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Corp. R&D Engineering Highlights: April 2012 of 20

Engineering Highlights: April 2012

CONTENTS

1. PROJECT ACTIVITIES 1.1 MICROPROCESSOR BASED 3-‐PHASE SECONDARY INJECTION

SIMULATION SYSTEM 1.2 DEVELOPMENT OF NEUTRAL POINT VOLTAGE DEVIATION CONTROLLER FOR NPC INVERTER 1.3 PROJECTS APPROVED

1.4 PROJECTS COMPLETED

2. PLANT/SITE SUPPORT ACTIVITIES

2.1 MAJOR ACTIVITIES INITIATED 2.2 MAJOR ACTIVITIES COMPLETED

3. EVENTS 4. HRD & ATE PROGRAMME

5. PATENTS & COPYRIGHTS FILED

6. PARTICIPATION IN COURSES / SEMINARS / CONFERENCES

CORP. R&D, HYDERABAD


1.0 PROJECT ACTIVITIES 1.1 MICROPROCESSOR BASED 3 PHASE SECONDARY INJECTION SIMULATION SYSTEM Summary of Development:

A microprocessor based 3-‐phase secondary injection simulation system was designed and

developed jointly by Corp. R&D and EDN, Bangalore. The design includes microprocessor based

sine-‐wave generation, amplification, coupling and feedback circuits. Generating the 3-‐ phase

voltage and current using digital methods results in highly accurate and stable output, required

for a calibration grade equipment. Over and above, it also has feedback control mechanism for

auto tuning of output voltage, current and phase angle to eliminate the error in actual output

and the set value, which gets introduced by circuit and loading conditions. This system was

developed for testing and precise calibration of Load Measuring Units (LMU), Load Shedding

Relays (LSR), Energy meters, Multifunction meters and various transducers viz Active power,

Reactive power & Power factor transducers. Due to its modular construction, it can be expanded

for higher VA rating, by inserting additional cards. The system has facility for power on

calibration and self-‐checks.

A) Description of Development:

The Simulation system was designed to generate 3-‐phase sinusoidal voltage varying from 0 to

155Vrms up to 20 VA burden. It generates three phase sinusoidal current varying from 0 to 1.2

amps rms up to 50 VA burden and 0 to 6.0 amps rms up to 50 VA burden. A provision has been

made in the simulation equipment to generate sinusoidal current at unity, leading and lagging

power factor with accuracy up to 3 decimal places, continuously variable from 0 to 1. Overall

functional diagram of 3 phase secondary injection simulation system is shown in Fig 1. The

simulation system was designed to operate at two most commonly used frequencies i.e. 50 Hz

and 60 Hz. The frequencies 50 Hz or 60 Hz of voltage & current signals are selectable in HMI.

The system ensures highly stable & accurate voltage, current and frequency for all the three

phases. Graphical display of sinusoidal waveforms and phaser diagrams for all the three phase

voltage and current were also implemented using Adobe flex software. Touch-‐Screen display

was provided to set and view the parameter values.


Fig1: Functional block diagram of 3-‐Ø Secondary Injection Simulation System

There are two modes of operation, selectable by toggle button in Human Machine Interface

(HMI):

a. Synchronous Mode: In this mode voltage, current & Power factor for all three phases

are same. HMI screen of keypad input method in synchronous mode is shown in Fig 2.

b. Normal Mode: In this mode Independent control of three phase voltage, current, &

Power factor are implemented. HMI screen of Stepper input method in normal

mode is shown in Fig 3.


The HMI of developed equipment runs on LINUX environment was user-‐friendly. It features

four different methods of operations (Keypad, Stepper, 3-‐Ø Star delta voltage and 3-‐Ø Star delta

Current). HMI screen of 3-‐Ø Star delta voltage method in synchronous mode is shown in Fig 4.

Fig2: Keypad input method of HMI in synchronous mode

Fig3: Stepper input method of HMI in normal mode


Fig4: 3-‐Ø Star delta voltage method in synchronous mode of HMI

A prototype has been developed and successfully tested with power electronics DCS panels at

EDN, Bangalore. A prototype of microprocessor based 3 phase secondary injection simulation

system is shown in Fig5.

