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HEAVY ELECTRICAL INDUSTRY IN INDIA
Heavy Electrical Industry covers power generation, transmission, distribution and utilization equipments. These include turbo generators, boilers, various types of turbines, transformers, switchgears and other allied items. Majority of the products manufactured by heavy electrical industry in the country, which includes items like transformers, switchgears etc. are used by all sectors of the Indian economy. Some major areas where these are used are the multi core projects for power generation including nuclear power stations, petrochemical complexes, chemical plants, integrated steel plants, non-ferrous metal units, etc.
India is the only other developing country besides China,which produces a full range of electric power generation and transmission equipment. In fact,the history and growth of (Bharat Heavy Electricals Ltd.), a public sector enterprise under in the country, symbolizes the overall growth pattern of heavy electrical industry in the country.BHEL has the unique distinction of being one of the very few companies in the world, manufacturing all major power generating equipment under one roof.
The industry has been upgrading the existing technology and is now capable of taking up turnkey contracts also for export markets. The industry has been delicensed. Foreign collaborations are allowed with 100 percent FDI.The country is planning to add 150,000 MW power generation capacity in the the next 10 years.This will generate substantial demand for heavy electrical equipments.
The heavy electrical industry is capable of manufacturing transmission and distribution equipment upto 400 KV AC and high voltage DC. The industry has taken up the work of upgradation and transmission to the next higher voltage system of 765 KV and have upgraded their manufacturing facilities to supply 765 KV class transformers, reactors, CTS, CVT, bushing and insulators, etc.
The investments in R & D by the electrical industry are amongst the largest in the corporate sector in India.Large electrical equipment used in steel plants, petrochemical complexes and other such heavy industries are also being manufactured in the country. The domestic heavy electrical equipment manufacturers are making use of the developments of the global market with respect to product designs and upgrading of manufacturing and testing facilities.The heavy electrical industry has established its reference in the global arena also.These encompass thermal, hydro and gas based power plants, substation projects, rehabilitation projects, besides a wide variety of products like transformers, photo voltaic equipments, insulators,switchgears, motors,etc.
Turbines and Generator Sets
The capacity established for manufacture of various kinds of turbines such as steam & hydro turbines including Industrial turbines is more than 7000 MW per annum in the country. Apart from BHEL, the public sector unit that has the largest installed capacity, there are units in the private sector also manufacturing steam & hydro turbines for power generation and industrial use. The manufacturing range of BHEL includes steam turbines upto 660 MW unit rating and the facilities are available for 1000 MW unit size. They have the capability to manufacture gas turbines upto 260 MW (ISO) rating and gas turbine based Co-generation and Combined Cycle Systems for the industry and utility applications. Custom built conventional hydro turbines of Kaplan, Francis and Pelton types with matching generators are also available indigenously.
AC Generators manufactured in India are on par with international AC Generators and consistently deliver high quality power with high performance. Domestic manufacturers are capable of manufacturing AC Generator right from 0.5 KVA to 25,000 KVA and above with specified voltage rating.The imports and exports of turbines and generators during 2005-06 were Rs. 2420 crore and Rs. 565 crore respectively.
Boilers
Bharat Heavy Electrical Ltd.(BHEL) is the largest manufacturer of boilers in the country (with more than 60% share) and has the capacity to manufacture boilers for Super Thermal Power Plants apart from utility boilers and industrial boilers. The industry has the capability to manufacture boilers with super critical parameters upto 1,000 MW unit size. The domestic industry has the capacity to meet the indigenous requirement / demand for boilers.The imports and exports of boilers during 2005-06 were Rs.160 crore and Rs.242 crore respectively.
Transformers
The domestic transformer industry is well established with capability to provide state of- the-art equipments. The industry has the capacity to manufacture whole range of power and distribution transformers including the REC rating of 25,53,100 KVA and also the extra High voltage ranges of 400 kV, 600 MVA. Special types of transformers required for furnaces, rectifiers electric tract etc. and series and shunt reactors as well as HVDC transmission upto 500 kV are also being manufactured in the country.The imports and exports of transformers during 2005-06 were Rs.1800 crore and Rs.1640 crore respectively.
