Final Report - Kisan

CENTRALISED STRUCTURAL CATALOGUE MANAGEMENT
A REPORT
ON
CENTRALISED STRUCTURAL CATALOGUE
MANAGEMENT
BY
E.KISAN 2008A4394G
AT
BHARAT HEAVY ELECTRICALS LIMITED

TIRUCHIRAPALLI
A Practice School – I station of
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE,

PILANI
(JULY, 2010)
IT Solutions & Services Page 1

A REPORT
ON
CENTRALISED STRUCTURAL CATALOGUE
MANAGEMENT
BY
E.KISAN 2008A4394G
B.E.(Hons) Mechanical Engg.
Prepared in partial fulfillment of the

Practice School – I course No.
BITS GC221
AT
BHARAT HEAVY ELECTRICALS LIMITED

TIRUCHIRAPALLI
A Practice School – I station of
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE,

PILANI
(JULY, 2010)

ACKNOWLEDGEMENT
I would like to express my gratitude to Mr. A.V. Krishnan, Executive

Director, BHEL, Tiruchirapalli who has given me this opportunity to do my
practice school in this company.
I wish to thank Mr. K. Chandrasekaran, AGM – HRDC and coordinator

of the PS programme in the organization and Mr. Narayan Doss, Senior
Manager – HRDC who has allowed me to do project work in BHEL.
I would like to express my sincere gratitude to Mr. M. S. Ramesh, SDGM,

ITS&S and Ms. N. Bhagyalakshmi, Dy. Manager, ITS&S for their timely
help and valuable suggestions which has encouraged me during the course
of this project.
I am in debt to express my gratitude to Mr. Tamilsevan.T, Assistant

Engineer II, ITS&S for his constant guidance and help rendered throughout
the course of the project.
Lastly, I would like to thank Dr. P. Srinivasan, PS instructor at BHEL,

who has been a constant moral support and guidance throughout the course
of practice school.

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

PILANI (RAJASTHAN)
Practice School Division
Station: Bharat Heavy Electricals Ltd. Centre: Tiruchirapalli

Duration: 54 days Date of Start: 24/05/2010
Date of Submission: 15/06/2010
Title: Centralized Structural Catalogue Management
Names of Experts Designation
Tamilselvan T. Asst. Engineer Gr.II
Name of the Student ID No. Discipline
E.kisan 2008A4PS394G B.E.(Hons)MechanicalEngg.
Name of PS Faculty: Dr. P. Srinivasan
Key Words: PDMS, SQL, VISUAL BASIC, CATALOGUE

MANAGEMENT AND ORACLE DATABASE.
Abstract: A brief overview of BHEL, and its various departments. A

detailed description to structural catalogue management software for oracle
database is given.
Signature of Student Signature of PS Faculty
Date: 16/07/2010 Date: 16/07/2010

TABLE OF CONTENTS(PART A)
1. BHEL ……………………………………2
1.1 OVERVIEW………………………….2
2. BHEL:TIRUCHIRAPALLI………………3
2.1 INTRODUCTION……………………3
2.2 PRODUCT PROFILE………………..4
3. SEAMLESS STEEL TUBE PLANT……..8
4. TUBULAR PRODUCTS SHOP…………12
4.1 INTRODUCTION…………………….12
4.2 PRODUCTION……………………….12
4.3 SAFETY………………………………14
5. VALVES DEPARTMENT………………..15
5.1 MANUFACTURING FACILITIES….15
5.2 PRODUCTS…………………………..16
5.3 SERVICES……………………………17
5.4 CUSTOMERS………………………...18
6. CCDP……………………………………...19
6.1 IGCC………………………………….19
7. ITS&S……………………………………..25
7.1 INTRODUCTION…………………….25
7.2 ITS&S WORK PROFILE……………..26
8. WRI………………………………………...28
8.1 INTRODUCTION…………………28
8.2 SERVICES…………………………29
8.3 FACILITIES………………………30
9. PRESS AND DRUM SHOP……………...32

1.BHARAT HEAVY ELECTRICALS LTD (BHEL)
1.1 OVERVIEW
Bharat Heavy Electricals Limited (BHEL) is largest engineering and

manufacturing enterprise in India in the energy related and infrastructure
sectors today. BHEL‘s Vision: BHEL‘s vision is to become a world class
engineering enterprise, committed to enhancing stakeholder value.
BHEL manufactures over 180 products under 30 major groups. BHEL
isequipped with 14 manufacturing divisions, 4 power sector regional
centres, 8 service centres, 18 regional offices and a large number of
project sites. BHEL‘s products meet the international standards and retain
accreditations from world‘s quality certifying firms. In more than 45
years of its existence, BHEL has installed equipment for over 1, 37,000
MW of power generation, for utilities, captive and industrial users. BHEL
supplied over 2, 00,000 MVA transformer capacity and sustained
equipment operating in transmission and distribution network up to 400
kV-AC & DC. Over 25,000 motors with drive control system, more than
900 electrostatic precipitators and one million valves have been supplied
by BHEL to Power projects, petro chemicals, refineries, Aluminium,
Fertilizer, cement and paper plants. BHEL also supplied traction electrics
and AC/DC locos to power over 12,000kms of railway network in India.
The greatest strength of BHEL is its highly
skilledand committed 44,000 employees. Every employee is given an
equal opportunity to develop himself and improve his position.
Continuous training and retraining, career planning, a positive work
culture, participative style of management have engendered development
of a committed and motivated work force leading to enhanced
productivity and higher levels of quality.

2. BHEL:TIRUCHIRAPALLI
2.1 INTRODUCTION
The High Pressure Boiler Plant of the Bharat Heavy Electricals Limited
was setup in 1963 for the manufacture of High Pressure Boilers. The plant
achieved its full annual capacity to design manufacture and supply high
pressure boiler equipmentupto 4000 MW in 1984 with boiler unit ratings
up to 500 MW. BHEL, Tiruchi has over the years seen formidable growth in
capacity, capability, turnover and profitability. Product diversification has
resulted in the development of new products enabling BHEL to absorb modern
technologies. Such innovations result in continuous updation of manufacturing
facilities to serve the customers in a more comprehensive way and for
improving quality and productivity.
BHEL, Tiruchi has added to its High Pressure Boiler Plant (HPBP), a
Seamless Steel Tube Plant (SSTP) at Tiruchirappalli (adjacent to the HPBP), a
Boiler Auxiliaries Plant (BAP) at Ranipet (in the state of Tamil Nadu), a
Piping Centre (PC) at Chennai in Tamil Nadu and an Industrial Valve Plant
(IVP) at Goindwal (in the Northern state of Punjab). HPBP and SSTP are spread
over 2908 acres of land at Tiruchi and BAP over 1256 acres at Ranipet. HPBP
and SSTP have a covered shop area of 2,50,000 square meters and BAP Ranipet
has 47,000 square meters of covered shop area.
2.2PRODUCT PROFILE
UTILITY BOILERS
For power generation applications, BHEL designs, engineers, manufactures,

supplies, erects and commissions boilers of any rating upwards of 30MW.For
higher capacities, BHEL also offers customers the option of Once-Through

type steam generators in addition to conventional natural and controlled

circulation types.
INDUSTRIAL BOILERS
BHEL supplies steam generators of rating up to 450 ton/hr for industrial

applications to suit the requirements of industries...
 Fertiliser
 Petrochemical
 Refinery
 Steel
 Paper
 Other process industries
CFBC boilers
BHEL manufactures state-of-the-art Circulating Fluidised Bed Combustion

(CFBC) boilers in collaboration with LurgisLentjesEnergietechnikGmbh
(LLB), Germany. LLB's rich experience and numerous installations
worldwide
BHEL CFBC boilers - Special design features
 Simplified fuel preparation equipment eliminating sophisticated and

maintenance-prone pulverizing equipment.
 Recycling hot cyclone for effective separation of solid particles
which are returned to the combustor.
 Special Fluidised Bed Heat Exchanger (FBHE) - patented design -
for effective utilisation of Energy in hot recycled solid particles.
 Higher boiler efficiency even on part loads due to better

burnability.
 Excellent operational flexibility - part load down to 25% MCR - and
ideally suited for wide load fluctuations.
 Compact plant design.
 No heat transfer surfaces in erosion prone combustor zone.
 Independent Reheat temperature control.
AFBC BOILER
BHEL is the pioneer in Atmospheric Fluidised Bed Combustion (AFBC)

technology - bubbling bed type - in India with a proven track record based on
extensive in-house R&D for better utilization of existing energy sources.
BHEL's AFBC Boilers - Unique Design Features
 Specially developed fuel feeders and feeding system to handle even

fuels with high moisture content
 Unique and simple protection feature for bed swept surfaces
 Innovative oil-fired start-up system, relatively free from manual
intervention which ensures trouble free unit start up
 Simpler operation
 Versatility in application
HeRECOVERY STEAM GENERATORS
Technology Highlights
 World-class technology
 High heat recovery efficiency
 Optimised design