Fig5: Prototype of 3-‐Ø Secondary Injection System


B) Genesis of Highlights:

The requirement of a CT/ PT feedback has been there in the testing shop-‐floors at EDN,

Bangalore ever since the AVR & other DCS panels are there in the product-‐line. But using CT/PT

transformers with rheostats had its limitations, mainly being the constant PF. Hence, the Analog

Secondary injection load kits were introduced. But in these kits, since the input is derived from

utility power, the desired stability was never achieved and hence there is no repeatability of the

test results. This is a major bottleneck during customer inspections. The system comprises of

many inductors, variacs, 3 phase transformers and other electrical components, which makes it

considerably heavy. Therefore, the equipment is nearly immobile and poor in quality as it does

not provide required accuracies during test, measurement and calibrations. To overcome all

these difficulties, it was decided to take up the project to bring the new generation

microprocessor based secondary injection system.

C) Benchmarks equaled or exceeded by Development:

Description Within BHEL Competitors

Present This development Microprocessor based three phase secondary injection simulation system.

First time development

• Developed unit cost is Rs. 2.5 lakhs

• PF variation is precise upto three decimal places(0.001).

• Operation at 50 and 60 Hz

• Being indigenous development, sales services are available in case of major breakdowns.

• Competitors’ unit cost is around Rs. 25.00 lakhs

• PF variation is only precise to one decimal place (0.1)

• Operation at single frequency (50 Hz).

• No after sales services in case of major breakdowns.

D) Importance of Development:

The developed 3-‐phase secondary injection simulation equipment is first of its kind in the C&I

Industry, wherein independent control of three phase voltage, current & power factor is

achieved. This system works for two frequencies 50 Hz and 60 Hz. The microprocessor based

version generates highly stable 3 phase voltages and currents with high accuracy. This

product has market potential as it can be used by other C&I vendors as well as various power

plant sites.


E) Benefits to BHEL (Tangible & Intangible):

This will help EDN, Bangalore to test and demonstrate the power electronic control panels with

high accuracy and repeatability of the test results . It is useful for the calibration at sites during

commissioning and maintenance of power electronics and C&I panels.

F) Future Plan:

To make the system light weighted for better portability, so that it can be conveniently used at

power plant sites during commissioning and troubleshooting.

1.2 DEVELOPMENT OF NEUTRAL POINT VOLTAGE DEVIATION CONTROLLER FOR NPC INVERTER

Summary of Development:

Recently, Corp. R&D along with BHEL EDN, Bangalore has developed 2.5 MVAR STATCOM for

voltage flicker mitigation for Bhilai Steel Plant. Neutral Point Clamped (NPC) three level voltage

source inverter is the basic building block of the STATCOM. Neutral point clamped inverters are

generally used for building high voltage and power inverter. But, NPC inverter has drawback of

neutral-‐point voltage deviation due to which DC link voltage is distributed unevenly across

cascaded capacitors and devices. This results in underutilization of devices with respect to their

voltage rating, unbalance in output currents and also increase in output voltage THD leading to

degradation of performance of the system. Hence, a closed loop control software function

module for neutral point voltage deviation control was developed and implemented on 2.5

MVAR STATCOM installed at Bhilai steel plant. The developed neutral point voltage deviation

control has improved the performance and reliability of operation of the 2.5 MVAR STATCOM.

Further, the developed software function module is generic in nature and can be used along

with NPC inverter for other Flexible AC Transmission Systems (FACTS) and custom power

devices.


Description of Development:

With the advancement of high power semiconductor devices, advanced power circuit topologies

and DSP based controllers, voltage source inverters are becoming popular and finding application in

Medium Voltage Drives (MVD), FACTS and custom power devices. The rating of these devices

ranges from few hundred kW to 100 MW. In these high power converters, NPC inverters are

becoming popular because of its advantage of realizing higher voltage output using lower voltage

devices without connecting in series, lower output voltage THD, reduced dv/dt stress on devices,

lower switching losses and simplicity in operation.

NPC inverter employs clamping diode and cascaded dc capacitors to produce ac voltage with

multiple levels. The DC input voltage of this inverter is split by two cascade dc capacitor, providing a

floating neutral point. In ideal case, this neutral point voltage with respect to negative DC voltage

should be half of the total DC voltage, but this neutral point voltage deviates because of the

following reasons.

a) Unbalance DC capacitor due to manufacturing tolerances.

b) Inconsistency in switching devices characteristics.

c) Unbalanced three phase operation.

d) Influence of small and medium voltage vectors in pulse width modulation technique.

