have a covered shop area of 2,50,000 square meters and BAP Ranipet

has 47,000 square meters of covered shop area.

2.2PRODUCT PROFILE

UTILITY BOILERS

For power generation applications, BHEL designs, engineers, manufactures,

supplies, erects and commissions boilers of any rating upwards of 30MW.For

higher capacities, BHEL also offers customers the option of Once-Through

http://www.utilityboiler.com/



http://www.bheltry-spares.com/hpbp.htm

http://www.bheltry-spares.com/seam.htm

http://www.bheltry-spares.com/auxilary.htm



type steam generators in addition to conventional natural and controlled

circulation types.

INDUSTRIAL BOILERS

BHEL supplies steam generators of rating up to 450 ton/hr for industrial

applications to suit the requirements of industries...

Fertiliser

Petrochemical

Refinery

Steel

Paper

Other process industries

CFBC boilers

BHEL manufactures state-of-the-art Circulating Fluidised Bed Combustion

(CFBC) boilers in collaboration with LurgisLentjesEnergietechnikGmbh

(LLB), Germany. LLB's rich experience and numerous installations

worldwide

BHEL CFBC boilers - Special design features

Simplified fuel preparation equipment eliminating sophisticated and

maintenance-prone pulverizing equipment.

Recycling hot cyclone for effective separation of solid particles

which are returned to the combustor.

Special Fluidised Bed Heat Exchanger (FBHE) - patented design -

for effective utilisation of Energy in hot recycled solid particles.

Higher boiler efficiency even on part loads due to better



burnability.

Excellent operational flexibility - part load down to 25% MCR - and

ideally suited for wide load fluctuations.

Compact plant design.

No heat transfer surfaces in erosion prone combustor zone.

Independent Reheat temperature control.

AFBC BOILER

BHEL is the pioneer in Atmospheric Fluidised Bed Combustion (AFBC)

technology - bubbling bed type - in India with a proven track record based on

extensive in-house R&D for better utilization of existing energy sources.

BHEL's AFBC Boilers - Unique Design Features

Specially developed fuel feeders and feeding system to handle even

fuels with high moisture content

Unique and simple protection feature for bed swept surfaces

Innovative oil-fired start-up system, relatively free from manual

intervention which ensures trouble free unit start up

Simpler operation

Versatility in application

HeRECOVERY STEAM GENERATORS

Technology Highlights

World-class technology

High heat recovery efficiency

Optimised design



Modular construction

Environment friendly

ADVANCE TECHNOLOGY PRODUCTS

Advanced Technology Products Department in BHEL, Tiruchy is

having main business with the various institutions / organisations under

Department of Atomic Energy, Government of India viz. Nuclear Power

Corporation of India Ltd. (NPCIL), Bhabha Atomic Research Centre (BARC),

Indira Gandhi Centre for Atomic Reasearch (IGCAR), Institute for Plasma

Research (IPR), Heavy Water Board, etc.

Advanced Technology Products Department in BHEL, Tiruchy is

having main business with the various institutions /organisations under

Department of Atomic Energy, Government of India viz. Nuclear Power

Corporation of India Ltd. (NPCIL), Bhabha Atomic Research Centre (BARC),

Indira Gandhi Centre for Atomic Reasearch (IGCAR), Institute for Plasma

Research (IPR), Heavy Water Board, etc.



3. SEAMLESS STEEL TUBE PLANT

The BHEL Seamless Steel Tube Plant (BHEL – SSTP) was set up in 1979, with

the equipment supplied by M/s Mannesmann Demag Meer of Germany, the

world leader in this field.

BHEL – SSTP manufactures Seamless Steel Tubes of world standards, catering

to the needs of a wide spectrum of customers from power stations,

petrochemicals, oil & gas exploration, automobiles, refineries, sugar industries,

textiles, etc.

BHEL – SSTP has most advanced facilities for the manufacture of seamless

steel tubes and pipes – both hot-finished and cold-drawn-in carbon and low

alloy steel grades. BHEL – SSTP offers seamless steel tubes and pipes in a

wide range of sizes with outer diameter ranging from 19mm to 133mm and wall

thickness from 2mm to 12.5mm.

An additional range of specialized applications...

BHEL – SSTP also has advanced facilities for the manufacture of import

substitute spiral finned tubes which have extended surface area designed for

maximum heat recovery.

The plant has also developed the manufacture of rifled tubes. BHEL‘s High

Pressure Boiler Plant manufacture studded pipes.

Towards ever shorter delivery periods

BHEL –SSTP stocks various grades of raw materials to meet short delivery

periods.

Meeting International Specifications…



At present, BHEL – SSTP manufactures Seamless Steel Tubes and Pipes to the

Following Specifications:

ASME SA53,106,179,192,209,210,213,333,334,335

BS 3059

DIN 2391

GOST API (Line pipes)

Seamless steel tubes and pipes can be supplied in random or fixed lengths. Edge

preparation is also done if it is required by the customer. BHEL-SSTP also

ensures adherence to the respective standards and cater to specific customer

requirements.

A WIDE RANGE OF APPLICATIONS

BHEL Seamless steel tubes are extensively used in power stations, marine

boilers, refineries and for oil & gas exploration applications besides industries

such as petrochemicals, fertilizers, textiles, automobiles, paper, sugar, etc.

BHEL Seamless cold – drawn low-carbon-steel heat exchanger tubes are used

for a variety of heat transfer applications.

SEAMLESS STEEL TUBES AND PIPES (APPLICABLE

SPECIFICATIONS)

Specification Grade Title

ASME SA

106

A,B,C Seamless carbon steel pipes for high

temperature services

SA 179 Seamless cold drawn low carbon steel

heat exchanger and condenser tubes

SA 192 Seamless carbon steel boiler tubes for

high pressure service.

SA210 A1,C Seamless medium carbon steel boiler and

super heater tubes.

SA209 T1 Seamless carbon-molybdenum alloy steel

boiler and super heater tubes.



Length :Random lengths ranging from 4 to 12 meters. Fixed lengths can also be

supplied on specific request.

Ends : Square cut or beveled as per standards/customers requirements.

SPIRAL FINNED TUBES (RANGE OF MANUFACTURE)

SA213 T2, T5,

T11,T12,T22

Seamless ferritic and austenitic alloy

steel boiler, super heater and heat

exchanger tubes.

SA333 1,6 Seamless and welded steel tubes for low

temperature applications.

SA334 1,6 Seamless and welded carbon alloy steel

tubes for low temperature applications.

SA335 P1,P2,

P5,P11, P12,

P22

Seamless ferritic alloy steel pipes for

high temperature applications.

BS 3059 320,360,

440,660,622

Steel boiler and super heater tubes.

DIN 2391 ST35,ST45,

ST53

Seamless precision steel tubes.

GOST 20,12xIM Ø Seamless steel pipes for stream boilers.

API 5L A,B,X42,X46,

X52

Line pipes

WELD High Frequency Resistance

Weld

Material for Tube/Fin Carbon steel, Alloy steel,

Stainless steel

(Any combination)



4.

Tubular Products Shop

4.1 INTRODUCTION

The tubular shop is one of the strong-holds of the production in BHEL Trichy.

Its contribution, among others, has ensured that around ¾ of the power

generated in India is backed by BHEL products.

4.2 PRODUCTION:

This plant produces the tubes which are to be used in the boilers for converting

water into steam by using the heat energy available in its environment inside the

boiler. There are different types of tubes produced here of various diameters,

lengths, shapes, etc.

Based on the operating conditions in the tube w.r.t different

phases the tubing system is divided into three different types.

Economizer: Water from the pump enters the boiler and sensible heat

addition takes place here. Water is converted into saturated liquid. For

this purpose, coil is an appropriate structure.

Water-wall Tubes: From the economizer, water moves to the drum which

separates steam and water. Water goes into the water-wall, which

acquires heat from the furnace and rises the steam into the drum. The

structure is in form of panels.