 Modular construction
 Environment friendly
ADVANCE TECHNOLOGY PRODUCTS
Advanced Technology Products Department in BHEL, Tiruchy is

having main business with the various institutions / organisations under
Department of Atomic Energy, Government of India viz. Nuclear Power
Corporation of India Ltd. (NPCIL), Bhabha Atomic Research Centre (BARC),
Indira Gandhi Centre for Atomic Reasearch (IGCAR), Institute for Plasma
Research (IPR), Heavy Water Board, etc.
Advanced Technology Products Department in BHEL, Tiruchy is

having main business with the various institutions /organisations under
Department of Atomic Energy, Government of India viz. Nuclear Power
Corporation of India Ltd. (NPCIL), Bhabha Atomic Research Centre (BARC),
Indira Gandhi Centre for Atomic Reasearch (IGCAR), Institute for Plasma
Research (IPR), Heavy Water Board, etc.

3. SEAMLESS STEEL TUBE PLANT
The BHEL Seamless Steel Tube Plant (BHEL – SSTP) was set up in 1979, with
the equipment supplied by M/s Mannesmann Demag Meer of Germany, the
world leader in this field.
BHEL – SSTP manufactures Seamless Steel Tubes of world standards, catering

to the needs of a wide spectrum of customers from power stations,
petrochemicals, oil & gas exploration, automobiles, refineries, sugar industries,
textiles, etc.
BHEL – SSTP has most advanced facilities for the manufacture of seamless
steel tubes and pipes – both hot-finished and cold-drawn-in carbon and low
alloy steel grades. BHEL – SSTP offers seamless steel tubes and pipes in a
wide range of sizes with outer diameter ranging from 19mm to 133mm and wall
thickness from 2mm to 12.5mm.
An additional range of specialized applications...
BHEL – SSTP also has advanced facilities for the manufacture of import
substitute spiral finned tubes which have extended surface area designed for
maximum heat recovery.
The plant has also developed the manufacture of rifled tubes. BHEL‘s High
Pressure Boiler Plant manufacture studded pipes.
Towards ever shorter delivery periods

BHEL –SSTP stocks various grades of raw materials to meet short delivery
periods.
Meeting International Specifications…

At present, BHEL – SSTP manufactures Seamless Steel Tubes and Pipes to the
Following Specifications:
ASME SA53,106,179,192,209,210,213,333,334,335
BS 3059
DIN 2391
GOST API (Line pipes)
Seamless steel tubes and pipes can be supplied in random or fixed lengths. Edge
preparation is also done if it is required by the customer. BHEL-SSTP also
ensures adherence to the respective standards and cater to specific customer
requirements.
A WIDE RANGE OF APPLICATIONS
BHEL Seamless steel tubes are extensively used in power stations, marine
boilers, refineries and for oil & gas exploration applications besides industries
such as petrochemicals, fertilizers, textiles, automobiles, paper, sugar, etc.
BHEL Seamless cold – drawn low-carbon-steel heat exchanger tubes are used
for a variety of heat transfer applications.
SEAMLESS STEEL TUBES AND PIPES (APPLICABLE

SPECIFICATIONS)
Specification Grade Title
ASME SA A,B,C Seamless carbon steel pipes for high

106 temperature services
SA 179 Seamless cold drawn low carbon steel

heat exchanger and condenser tubes
SA 192 Seamless carbon steel boiler tubes for

high pressure service.
SA210 A1,C Seamless medium carbon steel boiler and

super heater tubes.
SA209 T1 Seamless carbon-molybdenum alloy steel

boiler and super heater tubes.

SA213 T2, T5, Seamless ferritic and austenitic alloy

T11,T12,T22 steel boiler, super heater and heat
exchanger tubes.
SA333 1,6 Seamless and welded steel tubes for low

temperature applications.
SA334 1,6 Seamless and welded carbon alloy steel

tubes for low temperature applications.
SA335 P1,P2, Seamless ferritic alloy steel pipes for

P5,P11, P12, high temperature applications.
P22
BS 3059 320,360, Steel boiler and super heater tubes.

440,660,622
DIN 2391 ST35,ST45, Seamless precision steel tubes.

ST53
GOST 20,12xIM Ø Seamless steel pipes for stream boilers.
API 5L A,B,X42,X46, Line pipes

X52
Length :Random lengths ranging from 4 to 12 meters. Fixed lengths can also be
supplied on specific request.
Ends : Square cut or beveled as per standards/customers requirements.
SPIRAL FINNED TUBES (RANGE OF MANUFACTURE)
WELD High Frequency Resistance

Weld
Material for Tube/Fin Carbon steel, Alloy steel,

Stainless steel
(Any combination)

Fin Types Solid fins/Serrated fins
D – Diameter 19.1 mm to 114.3mm
t- Wall Thickness 2.4mm to 9.5mm

4.
Fin thickness 1.0 mm to 2.0 mm
H – Fin height 12.5mm to 25.0 mm
P-Fin pitch 40 to 280 per meter
L1-Length (Total) 3000 mm to 20000 mm
L2- Length(Finned) 2500mm to 19500 mm
Tubular Products Shop
4.1 INTRODUCTION
The tubular shop is one of the strong-holds of the production in BHEL Trichy.
Its contribution, among others, has ensured that around ¾ of the power
generated in India is backed by BHEL products.
4.2 PRODUCTION:
This plant produces the tubes which are to be used in the boilers for converting
water into steam by using the heat energy available in its environment inside the
boiler. There are different types of tubes produced here of various diameters,
lengths, shapes, etc.
Based on the operating conditions in the tube w.r.t different

phases the tubing system is divided into three different types.
 Economizer: Water from the pump enters the boiler and sensible heat
addition takes place here. Water is converted into saturated liquid. For
this purpose, coil is an appropriate structure.
 Water-wall Tubes: From the economizer, water moves to the drum which
separates steam and water. Water goes into the water-wall, which
acquires heat from the furnace and rises the steam into the drum. The
structure is in form of panels.

 Super-heater: The steam isolated from the drum is passed into the
different super-heater coils for sensible heat addition to required
temperature.
Also the tubing system varies as per the requirements at the
worksite. This requires the production of various types of tubes like
 Panels: Tubes running in parallel connected by fins.

Two types: Fusion Welded Panels (FWP) or Flat Fin Welded
Panels (FFWP)
 Coils: A number of tubing components are in the form of coils, viz.
economizer coils, Low Temperature Super-Heaters (LTSH), Platen
Super-Heaters, Final Super-Heaters, and Re-Heaters.
 Connecting tubes produced may be Upper Connecting Tubes, Lower
Connecting Tubes, etc.
TheTubes produced here are hollow cylinders with length much greater than
diameter, and bore not more than 76.1 mm, that which involves in heat as well
as mass transfer, as per ASME definitions. Tubes are used in Boilers for
converting water into steam.
The Tubular Products Shop of BHEL, Trichy, uses Carbon

Steel (SA210A1, SA191, and SA106GRB), Low Alloy Steel, High Alloy Steel,
and Stainless Steel for the manufacturing of tubing components. It imports
ready-made tubes of the materials T92 (from Germany) and P23 (from Japan)
for production of 660 and 800 MW boilers, as the Seamless Steel Tube Plant is
not capable of manufacturing tubes from these materials.
Also the production here includes various types of processes
 Edge Preparation: The process is called Automatic Tube Cutting and

Edge Preparation (ATCEP). Annually, 465,000 ends are prepared.
 Straight Tube Butt welding: (STB) involves welding of 180,000 joints,

annually.
 Roto-blast: This is a process before longitudinal welding is performed to

remove the surface coatings of tubes, and the scale is 1,185,000 pass
meters.
The annual production of the tubular plant is nearly 40,000

tones with each 500 MW boiler consists of 2,777 tones of tubes.

