PROFILE OF BHEL, RANIPET.

BHEL - AN OVER VIEW BHEL is the Largest Engineering and Manufacturing Enterprise in India in the energy Related / infrastructure sector today. BHEL was established more than 50 years ago. When its first plant was set up in Bhopal ushering in the indigenous Heavy electrical Equipment Industry in India, a dream which has been more than realized with a well recognized track record of performance. Rs.7286.6 crores with a Pre-Tax profit of Rs.662.8 crores in 2001 2002 BHEL caters to core sectors of the Indian Economy viz., Power Generation & Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defence etc,. The wide network of BHELs 14 Manufacturing Divisions, Four Power Sector Regional Centers over 100 Project sites, Eight service centers and 18 Regional officers, enables the Company to promptly serve its customers and provide them with suitable products, systems and services efficiently and at competitive prices. BHEL has already; attained ISO 9000 It has been earning profits continuously since 1971 72, and achieved a sales turnover of

Certification for Quality Management and ISO 14001 certification for Environment Management. BHEL CORPORATE PROFILE Bharat Heavy Electricals Limited is the largest Engineering and Manufacturing Organization in India. It was established to comprehensive range of products and services for Hydro Generators, Thermal Power Stations, Nuclear Power Station and Gas Turbine and Distribution at the initial stage.

To fulfill the objects the following concerns were established. 1. Heavy Electrical Plant - Bhopal (MP) - Aug 1956 2. High Pressure Boiler Plant - Trichy (TN) - May 1965 3. Heavy Power Equipment Plant - Hyderabad (AP) - Dec 1967 4. Heavy Electrical Equipment Plant - Hardwar (UP) - Jan 1967 5 . Boiler Auxiliaries Plant - Ranipet ( TN ) - Mar 1980 BHEL is in the field of Steam Generator, Serving the needs of various users, who are in need of reliable efficient Steam Generators. Modern Steam Generators are large complex equipment, incorporating the latest advancements in the fields of heat transfer, material science, electronics and other engineering sciences.

In the international level BHEL is among the Top 10 organizations in the world production Power Plant Equipment. So far BHEL has secured export orders from more than 40 countries to the tune of 4898 million rupees. BHELs roll in emphasizing on optimum utilization of Indian coal divising methods and equipments with lower energy consumption and working at a diversited minuture of energy. As on date BHEL has a Corporate Office at New Delhi and has 14 Manufacturing Units, 10 Service Centers are located in different places of the country. BHEL has a Corporate Profile and has it Liasion Offices in London, Moscow and Site Offices in Libya, Thailand and Malaysia. MAJOR FUNCTIONS OF BHEL POWER GENERATION:

Power Generation Sector comprises Thermal, Gas, Hydroand Nuclear Power Plant Business. As of 31-03-2001, BHEL supplied sets accounts for nearly 67232 MW or 64% of the total installed capacity of 1, 04, 917 MW in the country, as against nil till 1969 1970. BHEL has proven Turnkey capabilities for executing Power Projects. To make efficient, use of the High Ash Content Coal available in India, BHEL supplies circulating Fluidized Bed Combustion Boilers to both Thermal and Combined-Cycle Power Plants. The company manufactures 220/235/500 MW Nuclear Turbine Generator sets, land has commenced production of 500 MW Nuclear Turbine Generator sets. In all, orders for more than 700 utility of Thermal, Hydro, Gas and Nuclear. The Power Plant Equipment manufactured by BHEL is based on

contemporary Technology comparable to the world, and is also internationally competitive. POWER TRANSMISSION & DISTRIBUTION (T & D): BHEL offers wide-ranging Products and systems for T&D applications, Products manufactured include Power Transformers, Instrument Transformers, dry type Transformers, Series and Shunt Reactors, Capacitor, SF Circuit Breakers, Gas insulated Switch Gear and Insulators. EHV level series have been installed in KSEB, MSEB and Power Grid Networks. Complete HVDC systems can be delivered by BHEL. INDUSTRIES:

BHEL is a major contributor of equipment and systems to industries: Cement, Sugar, and Fertilizer. Refineries, Oil and Gas Petrochemicals and paper. The range of Systems & Equipment supplied includes: Captive Power Plants, DG Power Plants, Industrial Steam Turbines, Industrial Boiler and Auxiliaries, Gas Turbines, Pressure Vessels, Electric Machines, Seamless Steel Tubes, Reactors, Electrostatic Precipitators, Fabric Filters, Fluidized Bed Combustion Boilers. The company is a major producer of Large size Thyristor Devices. BHEL is the only company in India with the capability to make simulators for Power Plants. The company has commenced manufacture of large Desalination Plants to help augment the supply of Drinking Water to people. TRANSPORTATION: BHEL is Included in the Development Design, Engineering, Marketing, Production, Installation Maintenance and after-sales services. The

Electric and Diesel Traction Equipment on Indian Railways are largely powered by Electric Propulsion Systems produced by BHEL. The company also undertakes Retrofitting and over hauling. BHEL is geared up to Turnkey execution. BHEL is also diversifying in the area of Port Handling Equipments. TELECOMMUNICATION: BHEL also caters to Telecommunication sector by way of small, medium and large switching systems. RENEWABLE ENERGY: Technologies that can be offered by BHEL for Exploring NonConventional and Renewable sources of energy include, Wind Electric Generators, Solar Photo Voltaic systems, Solar Heating Systems and Solar Lanterns.

INTERNATIONAL OPERATIONS: BHELs products services and projects have been exported to 52 countries ranging from the United States in the Far East. The cumulative capacity of Power Generating Equipment supplied by BHEL outside India is over 3000 MW. The company overseas presence include several projects, 150 MW ( ISO ) Gas Turbine to Germany, utility boilers, open cycle Gas Turbine Power Plant to Malaysia , Turkey Power Station for Tripoli. Hydro Generator to New Zealand and Hydro Power Plant to Thailand. BHEL has recently executed major Gas Based Power Projects in Saudi Arabia and Oman. For outstanding performance in exports BHEL won the Top exporters shield from EEPC for the year 1994 1995.

PARTICIPATION IN THE GLOBAL COMPACT : The Global Compact is partnership between the United Nations. BHEL has joined the Global Compact of United Nations and has committed to support it, and set core values enshrined in its nine Principles.

BHEL UNITS & PRODUCT PROFILE High Pressure Boiler Plant - Trichy: Power Boilers, Industrial Boilers, Nuclear Steam Generators and Reactor Handlers, FBC/ CBFE Boilers, Heat Recovery Steam Generators, Heat Exchangers, Pressure Vessels, Reaction Columns, Piping Systems, Pipe Fittings, Gravimetric Feeders, Soot Blowers, Block Valves, Suspension System and Casting Support System, Thermo Pressed Components and Armored Vehicles for Defense.

Seamless Steel Tube Plant - Trichy: Seamless Steel Tube, Spiral Fin Welded Tubes Boiler Auxiliaries Plant - Ranipet: Electrostatic Precipitators, Fabric Filters, Air pre heaters, Fans, Wind Electric Generators, Ash Handling, Coal Handling Equipment, Desalination Plants, Defense Systems, Gates and Dampers and ISRO components. Industrial Valves Plant - Govindwal: Industrial Valves and Fabrication

Heavy Electrical Plant

- Bhopal:

Steam Turbines, Turbo Generators, Hydro sets, Switch Gear Centro glass, Rectifiers, Capacitors, Transformers, Motors, HVDC Large Electrical Power Supply Machines, Industrial Machines and Large Electrical Traction Machines Central Foundry Forge Plant - Hardwar: Heavy Castings and Forgings. Heavy Power Equipment Plant - Hyderabad: Power Generator sets, Industrial Turbo sets, Compressors Pumps and Heaters, Bowl Mills, Heat Exchangers, Oil Rigs, Gas Turbines, Switch Gear. Electronics Division - Bangalore:

Energy Meters, Water Meters, Control Equipments, Capacitors, Photo Voltaic Panels, Electronic Private Automatic Branch Exchange. Electronic Systems Division - Bangalore: Simulators, Telecommunication Systems and other advance

Microprocessor Based Control Systems. Electro Porcelain Division - Bangalore: Insulators and Bushings, Ceramic Liners. Insulators Plant - Jagadishpur: Insulators and Bushings.

Component Fabrication plant - Rudrapur: Solar cells, Solar Lanterns, Chargers and Solar Clocks. Heavy Electrical Equipment Plant - Hardwar: Turbo sets, Hydro sets, Electrical Machines, Industrial Control Panels, Winches, Gas Turbines and Light Aircrafts Transformers Plant - Jhansi: Transformers, AC Logos, AC EMU, Diesel Shunters

HISTORY OF BOILER AUXILIARIES PLANT

It was decided to set an Auxiliaries Plant for BHEL.Our then Defence Minister and Ex President of India Thiru R.Venketaraman, proposed to locate the plant at Ranipet of Tamil Nadu, to develop the North Arcot District an industrially

starved backward area. Hence this BOILER AUXILIARIES PLANT (BAP) was established at Ranipet as the 13th Manufacturing Units of BHEL. In the year 1980 March, BAP the 13th manufacturing unit of BHEL was set up as a part of the relocation of facilities from Trichy. BAP is located in a 1400 acres site , 120Kms from Chennai towards Bangalore. In 1982 October Production of Air Preheater was started on and later on Electrostatic Precipitator manufacturing was started. Later in the year 1985 it started its manufacturing of Fans. On October 5th, 1985 the BAP Ranipet was dedicated to the nation and its complex was named as Indira Gandhi Industrial Complex. The Investment that was put on BAP / Ranipet was around Rs.36 crores

PEOPLE ORIENTATION: To enable each employee to achieve his potential, improve his capabilities perceive his role and responsibilities and success of the company. To invest in human resources continuously and be alive to there needs. TECHNOLOGY: To achieve Technology excellence in operations by development of indigenous technologies and efficient absorption and adoption of imported Technologies to suit business needs and priorities and provide a competitive advantage of the company. IMAGE:

To fulfill the expectations which state holders like Government as Owner, Employee, Customs and Country at large have from BHEL. EVOLUTION Boiler Auxiliaries Plant, the 13th manufacturing unit of BHEL was set up at Ranipet in March 1980, as a part of the relocation of facilities from Trichy. BAP is the third phase expansion of BHEL / Trichy where in 4000 MW capacity addition in the country and enhancement of unit setup to 500 MW were envisaged. The capacity of BAP (Tonnage) is 57000 tons / year. It includes shop manufacturing off-loaded items, MSA, Direct to Site items produced items and direct dispatch items motors, bolts. Etc., Boiler Auxiliaries Plant/Ranipet started its production activities by manufacturing of Electrostatic Precipitator (ESP), Airpreheater (APH) and Draft Plant (Fans) as its main products. After a decade new products like Heat

Exchangers, Desalination Plants, Wind Electric Generators, Dampers louvers, Gates (Hot Air) were added to the product line. The unit has also manufactured tanks for ISRO, GSAT, INSAT-3 and IRS P5 applications. It has capacity to fabricate machine and assemble Launcher for TRISHUL Missiles, Mine Winder Components are also under production at Ranipet. INFRASTRUCTURES BAP was established with the following facilities. Office accommodation are provided in 3 main buildings viz., Engineering building, Administration building and Shop Office building. The P&A Department, EDs Secretariat, Purchase Department, Accounts Department and Ancillary Department are accommodated in the administrative building. The