Fin Types Solid fins/Serrated fins

D – Diameter 19.1 mm to 114.3mm

t- Wall Thickness 2.4mm to 9.5mm

Fin thickness 1.0 mm to 2.0 mm

H – Fin height 12.5mm to 25.0 mm

P-Fin pitch 40 to 280 per meter

L1-Length (Total) 3000 mm to 20000 mm

L2- Length(Finned) 2500mm to 19500 mm



Super-heater: The steam isolated from the drum is passed into the

different super-heater coils for sensible heat addition to required

temperature.

Also the tubing system varies as per the requirements at the

worksite. This requires the production of various types of tubes like

Panels: Tubes running in parallel connected by fins.

Two types: Fusion Welded Panels (FWP) or Flat Fin Welded

Panels (FFWP)

Coils: A number of tubing components are in the form of coils, viz.

economizer coils, Low Temperature Super-Heaters (LTSH), Platen

Super-Heaters, Final Super-Heaters, and Re-Heaters.

Connecting tubes produced may be Upper Connecting Tubes, Lower

Connecting Tubes, etc.

TheTubes produced here are hollow cylinders with length much greater than

diameter, and bore not more than 76.1 mm, that which involves in heat as well

as mass transfer, as per ASME definitions. Tubes are used in Boilers for

converting water into steam.

The Tubular Products Shop of BHEL, Trichy, uses Carbon

Steel (SA210A1, SA191, and SA106GRB), Low Alloy Steel, High Alloy Steel,

and Stainless Steel for the manufacturing of tubing components. It imports

ready-made tubes of the materials T92 (from Germany) and P23 (from Japan)

for production of 660 and 800 MW boilers, as the Seamless Steel Tube Plant is

not capable of manufacturing tubes from these materials.

Also the production here includes various types of processes

Edge Preparation: The process is called Automatic Tube Cutting and

Edge Preparation (ATCEP). Annually, 465,000 ends are prepared.

Straight Tube Butt welding: (STB) involves welding of 180,000 joints,

annually.

Roto-blast: This is a process before longitudinal welding is performed to

remove the surface coatings of tubes, and the scale is 1,185,000 pass

meters.

The annual production of the tubular plant is nearly 40,000

tones with each 500 MW boiler consists of 2,777 tones of tubes.



SAFETY

As BHEL is an ISO authorized company, the production process here in the

tubular plant are governed by the environmental and health management

standards. Other regulations in the production include ASME (American

Society for Mechanical Engineers) and IBR (Indian Boiler Regulation).

Because of BHEL‘s huge domination over the Power-

Generation Market, the Tubular Shop is reported to have enough orders

(~Rs. 22,000 Cr.) to last three years of production. It has a customer base of

Indian as well as foreign institutions. Its foreign customers include Libya,

Sudan, Malaysia and Egypt among others.



5.VALVES DEPARTMENT

5.1MANUFACTURING FACILITIES

20,000 SQ.M Area of covered Manufacturing Shops with state of art

CNC machine and general purpose machine.

Dedicated hydraulic testing stations with capacities upto 15000 psi

Steam and air testing facilities for safety and safety relief valves

Supported by well equipped analytical, metallurgical and non

destructive examination facilities.

Quality assurance services are backed by a team of qualified scientists

equipped with sophisticated instruments like spectroscopes, high

magnification microscopes, X-ray diffraction strain gauges and

fatigue and creep testing machines.

Non destructive testing facilities use x-rays up to 400 KV and

Isotopes up to 800 curies and magnetic particle inspection is by most

sensitive wet method.

Precision gauges, tools and instruments are calibrated at BHEL's

Nationally accredited calibration centre.

Well trained and experienced man power of 1250 employees.

BHEL High pressure cast steel valves and Quick closing non return

valves are manufactured with technology from TOA valve company

(Japan), Forged steel Valves, safety, safety relief and Y-type valves

with technology from Dresser Industries Inc-(USA), Oilfield

equipment with technology fromKVaerner National (USA), HP-LP

Bypass Systems with technology from SulzerThermtec (Switzerland)

and soot blowers with technology from Copes - Vulcan (USA).



5.2 PRODUCTS

Gate, Globe & Non-Return Valves

1. Forged Steel Valves

2. Cast Steel Bolted Bonnet Valves

3. Cast Steel high pressure valves (Oil Field equipment)

Oil Field Equipments

1. Well Heads and X-mas trees

2. Full Bore Valves

Safety Valves

Safety Relief Valves

Electrical Relief Valves

Quick Closing Non-Return Valves

Cold re heat line non return Valves

HP & LP By-Pass System

Soot Blowers

1. Long retractable soot blower

2. Wall deslagger

3. Rotary soot Blower

4. Furnace Temperature probe

Silencers (Steam Vent & ejector type)

Other Products

1. Direct Water level gauge

2. Reheater Isolating device

5.3 SERVICES

http://203.129.195.106/valves/Gate_Globe.jsp

http://203.129.195.106/valves/Oil_field.jsp

http://203.129.195.106/valves/Safety_valves.jsp

http://203.129.195.106/valves/safety_relief.jsp

http://203.129.195.106/valves/electrical_relief.jsp

http://203.129.195.106/valves/Cold_reheat.jsp

http://203.129.195.106/valves/HP_LP.jsp

http://203.129.195.106/valves/Soot_Blowers.jsp

http://203.129.195.106/valves/Silencer.jsp



Specially trained and experienced service team to service Valves and allied

equipment at

Power Plants

Process Plants

Onshore and Offshore Platforms.

Specialized tools developed for

Insitu repair of seats and seat rings in Gate, Globe, Check, Safety and

Safety Relief valves.

Services Include

Refurbishing of Seat surfaces

Servicing of Jammed Valves

Setting of Actuators

5.4 CUSTOMERS

INTERNATIONAL

TOA Valve Co., Japan

Dresser Ind.Inc., USA

Alstom Power USA

Tyco Flow Control USA

Yarway

Corporation USA

PT

SaranaAdikariyaUt

ama

Indonesia



PT South Pacific

Vis Indonesia

DOMESTIC

Petrochemicals

Sugar Plants

Neyveli Lignite Corporation

Cement Plants

Paper and Pulp Industries

Aluminium Plants

BPCL

Nuclear Power Corporation

Reliance Industries Limited

6. COMBINEDCYCLE DEMONSTRATION PLANT

6.1 Integrated Gasification Combined Cycle [IGCC]

What is an IGCC power plant?

An Integrated Gasification Combined Cycle (IGCC) power plant

combines a gasification system with a modern, highly efficient ―combined

cycle‖ electric power system (consisting of one or more gas turbines integrated

with a steam turbine). IGCC power plants are successfully operating worldwide

and have been operating commercially in Indiana and Florida for more than a

decade. Clean syngas is combusted in high efficiency gas turbines to produce

electricity. The excess heat from the gasification reaction is then captured,

converted into steam, and sent to a steam turbine to produce additional

electricity. The gas turbines can be operated on a backup fuel such as natural

gas during periods of scheduled gasifier maintenance or can co-fire the backup

fuel to compensate for any shortfall in syngas production.

Two Cycles involved in the IGCC

Combined cycle process combines two thermodynamic cycles namely

Rankine cycle and Brayton cycle



a) Rankine cycle:

The Rankine cycle is a thermodynamic cycle used to generate electricity in

many power stations, and is the real-world approach to the Carnot cycle.

Superheated steam is generated in a boiler, and then expanded in a steam

turbine. The steam turbine drives a generator, to convert the work into

electricity. The remaining steam is then condensed and recycled as feed-water

to the boiler. A disadvantage of using the water-steam mixture is that

superheated steam has to be used; otherwise the moisture content after

expansion might be too high, which would erode the turbine blades.

This cycle generates about 80% of all electric power used throughout the

world.