SAFETY
As BHEL is an ISO authorized company, the production process here in the

tubular plant are governed by the environmental and health management
standards. Other regulations in the production include ASME (American
Society for Mechanical Engineers) and IBR (Indian Boiler Regulation).
Because of BHEL‘s huge domination over the Power-

Generation Market, the Tubular Shop is reported to have enough orders
(~Rs. 22,000 Cr.) to last three years of production. It has a customer base of
Indian as well as foreign institutions. Its foreign customers include Libya,
Sudan, Malaysia and Egypt among others.

5.VALVES DEPARTMENT
5.1MANUFACTURING FACILITIES
 20,000 SQ.M Area of covered Manufacturing Shops with state of art

CNC machine and general purpose machine.
 Dedicated hydraulic testing stations with capacities upto 15000 psi
 Steam and air testing facilities for safety and safety relief valves
 Supported by well equipped analytical, metallurgical and non
destructive examination facilities.
 Quality assurance services are backed by a team of qualified scientists
equipped with sophisticated instruments like spectroscopes, high
magnification microscopes, X-ray diffraction strain gauges and
fatigue and creep testing machines.
 Non destructive testing facilities use x-rays up to 400 KV and
Isotopes up to 800 curies and magnetic particle inspection is by most
sensitive wet method.
 Precision gauges, tools and instruments are calibrated at BHEL's
Nationally accredited calibration centre.
 Well trained and experienced man power of 1250 employees.
 BHEL High pressure cast steel valves and Quick closing non return
valves are manufactured with technology from TOA valve company
(Japan), Forged steel Valves, safety, safety relief and Y-type valves
with technology from Dresser Industries Inc-(USA), Oilfield
equipment with technology fromKVaerner National (USA), HP-LP
Bypass Systems with technology from SulzerThermtec (Switzerland)
and soot blowers with technology from Copes - Vulcan (USA).

5.2 PRODUCTS
 Gate, Globe & Non-Return Valves

1. Forged Steel Valves
2. Cast Steel Bolted Bonnet Valves
3. Cast Steel high pressure valves (Oil Field equipment)
 Oil Field Equipments
1. Well Heads and X-mas trees
2. Full Bore Valves
 Safety Valves
 Safety Relief Valves
 Electrical Relief Valves
 Quick Closing Non-Return Valves
 Cold re heat line non return Valves
 HP & LP By-Pass System
 Soot Blowers
1. Long retractable soot blower
2. Wall deslagger
3. Rotary soot Blower
4. Furnace Temperature probe
 Silencers (Steam Vent & ejector type)
 Other Products
1. Direct Water level gauge
2. Reheater Isolating device
5.3 SERVICES

Specially trained and experienced service team to service Valves and allied
equipment at
 Power Plants
 Process Plants
 Onshore and Offshore Platforms.
Specialized tools developed for
 Insitu repair of seats and seat rings in Gate, Globe, Check, Safety and
Safety Relief valves.
Services Include
 Refurbishing of Seat surfaces

 Servicing of Jammed Valves
 Setting of Actuators
5.4 CUSTOMERS
INTERNATIONAL
 TOA Valve Co., Japan
 Dresser Ind.Inc., USA
 Alstom Power USA
 Tyco Flow Control USA
 Yarway
USA
Corporation
 PT
SaranaAdikariyaUt Indonesia
ama

 PT South Pacific
Indonesia
Vis
DOMESTIC
 Petrochemicals
 Sugar Plants
 Neyveli Lignite Corporation
 Cement Plants
 Paper and Pulp Industries
 Aluminium Plants
 BPCL
 Nuclear Power Corporation
 Reliance Industries Limited
6. COMBINEDCYCLE DEMONSTRATION PLANT
6.1 Integrated Gasification Combined Cycle [IGCC]
 What is an IGCC power plant?
An Integrated Gasification Combined Cycle (IGCC) power plant

combines a gasification system with a modern, highly efficient ―combined
cycle‖ electric power system (consisting of one or more gas turbines integrated
with a steam turbine). IGCC power plants are successfully operating worldwide
and have been operating commercially in Indiana and Florida for more than a
decade. Clean syngas is combusted in high efficiency gas turbines to produce
electricity. The excess heat from the gasification reaction is then captured,
converted into steam, and sent to a steam turbine to produce additional
electricity. The gas turbines can be operated on a backup fuel such as natural
gas during periods of scheduled gasifier maintenance or can co-fire the backup
fuel to compensate for any shortfall in syngas production.
 Two Cycles involved in the IGCC

Combined cycle process combines two thermodynamic cycles namely
Rankine cycle and Brayton cycle

a) Rankine cycle:
The Rankine cycle is a thermodynamic cycle used to generate electricity in
many power stations, and is the real-world approach to the Carnot cycle.
Superheated steam is generated in a boiler, and then expanded in a steam
turbine. The steam turbine drives a generator, to convert the work into
electricity. The remaining steam is then condensed and recycled as feed-water
to the boiler. A disadvantage of using the water-steam mixture is that
superheated steam has to be used; otherwise the moisture content after
expansion might be too high, which would erode the turbine blades.
This cycle generates about 80% of all electric power used throughout the
world.
Physical layout of four main devices used in Rankine cycle
Ts diagram of a typical Rankine cycle operating between pressures of

0.06bar and 50bar
b) Brayton cycle:
The Brayton cycle is a thermodynamic cycle that describes the workings of
the gas turbine engine, basis of the jet engine and others. It is named
after George Brayton , the American engineer who developed it, although it was

originally proposed and patented by Englishman John Barber in 1791. It is also

sometimes known as the Joule cycle
A Brayton-type engine consists of three components:
 A gas compressor
 A mixing chamber
 An expander
 Gas turbines – IGCC
In IGCC — where power generation is the focus — the clean syngas is

combusted (burned) in high efficiency gas turbines to generate electricity with
very low emissions. The turbines used in these plants are derivatives of proven,
natural gas combined-cycle turbines that have been specially adapted for use
with syngas. For IGCC plants that include carbon capture, the gas turbines must
be able to operate on syngas with higher levels of hydrogen. Although modern
state-of the- art gas turbines are commercially ready for this ―higher hydrogen‖
syngas, work is on-going in the United States to develop the next generation of
even more efficient gas turbines ready for carbon capture-based IGCC.
 Heat Recovery Steam Generator (HRSG) – IGCC
Hot gas from each gas turbine in an IGCC plant will ―exhaust‖ into a heat
recovery steam generator (HRSG). The HRSG captures heat in the hot exhaust
from the gas turbines and uses it to generate additional steam that is used to
make more power in the steam turbine portion of the combined-cycle unit.
 Steam turbines – IGCC
In most IGCC plant designs, steam recovered from the gasification

process is superheated in the HRSG to increase overall efficiency output of the
steam turbines, hence the name Integrated Gasification Combined Cycle. This
IGCC combination, which includes a gasification plant, two types of turbine
generators (gas and steam), and the HRSG is clean and efficient — producing
NOx levels less than 0.06lb per MMBtu (coal input basis) and combined cycle
efficiencies exceeding 65% when process steam integrated from the
gasification plant is included. Another example of the ―integrated‖ design in the

fully integrated IGCC is the IGCC gas turbine, which can provide a portion of
the compressed air to the oxygen plant. This reduces the capital cost of the
compressors while also decreasing the amount of power required to operate the
oxygen plant. Additionally, gas turbines use nitrogen from the oxygen plant to
reduce combustion NOx as well as increase power output.
Advantages of IGCC
 According to the Environmental Protection Agency, the higher

thermodynamic efficiency of the IGCC cycle minimizes CO2 emissions
relative to other technologies
 IGCC plants offer today‘s least-cost alternative for capturing CO2 from a
coal-based power plant. In addition, IGCC will experience less of an
energy penalty than other technologies if carbon capture is required.
While CO2 capture and sequestration will increase the cost of all forms of
power generation, an IGCC plant can capture and compress CO2 at one
half the cost of a traditional pulverized coal plant.
 Other gasification based options, including production of motor fuels,
chemicals, fertilizers or hydrogen, to name a few, have even lower carbon
capture and compression costs. This will provide a significant economic
and environmental benefit in a carbon constrained world.
 IGCC – BHEL’s approach
1. Fixed Bed Gasifier