Deviation in neutral point voltage will lead to premature failure of switching devices due to uneven

distribution of total dc voltage and increase in THD of inverter output voltage. This will adversely

affect the performance of operation and reliability of the system developed based on NPC inverter.

So to get the full benefit of the NPC based inverter in realizing high power MV industrial drives and

FACTS devices, neutral point voltage deviation control is required.

Fig. 1 shows the DC link voltage of upper and lower capacitor of 2.5 MVAR STATCOM without

neutral point voltage deviation controller. This DC link voltage deviation between upper and lower

capacitor results in unwanted tripping due to DC Link overvoltage.


Fig. 1

Fig. 2 shows DC link voltage of upper and lower capacitor of 2.5 MVAR STATCOM with neutral point

voltage deviation controller. After incorporation of the neutral point balancing function module,

both the upper and lower capacitor bank voltages have become equal.

Fig. 2


Control logics for neutral point balancing has been conceived, designed, simulated and

implemented with in-‐house efforts.

B) Genesis of Highlights:

The performance of STATCOM with NP voltage deviation control will be better than that

performance of STATCOM without NP voltage deviation control. Realising the importance of

STATCOM to Indian industries, Corp. R&D has taken up this project to improve the performance and

reliability of the STATCOM.

C) Benchmarks equaled or exceeded by Development:

Description Within BHEL

Competitors

Present This development

Development of Neutral Point Voltage Deviation Controller for NPC Inverter

Closed loop control of neutral point voltage of NPC inverter is not available.

Closed loop control of neutral point voltage in a NPC inverter has been developed and implemented in 2.5 MVAR STATCOM operating at Bhilai Steel Plant

Comparable

D) Importance of Development:

This development has resulted in development of in-‐house technical know-‐how of NP voltage

deviation control for Neutral Point Clamped three level voltage source inverters being used for

high power applications.

E) Benefits to BHEL (Tangible & Intangible):

The neutral point voltage deviation software function module developed in this project has

resulted in reliable operation of STATCOM. With implementation of neutral point voltage

deviation controller, the difference in capacitor voltages is maintained less than 100 V.

Whereas, without implementing neutral point voltage deviation controller the difference in

capacitor voltages used to be order of 400 V. As there was no closed loop control for capacitor

voltage difference, the system used to trip when individual capacitor voltage exceeds the DC link

over voltage limit. With introduction of the neutral point voltage deviation control module, the


tripping of STATCOM due to capacitor bank over voltage has been eliminated, whereas earlier it

used to trip after 3 / 4 hours interval.

F) Future Plan: It is proposed to develop high power FACTS devices e.g. Unified Power Flow Controller (UPFC),

Interline Power Flow Controller (IPFC), Voltage Source Converter based HVDC system etc.

1.3 PROJECTS APPROVED

# Project Outlay (Rs. Lakhs)

Duration

1. BYA-‐12-‐003-‐RD-‐43 Finite element analysis of 800 MW cooling water pump PL: Shri Pankaj D. Mahajan

24.09

Start: 04/2012 Compl: 11/2012

2. BYM-‐12-‐474-‐RD-‐71 Studies on corrosion and creep rupture behaviour of Super 304 H steel and its weld joints for advanced ultra super critical power plant boiler tube applications PL: Shri K S N Vikrant

80.02

Start: 04/2012 Compl: 03/2014

1.4 PROJECTS COMPLETED

# Project Achievements Future plan

1. BYH-‐11-‐025-‐RD-‐54 Development of P42 Interface Gateway for Procontrol HMI Upgradation (Rs. 23.53 Lakhs) PL: Shri Naren Jaiswal Singh Start : 09/2011 Compl :04/2012

• Protocol decoder for decoding Procontrol DCS data telegrams has been developed.

• Microcontroller based Gateway

with Protocol decoder, memory and Ethernet interface has been developed to interface the Procontrol DCS to maxDNA HMI system.

• The developed Gateway has been

successfully interfaced with Procontrol system at one end and maxDNA network on the other end and tested for data exchange between two networks in the Lab.

• EDN is working on the application software and customization of maxDNA HMI screens for typical power plant and the same will be tested with the developed interface at EDN for overall system integrity.

• EDN is identifying suitable site for installation of the total system comprising Interface gateways, maxDNA HMI and Engineering stations in a month for field trial.