Physical layout of four main devices used in Rankine cycle

Ts diagram of a typical Rankine cycle operating between pressures of

0.06bar and 50bar

b) Brayton cycle:

The Brayton cycle is a thermodynamic cycle that describes the workings of

the gas turbine engine, basis of the jet engine and others. It is named

after George Brayton , the American engineer who developed it, although it was

http://en.wikipedia.org/wiki/George_Brayton

http://en.wikipedia.org/wiki/Engineer



originally proposed and patented by Englishman John Barber in 1791. It is also

sometimes known as the Joule cycle

A Brayton-type engine consists of three components:

A gas compressor

A mixing chamber

An expander

Gas turbines – IGCC

In IGCC — where power generation is the focus — the clean syngas is

combusted (burned) in high efficiency gas turbines to generate electricity with

very low emissions. The turbines used in these plants are derivatives of proven,

natural gas combined-cycle turbines that have been specially adapted for use

with syngas. For IGCC plants that include carbon capture, the gas turbines must

be able to operate on syngas with higher levels of hydrogen. Although modern

state-of the- art gas turbines are commercially ready for this ―higher hydrogen‖

syngas, work is on-going in the United States to develop the next generation of

even more efficient gas turbines ready for carbon capture-based IGCC.

Heat Recovery Steam Generator (HRSG) – IGCC

Hot gas from each gas turbine in an IGCC plant will ―exhaust‖ into a heat

recovery steam generator (HRSG). The HRSG captures heat in the hot exhaust

from the gas turbines and uses it to generate additional steam that is used to

make more power in the steam turbine portion of the combined-cycle unit.

Steam turbines – IGCC

In most IGCC plant designs, steam recovered from the gasification

process is superheated in the HRSG to increase overall efficiency output of the

steam turbines, hence the name Integrated Gasification Combined Cycle. This

IGCC combination, which includes a gasification plant, two types of turbine

generators (gas and steam), and the HRSG is clean and efficient — producing

NOx levels less than 0.06lb per MMBtu (coal input basis) and combined cycle

efficiencies exceeding 65% when process steam integrated from the

gasification plant is included. Another example of the ―integrated‖ design in the

http://en.wikipedia.org/wiki/John_Barber_%28engineer%29

http://en.wikipedia.org/wiki/James_Prescott_Joule

http://en.wikipedia.org/wiki/Engine



fully integrated IGCC is the IGCC gas turbine, which can provide a portion of

the compressed air to the oxygen plant. This reduces the capital cost of the

compressors while also decreasing the amount of power required to operate the

oxygen plant. Additionally, gas turbines use nitrogen from the oxygen plant to

reduce combustion NOx as well as increase power output.

Advantages of IGCC

According to the Environmental Protection Agency, the higher

thermodynamic efficiency of the IGCC cycle minimizes CO2 emissions

relative to other technologies

IGCC plants offer today‘s least-cost alternative for capturing CO2 from a

coal-based power plant. In addition, IGCC will experience less of an

energy penalty than other technologies if carbon capture is required.

While CO2 capture and sequestration will increase the cost of all forms of

power generation, an IGCC plant can capture and compress CO2 at one

half the cost of a traditional pulverized coal plant.

Other gasification based options, including production of motor fuels,

chemicals, fertilizers or hydrogen, to name a few, have even lower carbon

capture and compression costs. This will provide a significant economic

and environmental benefit in a carbon constrained world.

IGCC – BHEL’s approach

1. Fixed Bed Gasifier

6.2 MWe IGCC commissioned in 1989

Fed about 1,000,000 units of power to TNEB grid

Limitations of fixed bed gasification

It consists of internal moving parts with higher degree of

mechanical complexity for pressurized operation

Lowest capacity per square meter of gasifier area

Sized coal above 6mm is required and fines may be deposited off or

handled separately too much variation in size , will lead to

channelling , clinkering and incomplete gasification of bigger sizes

The product gas contained tar, oil, phenols and coal fines. More

complicated clean up system is required to obtain cold clean gas.

Low temperature precludes heat recovery.

Control of temperature below ash fusion point is required to avoid

clinkering

High start up time is required



2. Fluidized Bed Gasifier

18 TPD PFBG - BHEL Corp. R&D, Hyderabad, commision, 1993

150 TPD PFBG - BHEL – CCDP, Tiruchy, commission – 1997

Series of trial operations being conducted since 1997

IGCC mode power generation demonstrated – march /june .1998

Advantages of Fluidized Bed Gasifier

Higher unit capacity

No tar or oil formation and easy gas cleaning

No liquid effluent formation

ability to accept finer coals

Best suited for high ash indian coals

3. BHEL ,Trichy PFBG IGCC Demo power plant

After the successful development of moving bed gasifier

technology under the CCDP programme, BHEL embarked on pressurised

bed gasification (PFBG) technology. Recognizing the opportunity to

generate electricity in an efficient and environment –friendly manner,

ICICI – India‘s leading financial institution – supported the PFBG Project

through the programme for Accelerated Commercial Energy Research

(PACER) under the US-AID programme.

Utilizing all the infrastructural facilities created by BHEL under its

CCDP programme, Asia‘s first IGCC plant, the 150 tonnes per day

pressurised fluidized – bed gasification system was designed, fabricated,

erected and commissioned indigenously.

The fluidized-bed gasifier is a refractory-lined vessel. The air and

steam mixture and coal are introduced through a conical distributor

located at the bottom of the gasifier.

The entrained ash and unburnt carbon particles are separated by the

cyclones in series. The carbon recycle is effected from cyclones using

coal gas. The coal gas at the exit of the third cyclone is cooled from

9000C to 540

0C in heat recovery boiler (HRB). The gas is further cooled

to 3700C in the gas cooler while superheating steam is utilized in the

gasification process and the rest expands in the steam turbine to generate

about 2.2MWe. The gas is further processed through the downstream in

the gas clearing system of the moving bed gasifier and admitted to the gas

turbine at 900C to generate 4.0 MWe.

A portion of the clean gas is compressed in the gas booster and is

utilised for fly-ash recycle in the cyclones and for the pressurization of

fly-ash locks and HRB lock.



7. INFORMATION TECHNOLOOGY AND SERVICES (ITS&S)

7.1 INTRODUCTION

The IT Solutions and Services department of BHEL, Trichy, commonly known

as just ITSS, plays a vital role in the smooth functioning of the whole

organization. Housed in the centre of the BHEL campus, it provides services

which are essential in both the manufacturing arm of BHEL as well as its day –

to – day functioning.

ITS&S focuses on providing services to meet the current needs of the

organization as well as devising new solutions for problems in its current and

future projects, in order to optimize the undertaken production work.

Its work can be summarized as follows:

- Developmental

Plant Modeling

Web – based Documentation Management System

Engineering Automation / Cycle time reduction

- Services

Updating and Maintaining Central Archives

O&M Manual Preparation

Standards

7.2 ITS&S Work Profile: An Outline

1) Plant Modelling

The three dimensional designing of power plants and processes is known as

plant modelling. It can be used to design any type of plant, from petrochemical



plants, offshore platforms, chemical and pharmaceutical plants, to power plants,

waste water treatment plants and cogeneration facilities. It has many

advantages, like being able to conduct strength and temperature analysis on

each component, or on the whole plant.

1.1) Need for Plant Modeling

Plant modeling of a power plant gives the visual representation of a

power plant and also helps to detect any interferences, clashes etc; before

any plant gets erected.

It reduces the total cost incurred as well as the total cycle time.

1.2) Software used by BHEL for Plant Modeling

PDS (Plant Design System) – Used earlier

PDMS (Plant Design Management System) – Used Now

PDMS – An Overview:

PDMS(Plant Design Management System) is a 3-D plant modeling

software package supplied by AVEVA Inc.(a UK based software

company).

It can be used to create three dimensional plant and equipment

models, extract isometric drawings and perform design interference

checks and detect equipment clashes.