 6.2 MWe IGCC commissioned in 1989
 Fed about 1,000,000 units of power to TNEB grid
Limitations of fixed bed gasification

 It consists of internal moving parts with higher degree of
mechanical complexity for pressurized operation
 Lowest capacity per square meter of gasifier area
 Sized coal above 6mm is required and fines may be deposited off or
handled separately too much variation in size , will lead to
channelling , clinkering and incomplete gasification of bigger sizes
 The product gas contained tar, oil, phenols and coal fines. More
complicated clean up system is required to obtain cold clean gas.
Low temperature precludes heat recovery.
 Control of temperature below ash fusion point is required to avoid
clinkering
 High start up time is required

2. Fluidized Bed Gasifier

 18 TPD PFBG - BHEL Corp. R&D, Hyderabad, commision, 1993
 150 TPD PFBG - BHEL – CCDP, Tiruchy, commission – 1997
 Series of trial operations being conducted since 1997
 IGCC mode power generation demonstrated – march /june .1998
Advantages of Fluidized Bed Gasifier

 Higher unit capacity
 No tar or oil formation and easy gas cleaning
 No liquid effluent formation
 ability to accept finer coals
 Best suited for high ash indian coals
3. BHEL ,Trichy PFBG IGCC Demo power plant

After the successful development of moving bed gasifier
technology under the CCDP programme, BHEL embarked on pressurised
bed gasification (PFBG) technology. Recognizing the opportunity to
generate electricity in an efficient and environment –friendly manner,
ICICI – India‘s leading financial institution – supported the PFBG Project
through the programme for Accelerated Commercial Energy Research
(PACER) under the US-AID programme.
Utilizing all the infrastructural facilities created by BHEL under its
CCDP programme, Asia‘s first IGCC plant, the 150 tonnes per day
pressurised fluidized – bed gasification system was designed, fabricated,
erected and commissioned indigenously.
The fluidized-bed gasifier is a refractory-lined vessel. The air and
steam mixture and coal are introduced through a conical distributor
located at the bottom of the gasifier.
The entrained ash and unburnt carbon particles are separated by the
cyclones in series. The carbon recycle is effected from cyclones using
coal gas. The coal gas at the exit of the third cyclone is cooled from
9000C to 5400C in heat recovery boiler (HRB). The gas is further cooled
to 3700C in the gas cooler while superheating steam is utilized in the
gasification process and the rest expands in the steam turbine to generate
about 2.2MWe. The gas is further processed through the downstream in
the gas clearing system of the moving bed gasifier and admitted to the gas
turbine at 900C to generate 4.0 MWe.
A portion of the clean gas is compressed in the gas booster and is
utilised for fly-ash recycle in the cyclones and for the pressurization of
fly-ash locks and HRB lock.


7. INFORMATION TECHNOLOOGY AND SERVICES (ITS&S)
7.1 INTRODUCTION
The IT Solutions and Services department of BHEL, Trichy, commonly known

as just ITSS, plays a vital role in the smooth functioning of the whole
organization. Housed in the centre of the BHEL campus, it provides services
which are essential in both the manufacturing arm of BHEL as well as its day –
to – day functioning.
ITS&S focuses on providing services to meet the current needs of the

organization as well as devising new solutions for problems in its current and
future projects, in order to optimize the undertaken production work.
Its work can be summarized as follows:
- Developmental
 Plant Modeling
 Web – based Documentation Management System
 Engineering Automation / Cycle time reduction
- Services
 Updating and Maintaining Central Archives
 O&M Manual Preparation
 Standards
7.2 ITS&S Work Profile: An Outline
1) Plant Modelling
The three dimensional designing of power plants and processes is known as

plant modelling. It can be used to design any type of plant, from petrochemical
plants, offshore platforms, chemical and pharmaceutical plants, to power plants,

waste water treatment plants and cogeneration facilities. It has many
advantages, like being able to conduct strength and temperature analysis on
each component, or on the whole plant.
1.1) Need for Plant Modeling
 Plant modeling of a power plant gives the visual representation of a

power plant and also helps to detect any interferences, clashes etc; before
any plant gets erected.
 It reduces the total cost incurred as well as the total cycle time.
1.2) Software used by BHEL for Plant Modeling
 PDS (Plant Design System) – Used earlier

 PDMS (Plant Design Management System) – Used Now
PDMS – An Overview:
 PDMS(Plant Design Management System) is a 3-D plant modeling
software package supplied by AVEVA Inc.(a UK based software
company).
 It can be used to create three dimensional plant and equipment
models, extract isometric drawings and perform design interference
checks and detect equipment clashes.
 The major disciplines of PDMS are :-
a) Equipment Modeling
b) Pipe Routing
c) Structural Support Modeling
d) HVAC modeling
2) Systems Work undertaken by ITS&S
 Dolphin – Web-based AMS

– Reliable Storage of Drawings, Search on ANY Drawing attribute, Mail
notifications, Info Desk, PDF Download
– 8.75 Lacs Drawing Images of FB, FBC&HRSG, Valves, ATP are
managed through Dolphin. [Apart from this All the Old GMS Sheets –

numbering over 70 lakh have been scanned providing instant access to

past records]
 O&M Management System

– A comprehensive system to Input, Index, Monitor, Compile andPrint
O&M Manuals
 e-Filer, i-Vault
– Features – Secure File storage in SAN (on both primary andsecondary
sites)
– Titles, Key words and other attributes stored in secure database with
individual user accounts and authentication
 Quest – Engineering Information Portal

– The KM content gateway for Engineering with access to Standards,
Other Engineering Documents, Technical Collaboration content, Tools
for KM Circle generated content and KM Administration
 Library Digitization initiatives

– 10,500 technical journal articles have been digitized and stored in
electronic form via ‗Journal Management System‘ with easy search
capability.
–About 1100 reports of different departments have been digitized and
stored in ‗Ivault‘ for online reference.
–Implementation of ‗E-filer‘ system has led to complete elimination of
hard-copy office correspondance.

8.WELDING RESEARCH INSTITUTE (WRI)
8.1 INTRODUCTION
Welding Research Institute (WRI) was established in November 1975by

Government of India with UNIDO and UNDP assistance under the
management of Bharat Heavy Electricals Limited , Tiruchirappalli , India.
WRI has been constantly interacting with world renowned institutions for
updating the knowledge base on latest technologies and assimilating
experience.This Institute has been established to cater to the welding needs of
the Indian welding industries and for contributing to the growth of welding and
allied technologies.
The major activities of the Institute include
 Research and Developement on various welding processes and

technologies
 Metallurgical investigations
 Dissemination of knowledge in welding
 Consultancy services
The Institute has the following recognitions to its credit
 Recognized by Bureau of Indian Standards (BIS) for testing of

welding electrodes
 Authorised by Indian Boiler Board (IBR) for training and certification
of welders
 Recognizedcentre for research studies by IIT - Chennai, IISc,
Bangalore, NIT- Tiruchirappalli and PSG - Coimbaotre.
8.2 SERVICES

Welding Research Institute, has successfully completed number of consultancy

projects for various customers, in the field of equipment development,
consumable & power source testing, process & technology development,
metallurgical investigation, repair and reclamation, distortion control,
structural integrity analysis, remnant life estimation, condition assessment etc.
About 2300 consultancy services have been completed for 120 organisations
covering Heavy Engineering, Power, Petro-Chemical, Transport, Metal
Processing, Defence, Space, Oil, Ship Building, Consumable & Welding
equipment, Electronics industries etc.
 Annual Consultancy Contract Scheme(ACCS)

 Privileged Industrial Member Enterprise(PRIME)
8.3 FACILITIES
WRI is well equipped with welding and testing facilities under one roof. Some
of the unique facilities are listed below:
Testing Facilities
1. Mechanical Testing
 Universal Testing Machine - 600kN
 Micro hardness tester – 50gm–1 kg load
 Impact Tester - 406 Joules
 Pellini drop weight tester–41 kgs
 Instron 8502 servo hydraulic - 250 kN
 Instron 1603 EMR type - 100 kN
 Instron 1276 servo hydraulic - 1000 kN
2. Metallurgical Testing
 Scanning Electron Microscope – 200,000 X
 Light Optical Microscopes – 1600 X
 Differential Interference Contrast microscope – 1000 X
 In-situ metallographic Polishing kit
3. Stress Analysis
 X-ray Stress Analyser (AST-X2001)
 Multipoint Digital Strain Meter
 RS-200 Milling Guide for Residual Stress Measurement
 FEM software – ANSYS 5.0
4. Non Destructive Testing