2.0 PLANT/SITE SUPPORT ACTIVITIES

2.1 MAJOR ACTIVITIES INITIATED

# Plant/Site Support Activity

Referred by

Proposed Work

1. Metallurgical investigation and failure analysis of Sheared Shaft from XRP 1003 Bowl Mill, NTPC Korba, Unit-‐7, Mill-‐D

BHEL , Hyderabad

Metallurgical investigations, visual inspection, stereomicroscopy, micro structural studies, impact testing and tensile testing are planned to be carried out on the samples of failed sheared off pinion shaft , provided by BHEL, Hyderabad.

2. Performance evaluation of ceramic lined coal nozzles at Bellary TPS-‐II

BHEL , Trichy

Erection of total 16 nos of ceramic lined coal nozzles in 4 corners of Boilers at elevations at Bellary TPS and to carry out performance evaluation.

3. Type testing of 17 Nos. 5kVA, 3000 rpm PMGs sent by BHEL , Hyderabad

BHEL , Hyderabad

The tests like open circuit characteristics, load characteristics, heat run test, 3-‐phase sudden short circuit test at rated voltage, over speed test, insulation resistance measurement and high voltage tests will be carried out using the facility established at COE, PMM .

4. Vibration Analysis of Coal Mill at 500 MW Tata Power Maithon

BHEL, Hyderabad

Vibration measurement and analysis to be carried out.

5. CFD analysis of TLT PA fan blade to evaluate the effect of geometrical modification

BHEL , Ranipet

Design of TLT PA fan is provided by BHEL collaborator and is being manufactured regularly at BHEL, Ranipet. During the manufacturing process, it was observed that the leading edge of the fan impeller was reduced by 6 mm in chord direction. Through the CFD analysis , pressure head developed by both the blades will be studied and compared. Analysis will be carried out at design point of operation and in two off design point of operation. The work requires geometry creation, meshing, solver run and post processing at various operating point.

6. Establishment of coating procedure including robot programming for HVOF coating of Pelton runner for Tapovan Vishnugad Hydro Project

BHEL, Bhopal

The robot programming of pelton runner will be developed. Suitable fixtures will be designed to establish the HVOF gun approach in the different area of runner buckets. Six nos of runners will be HVOF coated using the developed robot program.



Referred by

Proposed Work

7. Structural Analysis of hot PA duct of NLC 250MW

BHEL, Trichy

Development of FE Model as per existing design. Static analysis due to operating Conditions (temperature and pressure).

8. Silver plating on axial holes of 270MW TG rotor

BHEL, Hyderabad

Anode holder will be designed and fabricated for electroplating of silver on axial holes of 270 MW TG rotor. The thickness of the plating will be 5-‐10 microns over the length of 100mm. For above work design detail includes seals, electrode arrangement and pump for electrolyte will be made. Silver plating on axial holes of 270 MW TG Rotor will be carried out.

2.2 MAJOR ACTIVITIES COMPLETED


Referred By

Achievements

1. Creep Testing on T22 steel tubes from Wanakbori TPS Boiler #4, 210 MW, for determining remaining creep life

BHEL, Trichy The creep testing on T22 steel tubes up to the test duration of 3320 hours helped in determining the remaining creep lives of the tubes and ensured that the tubes would not fail in service before the predicted life, hence they will provide uninterrupted service in the boiler till at least 10,000 hours.

2.

Characterization of P91 weldment impact specimens

WRI, Trichy The results of this analysis are extremely helpful in understanding the structure of the fractured surface at high magnifications. These results also provide evidence to understand the cause for the poor toughness by clearly indicating the presence of silica on the surface of the fractured impact specimen.

3.

Conversion of thrust bearing pad support of 60 MW Hydro generator (one set i.e., 8nos) of NHPC Baira Siul into load sensors

BHEL, Bhopal The pad supports are converted into load cell used on site for load equalization. The process of load equalization was necessary for alignment of rotor and proper functioning of thrust bearing. Load equalization enhances bearing life, prevents overheating of bearing pads, reduces downtime and helps in smooth functioning of machine.


