PRACTICAL TRAINING TAKEN AT

Bharat Heavy Electricals Limited(BHEL) Bangalore(Karnataka)

DURATION: 02/06/2014 TO 14/07/2014SESSION :2013-2014

Submitted to:-

Prof. chander shekhar

(b.tech,m.tech)

Presented by:-Sunil GaurBatch: m-3

The Main gate of bhel EDNP.B. NO.2606,Mysore road,Bangalore-560026,INDIA

Company overview• BHEL Electronics Division is a leading supplier of new Generation Power Plant

Automation and Control System.

• 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 when its first plant was setup in

Bhopal.

• 65% of overall electricity is generated by BHEL. And 75% of overall electricity is

generated by the BHEL’s equipments .

• BHEL EDN, Bangalore was found in 1976, mainly to establish a strong base in the

area of power and industrial electronics.

• It is one of the only 7 mega Public Sector Undertakings (PSUs) of India

clubbed under the esteemed 'Maharatna' status.On 1 February 2013,

the Government of India granted Maharatna status to Bharat Heavy

Electricals Limited

• Registered Office & Corporate HQ : New

Delhi

NEW DELHI

BARODA

NAGPUR

PATNACALCUTTA

VARANASI

GOINDWAL

HARIDWAR

RUDRAPUR

JAGDISHPURJHANSI

BHOPAL

HYDERABAD

BANGALORE

RANIPET

TIRUCHIRAPALLY

CORPORATE OFFICE

MANUFACTURING ATIONS

SERVICE CENTRES

• 4 Power Sector Regional Setups

• 18 ROD offices

• Corporate Research &

Development Division : Hyderabad

• 8 Service Centre

• 15 Manufacturing Plants

Sl.No Manufacturing

Units

Location Products

1. Heavy Electrical Plant Bhopal Steam turbine, Turbo generator, Hydro turbine ,

Hydro generator, Switchgear , Transformers,

Motors.

2. Transformer Plant Jhansi Dry/Special Transformers, Electric & Diesel

Locomotives, Transformers, Bus Ducts

3. Heavy Electrical

Equipment plant

Haridwar (HEEP) Steam and Gas Turbine ,Turbo generators ,Hydro

Turbines and Generators, Large AC/DC motors.

4. Central Foundry

Forge Plant

Haridwar Heavy Casting, Steel Castings and Steel Forgings

5 Heavy Power

Equipment Plant

Hyderabad Power Generating Sets, Industrial Turbo Sets,

Compressors, Pumps, Heaters, Bowl Mills, Gas

Turbines, Switchgear.

6 High Pressure Boiler

Plant

Tiruchirappalli Power Boilers, Industrial Boilers, Nuclear Steam

Generating Equipment.

7 Boiler auxiliary plant Ranipet Air Pre Heaters, Fans, ESP.

CERTIFICATIONS AWARDED TO BHEL

• The Unit is awarded with the following certifications:

• ISO 9001: Quality Systems and Procedures

• ISO 14001: Environment Management System Certification

• OHSAS 18001: Occupational Health and Safety Assessment Series.

• ISO 27001: Information Security Management System Standard.

• BUSINESS EXCELLENCE – Significant achievement

• It is the 7th largest power equipment manufacturer in the world.

• BHEL received the National Intellectual Property Award 2014 and WIPO Award for Innovative Enterprises 2014

• BHEL won the DSIJ Award 2013 for the Most Efficient Maharatna PSU

• It won the Golden Peacock Award 2013 for Innovation Management

• The company received the India Pride Award 2013 for Excellence in Heavy Industries

Shareholding• BHEL's equity shares are listed on Bombay Stock Exchange and National Stock Exchange of

India. Central Government of India and State governments in India hold majority of the shares of BHEL.

Shareholders (as on 30-Mar-2014) Shareholding

• Central Government of India and State governments 63.06%

• Foreign Institutional Investors (FII) 16.14%

• Insurance companies 11.01%

• Banks, Financial Institutions and Mutual Funds 05.46%

• Individual shareholders 02.89%

• Others 01.44%

• Total 100.00%

BHEL ANNUAL FINANCIAL STATISTICS

2011-12 % Increase

Turnover (Crore) 49,301 19.4

Profit Before Tax (Crore) 10,001 17.8

Net Profit (Crore) 6,868 21.2

BHEL-EDN ANNUAL FINANCIAL STATISTICS

2011-12 % Increase

Turnover (Crore) 2301 14

Profit Before Tax (Crore) 827 9

COMPANY MANAGEMENT

• CHAIRMEN & MD

Mr. B.prasada RAO

( since 1 oct.2009)

• Director HRMr. R. KRISHNAM( since 1 april 2012)

PRODUCT PROFILE OF BHEL-EDN

• Steam Generator Controls ( Boiler Controls)

• Turbine Generator Controls

• Balance of Plant

• HMI/SCADA (Human Machine Interface)

• Static Excitation Equipment / Digital Voltage Regulators

• Variable Frequency Drives

• Traction Drives

• Gas Turbine Controls

• Transmission systems controls

• High Current Rectifiers

• Power Devices

• Photovoltaic cells/ Space grade solar cells

• Induction Heating Equipments (ESD)

• Defence Equipments (ESD)

TRACTION DRIVES

• These panels control the traction motors.