 Ultrasonic Test Equipment - upto 1 dB
 In-situ Magnetic Particle Testing
 Radiographic test equipment – 400 kV
 Gamma ray test
Welding Facilities
1.Fusion Welding
 Solid state NdYAG Laser welding Machine-2kW
 Surface Tension Transfer MAG welder – 400 A
 Synergic MIG welding – 500 A
 Chamber for Titanium welding – f 1200 mm
 Tandem submerged Arc welder – 1200 A
 Time Twin welding equipment
2. Solid Phase Welding, Surfacing & Others

 Friction welder -15 tonnes
 Microjoining – for <1mm sheets
 Resistance Spot Welding

 Resistance Projection Welding
 Resistance Seam welder – for 2 mm sheets
 Flash Butt Welding

9. PRESS SHOP AND DRUM SHOP
The BHEL Trichy has equipped all its units with cutting edge technology and
sophisticated machines to facilitate its manufacturing needs. It has in its arsenal
an 8000 ton Hydraulic press, a Four Roll Plate Bending Machine and a large
capacity Induction Pipe Bending Machine to name a few. It has also installed
the plants with state-of-the-art analytical, mechanical and non-destructive
testing facilities to ensure the delivery of products of the finest quality.
The various processes in press and drum shop are:
SHELL FORMATION:
At first plates are received from the stores. They are verified for the material
specification and are subjected to Shear UT. Plates are then marked for cutting
to the required dimensions considering the test plates for Long seam and
cirseam. Before gas cutting the plates are heated to a temperature of 150 deg
(Preheating). Gas cut edges is cleaned and the plates are loaded to the furnace
for heating it to a temperature of 870-900 deg. This is done such that ROH is
150 deg /hr, soaking it for 200 minutes and cooling it by open air. This shell
plates are transferred to 8000 T press where it pressed to form a half shell.
Special care is taken that the forming process is done above 620 deg. If the
pressing is done below 620 deg C then Inter stage heat treatment is done.
Then the pressed plates are subjected to shot blasting for surface finish. And
then half shell formed is cold calibrated as per dimensions. After gas cutting the
half shells are sent to Drum shop for long seam EP preparation and further
processes. Then with row of burners along the length preheating to 150 deg C is
done for tack welding the fit ups, start up and test plates. Long seam joint is
welded from inside by FCAW with CO2 as shielding gas manually and then
surface is cleaned and ground. Straps from outside are removed and preheating
is done for outside welding to the temperature of 150 deg C. SAW (Submerged
Arc Welding) is the process of welding from the outside and is done as per the
WPS.Inspection is carried out on the joints welded and MT, RT and UT are
conducted.
The shell thus formed is Edge prepared on both the ends. Edge prepared ends is
inspected for compliance with the drawing. The two closed shells formed are
joined by cir seam welding for which internal welding is done by SMAW and
outer side is done by SMAW R + 2 mm for after gouging for effective lip
matching and then remaining portion by SAW process. All the welding
processes are accompanied by preheating to the temperature of 150 deg C.

DISHED END FORMATION:
Raw material for dished ends are received from stores and verified for material
spec, melt no. and plate no. for identification purpose. Marking for cutting the
plan as per drawing is done and verified. Marked portion is cut using gas cutting
operation for which the plate marked portion is preheated to 150 deg C. The gas
cut portion is cleaned and ground. The locater hole marking at the center of the
blank is carried out and accordingly drilling is done in steps.
Then the plates are loaded into the furnace with thermocouples and care is taken
such that direct flame impingement is avoided. The heating of plate is done to a
temperature of 870-900 deg C with ROH at 150 de C/Hr if the plate thickness is
above 100 mm else at the rate of 200 deg C/Hr. Soaking is done at rate of 1.25-
mts/mm thickness of plate with the cooling medium being air.
Heated plate is then pressed to the shape as dimensions in the drawing using
matching bullet and tool. Thus formed plate is subjected to shot blasting and
depressions if any are merged gradually to the base metal surface. Inspection is
done for profile, thickness, diameter, circularity and then the identifications are
transferred and punched. Manhole on both the dished ends is marked and pre-
drilling for gas cutting is done. Preheating is done and the manhole is formed
using gas-cutting process.
CIR SEAM WELDING
Preheating to 150 deg C is done and the tack welding of door components and
relevant DE is done. Cleaning and grinding of weld is done and is subjected to
MT. The door assembly is placed inside the drum before welding the last cir
seam. Fitting and tack welding of cir seam joint is done after pre heating to 150
deg C.
NOZZLE DRILLING AND ATTACHMENTS ON SHELL
Pilot drilling is done for full throat nozzle openings. After pilot drilling
operation the opening areas are preheated to 150 deg C for gas cutting the full
throat opening. The gas cut portion is cleaned and ground and then subjected to
MT and UT. Before tack welding the full throat nozzle with fit up on the shell,
preheating to 150 deg c is done. After verifying the alignment, orientation and
dimension, full throat welding is done as per WPS.
STRESS RELIEVING:
All the balance attachments are welded before SR. If any depressions are found
then it is ground and merged smoothly.

HYDRO TEST:
Drum is filled with water with a temperature range of 21 to 46 deg C and is

pressurized gradually to the pressure mentioned in the drawing (generally it is
pressurized to 1.5 times the design pressure). This is maintained for 30 mts.
Shroud hydro is conducted only for the shroud portion in case of 500MW
boilers.
FINAL HANDING OVER:
Drum is cleaned and is checked for free from foreign materials. Protective
plastic caps for all nozzles and nipples are provided. Paint is applied as per
painting scheme; axis and other important locations are marked. Authorized
Inspectors seal is stamped. Handing over to shipping for shipping is done.
1. HEADERS
The header is a manifold that forms the connection between the two pressure
part systems. It acts as a mixing chamber, equalizing the temperature of the
fluid. The header is basically a pipe suitably provided with inlet and outlet
connections so that the flow in the system is uniform and as desired.
Types of Headers:
 Header - both ends closed with hemispherical end cover

 Header – both ends closed with flat end cover
 One end closed with h.s.e.c and other end open
 Headers with both ends open
 Header with tee at quarter points (or at center):
In the micro level the headers may have the following components
1. Pipe
2. Tube
3. End Covers
4. Tees
5. Elbows
6. Support and lifting lugs
7. Hanger Rods & U Rods
8. Hand Hole Pipes
9. Lining and Insulation Attachments

MANUFACTURING SEQUENCE OF HEADERS:
1) LAYOUT MARKING
2) EDGE PREPARATIO
3) SOCKET SEAT DRILLING
4) BUTT JOINT
5) STUBS & ATTACHMENTS
6) SR & FINAL INSPECTION
THE BASIC DESIGN OF THE HEADER INVOLVES THE FOLLOWING

STEPS
1. The basic parameters of the header have to be obtained from the piping
and tubing list from the BPP. The basic configuration may be the length
of the header pipe, diameter of the header, thickness, design temperature,
pressure, etc.,
2. The arrangement of the nipples around the header pipe has to be decided
from the PPA drawing.
3. The header whether it is closed at one end/both the ends (with
hemispherical or flat end cover) or open at one end/both the ends is also
decided from the PPA drawing.
4. The other stubs that has to be given in the header for the vents and drain
is decided from the water and steam scheme which includes all the
fittings, valves and instrumentation from the Boiler Mountings section.
2. TUBES:
The nipples and the stubs those are present in the header, which has diameter
less than 76.2mm falls under the category of Tubes. Other than that certain
instrument inserts also falls under that category of tubes.
3. END COVERS:
As discussed above, the closed headers may have end covers. The end
covers are of two types:

i. Hemispherical End Cover

ii. Flat End Cover.
Due to the uniform stress distribution the Hemispherical end cover is

preferred mostly. In cases where there is a space limitation Flat end cover is
preferred.
4. TEE PIECE:
The header may be fitted with the tee piece, which may be used for the inlet or
for the outlet purpose. The Tee piece is usually provided at the quarter points
(i.e., the approximately at a distance of 0.25L from the ends, L = length of the
header) assuming that the flow is equal.
5. ELBOW:
The headers with elbow for the inlet or outlet will be considered as a pipe with a
bend. The selection of the elbow is done from the standard drawing 2-03-000-
00035 Formed Elbow - 90° (Raw Forming). The calculation is as explained in
Tee selection.
PROJECTS COMPLETED
 Heat treatment of Steam Generator Component