The major disciplines of PDMS are :-

a) Equipment Modeling

b) Pipe Routing

c) Structural Support Modeling

d) HVAC modeling

2) Systems Work undertaken by ITS&S

Dolphin – Web-based AMS

– Reliable Storage of Drawings, Search on ANY Drawing attribute, Mail

notifications, Info Desk, PDF Download

– 8.75 Lacs Drawing Images of FB, FBC&HRSG, Valves, ATP are

managed through Dolphin. [Apart from this All the Old GMS Sheets –



numbering over 70 lakh have been scanned providing instant access to

past records]

O&M Management System

– A comprehensive system to Input, Index, Monitor, Compile andPrint

O&M Manuals

e-Filer, i-Vault

– Features – Secure File storage in SAN (on both primary andsecondary

sites)

– Titles, Key words and other attributes stored in secure database with

individual user accounts and authentication

Quest – Engineering Information Portal

– The KM content gateway for Engineering with access to Standards,

Other Engineering Documents, Technical Collaboration content, Tools

for KM Circle generated content and KM Administration

Library Digitization initiatives

– 10,500 technical journal articles have been digitized and stored in

electronic form via ‗Journal Management System‘ with easy search

capability.

–About 1100 reports of different departments have been digitized and

stored in ‗Ivault‘ for online reference.

–Implementation of ‗E-filer‘ system has led to complete elimination of

hard-copy office correspondance.



8.WELDING RESEARCH INSTITUTE (WRI)

8.1 INTRODUCTION

Welding Research Institute (WRI) was established in November 1975by

Government of India with UNIDO and UNDP assistance under the

management of Bharat Heavy Electricals Limited , Tiruchirappalli , India.

WRI has been constantly interacting with world renowned institutions for

updating the knowledge base on latest technologies and assimilating

experience.This Institute has been established to cater to the welding needs of

the Indian welding industries and for contributing to the growth of welding and

allied technologies.

The major activities of the Institute include

Research and Developement on various welding processes and

technologies

Metallurgical investigations

Dissemination of knowledge in welding

Consultancy services

The Institute has the following recognitions to its credit

Recognized by Bureau of Indian Standards (BIS) for testing of

welding electrodes

Authorised by Indian Boiler Board (IBR) for training and certification

of welders

Recognizedcentre for research studies by IIT - Chennai, IISc,

Bangalore, NIT- Tiruchirappalli and PSG - Coimbaotre.

8.2 SERVICES



Welding Research Institute, has successfully completed number of consultancy

projects for various customers, in the field of equipment development,

consumable & power source testing, process & technology development,

metallurgical investigation, repair and reclamation, distortion control,

structural integrity analysis, remnant life estimation, condition assessment etc.

About 2300 consultancy services have been completed for 120 organisations

covering Heavy Engineering, Power, Petro-Chemical, Transport, Metal

Processing, Defence, Space, Oil, Ship Building, Consumable & Welding

equipment, Electronics industries etc.

Annual Consultancy Contract Scheme(ACCS)

Privileged Industrial Member Enterprise(PRIME)

8.3 FACILITIES

WRI is well equipped with welding and testing facilities under one roof. Some

of the unique facilities are listed below:

Testing Facilities



1. Mechanical Testing

Universal Testing Machine - 600kN

Micro hardness tester – 50gm–1 kg load

Impact Tester - 406 Joules

Pellini drop weight tester–41 kgs

Instron 8502 servo hydraulic - 250 kN

Instron 1603 EMR type - 100 kN

Instron 1276 servo hydraulic - 1000 kN

2. Metallurgical Testing

Scanning Electron Microscope – 200,000 X

Light Optical Microscopes – 1600 X

Differential Interference Contrast microscope – 1000 X

In-situ metallographic Polishing kit

3. Stress Analysis

X-ray Stress Analyser (AST-X2001)

Multipoint Digital Strain Meter

RS-200 Milling Guide for Residual Stress Measurement

FEM software – ANSYS 5.0

4. Non Destructive Testing

Ultrasonic Test Equipment - upto 1 dB

In-situ Magnetic Particle Testing

Radiographic test equipment – 400 kV

Gamma ray test

Welding Facilities

1.Fusion Welding

Solid state NdYAG Laser welding Machine-2kW

Surface Tension Transfer MAG welder – 400 A

Synergic MIG welding – 500 A

Chamber for Titanium welding – f 1200 mm

Tandem submerged Arc welder – 1200 A

Time Twin welding equipment

2. Solid Phase Welding, Surfacing & Others

Friction welder -15 tonnes

Microjoining – for <1mm sheets



Resistance Spot Welding

Resistance Projection Welding

Resistance Seam welder – for 2 mm sheets

Flash Butt Welding



9. PRESS SHOP AND DRUM SHOP

The BHEL Trichy has equipped all its units with cutting edge technology and

sophisticated machines to facilitate its manufacturing needs. It has in its arsenal

an 8000 ton Hydraulic press, a Four Roll Plate Bending Machine and a large

capacity Induction Pipe Bending Machine to name a few. It has also installed

the plants with state-of-the-art analytical, mechanical and non-destructive

testing facilities to ensure the delivery of products of the finest quality.

The various processes in press and drum shop are:

SHELL FORMATION:

At first plates are received from the stores. They are verified for the material

specification and are subjected to Shear UT. Plates are then marked for cutting

to the required dimensions considering the test plates for Long seam and

cirseam. Before gas cutting the plates are heated to a temperature of 150 deg

(Preheating). Gas cut edges is cleaned and the plates are loaded to the furnace

for heating it to a temperature of 870-900 deg. This is done such that ROH is

150 deg /hr, soaking it for 200 minutes and cooling it by open air. This shell

plates are transferred to 8000 T press where it pressed to form a half shell.

Special care is taken that the forming process is done above 620 deg. If the

pressing is done below 620 deg C then Inter stage heat treatment is done.

Then the pressed plates are subjected to shot blasting for surface finish. And

then half shell formed is cold calibrated as per dimensions. After gas cutting the

half shells are sent to Drum shop for long seam EP preparation and further

processes. Then with row of burners along the length preheating to 150 deg C is

done for tack welding the fit ups, start up and test plates. Long seam joint is

welded from inside by FCAW with CO2 as shielding gas manually and then

surface is cleaned and ground. Straps from outside are removed and preheating

is done for outside welding to the temperature of 150 deg C. SAW (Submerged

Arc Welding) is the process of welding from the outside and is done as per the

WPS.Inspection is carried out on the joints welded and MT, RT and UT are

conducted.

The shell thus formed is Edge prepared on both the ends. Edge prepared ends is

inspected for compliance with the drawing. The two closed shells formed are

joined by cir seam welding for which internal welding is done by SMAW and

outer side is done by SMAW R + 2 mm for after gouging for effective lip

matching and then remaining portion by SAW process. All the welding

processes are accompanied by preheating to the temperature of 150 deg C.



DISHED END FORMATION:

Raw material for dished ends are received from stores and verified for material

spec, melt no. and plate no. for identification purpose. Marking for cutting the

plan as per drawing is done and verified. Marked portion is cut using gas cutting

operation for which the plate marked portion is preheated to 150 deg C. The gas

cut portion is cleaned and ground. The locater hole marking at the center of the

blank is carried out and accordingly drilling is done in steps.

Then the plates are loaded into the furnace with thermocouples and care is taken

such that direct flame impingement is avoided. The heating of plate is done to a

temperature of 870-900 deg C with ROH at 150 de C/Hr if the plate thickness is

above 100 mm else at the rate of 200 deg C/Hr. Soaking is done at rate of 1.25-

mts/mm thickness of plate with the cooling medium being air.

Heated plate is then pressed to the shape as dimensions in the drawing using

matching bullet and tool. Thus formed plate is subjected to shot blasting and

depressions if any are merged gradually to the base metal surface. Inspection is

done for profile, thickness, diameter, circularity and then the identifications are

transferred and punched. Manhole on both the dished ends is marked and pre-

drilling for gas cutting is done. Preheating is done and the manhole is formed

using gas-cutting process.

CIR SEAM WELDING

Preheating to 150 deg C is done and the tack welding of door components and

relevant DE is done. Cleaning and grinding of weld is done and is subjected to

MT. The door assembly is placed inside the drum before welding the last cir

seam. Fitting and tack welding of cir seam joint is done after pre heating to 150

deg C.