3.0 EVENTS

Corp. R&D Felicitates Shri R Krishnan, Director(HR)

The employees of Corp. R&D accorded a warm and cordial felicitation to Shri R Krishnan on his

appointment as Director (Human Resources) on the Board of BHEL on 7 April 2012. Many

speakers including GMs as well as representatives of the unions and associations recalled their

memorable interactions with him, especially during his tenure as the Head of Corp. R&D. Dr. S

Sekar, GM (R&D) in his address referred to the immense admiration and affection that the

employees of Corp. R&D had for Shri Krishnan and said that the division witnessed a remarkable

era under his leadership. Shri Krishnan, in his address, said that he cherishes every moment

that he spent in Corp. R&D and added that he looked forward to more and more technological

achievements from the division in the future. He reminded the employees of the tremendous

responsibilities that the company has placed on the division and added that innovation will be

the flag-‐bearer of growth in the years ahead. Shri Krishnan was honoured with traditional

reverence and respect by Dr. Sekar and GMs, on behalf of all the employees of the division.

Mrs. Usha Krishnan and office bearers of the Ladies’ Welfare Association led by Mrs. Usha Sekar

were also present on the occasion.

Annual Press Conference

The Annual Press Conference of Corp. R&D was held on 12 April 2012. Dr. S Sekar, GM (R&D)

presented the significant highlights of the division’s performance during the year, to the

journalists from the major print and electronic media. Earlier, Shri H Krishnan, GM (MDM&P)

welcomed the gathering. Senior officials of Corp. R&D were also present on the occasion.

Senior Naval Official Visits Corp. R&D Vice Admiral NN Kumar, Controller of Warship Production and Acquisition (CWP&A) of the

Indian Navy, paid a visit to Corp. R&D on 16 April 2012. He was accompanied by senior officials

of Defence Machinery Development Establishment, led by Commodore R Viswanathan.

Dr. S Sekar, GM (R&D) and his senior colleagues welcomed Vice Admiral Kumar. A presentation

on the developments made in the area of Permanent Magnet Machines (PMM) for strategic

applications, was made to Vice Admiral NN Kumar and the other officials. Later, they visited the

COE for Permanent Magnet Machines and saw the various facilities available as well as the other


projects being undertaken there. Recording his impressions in the visitors’ book Vice Admiral

NN Kumar wrote “Happy to see the work being undertaken at COE-‐PMM and the work on

superconducting machine. There is scope for enhance interaction to indigenise the same for

submarine applications. Wishing the COE-‐PMM the very best and looking forward to greater its

cooperation with Indian Navy”.

Visit of IEMs to Corp. R&D Shri JM Lyngdoh, former Chief Election Commissioner, Shri Kanwarjit Singh, former Chief

Commissioner of Income Tax and Shri DP Bagchi, former Chief Secretary of Odisha, visited Corp.

R&D on 18 April 2012, as a part of their responsibility as Independent External Monitors (IEM)

for Unit Review Meeting. On their arrival, they were received by Dr. S Sekar, GM (R&D) and his

senior colleagues. The IEMs spent some time interacting with the newly recruited

engineers/executives during which they advised them to whole-‐heartedly participate in the R&D

activities undertaken by BHEL which are aligned with the national mission of infrastructure

development. The also gave tips about maintaining transparency in official dealings as expected

from an employee of reputed government organisations like BHEL. A brief presentation outlining

the general information about Corp. R&D was made to the IEMs at a group meeting with the

senior officials led by Dr. Sekar. The IEMs who had shown keen interest in frontier area

development activities also visited the COE for Permanent Magnet Machines and Centre for

Nanotechnology (CNT) and witnessed the on-‐going R&D work as well as the in-‐situ

demonstration of the major facilities. Later recording their impressions in the visitors’ book, the

IEMs wrote:

“For a change one really feels that some new products are going to be the outcome of so much

dedicated and intelligent work” – Shri JM Lyngdoh

“This has been a great visit. The genuine focus on research in terms of funds, manpower as well

as career path for those engaged in research can be a model for other PSUs” – Shri Kanwarjit

Singh

“This is indeed a memorable visit. BHEL engineers and scientists are successfully engaged in

tackling issues relating to the frontier areas of technology. I wish they will really become world-‐

class players very soon” – Shri DP Bagchi.


Corp. R&D Hosts Inter-‐Unit Meeting on Solar Energy Programme

An inter-‐unit meeting on Solar Energy Programme was organised on 20 April 2012 at Corp. R&D

to share experiences and plan for further activities aligned with the company’s Strategic Plan

2012-‐17 and National Solar Energy Mission. Dr. S Sekar, GM (R&D), inaugurated the meeting.

