Thermal group of BHEL-Bhopal was formulated in year 1968 (Initial collaboration with M/s AEI -U.K. took place in year 1970) and started its production from year 1971 onwards.  Subsequently, new collaboration agreement with M/s BALCKE DURR- Germany for Moisture Separator Re-Heater (MSR) took place in 1987.  MSR to this new design were manufactured and supplied for 236 MW RAPP 3, 4 & KAIGA 1, 2 and 500 MW TAPP 3&4 Nuclear plants.  

BHEL-Bhopal Thermal group  products manufactured and supplied all over India to different State Electricity Boards and exported to countries like LIBYA, Malaysia, Azerbaizan, Bangladesh, OMAN etc. major customers of thermal equipments are State Electricity Boards and NTPC. Similarly Industrial Heat Exchangers have been supplied to IFFCO, FEDO, RELIANCE, GAIL, ONGC, IOCL, etc. Production of some of the other products like Rubber Expansion Joints, Flash Tanks, Miscellaneous storage tanks and Butterfly valves added in subsequent years.

All the Thermal products are tailor made and customer specific product. and Customer requirements are continuously captured through pre-tender and post tender discussions, contract review etc. Perception is collected thru customer surveys. 

Thermal group products are Technology intensive and therefore Technology development is of strategic importance. Product technology is continuously upgraded through in house development projects/ or Technical Collaboration.

Heat Exchanger

Auxiliary Heat Exchangers

Different types of auxiliary heat exchangers are being manufactured at BHEL. Depending upon application these auxiliary Heat Exchangers are named as

. Air Coolers (CACW)

. Oil Coolers (Shell & tube type / Frame and tube type (Single tube & Concentric double tube construction) / OFAF), Plug in type

. Water Water Cooler (Shell & Tube type)

. Hydrogen Cooler etc. (Frame and tube type).

. Air Cooler CACA ( Duct and tube type)

These coolers are accessories to main equipment’s such as Generator, Turbine, Transformer , Motors, etc. hence special attention is given to make these coolers compact in design and for trouble free service.

To ensure long life of these coolers materials for different components is decided carefully considering its application and water chemistry. Constructionally these coolers are very easy to maintain.

Technical Information/Application

Air coolers, Oil coolers, Water-Water coolers and Hydrogen Coolers act as accessories to Transformers, turbines, Motors and Generators, etc.

In Generator, Air Coolers are used to cool the generator air which is a closed circuit air of maintained humidity and which in turn cools winding of stator. In turbine, oil coolers are used to cool bearing oil or the oil which in turn cools the rotating parts. Similarly, Transformer Coolers are used to cool transformer oil by air or water. These coolers play an important role in smooth functioning of the main equipments. CACW type and CACA type air coolers are also used for cooling air, which in turn cools motor windings.

Industrial Heat Exchangers

Industrial Heat Exchangers, as the name implies are  used  in  industries  dealing  in   various types of chemicals. In general Heat Exchangers used are of shell and tube type construction. Main components of  shell and  tube type heat exchangers are tube nest assembly; shell assembly and types of enclosure i.e. end closing.

BHEL is manufacturing different types of shell and tube type heat exchangers   for  Industries  like  Refineries , Petrochemicals   and Fertilizers, etc. Since different  type  of  chemicals  is involved   in Industrial Heat Exchangers, material selection becomes an important criteria.

BHEL is capable of doing special types of mechanical design apart
from   normal  design  of  shell, tubes , dished ends ,flat covers, backing  ring  and  flanges  etc. Special type of mechanical design covers design of eccentric/concentric types of shell i.e. kettle type construction , reverse flange type design, fixed  tube  sheet with bellows, high  pressure  enclosures  , and   double    pipe type heat exchangers.

BHEL  is  having  a vast  experience of manufacturing and supply  of Heat  Exchangers  with  Carbon steel , stainless steel, Alloy Steel and Non-ferrous tubes and shell materials. In   addition  to   the  type  as  mentioned  earlier , Cladded Exchangers also have been supplied by BHEL. Various types of constructional features as described in TUBULAR EXCHANGER MANUFACTURER’S ASSOCIATED (TEMA) Standard can be offered by BHEL.

Feed Water Heaters

BHEL is manufacturing feed water heaters for power stations of Unit Rating up-to 250 MW Thermal Power Project since more than last 25 years. Feed water heaters (both High pressure and Low pressure) are used in feed heating system of regeneration cycle by heating feed water by steam extracted from suitable stages of turbine. Over the years design and technological developments took place and at present feed heaters with stainless steel tube materials are being used for longer life expectancy. Both Horizontal and vertical type of heaters are manufactured with highest standard of engineering to provide reliability in operation. Feed water heaters are designed as per HEI standard and high pressure heaters comes under purview of Indian Boiler Regulations. Hence these are designed and manufactured in strict compliance to applicable code requirements.

Technical Information/Application

- The high pressure & Low pressure feed water heaters are employed to increase the overall efficiency of the regenerative cycle by heating the feed water by the steam extracted from suitable stages of the turbine.
-  The feed water passes through the 'U' tubes and the steam/drain (condensed steam) passed over the tubes. These heaters are located in feed water heating cycle and feed water going to boilers is heated with steam extracted from different stages of turbine resulting in saving of energy and increased efficiency. Feed heaters play a vital role in power plant. The heaters are, therefore, subjected to very onerous duty and hence the design and manufacture of both type of heaters, i.e. High Pressure heaters and Low pressure feed water heaters complies with the highest standard of engineering to provide adequate reliability in the operation of these heaters. Both High pressure & Low pressure feed water heaters come under purview of Indian Boiler Regulation hence compile with all code requirements.

Moisture Separator Re-heater (MSR)

In Nuclear Turbines the Moisture separator re-heater  is a thermo-hydraulic junction where two-phase (steam/ water) flows interact, while separating the high energy phases and exchanging heat.

The superheated steam contributes a net electric production gain and promotes extended turbine blade life.

Projectwise Details Of 236 Mw And 500 Mw Moisture Separator And Re-Heaters  Manufactured
And Supplied By Bhel Bhopal (22  No’s).

SL.NO.	PROJECT	No's	YEAR OF SUPPLY
1.	KALPAKKAM-I           (MAPS)	02	1975
2.	KALPAKKAM-II          (MAPS)	02	1976
3.	NARORA - I                (NAPS)	02	1982
4.	NARORA - II               (NAPS)	02	1983
5.	KAKRAPARA - I         (KAPS)	02	1991
6.	KAKRAPARA - II        (KAPS)	02	1991
7.	RAPP - III                    (RAPS)	01	1993
8.	RAPP- IV                     (RAPS)	02	1994
9.	KAIGA - I                     (KGS)	02	1993
10.	KAIGA - II                    (KGS)	02	1994
11.	TARAPUR-III      (TAPP)	01	2002
12	TARAPUR-IV      (TAPP)	02	2003
	TOTAL	22

he MSR purpose is to provide superheated steam to the L.P turbine by first drying and then reheating the steam, exhausting from the H.P turbine.
 

Note :

1. Above s.no 1 to 6 - 236 mw moisture separator and re-heaters were manufactured and supplied as per the design from then m/s GEC UK(presently M/S Alstom UK).
2. Above sno 7 to 12 - 236 mw and 500 mw moisture separator and re-heaters were manufactured and supplied as per the design of M/s BALCKE DURR Germany.