Switchgear and Control Gear
In India, the entire range of circuit breakers from bulk oil, minimum oil, air blast, vacuum to SF6 are manufactured to standard specification for the benefit of customers. The ranges of products produced cover the entire voltage range for 240V to 800KV, switchgear and control gear, MCBs, air circuit breakers, switches, rewireable fuses and HRC fuses with their respective fuse bases, holders and starters. The industry is competitive in the field of design and engineering as the skill sets available in the country are relatively less expensive.The imports and exports of the above equipments during 2005-06 were around Rs.1690 crore and Rs. 1108 crore respectively.
Electrical Furnaces
Electrical Furnaces are used in Metallurgical and Engineering industries like forging and foundry, machine tools, automobiles etc. Adequate capacity for production of these products has been established.The imports and exports of electrical furnances during 2005-06 were aound Rs.186 crore and Rs. 108 crore respectively.
Shunting Locomotives
Shunting Locomotives for localized/ internal transport facilities are used in railways, steel, plants, thermal power plants, etc. BHEL’s Jhansi unit among others is manufacturing such locomotives. The installed capacity is adequate to meet the domestic demand.
HEAVY ELECTRICAL INDUSTRY IN BHEL
The first plant of what is now known as BHEL was established more than 40 years ago at
Bhopal and was the genesis of the heavy electrical equipment industry in India.
`BHEL is, today the largest engineering and manufacturing enterprise of its kind in India, with a well recognized track record of performance, earning profits continuously since 1971-72 .It achieved a sales turnover of Rs-6347 Cr. with a pre-tax profit of Rs 2941Cr.
in 2000-2001.
BHEL caters to core sectors of the Indian economy viz. Power Generation and Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defenses.
The wide network of BHEL’s 14 manufacturing divisions, 4 power sectors regional centers, over 100 project sites, 8 service centers and 4 regional offices, enables the company to be closer to its customers and provide them with suitable products, systems and services efficiently and at competitive prices. Having attained ISO 9000 certification, BHEL is now well on its journey towards TOTAL QUALITY MANAGEMENT .On the environmental management front, the major units of BHEL have already acquired the ISO-14001 certification.
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 – a dream that has been more than realized with a well– recognized track record of performance. The Company has been earning profits continuously since 1971-72 and 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, Telecommunication, Renewable Energy, etc. BHEL has acquired certification to Quality Management System (ISO:9001), Environmental Management System (ISO:14001) and Occupational Health & Safety Management System (OHSAS:18001) and is also well on its journey towards Total Quality Management (TQM).
The company inherent potential coupled with its strong performance over the years has resulted in it being chosen as on of the Navratna PSUs which enjoy the support from the government their endeavors to become global players. with its prudent financial management. BHEL occupies an all-important niche as evident by its ranking by CII amongst top eight PSUs based on financial performance. Recently in survey conducted by business India, BHEL has been rated as seventh Best Employer in India.
BHEL has
 Installed Equipment for over 90,000 MW of power generation – for utilities, captive and Industrial users.
 Supplied over 225000 MV transformer capacity and other equipment operating in transmission & distribution network up to 400 KV (AC & DC).
 Supplied over 25000 motors with Drive Control System to Power projects, Petrochemicals, Refineries, Steel, Aluminum, Fertilizers, Cement plants, etc.
 Supplied Traction electrics and AC/DC locos to power over 12000kms Railway networks.
 Supplied over one million valves to power plants and other Industries.
BHEL’s operations are organized around three business sectors, namely Power, Industry- including Transmission, Transportation, Telecommunication & Renewable Energy and Overseas Business. This enables BHEL to have a strong customer orientation, to be sensitive to his needs and respond quickly to the changes in the market.
BHEL’s Vision is to become a World-Class Engineering Enterprise, committed to enhancing Stakeholder value. The greatest strength of BHEL is its highly skilled and committed 44,000 employees. Every employee is given an equal opportunity to develops himself and grow in his career.

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1. INTRODUCTION.
In past few years the field of communication has been developing with no leaps or bounds. It has become a necessity of each human being to be connected with each other. Telephone is rapidly becoming a tool to quench this thirst.
In Automatic Telephony, operators are not required to establish connections manually between the different calling and the called subscribers as are required in the case of manual telephone systems. In these system subscribers those selves establish required connections by operating the different switches placed at the central place known as the EXCHANGE from their telephones at remote place from it. The automatic telephone systems are rapidly replacing manual ones due to their outstanding merits over the latter types, some of which are enumerated below:
* In Automatic Telephony higher level of secrecy is maintained due to absence of
Operators who can overhear the conversation if they like in the manual telephone
Systems.