Senior executives from various divisions, including Shri Arvind Gupta, GM (TC&PEG)

HPEP/Hyderabad, Shri VK Midha, GM (CPP & Renewables) Industry Sector/New Delhi, Shri Guru

Raj S Rotti, GM (PV), ISG/Bangalore and Dr. RK Bhogra, Consultant (Solar), as well as senior

officials from the units and Corp. R&D, attended the meeting. Various presentations were made

and discussions were held on solar business opportunities, business sharing with Abengoa Solar

of Spain, solar PV business experience and targets for next five years, CSP and solar PV

technology update and future scenario, concentrated solar hot air turbine, evacuated tube

receiver, self-‐cleaning coating on glass substrate and setting up different CSP and PV plants at

various units. The meeting also resolved to bring out a road map of activities in the area of solar

energy.

World IP Day at Corp. R&D World Intellectual Property Day (IP) Day was observed on 26 April 2012 at Corp. R&D.

Dr. S Sekar, GM (R&D) addressed the gathering before giving away certificates to eligible IP

awardees. In his address, he stressed on the need to uphold the image of company as an

innovative organisation with a growing R&D budget, and enjoined all inventors/authors to take

up a proper search to identify areas of development, improvement and patentability when

taking up projects and paving the way for creating a knowledge portal. Shri YNRN Satyakumar,

GM (MM&PCI) spoke about the global scenario of IP and the aggressive patenting strategy

adopted by competitors and emphasised on the necessity of protecting BHEL’s own inventions.

Earlier, Shri S Chakravarti, AGM (BEG&ITS) provided a brief round-‐up on the IPR activities

undertaken by BHEL during the year and the trend of IP filings from 2005 onwards. A total of 175

certificates were presented to authors/inventors individually, comprising of 13 granted patents,

16 registered copyrights, one design registration and 35 filing of complete patent applications.

Director (HR) Visits Corp. R&D Shri R Krishnan. Director (HR) paid a visit to Corp. R&D on 28 April 2012. He was received by

Dr. S Sekar, GM (R&D) and his senior colleagues. A presentation on 14-‐digit conversion of

material code, which is a part of the “One BHEL” Enterprise Resource Planning (ERP)

implementation, was made to him. This was followed by a discussion with senior officials.


4.0 HRD & ATE PROGRAMME

• A programme on “Smart Grid Opportunities & Challenges” was conducted on 2nd April

2012, to provide an opportunity to listen from an international expert on the above

topic and interact with him to gain an insight into his experience and knowledge.

Hundred and fifty employees participated in the programme. The faculty was Prof.

Saifur Rahman (Electrical and Computer Engineering), Virginia Tech University, USA.

• A lecture on “Intellectual Property Management” was organized on 3rd April 2012, to

familiarize all the Engineer/Executive Trainees with Intellectual property concept of

BHEL. Thirty two Engineer/Executive Trainees attended the lecture.

• Lectures by GM (TCH) and LMs were organized on 13th April 2012, to familiarize

Engineer/Executive Trainees with all departments under GM (TCH) and related works.

Thirty two Engineer/Executive Trainees attended these lectures.

• A lecture delivered by AGM(SPD) on “Turbo machinery” was organized on 20th April

2012, to give a detail in-‐sight about hydro machines, their working principle and

capability of BHEL. Thirty two Engineer/Executive Trainees attended the lecture.

• Lectures by GM (TES) and LMs were organized on 23rd April 2012, to familiarize

Engineer/Executive Trainees with all departments under GM (TES) and related works.

Thirty two Engineer/Executive Trainees attended these lectures.

• A programme on “Stress management for Better Health” for all employees was

conducted on 28th April 2012, to improve their working efficiency and to develop

positive attitude. Ninety five employees participated in the programme. The faculties

were from ‘VIKALP’ social organization, Nagpur.


5.0 PATENTS & COPYRIGHTS FILED

5.1 PATENTS FILED

1. An improved device for supporting the emitting frame set during erection and maintenance of Electrostatic Precipitators

Ranipet

2.