 Establishment of solid phase welding technology for aluminium
alloys
 Laser welding technology development for coated steels
 Application of weld sequence for distortion control in panels
 Development of laser and TIG welding technology for reheater
spray control valve
 Arc welding power source evaluation system
 Development of a Lathe type Rotating Fixture for Welding
Bifurcates
 Development Of Magnetically Rotating Arc Welding System
For Welding Of Tubes
 Development Of High Performance Robot Welding System
Using Time Twin Process
 Cold Wire Addition Process For Long Seam Butt-Joints Using
Tandem Submerged Arc Welding

 Electro Gas Welding System

 Internal Deep Bore Stelliting Machine
 Low Pressure Plasma Spraying System
 Overlaying Machine for Bowl mill Rolls
 Automatic Tube Butt Welding Machine
 Twin wire CO2 welding
 Feedback controller for Resistance welding
 Transistorised Power Source
 Seam tracker for arc welding system
 Versatile All Position In-situ metallographic polishing
Equipment (VAPINE)
 Narrow Gap Submerged Arc Welding Technology
 Applications of high energy density Electron Beam Welding
Technology

TABLE OF CONTENTS(PART B)
1. Bharat Heavy Electricals limited----------------------------------------------------7
1.1Overview
1.2Bhel Trichy Introduction
2. Approach To Central Structural Catalogue management---------------------11
2.1Introduction
2.2System
3. Aveva PDMS------------------------------------------------------------------------------13
3.1Design
3.2PARAGON
4. PARAGON---------------------------------------------------------------------------------15
4.1PARAGON(detailed description)
4.2Hierarchy of PARAGON
4.3Administative elements
4.4Specifications
5. PML-------------------------------------------------------------------------------------------21
5.1PML types
5.2PML objects
5.3 PML functions
5.4PML macros
6. SQL--------------------------------------------------------------------------------------------23
6.1SQL elements
6.2Queries
6.3Data verification
6.4Data types
7. Visual Basic----------------------------------------------------------------------------------27

7.1Language features
7.2More about VB6.0
7.3VB outputs
7.4VB uses
7.5Flow chart of the VB software
7.6Screenshots
8. Conclusion---------------------------------------------------------------------------------36
9. References----------------------------------------------------------------------------------37

1. BHARAT HEAVY ELECTRICALS LIMITED
1.1 OVERVIEW
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. The company has been earning profits since 1971-72 and
has been 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, Renewable Energy etc. the wide
network of BHEL‘s 14 manufacturing divisions, 4 Power Sector regional
centres, over 100 project sites, 8 service centres, 18 regional offices and 1
subsidiary enables the company to promptly serve its customers and provide
them with suitable products, systems and services efficiently and at
competitive prices. The high level of quality and reliability of its products is
due to the emphasis on desing, engineering and manufacturing to
international standars by acquiring and adapting some of the best
technologies from leading companies in the world, together with the
technologies developed in its own R&D centres.
BHEL‘s operations are organized around three business sectors, namely,

Power, Industry and Overseas Business. This enables BHEL to have a
strong customer orientation, to be sensitive to the customer‘s needs and
respond quickly to even minute changes in the market.
BHEL‘s vision is to become a world-class engineering enterprise, committed

to enhancing stakeholder value. The company is striving to give shape to its

aspirations and fulfill the expectations of the country to become a global

player.
The greatest strength of BHEL is its highly skilled and committed 42,600
employees. Every employee is given an equal opportunity to develop
himself and grow in his career. Continuous training and retraining, career
planning, a positive work culture and participative style of management
have engendered a development of a committed and motivated workforce
setting new benchmarks in terms of productivity, quality and
responsiveness.
1.2 BHEL, Tiruchi:

1.2.1. Introduction:
The High Pressure Boiler Plant (HPBP) of BHEL was set up at Tiruchi in
1963 for the manufacture of High Pressure boilers. The plant achieved its
initial full annual capacity of 400 MW in 1984 with boiler ratings up to 500
MW. But this capacity has been increased to 15000 MW to meet the
growing demand along with the addition of the Seamless Steel Tube Plant
(SSTP). The HPBP and SSTP are spread over 2908 acres of land and has a
covered shop area of 2,50,000 square meters.
1.2.2. Technology Assimilation and Facilities
With a judicious mix of in-house R&D and selective technology tie ups,
BHEL Tiruchi has developed excellent engineering and R&D capabilities.
Due to these, BHEL Tiruchi has been identified as a nodal agency for all
Fossil Fuel Based Research Activities. With superior engineering and R&D
capabilities, BHEL Tiruchi is well poised to introduce new products such as
boilers and auxiliaries of higher ratings (in the range of 800 MW), Super

Critical Once-Through Boilers, Fabric Filters and Flue Gas

Desulphurization system.
BHEL Tiruchi has equipped all its units with cutting edge technology and
sophisticated machines to facilitate its manufacturing needs. It has in its
arsenal an 8000 ton Hydraulic press, a Four Roll Plate Bending Machine
and a large capacity Induction Pipe Bending Machine to name a few. It has
also installed the plants with state-of-the-art analytical, mechanical and non-
destructive testing facilities to ensure the delivery of products of the finest
quality.
1.2.3. Customer Services:
At BHEL Tiruchi, every system is tuned towards serving the customer. The
entire project management required for the timely execution of the
customer‘s orders is handled through a computerized network. Planned
production of components in workshops as well as timely ordering on
outside vendors is carried out to ensure dispatch of components matching
construction schedule at the sites. This helps BHEL Tiruchi in maintaining
product deliveries with shortest lead times.
Services are provided during and after the commissioning of equipment by

the Field Engineering Services. With this dedicated team of engineers and
technicians, site problems are attended to with the utmost urgency. Effective
interaction is maintained with customers to have continuous feedback on
equipment performance.
Supply of spares and after-sales-services are two other major components of

BHEL Tiruchi‘s service support. BHEL Tiruchi ensures timely supply of
spares for the proper upkeep of equipment and the maximization of
equipment utilization.

Techniques and methodologies have been developed to assess the residual

life of components, based on which selective replacement decision can be
made to extend the productive life of the equipment.
1.2.4. Global Links:
BHEL Tiruchi has so far supplied boilers for a cumulative capacity of 1350
MW of power generation capacity to Malaysia, Libya, Iran, Egypt etc.
BHEL‘s Valves have been exported to Malta, Cyprus Malaysia and
Indonesia while pressure part equipment and spares have been exported to
the USA. Boiler components have been supplied to China and Seamless
Steel Tubes have been exported to Malaysia
1.3. Certification
BHEL has been able to acquire the following certifications:
 ISO 9000 certification in 1993. In doing so became the first state

owned company to acquire it for all its operations.
 The ―CII-EXIM Commendation Certificate‖ on the HPBP at Tiruchi
for ‗Commitment to Total Quality Management (TQM)‘ by the
Confederation of Indian Industries (CII)
 ISO 14001 Standard – signifying its clear commitment to a clean and
pollution-free environment.

2.Approach for Centralized Structural Catalogue

Management
2.1Introduction
In an era of Information Technology, engineering automation becomes a

vital part of the business. In the modern day scenario there are numerous
softwares in each field (Structural, Piping, Ducting and etc.,) that can be
adopted for engineering automation. A lot of effort is put in, to achieve this
milestone, but at the end of the day there is always an uncertainty that if
new software comes with greater advantage or with lesser price, what
should we do. Software vendors take advantage of the situation and raise
the price of the product. Since the data is stored within a software, we
become dependent and switch over to another causes a huge effort to be put
in.
Strucad/Xsteel are the softwares being used by Structures department for

3D modeling of Structures. PDMS is used to integrate/model the total plant
to identify interferences and drawing extractions. Effort cannot be
duplicated to model structures in both the platforms. Hence it would be wise
to import/export data from one to another in a most appropriate manner
without any data loss. There is also a growing need for data exchange from
one package to another (Strucad/Xsteel/AutoCAD to PDMS).
For this to be done there is a need for a mapping table which specifies the
relation between the packages. Also there is a possibility of duplication of
work in catalogue management. If a section is to be added it has to be added
in multiple platforms. Based on softwares, addition of new variant becomes
complex.