NOZZLE DRILLING AND ATTACHMENTS ON SHELL

Pilot drilling is done for full throat nozzle openings. After pilot drilling

operation the opening areas are preheated to 150 deg C for gas cutting the full

throat opening. The gas cut portion is cleaned and ground and then subjected to

MT and UT. Before tack welding the full throat nozzle with fit up on the shell,

preheating to 150 deg c is done. After verifying the alignment, orientation and

dimension, full throat welding is done as per WPS.

STRESS RELIEVING:

All the balance attachments are welded before SR. If any depressions are found

then it is ground and merged smoothly.



HYDRO TEST:

Drum is filled with water with a temperature range of 21 to 46 deg C and is

pressurized gradually to the pressure mentioned in the drawing (generally it is

pressurized to 1.5 times the design pressure). This is maintained for 30 mts.

Shroud hydro is conducted only for the shroud portion in case of 500MW

boilers.

FINAL HANDING OVER:

Drum is cleaned and is checked for free from foreign materials. Protective

plastic caps for all nozzles and nipples are provided. Paint is applied as per

painting scheme; axis and other important locations are marked. Authorized

Inspectors seal is stamped. Handing over to shipping for shipping is done.

1. HEADERS

The header is a manifold that forms the connection between the two pressure

part systems. It acts as a mixing chamber, equalizing the temperature of the

fluid. The header is basically a pipe suitably provided with inlet and outlet

connections so that the flow in the system is uniform and as desired.

Types of Headers:

Header - both ends closed with hemispherical end cover Header – both ends closed with flat end cover One end closed with h.s.e.c and other end open

Headers with both ends open

Header with tee at quarter points (or at center):

In the micro level the headers may have the following components

1. Pipe

2. Tube

3. End Covers

4. Tees

5. Elbows

6. Support and lifting lugs

7. Hanger Rods & U Rods

8. Hand Hole Pipes

9. Lining and Insulation Attachments



MANUFACTURING SEQUENCE OF HEADERS:

1) LAYOUT MARKING 2) EDGE PREPARATIO 3) SOCKET SEAT DRILLING 4) BUTT JOINT

5) STUBS & ATTACHMENTS

6) SR & FINAL INSPECTION

THE BASIC DESIGN OF THE HEADER INVOLVES THE FOLLOWING

STEPS

1. The basic parameters of the header have to be obtained from the piping

and tubing list from the BPP. The basic configuration may be the length

of the header pipe, diameter of the header, thickness, design temperature,

pressure, etc.,

2. The arrangement of the nipples around the header pipe has to be decided

from the PPA drawing.

3. The header whether it is closed at one end/both the ends (with

hemispherical or flat end cover) or open at one end/both the ends is also

decided from the PPA drawing.

4. The other stubs that has to be given in the header for the vents and drain

is decided from the water and steam scheme which includes all the

fittings, valves and instrumentation from the Boiler Mountings section.

2. TUBES:

The nipples and the stubs those are present in the header, which has diameter

less than 76.2mm falls under the category of Tubes. Other than that certain

instrument inserts also falls under that category of tubes.

3. END COVERS:

As discussed above, the closed headers may have end covers. The end

covers are of two types:



i. Hemispherical End Cover

ii. Flat End Cover.

Due to the uniform stress distribution the Hemispherical end cover is

preferred mostly. In cases where there is a space limitation Flat end cover is

preferred.

4. TEE PIECE:

The header may be fitted with the tee piece, which may be used for the inlet or

for the outlet purpose. The Tee piece is usually provided at the quarter points

(i.e., the approximately at a distance of 0.25L from the ends, L = length of the

header) assuming that the flow is equal.

5. ELBOW:

The headers with elbow for the inlet or outlet will be considered as a pipe with a

bend. The selection of the elbow is done from the standard drawing 2-03-000-

00035 Formed Elbow - 90° (Raw Forming). The calculation is as explained in

Tee selection.

PROJECTS COMPLETED

Heat treatment of Steam Generator Component

Establishment of solid phase welding technology for aluminium

alloys

Laser welding technology development for coated steels

Application of weld sequence for distortion control in panels

Development of laser and TIG welding technology for reheater

spray control valve

Arc welding power source evaluation system

Development of a Lathe type Rotating Fixture for Welding

Bifurcates

Development Of Magnetically Rotating Arc Welding System

For Welding Of Tubes

Development Of High Performance Robot Welding System

Using Time Twin Process

Cold Wire Addition Process For Long Seam Butt-Joints Using

Tandem Submerged Arc Welding



Electro Gas Welding System

Internal Deep Bore Stelliting Machine

Low Pressure Plasma Spraying System

Overlaying Machine for Bowl mill Rolls

Automatic Tube Butt Welding Machine

Twin wire CO2 welding

Feedback controller for Resistance welding

Transistorised Power Source

Seam tracker for arc welding system

Versatile All Position In-situ metallographic polishing

Equipment (VAPINE)

Narrow Gap Submerged Arc Welding Technology

Applications of high energy density Electron Beam Welding

Technology



TABLE OF CONTENTS(PART B)

1. Bharat Heavy Electricals limited----------------------------------------------------7

1.1Overview

1.2Bhel Trichy Introduction

2. Approach To Central Structural Catalogue management---------------------11

2.1Introduction

2.2System

3. Aveva PDMS------------------------------------------------------------------------------13

3.1Design

3.2PARAGON

4. PARAGON---------------------------------------------------------------------------------15

4.1PARAGON(detailed description)

4.2Hierarchy of PARAGON

4.3Administative elements

4.4Specifications

5. PML-------------------------------------------------------------------------------------------21

5.1PML types

5.2PML objects

5.3 PML functions

5.4PML macros

6. SQL--------------------------------------------------------------------------------------------23

6.1SQL elements

6.2Queries

6.3Data verification

6.4Data types

7. Visual Basic----------------------------------------------------------------------------------27



7.1Language features

7.2More about VB6.0

7.3VB outputs

7.4VB uses

7.5Flow chart of the VB software

7.6Screenshots

8. Conclusion---------------------------------------------------------------------------------36

9. References----------------------------------------------------------------------------------37



1. BHARAT HEAVY ELECTRICALS LIMITED

1.1 OVERVIEW

BHEL is the largest engineering and manufacturing enterprise in India in

the energy-related/infrastructure sector, today. BHEL was established more

than 40 years ago, ushering in the indigenous Heavy Electrical Equipment

industry in India. The company has been earning profits since 1971-72 and

has been paying dividends since 1976-77.

BHEL manufactures over 180 products under 30 major product groups and

caters to core sectors of the Indian economy viz. Power Generation &

Transmission, Industry, Transportation, Renewable Energy etc. the wide

network of BHEL‘s 14 manufacturing divisions, 4 Power Sector regional

centres, over 100 project sites, 8 service centres, 18 regional offices and 1

subsidiary enables the company to promptly serve its customers and provide

them with suitable products, systems and services efficiently and at

competitive prices. The high level of quality and reliability of its products is

due to the emphasis on desing, engineering and manufacturing to

international standars by acquiring and adapting some of the best

technologies from leading companies in the world, together with the

technologies developed in its own R&D centres.

BHEL‘s operations are organized around three business sectors, namely,

Power, Industry and Overseas Business. This enables BHEL to have a

strong customer orientation, to be sensitive to the customer‘s needs and

respond quickly to even minute changes in the market.

BHEL‘s vision is to become a world-class engineering enterprise, committed

to enhancing stakeholder value. The company is striving to give shape to its



aspirations and fulfill the expectations of the country to become a global

player.

The greatest strength of BHEL is its highly skilled and committed 42,600

employees. Every employee is given an equal opportunity to develop

himself and grow in his career. Continuous training and retraining, career

planning, a positive work culture and participative style of management

have engendered a development of a committed and motivated workforce

setting new benchmarks in terms of productivity, quality and

responsiveness.

1.2 BHEL, Tiruchi:

1.2.1. Introduction:

The High Pressure Boiler Plant (HPBP) of BHEL was set up at Tiruchi in

1963 for the manufacture of High Pressure boilers. The plant achieved its

initial full annual capacity of 400 MW in 1984 with boiler ratings up to 500

MW. But this capacity has been increased to 15000 MW to meet the

growing demand along with the addition of the Seamless Steel Tube Plant

(SSTP). The HPBP and SSTP are spread over 2908 acres of land and has a

covered shop area of 2,50,000 square meters.