Design Engineering, Informatics Center, Marketing, Commercial, Central Library, Archives, Technical Services are located in the Engineering Building. Production Supporting Services, HRDC, Time Office, FMC, Welfare, Erection Services, Safety Engineering and Stores Department are located nearer to shop. The Production shop supported by material preparation shop and Fan Testing Station. It performs the manufacturing activities. The production shop consists of 7 bays. One bay is allocated for material preparation, one bay is allocated for machines (F3 bay) and other two are called Feeder bays for the assembly bays (5 in nos.). A1, A2, A3 (Air pre heater bays), F1 and F2 (Fans) bays and F3 bay is the Machine Shop, which is divided in to light Machine and heavy machine shop. An Oxygen Plant, Acetylene Plant and Compressor Plant along with a Stores Complex, consists of Raw Material Stores (RMS) open yards with gantry cranes, Sub-delivery stores (SD) Consumable, Stores, Inflammable Stores are also available. COMPANY OBJECTIVES BUSINESS MISSION: To maintain a leading position as suppliers of quality equipment systems and services in the field of conversion, Transmission, Utilization and conservation of energy for application in the area of Electric Power Transportation Oil and Gas exploration and Industries. To utilize companys capabilities and resources to expand business into allied areas and other priority sectors of the economy like Defence, Communication and Electronics. GROWTH:

To ensure a steady growth by enhancing the competitive edge of BHEL in existing business, new areas and international operations. PROFITABILITY: To provide a reasonable and adequate return on capital employed primarily through improvements in operation, efficiency, capacity, utilization and productivity and general adequate internal resources to Finance the Companys Growth. CUSTOMER FOCUS: To build a high degree of customer confidence by providing increased value of his money through international standards of produce quality, performance and superior customer services.

PRODUCTS MANUFACTURING IN BAP BAP at Ranipet started its production activities by manufacturing ESP (Electro Static Precipitator) APH (Air Pre-Heater) FANS As its main products. After a decade, new products like Heat Exchangers Desalination Plants Wind Electric Generators Damper for louvers, gates(hot air) Ash and Coal Handling Fabric Filters

 Chimney shell Ducts and Ducts supports ISRO components Defence

PERSONNEL AND ADMINISTRATION:

PERSONNEL: MAJOR FUNCTIONS: RECRUITMENT AND SELECTION: Responsible for the recruitment in the factory. HRDC (Training and Development): Trains employees at all levels on current issues, topics of interest etc., Co ordinates and trains Engineer Trainees in the inner and intra unit level. Provides training for Trainees and projects for under Act of Apprentice. Arrange for in plant Trainees and project for students from Educational Institutions. Maintains leave registers the attendance, etc for the ETS, technical apprentices, etc., and disperses their salary, stipend. ESTABLISHENT Maintains history of each employee (personnel file records). Maintains the pay details, transfer (inter and intra departmental) details and Department allocation details. Keeps control of records of leaves, Increments promotions.

 Disciplinary actions taken, Rewards given etc., Maintains the record of loans and advances, LIC details. INDUSTRIAL RELATIONSHIP: Deals with trade unions and Bi partite committee where both management and workers take part in the committee. WELFARE: Take care of the statutory and non statutory welfare measure of the employees. NON STATUTORY MEASURES: On contract buses. Hospital. Blood donation. Ladies welfare center. Elections. Inter unit sports activities. Canteen. Statutory measures. Renewal of factory license. Maintenance of leave register. ESI PUBLIC RELATIONS: Communicates with the different unions and record of their activities. Leeds the negotiations between management and union representative

ADMINISTRATION: MAJOR FUNCTIONS: ADMINISTRATION OF TOWNSHIP: Deals with the allotment and vacation of Township quarters. Maintains the seniority lists for the quarters. Maintains the Township buildings. Deals with the allotment and vocation of shops in the shopping. Complex. Central Dispatch: Receives the outgoing mails from other departments. Arranges for the dispatch of the mails to be sent. Receives the inward mails and distributes them to the concerned departments.