The working of an Automatic Telephone system does not depend for its efficiency
On the personal efficiencies of the operators.
* There is no possibility of the calls being missed or wrong metering being done due to faults of operators or due to phonetic errors between the subscribers and the operators.
As no operator is required, the running cost of the exchange is reduced.
COMMUNICATION Dia.I
2. THE ORGANIZATION.
BHEL was primarily set up to meet the needs of the power sector in the country. The first plant was established nearly 35 years ago at Bhopal, which heralded the genesis of the heavy electrical equipment in India. BHEL is today the largest engineering enterprise in India, with excellent track record of performance, making profits continuously since 1971-72. It achieved a sales turnover of Rs. 3154 carores with a pretax Profit of Rs.201 carores, in 1990-91.
The areas of BHEL operations broadly cover conversion, transmission, utilization and conservation of energy in core sectors of the economy like Power, Industry and Transportation, etc., and fulfill vital infrastructure needs of the country.
Today, BHEL has 13 manufacturing divisions, 8 service centers and 4 Power Sector Regional Centers, in addition to over 150 project sites spread all over India and even abroad to provide prompt and effective service to customers.
BHEL Hardwar is one of the premier organizations which is honored by I.S.O.-9002 specifications.
3. TELECOMMUNICATION.
BHEL manufactures EPABX and MAX systems based on C-Dot technology and has plans to make other ranges of telecommunication equipment also.
These are basically used for connecting links between various modules like peripherals, exchange and its equipments. It is necessary to run a number of internal cables of suitable conductors between the following stages and frames:-
1. Handset to exchange's cable chamber
2. Cable chamber to M.D.F.
3. M.D.F. to I.D.F.
4. I.D.F. to Number Block
5. Number Block to Exchange Equipment
6. Between two exchanges
7. Between two cities
8. Between two countries
Prior to advent of Electronic Exchanges inter-connection of various circuits are made by mechanical contacts that are operated by mechanical movements produced by the attraction of an iron armature of an electromagnet or by the operation of an electric motor. There are some disadvantages of such systems for using mechanical contacts, due to following reasons:
• Contacts are subjected to wear and tear.
• Require adjustments time to time.
• Maintenance is highly precise.
• Prone to corrosion. Etc...
But now-a-days Electronic Exchanges are used. In Electronic exchange electronic devices effect the inter-connection between different transmission circuits and Electro-mechanical relays and switches are dispensed with. Such electronic devices remove difficulties associated with mechanical contacts. The greatest advantage of using electronic devices in place of electromechanical devices is that no time is loosed in making a connection and a very high speed of operation is possible.

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TRAINING SEMINAR ON BHEL
HISTORY
ESTABLISHED IN 1965
FIRST HEAVY ENGINEERING INDUSTRY IN INDIA, SETUP AT BHOPAL (MP)
SUPPLIES EQUIPMENTS CAPABLE FOR GENERATING 6000MW/YEAR
EXPORTS REACHED Rs.122 CRORES, HIGHEST FOR ANY YEAR IN 1978-79
HEAD OFFICE IN NEW DELHI
BHEL IN PRESENT SCENARIO….
A widespread network comprising of 14 manufacturing companies
With an export presence in more than 60 countries
Supplied over 25000 Motors with Drive Control System to power projects, Petrochemicals Refineries, Steel, Aluminum, Fertilizer, Cement plant, etc.
 150 Project sites
Supplied Traction electrics and AC/DC locos over 12000kms Railway network.
Supplied over one million Values to Power Plants and other Industries
Installed equipment for over 90,000MW of power generation for Utilities, captive and Industrial users.
14 Manufacturing Divisions
 9 Service Centers
 4 Power Sector Regional Centers
CLIENTS INCLUDE..
POWER
INDUSTRY
TRANSPORTATION
TRANSMISSION
TELECOMMUNICATION
DEFENCES ETC.
BHEL HARIDWAR
HAS 8 DIFFERENT BLOCKS
Block-1:- In block one turbo generator, generator, exciter motors (A.C&D.C) are manufactured & assembled
Block-2:- In block two large size fabricated assemblies\component for power equipment are manufactured & assembled.
