Bharat Heavy Electricals Limited : BHEL’s contribution towards self-reliant India

By Rajesh Kohli

Executive Director (Corporate Technology Management) | Bharat Heavy Electricals Limited

Established in 1956, BHEL is the largest government-owned power generation equipment manufacturer in India. BHEL has a pan India network of 16 manufacturing facilities, 2 repair units, 8 service centres, 15 centres of excellence, 5 specialized institutes for carrying out advanced R&D in various engineering disciplines and is currently executing projects at more than 140 sites. BHEL offers one-stop solutions backed by its core design, engineering and manufacturing strengths coupled with a committed pool of more than 29,000 employees (including about 8,300 skilled engineers), contemporary technologies and state-of-art manufacturing and testing facilities. The company undertakes projects and contracts in all modes including EPC, Supply, Supply & Supervision, Consortium, Contract Manufacturing, etc., as per customer requirements.

BHEL has been actively involved in Research and Development (R&D) and has set up several R&D centers across India, working on developing new technologies and solutions. BHEL’s R&D efforts have resulted in the development of several innovative products and solutions, reducing cost and increasing efficiency.

Innovation serves as the backbone of progress, propelling the remarkable growth story of BHEL that has transformed our lives, nurtured the aspirations of our great nation, and offered solutions to address contemporary challenges. Technology development is an integral part of growth in core areas and new businesses. BHEL focuses its R&D efforts on power, transportation, defense & aerospace, transmission, and emerging technologies such as green hydrogen, fuel cell technology, coal-to-chemicals etc. BHEL is also working towards development of critical technologies in the areas of railway propulsion systems, high speed locomotives, urban mobility solutions, equipment for defence applications, space grade solar batteries and electric vehicle chargers. BHEL has played significant role in shaping modern India’s industrial landscape by contributing in the following sectors:

Power: BHEL has been instrumental in achieving self-reliance in Power sector by providing equipment, services, and solutions for power generation, transmission, and distribution for several thermal, hydro, and nuclear power plants across India. BHEL has proven turnkey capabilities for executing power projects from concept to commissioning and is capable of executing coal-based power projects on Engineering, Procurement & Construction (EPC) basis for subcritical & supercritical technologies up to 1,000 MW rating. BHEL sets contribute about 55% of the total Power generation capacity (Thermal) in India. BHEL, NTPC and Indira Gandhi Centre for Atomic Research (IGCAR) have successfully completed the R&D phase for design and manufacturing of Advanced Ultra Supercritical (AUSC) Technology for higher efficiency and low emission thermal power plants. Under the AUSC R&D phase, BHEL has indigenously designed and developed Power Cycle Equipment (Boiler, Turbine & associated equipment) as well as carried out system engineering suitable for high temperature & pressure required for AUSC based thermal power plants.

BHEL is a leader in the hydro segment in India with over five decades of experience with a portfolio of 550+ hydroelectric sets with 32 GW+ capacity commissioned in India and abroad. BHEL has the capability to deliver complete Hydro Power and Lift Irrigation Projects including design, engineering, supply/ logistics and erection & commissioning. Hydro turbines in the range of 5 MW to 400 MW unit sizes of various impeller types namely Francis, Kaplan and Pelton along with matching generators are designed, engineered, manufactured and tested at BHEL’s manufacturing plants. BHEL has designed, manufactured and commissioned highest head Francis Turbine (150 MW) in India for NEEPCO Kameng HEP, Arunachal Pradesh. BHEL has successfully executed Pump-Motor sets order for LIS projects in Telangana for world’s largest multi-stage lift irrigation project at Kaleshwaram. BHEL is currently in process of manufacture and supply of India’s highest unit-rating Kaplan hydro turbines for E&M works for 12×80 MW Polavaram HEP in Andhra Pradesh for APGENCO. BHEL has recently won a prestigious order for the Electro-Mechanical (E&M) works of the India’s largest capacity hydropower project of 2,880 MW Dibang Multipurpose Project in Arunachal Pradesh.

BHEL is the only company associated with all three stages of Indian Nuclear Power Programme by providing sustainable solutions for over 5 decades and has supplied 44 nuclear steam generators till date. BHEL is the only manufacturer of Steam Turbine for nuclear application in India. 74% installed capacity of indigenous Pressurized Heavy Water Reactors and nearly 50% of total capacity in country is equipped with BHEL STG Sets. In 2018, NPCIL’s Kaiga Unit 1 created a world record of longest continuous operation of 962 days. The Steam Turbine Generator set for the plant has been supplied by BHEL and is under operation since November 2000.

With its state-of-art technology and engineering expertise, BHEL has helped India become self-sufficient in power generation sector.