• Traction drive systems are extensively used in 1600 HP Broad Gauge AC or AC/DC Electrical Multiple Units (EMUs) and 6000 HP three Phase AC Locomotives for Indian Railways.

• Gate Turn Off Thyristor (GTO)/Insulated Gate Bipolar Transistor (IGBT) are now-a-days used for Traction applications.

GTO Based traction converter

max/metso DNA PANELS:

Steam Generator Controls: These panels monitor and control the boiler parameters.Eg: FSSS- Furnace Safeguard Supervisory System

SBC- Soot Blower Controls SADC- Secondary Air Damper Controls APRDS- Aux PRDS Control systemHP BYPASS- HP Bypass controls

Turbine Generator Controls: These panels monitor and control the turbineparameters.Eg: ATRS ( Auto Turbine Run-up System)Turbine System ControlOil level ControlCondenser & Evacuation System ControlTSE- Turbine Stress Evaluation ControlEHTC– Electro Hydro Turbine ControlLPBP– Low Pressure By-Pass ControlTurbine Protection ControlATT– Automatic Turbine Testing

Balance of Plant Control: These panels monitor and control:Coal Handling PlantsAsh Handling Plants, C&IID fans, FD fans

VARIABLE FREQUENCY DRIVE/ LOAD COMMUTED INVERTER

These panels control the speed of the following machines by varying the frequency:• fans (ID fan, FD fan, Primary air fan), pumps (feed water, condensate and circulating),

compressors• run up systems for gas turbines• frequency converters, motor starters,• start up of synchronous generators as condensers or start up of hydro generators in

pump storage.It consists of Control and Excitation Panel, Fan and Filter Panel and Bridge Panel

GAS TURBINE CONTROLS

• These panels monitor and control the gas turbine parameters.

• Naphta and Natural gas are used as the fuel-Gas is compressed and ignited for turbine control

• In EDN , it develop software, 9-253 MW controls available

• Widely used in refineries

SYSTEM TESTING• It checks the operation of finished goods.

• System testing receives engineering drawing , signal flow diagram and conducts various test like continuity test , high voltage test, functional test.

• Air conditioned test area of appox 2500 m sqr.

• Capacity to line up and test upto 600 cubicales at a time across 5 test shops.

• 3 types of test

• continuity test

• High voltage test

• Functional test

Si Wafer

Air coatingScreen printing

Texturisation

firingCell

testingCell

DiffusionPlasma Etching

PSG Removal

LaminationTesting and

framingPV module

PHOTOVOLTAIC Manufacturing flow chart :-

What exactly the SPV system??

PV manufacturing

What materials are used to produce solar cells?The most important material for solar cells production is silicon. At the time being, it is almost the only material used for solar cell mass production.

Monocrystalline silicon Polycrystalline silicon

• Formation of microscopic pyramids on surface of wafer is called texturization.Sodium Hydroxide is widely used for this stage of process. Pyramids size must be optimized, since very small pyramids lead to high reflection, while very large one can hinder the formation of the contacts.

Texturization

diffusion• Photo voltaic cell is nothing but PN junction diode, in this

stage PN junction is formed through process of diffusion .Phosphorous is universally used as the n-type dopant for silicon solar cells .Since solid state diffusion demands high temperature,it is very important that surfaces are contamination free before process. Wafers are placed in quartz tray and kept in a diffusion furnace at temperature of 700˚C.Furnace is filled with N2 gas it prevent reacting takes place with some other impurities.

N-type regions at the wafers edges would interconnect the front and back contacts .The junction would be shunted by this path translating into a very low shunt resistance. In order to isolate

this edges etch with plasma is widely employed.

Plasma etching

Air coating• Cell efficiency is further raised by anti reflection coating on surface of texurized,diffused silicon wafer.

Silicon nitride is widely used as masking film in microelectronics.

For solar cells,it present the advantage of performing as an effective

Anti-reflection coating Films can be deposited by several techniques

,but most commonly used process is CVD,involves

reaction of silane gas and Ammonia.

Screen printing

Front Contact printing: The requirement for the frontmetallization are low contact resistance to silicon, low bulk resistivity, low line width

Back contact print: Same operations are performed on the back side of the cell except the paint contains both silver and aluminum& the print pattern is different.

firing• Organic compound of the paste must be burnt

off, the metallic grains must sinter together to form a good conductor, and they must form an intimate electric contact to the underlying silicon and the back contact on the parasitic n type rear layer.

Cell testing

• Solar cells so manufactured are illuminated under an artificial light source with a spectral content similar to sunlight at 25˚C to get I-V curve. Defective devices are rejected & rests are classified according to their output. Here we established a number of classification based on its short circuit current at particular voltage near maximum power point. Module subsequently built with cells of the same classification, thus guaranteeing minimum mismatch loss.

lamination

framing

• The automatic framing station is used for aligning rectangular

Aluminum frame pieces by applying proper force to ensure

accurate frame assembly. It also punches the frames at the

corner block positions for rigidity.

Pv module