1.2.2. Technology Assimilation and Facilities

With a judicious mix of in-house R&D and selective technology tie ups,

BHEL Tiruchi has developed excellent engineering and R&D capabilities.

Due to these, BHEL Tiruchi has been identified as a nodal agency for all

Fossil Fuel Based Research Activities. With superior engineering and R&D

capabilities, BHEL Tiruchi is well poised to introduce new products such as

boilers and auxiliaries of higher ratings (in the range of 800 MW), Super



Critical Once-Through Boilers, Fabric Filters and Flue Gas

Desulphurization system.

BHEL Tiruchi has equipped all its units with cutting edge technology and

sophisticated machines to facilitate its manufacturing needs. It has in its

arsenal an 8000 ton Hydraulic press, a Four Roll Plate Bending Machine

and a large capacity Induction Pipe Bending Machine to name a few. It has

also installed the plants with state-of-the-art analytical, mechanical and non-

destructive testing facilities to ensure the delivery of products of the finest

quality.

1.2.3. Customer Services:

At BHEL Tiruchi, every system is tuned towards serving the customer. The

entire project management required for the timely execution of the

customer‘s orders is handled through a computerized network. Planned

production of components in workshops as well as timely ordering on

outside vendors is carried out to ensure dispatch of components matching

construction schedule at the sites. This helps BHEL Tiruchi in maintaining

product deliveries with shortest lead times.

Services are provided during and after the commissioning of equipment by

the Field Engineering Services. With this dedicated team of engineers and

technicians, site problems are attended to with the utmost urgency. Effective

interaction is maintained with customers to have continuous feedback on

equipment performance.

Supply of spares and after-sales-services are two other major components of

BHEL Tiruchi‘s service support. BHEL Tiruchi ensures timely supply of

spares for the proper upkeep of equipment and the maximization of

equipment utilization.



Techniques and methodologies have been developed to assess the residual

life of components, based on which selective replacement decision can be

made to extend the productive life of the equipment.

1.2.4. Global Links:

BHEL Tiruchi has so far supplied boilers for a cumulative capacity of 1350

MW of power generation capacity to Malaysia, Libya, Iran, Egypt etc.

BHEL‘s Valves have been exported to Malta, Cyprus Malaysia and

Indonesia while pressure part equipment and spares have been exported to

the USA. Boiler components have been supplied to China and Seamless

Steel Tubes have been exported to Malaysia

1.3. Certification

BHEL has been able to acquire the following certifications:

ISO 9000 certification in 1993. In doing so became the first state

owned company to acquire it for all its operations.

The ―CII-EXIM Commendation Certificate‖ on the HPBP at Tiruchi

for ‗Commitment to Total Quality Management (TQM)‘ by the

Confederation of Indian Industries (CII)

ISO 14001 Standard – signifying its clear commitment to a clean and

pollution-free environment.



2.Approach for Centralized Structural Catalogue

Management

2.1Introduction

In an era of Information Technology, engineering automation becomes a

vital part of the business. In the modern day scenario there are numerous

softwares in each field (Structural, Piping, Ducting and etc.,) that can be

adopted for engineering automation. A lot of effort is put in, to achieve this

milestone, but at the end of the day there is always an uncertainty that if

new software comes with greater advantage or with lesser price, what

should we do. Software vendors take advantage of the situation and raise

the price of the product. Since the data is stored within a software, we

become dependent and switch over to another causes a huge effort to be put

in.

Strucad/Xsteel are the softwares being used by Structures department for

3D modeling of Structures. PDMS is used to integrate/model the total plant

to identify interferences and drawing extractions. Effort cannot be

duplicated to model structures in both the platforms. Hence it would be wise

to import/export data from one to another in a most appropriate manner

without any data loss. There is also a growing need for data exchange from

one package to another (Strucad/Xsteel/AutoCAD to PDMS).

For this to be done there is a need for a mapping table which specifies the

relation between the packages. Also there is a possibility of duplication of

work in catalogue management. If a section is to be added it has to be added

in multiple platforms. Based on softwares, addition of new variant becomes

complex.



With this background an approach/system has been evolved

especially for structural catalogue management.

2.2System

The data pertaining to BHEL sections shall be stored in a centralized

database (Oracle). Different types of sections and parametric definition will

be stored in one table(called master table) and parametric values will be

stored in another table(called catalogue table). Any addition to catalogue

will be done here which will trigger individual packages for an update.

Mapping of each section between packages shall be available.



3. AVEVA PDMS

AVEVA Plant Design Management System (PDMS) is a multi-discipline

3-D modeling system that allows you to simulate a detailed, full size model

of all the significant parts of a process plant. It allows us to see a full colour

representation of the plant model as the design progresses.

AVEVA PDMS can be used to design any type of plant from petrochemical

plants, offshore platforms, chemical and pharmaceutical plants, consumer

products (food, beverages, cosmetics, soap, paper, and so forth), to power

plants, waste water treatment plants, and cogeneration facilities. It is used to

create three-dimensional plant models, create equipments models, extract

isometric drawing, and perform design interference checks and equipment

clashes.

Specifically, the Plant Design Management System (PDMS) integrates

many discipline specific software modules. These modules automate the

many phases of a plant design project like interference checking, design

review etc.

PDMS comprises of the following functional parts:

• Modules

• Applications.

3.1Module

A module is a subdivision of PDMS that allows a user to carry out specific

types of operation. PDMS has the following modules



3.1.2PARAGON, which we use for creating 3D model of

structural component Used to generate and modify catalogues, with

facilities for catalogue component construction with visual control

(including 3D color•shaded representations of the item being

designed). The catalogues in PDMS serve a similar purpose to the

manufacturers catalogues, which user would refer to when using

conventional design methods. The PDMS component catalogue is

used to specify the geometry, connection information, obstruction and

detailing data of steelwork, piping, and HVAC and cable tray

components.It should be noted that, where the design data is specific

to a particular design, catalogues and specifications may be specific to

a company but general to a number of projects in that company. For

example, the same catalogue component may also appear in other

designs proceeding at the same time.

3.1.1DESIGN, Design is the main, graphically driven

constructor module within PDMS. Design enables a full sized

three•dimensional plant model to be defined in the Design database,

with selected views of the current state of the design shown on the

graphics screen as the design progresses. All parts of the design

(including equipment, and piping and structural steelwork lauserts)

can be created. Component selection is provided through

Specifications that dictate which Catalogue Components can be used.

Each part of the design model can be displayed in color shaded ‗solid‘

color coded representations for ease of interpretation. Design can

check for interferences (clashes) between items created in the design.



The module that is used to create models is PARAGON module.

4.PARAGON MODULE (A DETAILED

DESCRIPTION)

PARAGON module used to generate or modify a PDMS Catalogue,

with facilities for constructing Catalogue Components under fully

interactive visual control, including 3Dcolour--shaded representations

of the items being designed. Paragon combines aspects of both

catalogue creation and model design functionality within a single

module. This means that a catalogue designer not only has write

access to a project‘s catalogue databases, but may also read data from

the design databases. If given write access, the catalogue designer

could also experiment with new catalogue component configurations

in a trial design database. This approach simplifies catalogue

maintenance and design. Similarly, it is often useful for a plant design

engineer to have access to the catalogue to query details of specific

components. Paragon has a graphical user interface consisting of

forms and menus. The interface provides access to the most

commonly used facilities. PARAGON is the PDMS application

through which the database containing the geometry definition is

created.

4.2Hierarchy of PARAGON:

CATA is the highest level element of the Catalogue hierarchy.



A snapshot of hierarchy level:

SECTION

CATAGORY

POINT SET

COMPONENT

GEOMETRY

DATA SET

BOLT SET

CATALOGUE



4.3Administrative Elements

CATAlogue

Description: Description of catalogue

Purpose: Purpose should be the same as the SPEC with which the

catalogue is to be used (STL, FITT, JOIN, PFIT etc.)