An improved process for assembling ESP internals -‐do-‐

3. A device for measuring conductivity of flue gas dust to enhance performance of Electrostatic Precipitators and a process for determining ammonia dosages to be injected into the chamber of the device

-‐do-‐

4. An improved heat pipe radiator device for cooling transformer oil Corp. R&D

5. A method for manufacturing brush seals for turbo-‐machinery operable at lower radial rotor-‐stator clearances with improved leakage performance

-‐do-‐

6. An improved device for drilling of holes on insert cover of a stator body in a Turbogenerator

Haridwar

7. Design of universal adjustable device for root and shroud milling of steam turbine blades on CNC horizontal machining center

-‐do-‐

8. An improved process for flow circulation of pre-‐start urging air in cast iron enclosure of TEFC (Totally Enclosed Fan Cooled)A.C induction motor installed in hazardous zones

Bhopal

9. A non-‐destructive testing method for selecting different grade ferrous materials, different ferrous grade weld metals and residual (Mechanical properties) of the ferrous materials based on measured coercive force values

Trichy

10. A method of controlling distortion in a welding procedure of tension bars to each of two transition panels disposed back to back

-‐do-‐

5.2 COPYRIGHTS FILED

1. Software simulator for testing programmable automation controller and SCADA Ranipet

2. Control logic for flue gas conditioning system -‐do-‐

3. Combined man machine interface system for ESP controller of two boiler units -‐do-‐

4. Creation of database and user defined function for implementing the momentum source term in CFD analysis of electrostatic precipitator

Corp. R&D


5. Customized method established for automatic inspection of Francis hydro runner models using CAMIO 4.4 software

-‐do-‐

6. Signal Validation (SiVa) for thermal power plants -‐do-‐

7. Maintenance Management System with On-‐line Process Connectivity -‐do-‐

8. Design of movable control panel for use in generator test area Bangalore

9. Historical Replay System for DCS HMI -‐do-‐

10. PPC L3 (Combined bill of materials ) Planning System Haridwar

11. Bilingual instructions for SRGM Electrical Assemblies -‐do-‐

12. Manufacturing Information Documentation (MID) System -‐do-‐

13. Bilingual instructions for SRGM mechanical assemblies -‐do-‐

14. Schematic for generator protection during testing at generator new test bed -‐do-‐

15. Online duct erection manual in dynamic 3D PDF format Trichy

16. Automation of wind box connecting duct (210/250/270 MW) through 3D parametric solid modelling using UGS NX

-‐do-‐

17. Engineering Manual for furnace flame monitoring system – BHELSCAN -‐do-‐

18. Engineering Manual for electronic water level indicator -‐ BHEL VISION 20M -‐do-‐

19. 2D module wise automation of bend duct with internal truss -‐do-‐

20. 2D module wise automation of bend duct without internal truss -‐do-‐

21. Computer program for automatic generation of labyrinth seal manufacturing drawings

Hyderabad

22. Commissioning operation and maintenance manual for ball tube mill BBD 4772 -‐do-‐


23. Computer program to generate drawing for rotor lamination of open/semi closed slots

-‐do-‐

24. Computer program to generate drawing of skewed stator lamination of 4 pole generators

-‐do-‐

25. Control system configuration and Control scheme for operation grade decay heat removal (OGDHR) system for PFBR nuclear power plant

PEM, New Delhi

26. TG hall layout for 80 MW set with air cooled condenser -‐do-‐

6.0 PARTICIPATION IN COURSES / SEMINARS / CONFERENCES

• Shri N. Satya Siva Kumar, Sr. Engineer (TDL) attended a workshop on “Advanced System Integration and Artificial Intelligence” organized by CII & IIT, New Delhi on 6th April 2012.

• Shri K. Janakinath, Sr. DGM (HSE) attended a training workshop on “Accident Investigation and Analysis” organized by National Safety Council at Mumbai during 12th – 13th April 2012.

• Shri Sushanta Roy, Dy. Manager (ICH) attended a training workshop on “Water

Treatment Designing & Calculation” organized by EA water (P) Ltd. at Hyderabad during

17th – 18th April 2012..

• Ms. Alka, Engineer Trainee (ICH) and Shri Trishal Karan Bhagat, Engineer Trainee (ICH)

attended a programme on “Essential Boiler Water Chemistry for Operation &

Maintenance Engineers” organized by Engineering Academy for Self Excellence and

Learning Pvt. Ltd. (EASEL) at Gujarat during 17th – 19th April 2012.

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