Transmission: BHEL has played a significant role in the transmission sector, contributing valuable efforts to the nation-building process. Leveraging its expertise and technological prowess, BHEL has been pivotal in strengthening the power transmission infrastructure of the country. Notably, BHEL has successfully commissioned over 240+ Electrical Substations and completed 6 major HVDC Projects. BHEL played a significant role in the world’s first multi-terminal ±800kV HVDC Project at Agra. Power can flow in either direction through this power transmission express highway from Biswanath Chariali, Assam to Agra in UP. In addition, BHEL’s contributions include the supply of Transformers/Reactors, totaling a capacity of over 730,000 MVA to PGCIL, NTPC, NHPC and state utilities. BHEL successfully designed, manufactured, installed and commissioned India’s first 400kV class Phase Shifting Transformer (PST) for TSGENCO – 315 MVA ± 15° PST at 400/220 kV Kothagudem substation. As India’s power demands continue to evolve, BHEL remains pivotal in shaping the future of India’s power transmission sector.

Transportation: BHEL has been a trusted partner of Indian Railways (IR) for the past six decades, providing a diverse range of products and propulsion systems for various rolling stock. The first IGBT-based Air-conditioned EMU train in India incorporates BHEL-supplied Electrics and Controls. BHEL has successfully designed and supplied MEMU trains to Indian Railways, featuring 3-phase electrics and Ethernet-based communication. The development of the WAG-7 (5000 HP) Locomotive by BHEL, equipped with a Regenerative Braking System for DC Motors has resulted in a significant saving in energy consumption. Additionally, BHEL has developed an Indigenous Propulsion System for the upgraded 9000 HP (WAG9HH) locomotive. BHEL and Titagarh Rail Systems Ltd. (TRSL) will be delivering Vande Bharat Sleeper Trains, transforming passenger transportation for Indian Railways.

Defence and Aerospace: BHEL has actively engaged in the defense business for over three decades, establishing a solid track record of competitiveness, adherence to quality, reliable supplies, and lifelong product support. BHEL has supplied 40+ Super Rapid Gun Mount (SRGM) Systems that is the main gun onboard naval warships of the Indian Navy, offering comprehensive on-board services and long-term product support, including maintenance and overhaul. Notably, BHEL stands as the sole indigenous supplier of compact heat exchangers for fighter aircraft applications. BHEL takes great pride in its association with INS Vikrant, India’s first Indigenous Aircraft Carrier. Furthermore, BHEL has been a trusted provider of steam turbines, alternators, and power generation equipment/systems (electrical/mechanical) for marine applications. BHEL has made a substantial contribution to India’s space exploration endeavors by supplying indigenously produced space-grade solar cells and solar panels for space missions. India’s third lunar mission, Chandrayaan3 is equipped with BHEL manufactured Batteries , Power Supply Units for Lander Module (Critical equipment of Lander Module to Moon) and Propulsion Module (Supplying power during launch and maneuvering). The mission is also equipped with BHEL make friction welded bimetallic adaptors and Titanium Propellant Tanks. BHEL has been partnering with ISRO for powering India’s space aspirations since two decades. Presently, BHEL is actively involved in the development of pump modules for airborne applications and reserve propulsion systems for strategic applications.

Industry Sector: BHEL has been a significant contributor to the industry sector in India. With its expertise in power solutions and heavy electrical equipment manufacturing, BHEL has played a vital role in establishing industrial infrastructure across various sectors. The industrial equipment provided by BHEL has effectively supported the growth and productivity of industries, including steel plants, cement factories, and refineries. Over the last five decades, BHEL has designed and supplied more than 33,500 AC machines for various drive applications in both the Indian and overseas markets. Furthermore, BHEL has been a prominent manufacturer of oil rigs for the Indian oil and gas industry for the past five decades. In addition to oil rigs, BHEL offers individual equipment such as Draw works, Travelling blocks, Crown blocks, Swivels, Mud systems, and Rig auxiliary systems. BHEL has also successfully indigenized Sucker Rod Pump as a substitute for imports, supporting Indian oil and gas sector.

BHEL has played a crucial role in the Make in India initiative. With its state-of–art manufacturing facilities and engineering expertise, BHEL has been able to provide indigenously manufactured equipment and components reducing India’s dependence on imports. This has not only helped the country save foreign exchange but has also created opportunities for local manufacturers to grow. BHEL has played a significant role in making India self-reliant. BHEL has immense contribution to the heavy industry sector, Indian economy, Make in India initiative and R&D in the country. With its state-of-art technology, engineering expertise, and commitment to the country’s development, BHEL is a shining example of how public sector undertakings can contribute to the growth and development of a self-reliant nation.

(Shilpa Bichitra | Special Edition | 2023)