PERSONNEL AND ADMINISTRATIVE SYSTEM: The payroll & personnel system is an integrated version of the payroll system and personnel and administration system. implemented to capture the following data. Employees personnel details. Pay details. Qualification, family details, residence, LIC etc., Interest subsidies for House, PC & Vehicle. Festival loan details. Quarters allocation. It has been designed and

 Conveyance details. Bus pass details (OC & School BUS).

HRD MISSION To promote and inculcate a value based culture utilising the fullest potential of Human Resources for achieving the BHEL mission HRDC HIGHLIGHTS Formation of Apex Body for HRD. Identification of Department Coordinators for Training. Undertaking Training Effectiveness Measurement. Design of structured method for Inplant Training. Entertaining participants of sister units in development programmes. Entertaining participants from other Industries / Institutions in development programmes. Identification of Training Needs to fill up the competency gap. Hosted 50th HRD Heads Meet at BAP Ranipet. .Engaged 89 internal resource persons for handling

sessions in in-house programmes. BHEL is committed to Total Quality Management (TQM) system,

in line with CII / EFQM guide lines and improvement action plans are being implemented in BHEL. BAP/Ranipet is using techniques like, Bench Marking, Six Sigma, Kaizen etc,. The TQM efforts are aimed at improving quality of Products, Customer focus, timely submission/delivery, technology and process up gradation on continuous basis. The second total quality assessment was carried at during September 99. ISO 9000 Re-Certification was successfully completed for the third consecutive time and Surveillance Audit completed with NIL NCRs. In line with the corporate Environment Management Policy, activities are initiated for ISO

14000 certification. The quality circle movement is re-vitalized and a minimum No. of circles is active in the limit. TECHNOLOGY UPGRADATION: BHEL has upgraded its products and related technologies to contemporary levels through continued in house efforts and acquisition of technology from leading engineering organizations in the world viz., Siemens, General Electric, Asian Brown Boveri and Hitachi etc., BHEL corporate R & D center at Hyderabad spread over a 140 acre complex. Several state of the art Technologies developed in house have been

commercialized like Fluidized Bed Combustion Boilers, Direct Ignition of Pulverized DIPC etc., BHEL has also transferred technologies developed in house including FBC Boilers

ABOUT THE ORGANISATION

Bharat Heavy Electricals Limited [BHEL], Ranipet plant is located at the entrance of Ranipet town from Vellore, on the left side of the Bangalore Chennai highway. The company premises cover a formerly barren land but which is currently covered by over 200 lakh trees of different type planted by BHEL Ranipet administration. BHEL is a government concern and as such part of the land it occupies was given by the government of India and part of this land was contributed by neighboring people to the BHEL, Ranipet on the understanding that

is would provide employment opportunities to these people a promise which BHEL Ranipet has respected to date. Despite the fact this company premises are surrounded by almost barren lands, the company occupies an evergreen land because of the presence of the trees and constant irrigation that is conducted by BHEL Administration. This has not only made the environment at BHEL, Ranipet conductive for workers , but also very attractive.

Organizational Arrangement :
Bharat Heavy Electricals Limited [BHEL] is the largest engineering and manufacturing enterprise in India and it is among top 10 power equipment manufacturer world wide.

It was established more than 55years ago when its first units was set up in Bhopal in an area of self reliance in heavy electrical equipments in India. It was incorporated in 1957 and the company presently has 150 products under 30 major products needs. The company caters for the care sector of Indian economy viz. power generation and transmission, industry, transportation, telecommunication,

renewable energy, defence, etc., The company has a wide network of 14 manufacturing divisions, 4 power sector regional centres, over 100 project sites, 8 service centres and 18 regional offices. This enables the company to completely serve its customers and

provide total installed capacity of power plants in the company is met from the equipments supplied by BHEL.