Block-3:- In block -3 steam turbine, hydro turbines, and gas turbines, turbines blade are manufactured & assembled
Block-4:- In block -4winding for turbo generator, hydro generator, insulation of A.C&D.C motors insulating component for turbo generator, hydro generator motors are manufactured & assembled
Block-5:- In block -5 fabricated parts of steam turbine water box, hydro turbine turbines parts are manufactured & assembled
Block-6:- In block -6 fabricated oil tanks hollow guide blades, rings, stator frames rotor spiders are manufactured & assembled
Block-7:- In block -7all types of dies including stamping dies, stamping for generators &motors are manufactured & assembled
Block-8:- In block -8 LP heaters, ejectors, steam coolers, oil coolers, ACG coolers, oil tanks are manufactured & assembled
BLOCK-4MANUFACTURING OF BAR BY STEP:
Conductor cutting
lower bar
upper bar
Transposition
Crossover insulation
Forming
Brazing of coil lugs
Nitrogen leak test
Thermal shock test
Helium leak test
Insulation
Impregnation and baking
thermo reactive system
micalastic system
VIP micalstic system
Finishing
Conducting varnish coating
OCP(outer corona)
ECP(end corona protection)
Testing
h.v. test
BLOCK – 01Conventional Bay-wise broad distribution 
LSTG Area large size turbo generators
BAY-1 hydro generators, their exciters, PMG and Large size Turbo- Generators
BAY-2 Turbo-generators, their exciters and Heavy Electrical Motors
BAY-3 Medium size Electrical Motors
Block-1 is designed to manufacture hydro-generators and large and medium size AC and DC Electrical machines.
The Block consists of 3 Bays: Bay-1(36*482 meters),Bay- 2, (36*360 meters) and Bay-3 of size 24*360 meters each. For handling and transporting the various components over-head crane facilities are available, depending upon the products manufactured in each bay. There are also a number of self propelled electrically driven transfer trolleys for the inter-bay movements of components/assemblies

MANUFACTURING PROFILE

Generator
1) Kraft Work Union-
i) THDF
ii) THRI
iii) TARI
TARI: Capacity 500 MW, Cooling is done by air.
THRI: Capacity 130-400 MW. Water is the cooling medium. Stator is indirectly cooled while Rotor is radially cooled.
Hydrogen Cooled Turbo generators Of 140-260 Mw Range (Type: THRI ) Salient Design Features
Stator core and rotor winding directly
hydrogen cooled
Indirect cooling of stator winding
Rigid core bar mounting
Micalastic insulation system
End shield mounted bearings
Top ripple springs in stator slots
Ring type shaft seals
Symmetrical ventilation.
Salient Technical Data
Rated output : 588 MVA, 500 MV
Terminal voltage : 21 KV
Rated stator current : 16 KA
Rated frequency : 50 Hz
Rated power factor : 0.85 Lag
Efficiency : 98.55%
Important Weights
Heaviest Lift of Generator Stator : 255 Tons
Rotor Weight : 68 Tons
Total Weight of Turbo Generator : 428 Tons
Large DC MachinesSalient features of large custom-built m/c
Compact design with smaller size.  
MICALASTIC insulation using VPI technology for high electrical and mechanical strength
Sturdy mechanical construction to meet frequent reversals
Low moment of inertia
Skewed armature slots for reduced noise level
Fully compensated for high overloads & wide speed range.
Technical Data
Ratings:-from 1400 kW at 1000 rpm to 12000 kW at 70 rpm
Voltage: - up to 1200 V. Higher voltages on request
Mountings: - both horizontal and vertical
MEDIUM SIZE AC MOTORS
salient features
Very high efficiency.
Torsionally rigid, rugged housing and end shields made of cast iron.
External and internal ribbing on slip ring enclosure and servicing cover.
MICALASTIC insulation using VPI technology.
Proven anti-friction bearing concept.
Compact dimensions.
Technical Data
Ratings: -200 to 2500 kW
Voltage range: - 3.3 to 11 kV, 50 Hz.
Number of poles: -4 to 12
Shaft heights (in mm.):- 355, 400, 450, 500 and 560
STATOR
the main part of every motor and generator
very hard, size depends upon its characteristics
Stator frame
suitably ribbed with annular rings
CONCLUSION
WE GOT KNOWLEDGE ABOUT TGs & MOTORS.
BASICALLY THE WHOLE PROCESS OF MAKING A TURBO GENERATOR RIGHT FROM THE ENRICHMENT OF THE ROTOR TO THE TESTING BED.
APART FROM THAT WE LEARNED HOW DOES THE INDUSTRIES WORK.