Cstandard: Catalogue standard

STSEction - Structural Section

Description: Description of Section

Gtype: Generic type of element contained in section; this should be

the same as the type of element used in DESIGN, e.g. BEAM

STCAtegory - Structural Category

Description: Description of category

Purpose: Purpose should equate to the STYP of the items as

defined in the Spec



Function: Description

Gtype: Identifies the Generic element type

PTSE - Point Sets

Description: Description of point set


Skey: Symbol Key to which point set relates

Purpose: Purpose of point set

GMSE - 3D Geometry Set

Description: Description of geometry set


Purpose: Purpose of geometry set

NGMS - Negative Geometry Sets

Description: Description of geometry set


Purpose: Purpose of geometry set

DTSE – Datasets

Description: Description of dataset


Purpose: Purpose of dataset



PTSS - Point sets

Description: Description of point set


Purpose: Purpose of point set

GMSS - 2D Geometry Set

Description: Description of geometry structural set


Purpose: Purpose of geometry structural set

A screenshot of PARAGON in PDMS (12.0)



To GET the structural component in design module we need to create

specification world.

4.4Specifications

The following conventions for structural specifications must be

followed to ensure that a correct specification is built. The application

follows strict rules when building these specifications and reads the

specification in a tabulated format. Description should be given at the

correct level and any question of Tanswers must be input for the

forms and menus to be correctly built. The steelwork specifications

work in a different way to piping specifications, where there can be

more than one answer.



PDMS only understands PML(programmable macro language).

5.PML(programmable macro language)

PML means programmable macro language used to design a

graphical user interface which suits our business needs. PDMS

understands only PML.

5.1PML TYPES

PML program can be broadly classified into 4 types based on the

functionality or purpose.

PML OBJECTS

PML FUNCTIONS

PML FORMS

PML MACROS

5.1.1PML OBJECTS

PML uses object programming concept.

An object may be :

a physical object (Engineering elements like boiler, motor)

An abstract object.

An object may defined using parameters or dimensional

elements. The parameters might be:

o Geometrical parameters

o Performance parameters

o Positional and orientation parameters

o Specialty parameters (Aesthetic parameters like

paint colour, translucency and etc.,)

An object might have a graphics.



Functions which do not return results are called as PML

PROCEDURES.

5.1.3PML FORMS

PML forms are also objects.

PML form is a PML program which is used to design the graphical

user interface (GUI).

These are mainly used to get input values from the user and transfer

these values to functions or macros to carrusert specific action.

In simple terms these are the front end which interacts with the user,

guiding them on operating the PML program.

5.1.4PML MACROS

PML macros are command sequences which are stored as text files.

To access a macro file and input the command sequence to our

program, we run the macro.

The file is scanned line by line, with exactly the same effect as if we

are typing the commands from the keyboard.

5.1.2PML FUNCTIONS

PML functions and methods may optionally have arguments, which

can be used to return values.

Arguments have a data type which is specified in the function or

method definition and they are checked when the function or method

is called.

Functions and methods can optionally return values as their results.

define function !!Perimeter (!Length is real, !Width is real) is real

!Perimeter = (!Length + !width) * 2

return !Perimeter

End function



Macros are permanent records which may be called within any

working session of a program.

A macro which is used to add new structural component of type

welded beam(WLB) is :

/WB300x300-25/16

handle(2,109)

/SSSCNWLB

new sprf /WB300x300-25/16

gtyp SCTN

para 300 300 16 25

gmss /SSSCNWLBGMSS

ptss /SSSCNWLBPTSS

DTSE /SSSCNWLBDTSE

Endhandle

This will automatically create one new structural component of WLB of

GIVEN PARA,GMSS,PTSS and DTSE.

To add records (parametric values and various other descriptions) in

ORACLE database we use SQL language.

6.SQL

SQL stands for structured query language. It is a universal language used for

retrieving and manipulating data in a relational data base management

system(RDBMS).

6.1Language elements

The SQL language is sub-divided into several language elements, including:

Clauses, which are in some cases optional, constituent components of

statements and queries.



Expressions, which can produce either scalar values , tables consisting

of columns and rows of data.

Predicates which specify conditions that can be evaluated to

SQL three-valued logic (3VL) Boolean truth values and which are

used to limit the effects of statements and queries, or to change

program flow.

Queries which retrieve data based on specific criteria.

Statements which may have a persistent effect on schemas and data,

or which may control transactions, program flow, connections,

sessions, or diagnostics.

o SQL statements also include the semicolon (";") statement

terminator. Though not required on every platform, it is defined

as a standard part of the SQL grammar.

Insignificant whitespace is generally ignored in SQL statements and

queries, making it easier to format SQL code for readability.

6.2Queries

The most common operation in SQL is the query, which is performed with

the declarative SELECT statement. SELECT retrieves data from one or

more tables, or expressions. Standard SELECT statements have no

persistent effects on the database. Some non-standard implementations

of SELECT can have persistent effects, such as the SELECT INTO syntax

that exists in some databases. Queries allow the user to describe desired

data, leaving the database management system (DBMS) responsible

for planning, optimizing, and performing the physical operations necessary

to produce that result as it chooses.

http://en.wikipedia.org/wiki/Scalar_(computing)

http://en.wikipedia.org/wiki/Table_(database)

http://en.wikipedia.org/wiki/Column_(database)

http://en.wikipedia.org/wiki/Row_(database)

http://en.wikipedia.org/wiki/Ternary_logic

http://en.wikipedia.org/wiki/Truth_value

http://en.wikipedia.org/wiki/Semicolon

http://en.wikipedia.org/wiki/Whitespace_(computer_science)

http://en.wikipedia.org/wiki/Select_(SQL)

http://en.wikipedia.org/wiki/Table_(database)

http://en.wikipedia.org/wiki/Database_management_system

http://en.wikipedia.org/wiki/Query_plan

http://en.wikipedia.org/wiki/Query_optimizer



A query includes a list of columns to be included in the final result

immediately following the SELECT keyword. An asterisk ("*") can also be

used to specify that the query should return all columns of the queried

tables. SELECT is the most complex statement in SQL, with optional

keywords and clauses that include:

The FROM clause which indicates the table(s) from which data is to

be retrieved. The FROM clause can include optional JOIN subclauses

to specify the rules for joining tables.

The WHERE clause includes a comparison predicate, which restricts

the rows returned by the query. The WHERE clause eliminates all

rows from the result set for which the comparison predicate does not

evaluate to True.

The GROUP BY clause is used to project rows having common

values into a smaller set of rows. GROUP BY is often used in

conjunction with SQL aggregation functions or to eliminate duplicate

rows from a result set. The WHERE clause is applied before

the GROUP BY clause.

The HAVING clause includes a predicate used to filter rows resulting

from the GROUP BY clause. Because it acts on the results of

the GROUP BY clause, aggregation functions can be used in

the HAVING clause predicate.

The ORDER BY clause identifies which columns are used to sort the

resulting data, and in which direction they should be sorted (options

are ascending or descending). Without anORDER BY clause, the

order of rows returned by an SQL query is undefined.

http://en.wikipedia.org/wiki/From_(SQL)

http://en.wikipedia.org/wiki/Join_(SQL)

http://en.wikipedia.org/wiki/Where_(SQL)

http://en.wikipedia.org/wiki/Group_by_(SQL)

http://en.wikipedia.org/wiki/Having_(SQL)

http://en.wikipedia.org/wiki/Order_by_(SQL)



6.3Data definition

The Data Definition Language (DDL) manages table and index structure.

The most basic items of DDL are the CREATE,ALTER,RENAME,DROP

and TRUNCATE statements:

CREATE creates an object (a table, for example) in the database.

DROP deletes an object in the database, usually irretrievably.

ALTER modifies the structure of an existing object in various ways—

for example, adding a column to an existing table.