With this background an approach/system has been evolved

especially for structural catalogue management.
2.2System
The data pertaining to BHEL sections shall be stored in a centralized

database (Oracle). Different types of sections and parametric definition will
be stored in one table(called master table) and parametric values will be
stored in another table(called catalogue table). Any addition to catalogue
will be done here which will trigger individual packages for an update.
Mapping of each section between packages shall be available.

3. AVEVA PDMS
AVEVA Plant Design Management System (PDMS) is a multi-discipline

3-D modeling system that allows you to simulate a detailed, full size model
of all the significant parts of a process plant. It allows us to see a full colour
representation of the plant model as the design progresses.
AVEVA PDMS can be used to design any type of plant from petrochemical
plants, offshore platforms, chemical and pharmaceutical plants, consumer
products (food, beverages, cosmetics, soap, paper, and so forth), to power
plants, waste water treatment plants, and cogeneration facilities. It is used to
create three-dimensional plant models, create equipments models, extract
isometric drawing, and perform design interference checks and equipment
clashes.
Specifically, the Plant Design Management System (PDMS) integrates

many discipline specific software modules. These modules automate the
many phases of a plant design project like interference checking, design
review etc.
PDMS comprises of the following functional parts:
• Modules
• Applications.
3.1Module
A module is a subdivision of PDMS that allows a user to carry out specific

types of operation. PDMS has the following modules

 3.1.1DESIGN, Design is the main, graphically driven

constructor module within PDMS. Design enables a full sized
three•dimensional plant model to be defined in the Design database,
with selected views of the current state of the design shown on the
graphics screen as the design progresses. All parts of the design
(including equipment, and piping and structural steelwork lauserts)
can be created. Component selection is provided through
Specifications that dictate which Catalogue Components can be used.
Each part of the design model can be displayed in color shaded ‗solid‘
color coded representations for ease of interpretation. Design can
check for interferences (clashes) between items created in the design.
 3.1.2PARAGON, which we use for creating 3D model of

structural component Used to generate and modify catalogues, with
facilities for catalogue component construction with visual control
(including 3D color•shaded representations of the item being
designed). The catalogues in PDMS serve a similar purpose to the
manufacturers catalogues, which user would refer to when using
conventional design methods. The PDMS component catalogue is
used to specify the geometry, connection information, obstruction and
detailing data of steelwork, piping, and HVAC and cable tray
components.It should be noted that, where the design data is specific
to a particular design, catalogues and specifications may be specific to
a company but general to a number of projects in that company. For
example, the same catalogue component may also appear in other
designs proceeding at the same time.

The module that is used to create models is PARAGON module.
4.PARAGON MODULE (A DETAILED

DESCRIPTION)
PARAGON module used to generate or modify a PDMS Catalogue,

with facilities for constructing Catalogue Components under fully
interactive visual control, including 3Dcolour--shaded representations
of the items being designed. Paragon combines aspects of both
catalogue creation and model design functionality within a single
module. This means that a catalogue designer not only has write
access to a project‘s catalogue databases, but may also read data from
the design databases. If given write access, the catalogue designer
could also experiment with new catalogue component configurations
in a trial design database. This approach simplifies catalogue
maintenance and design. Similarly, it is often useful for a plant design
engineer to have access to the catalogue to query details of specific
components. Paragon has a graphical user interface consisting of
forms and menus. The interface provides access to the most
commonly used facilities. PARAGON is the PDMS application
through which the database containing the geometry definition is
created.
4.2Hierarchy of PARAGON:
CATA is the highest level element of the Catalogue hierarchy.

CATALOGUE
SECTION
CATAGORY
COMPONENT
POINT SET
GEOMETRY
DATA SET
BOLT SET
A snapshot of hierarchy level:

4.3Administrative Elements
 CATAlogue
Description: Description of catalogue
Purpose: Purpose should be the same as the SPEC with which the
catalogue is to be used (STL, FITT, JOIN, PFIT etc.)
Cstandard: Catalogue standard
 STSEction - Structural Section
Description: Description of Section
Gtype: Generic type of element contained in section; this should be
the same as the type of element used in DESIGN, e.g. BEAM
 STCAtegory - Structural Category
Description: Description of category
Purpose: Purpose should equate to the STYP of the items as
defined in the Spec

Function: Description
Gtype: Identifies the Generic element type
 PTSE - Point Sets
Description: Description of point set
Skey: Symbol Key to which point set relates
Purpose: Purpose of point set
 GMSE - 3D Geometry Set
Description: Description of geometry set
Purpose: Purpose of geometry set
 NGMS - Negative Geometry Sets
Description: Description of geometry set
Purpose: Purpose of geometry set
 DTSE – Datasets
Description: Description of dataset
Purpose: Purpose of dataset

 PTSS - Point sets
Description: Description of point set
Purpose: Purpose of point set
 GMSS - 2D Geometry Set
Description: Description of geometry structural set
Purpose: Purpose of geometry structural set
A screenshot of PARAGON in PDMS (12.0)

To GET the structural component in design module we need to create

specification world.
4.4Specifications
The following conventions for structural specifications must be

followed to ensure that a correct specification is built. The application
follows strict rules when building these specifications and reads the
specification in a tabulated format. Description should be given at the
correct level and any question of Tanswers must be input for the
forms and menus to be correctly built. The steelwork specifications
work in a different way to piping specifications, where there can be
more than one answer.

PDMS only understands PML(programmable macro language).
5.PML(programmable macro language)
PML means programmable macro language used to design a

graphical user interface which suits our business needs. PDMS
understands only PML.
5.1PML TYPES
PML program can be broadly classified into 4 types based on the

functionality or purpose.
 PML OBJECTS
 PML FUNCTIONS
 PML FORMS
 PML MACROS
5.1.1PML OBJECTS
 PML uses object programming concept.

 An object may be :
a physical object (Engineering elements like boiler, motor)
An abstract object.
An object may defined using parameters or dimensional
elements. The parameters might be:
o Geometrical parameters
o Performance parameters
o Positional and orientation parameters
o Specialty parameters (Aesthetic parameters like
paint colour, translucency and etc.,)
An object might have a graphics.

5.1.2PML FUNCTIONS
 PML functions and methods may optionally have arguments, which

can be used to return values.
 Arguments have a data type which is specified in the function or
method definition and they are checked when the function or method
is called.
 Functions and methods can optionally return values as their results.
define function !!Perimeter (!Length is real, !Width is real) is real
!Perimeter = (!Length + !width) * 2
return !Perimeter
End function
Functions which do not return results are called as PML
PROCEDURES.
5.1.3PML FORMS
 PML forms are also objects.

 PML form is a PML program which is used to design the graphical
user interface (GUI).
 These are mainly used to get input values from the user and transfer
these values to functions or macros to carrusert specific action.
 In simple terms these are the front end which interacts with the user,
guiding them on operating the PML program.
5.1.4PML MACROS
 PML macros are command sequences which are stored as text files.
 To access a macro file and input the command sequence to our
program, we run the macro.
 The file is scanned line by line, with exactly the same effect as if we
are typing the commands from the keyboard.

 Macros are permanent records which may be called within any

working session of a program.
A macro which is used to add new structural component of type
welded beam(WLB) is :
/WB300x300-25/16
handle(2,109)
/SSSCNWLB
new sprf /WB300x300-25/16
gtyp SCTN
para 300 300 16 25
gmss /SSSCNWLBGMSS
ptss /SSSCNWLBPTSS
DTSE /SSSCNWLBDTSE
Endhandle
This will automatically create one new structural component of WLB of
GIVEN PARA,GMSS,PTSS and DTSE.
To add records (parametric values and various other descriptions) in

ORACLE database we use SQL language.
6.SQL
SQL stands for structured query language. It is a universal language used for
retrieving and manipulating data in a relational data base management
system(RDBMS).
6.1Language elements
The SQL language is sub-divided into several language elements, including:

 Clauses, which are in some cases optional, constituent components of
statements and queries.

 Expressions, which can produce either scalar values , tables consisting

of columns and rows of data.
 Predicates which specify conditions that can be evaluated to
SQL three-valued logic (3VL) Boolean truth values and which are
used to limit the effects of statements and queries, or to change
program flow.
 Queries which retrieve data based on specific criteria.
 Statements which may have a persistent effect on schemas and data,
or which may control transactions, program flow, connections,
sessions, or diagnostics.
o SQL statements also include the semicolon (";") statement
terminator. Though not required on every platform, it is defined
as a standard part of the SQL grammar.
 Insignificant whitespace is generally ignored in SQL statements and
queries, making it easier to format SQL code for readability.
6.2Queries
The most common operation in SQL is the query, which is performed with
the declarative SELECT statement. SELECT retrieves data from one or
more tables, or expressions. Standard SELECT statements have no
persistent effects on the database. Some non-standard implementations
of SELECT can have persistent effects, such as the SELECT INTO syntax
that exists in some databases. Queries allow the user to describe desired
data, leaving the database management system (DBMS) responsible
for planning, optimizing, and performing the physical operations necessary
to produce that result as it chooses.