Example:

o CREATE TABLE My_table

(

my_field1 INT,

my_field2 VARCHAR(50),

my_field3 DATE

PRIMARY KEY (my_field1, my_field2)

);

6.4Data types

Each column in an SQL table declares the type(s) that column may contain.

ANSI SQL includes the following data types.

CHARACTER(n) or CHAR(n) — fixed-width n-character string,

padded with spaces as needed.

CHARACTER VARYING(n) or VARCHAR(n) — variable-width

string with a maximum size of n characters.

NATIONAL CHARACTER(n) or NCHAR(n) — fixed width string

supporting an international character set

NATIONAL CHARACTER VARYING(n) or NVARCHAR(n) —

variable-width NCHAR string.

http://en.wikipedia.org/wiki/Data_Definition_Language

http://en.wikipedia.org/wiki/Create_(SQL)

http://en.wikipedia.org/wiki/Drop_(SQL)

http://en.wikipedia.org/wiki/Alter_(SQL)



To create a software that will continently add new records from the excel

sheet to the ORACLE database and for generating macros we use Visual

Basic. There are many visions of Visual Basic and we have used Visual

basic 6.0 for fulfilling our requirement.

7.VISUAL BASIC

VISUAL BASIC is a high level programming language which evolved from

the earlier DOS version called BASIC. BASIC means Beginners' All-

purpose Symbolic Instruction Code. It is a very easy programming

language to learn. The code look a lot like English Language. Different

software companies produced different versions of BASIC, such as

Microsoft QBASIC, QUICKBASIC, GWBASIC ,IBM BASICA and so on.

However, people prefer to use Microsoft Visual Basic today, as it is a well

developed programming language and supporting resources are available

everywhere. Now, there are many versions of VB exist in the market, the

most popular one and still widely used by many VB programmers is none

other than Visual Basic 6.

VISUAL BASIC is a VISUAL and events driven Programming Language.

These are the main divergence from the old BASIC. In BASIC,

programming is done in a text-only environment and the program is

executed sequentially. In VB, programming is done in a graphical

environment. In the old BASIC, you have to write program code for each

graphical object you wish to display it on screen, including its position and

its color. However, In VB , you just need to drag and drop any graphical

object anywhere on the form, and you can change its color any time using

the properties windows.

On the other hand, because the user may click on a certain object

randomly, so each object has to be programmed independently to be able to

response to those actions (events). Therefore, a VB Program is made up of



many subprograms, each has its own program code, and each can be

executed independently and at the same time each can be linked together in

one way or another.

7.1Language features

Like the BASIC programming language, Visual Basic was designed to be

easily learned and used by beginner programmers. The language not only

allows programmers to create simple GUI applications, but can also

develop complex applications. Programming in VB is a combination of

visually arranging components or controls on a form, specifying attributes

and actions of those components, and writing additional lines of code for

more functionality.

7.2More about visual basic

Visual Basic (VB) is the third-generation event-driven programming

language and integrated development environment (IDE) from

Microsoft for its COM programming model. VB is also considered a

relatively easy to learn and use programming language, because of its

graphical development features and BASIC heritage.

7.3VB outputs

Visual Basic was derived from BASIC and enables the rapid application

development (RAD) of graphical user interface (GUI) applications, access

to databases using Data Access Objects, Remote Data Objects, or ActiveX

Data Objects, and creation of ActiveX controls and objects. Scripting

languages such as VBA and VBScript are syntactically similar to Visual

Basic, but perform differently.

A programmer can put together an application using

the components provided with Visual Basic itself. Programs written in

http://en.wikipedia.org/wiki/BASIC

http://en.wikipedia.org/wiki/Graphical_user_interface

http://en.wikipedia.org/wiki/GUI_widget

http://en.wikipedia.org/wiki/GUI_widget

http://en.wikipedia.org/wiki/Form_(programming)

http://en.wikipedia.org/wiki/Source_code



Visual Basic can also use the Windows API, but doing so requires external

function declarations.

Like the BASIC programming language, Visual Basic was designed

to be easily learned and used by beginner programmers. The language not

only allows programmers to create simple GUI applications, but can also

develop complex applications. Programming in VB is a combination of

visually arranging components or controls on a form, specifying attributes and

actions of those components, and writing additional lines of code for more

functionality. Since default attributes and actions are defined for the

components, a simple program can be created without the programmer

having to write many lines of code. Visual Basic also provides us the OLE

tool which can easily create data links to any database and then create more

interactive applications. Any VB program can be linked to any popular

database such as Oracle or Microsoft Access. This linkage needs an OLE

DB driver which now comes preinstalled with every windows version. It

means that even if the server computer doesn‘t have VB installed still it can

run the program and give the desired results. The VB programmer has to

write the code for querying the database for the desired results. An example

of such an application will be the username and password authentication

program. When we enter the username and password the program queries

the data base with the unique username and once a match is found it

matches the password; only then the authentication is completed.

7.4 VB uses

Visual Basic can also be used to link any video or audio format for better

presentation and usability. Its ActiveX controls allow the user to create

visually appealing components in the program for e.g.:- the progress bar that

can be seen while installing any program. Visual Basic has the ability to



embed various file formats into its forms some of which

are.avi,.wmv,.swf,.flv..and many other formats as well.

7.5Flow diagram of the VB software:

Records in designers excel sheet

Records are copied to predefined design template

Records are matched in ORACLE database

If it‘s not there in database

If it‘s there in database

New records are being added

Existing records are not added

PDMS macro are generated



7.6Types of structures in which user can add new component

*out of 16 types designer can only add in 7 types and for the rest designer

need have administrator permission

S.No Sheet Name Description

1 ISA Indian Standard Angle

2 ISB Indian Standard Beam

3 ISC Indian Standard Channel

4 IST Indian Standard Tee

5 CBX Channel Box

6 JNB Jindal Beam

7 WLB Welded Beam

8 RPI Rolled Plus I

9 WPI Welded Plus I

10 WBC Welded Box Column

11 WBB Welded Box Beam

12 SAN Star Angle

13 DAN Double Angle

14 DCL Double Indian Chandard Channel

15 DIB Double Indian Standard Beam

16 DJN Double Jindal Beam



7.7SCREEN SHOTS OF

STRUCTURAL CATALOGUE ADDITION SOFTWARE

LOGIN FORM

MAIN FORM



DESIGN TEMPLATE

AFTER ADDING RECORDS BY DSIGNER



SPECIFYING THE PATH

CONFIRMATION MESSAGE



PDMS MACRO GENERATION

PDMS MACRO TEXT FILE



8.CONCLUSION

We have made a software in Visual Basic(6.0) which can be used by

the designer to add new structural components to existing oracle database.

We have made user friendly Graphical User Interfaces(GUI) in which user

will guided thought out the software and errors will be displaying along

with the suggestions to add new records having different parametric values.

For the security purpose the initial GUI of the software is a LOGIN form so

that authorized users can only add to the database. And there will be no

mishandling of the centralized oracle database.

For any reasons if the administrator need to have some modifications he has

provided with the original VB code.

The code is so well written that if a new type if design comes the

administrator can add the new type within few minutes along with the

previous 16 types.



9.REFERENCES

AVEVA PDMS MANUALS

o catalogues and specifications user guide

o catalogues and specifications reference manual

o design conventions for catalogues and specifications

o introduction to templates user guide

WIKIPEDIA

BEGINNING SQL BY PAUL WILTON ,JOHN COLBY,

PUBLISHER- WILEY DREAMTECH

PML

BHEL WEBSITE AND MAGAZINES

VISUAL BASIC 6 PROGRAMMING IN 2 AND HALF

DAYS BY RICHARD MANSFIELD,PUBLISHER-

HUNGRY MINDS

LEARN MICRO SOFT VISUAL BASIC 6.0 NOW BY

MICHAEL HALVORSON ,PUBLISHER-PRENTICE HALL

OF INDIA PVT.LTD

VISUAL BASIC 6 : THE COMPLETE REFERENE BY

NOEL JERKE ,, PUBLISHER- TATA MC-GRAW HILL

PUBLISHING COMPANY LIMITED