A query includes a list of columns to be included in the final result

immediately following the SELECT keyword. An asterisk ("*") can also be
used to specify that the query should return all columns of the queried
tables. SELECT is the most complex statement in SQL, with optional
keywords and clauses that include:
 The FROM clause which indicates the table(s) from which data is to
be retrieved. The FROM clause can include optional JOIN subclauses
to specify the rules for joining tables.
 The WHERE clause includes a comparison predicate, which restricts
the rows returned by the query. The WHERE clause eliminates all
rows from the result set for which the comparison predicate does not
evaluate to True.
 The GROUP BY clause is used to project rows having common
values into a smaller set of rows. GROUP BY is often used in
conjunction with SQL aggregation functions or to eliminate duplicate
rows from a result set. The WHERE clause is applied before
the GROUP BY clause.
 The HAVING clause includes a predicate used to filter rows resulting
from the GROUP BY clause. Because it acts on the results of
the GROUP BY clause, aggregation functions can be used in
the HAVING clause predicate.
 The ORDER BY clause identifies which columns are used to sort the
resulting data, and in which direction they should be sorted (options
are ascending or descending). Without anORDER BY clause, the
order of rows returned by an SQL query is undefined.

6.3Data definition
The Data Definition Language (DDL) manages table and index structure.
The most basic items of DDL are the CREATE,ALTER,RENAME,DROP
and TRUNCATE statements:
 CREATE creates an object (a table, for example) in the database.
 DROP deletes an object in the database, usually irretrievably.
 ALTER modifies the structure of an existing object in various ways—
for example, adding a column to an existing table.
 Example:
o CREATE TABLE My_table
(
my_field1 INT,
my_field2 VARCHAR(50),
my_field3 DATE
PRIMARY KEY (my_field1, my_field2)
);
6.4Data types
Each column in an SQL table declares the type(s) that column may contain.
ANSI SQL includes the following data types.
 CHARACTER(n) or CHAR(n) — fixed-width n-character string,
padded with spaces as needed.
 CHARACTER VARYING(n) or VARCHAR(n) — variable-width
string with a maximum size of n characters.
 NATIONAL CHARACTER(n) or NCHAR(n) — fixed width string
supporting an international character set
 NATIONAL CHARACTER VARYING(n) or NVARCHAR(n) —
variable-width NCHAR string.

To create a software that will continently add new records from the excel
sheet to the ORACLE database and for generating macros we use Visual
Basic. There are many visions of Visual Basic and we have used Visual
basic 6.0 for fulfilling our requirement.
7.VISUAL BASIC
VISUAL BASIC is a high level programming language which evolved from

the earlier DOS version called BASIC. BASIC means Beginners' All-
purpose Symbolic Instruction Code. It is a very easy programming
language to learn. The code look a lot like English Language. Different
software companies produced different versions of BASIC, such as
Microsoft QBASIC, QUICKBASIC, GWBASIC ,IBM BASICA and so on.
However, people prefer to use Microsoft Visual Basic today, as it is a well
developed programming language and supporting resources are available
everywhere. Now, there are many versions of VB exist in the market, the
most popular one and still widely used by many VB programmers is none
other than Visual Basic 6.
VISUAL BASIC is a VISUAL and events driven Programming Language.
These are the main divergence from the old BASIC. In BASIC,
programming is done in a text-only environment and the program is
executed sequentially. In VB, programming is done in a graphical
environment. In the old BASIC, you have to write program code for each
graphical object you wish to display it on screen, including its position and
its color. However, In VB , you just need to drag and drop any graphical
object anywhere on the form, and you can change its color any time using
the properties windows.
On the other hand, because the user may click on a certain object
randomly, so each object has to be programmed independently to be able to
response to those actions (events). Therefore, a VB Program is made up of

many subprograms, each has its own program code, and each can be
executed independently and at the same time each can be linked together in
one way or another.
7.1Language features
Like the BASIC programming language, Visual Basic was designed to be

easily learned and used by beginner programmers. The language not only
allows programmers to create simple GUI applications, but can also
develop complex applications. Programming in VB is a combination of
visually arranging components or controls on a form, specifying attributes
and actions of those components, and writing additional lines of code for
more functionality.
7.2More about visual basic
Visual Basic (VB) is the third-generation event-driven programming

language and integrated development environment (IDE) from
Microsoft for its COM programming model. VB is also considered a
relatively easy to learn and use programming language, because of its
graphical development features and BASIC heritage.
7.3VB outputs
Visual Basic was derived from BASIC and enables the rapid application
development (RAD) of graphical user interface (GUI) applications, access
to databases using Data Access Objects, Remote Data Objects, or ActiveX
Data Objects, and creation of ActiveX controls and objects. Scripting
languages such as VBA and VBScript are syntactically similar to Visual
Basic, but perform differently.
A programmer can put together an application using
the components provided with Visual Basic itself. Programs written in

Visual Basic can also use the Windows API, but doing so requires external
function declarations.
Like the BASIC programming language, Visual Basic was designed
to be easily learned and used by beginner programmers. The language not
only allows programmers to create simple GUI applications, but can also
develop complex applications. Programming in VB is a combination of
visually arranging components or controls on a form, specifying attributes and
actions of those components, and writing additional lines of code for more
functionality. Since default attributes and actions are defined for the
components, a simple program can be created without the programmer
having to write many lines of code. Visual Basic also provides us the OLE
tool which can easily create data links to any database and then create more
interactive applications. Any VB program can be linked to any popular
database such as Oracle or Microsoft Access. This linkage needs an OLE
DB driver which now comes preinstalled with every windows version. It
means that even if the server computer doesn‘t have VB installed still it can
run the program and give the desired results. The VB programmer has to
write the code for querying the database for the desired results. An example
of such an application will be the username and password authentication
program. When we enter the username and password the program queries
the data base with the unique username and once a match is found it
matches the password; only then the authentication is completed.
7.4 VB uses
Visual Basic can also be used to link any video or audio format for better
presentation and usability. Its ActiveX controls allow the user to create
visually appealing components in the program for e.g.:- the progress bar that
can be seen while installing any program. Visual Basic has the ability to

embed various file formats into its forms some of which

are.avi,.wmv,.swf,.flv..and many other formats as well.
7.5Flow diagram of the VB software:
Records in designers excel sheet
Records are copied to predefined design template
If it‘s there in database

Records are matched in ORACLE database
If it‘s not there in database
Existing records are not added

New records are being added
PDMS macro are generated

7.6Types of structures in which user can add new component
S.No Sheet Name Description

1 ISA Indian Standard Angle
2 ISB Indian Standard Beam
3 ISC Indian Standard Channel
4 IST Indian Standard Tee
5 CBX Channel Box
6 JNB Jindal Beam
7 WLB Welded Beam
8 RPI Rolled Plus I
9 WPI Welded Plus I
10 WBC Welded Box Column
11 WBB Welded Box Beam
12 SAN Star Angle
13 DAN Double Angle
14 DCL Double Indian Chandard Channel
15 DIB Double Indian Standard Beam
16 DJN Double Jindal Beam
*out of 16 types designer can only add in 7 types and for the rest designer
need have administrator permission

7.7SCREEN SHOTS OF
STRUCTURAL CATALOGUE ADDITION SOFTWARE
LOGIN FORM
MAIN FORM

DESIGN TEMPLATE
AFTER ADDING RECORDS BY DSIGNER

SPECIFYING THE PATH
CONFIRMATION MESSAGE

PDMS MACRO GENERATION
PDMS MACRO TEXT FILE

8.CONCLUSION
We have made a software in Visual Basic(6.0) which can be used by
the designer to add new structural components to existing oracle database.
We have made user friendly Graphical User Interfaces(GUI) in which user
will guided thought out the software and errors will be displaying along
with the suggestions to add new records having different parametric values.
For the security purpose the initial GUI of the software is a LOGIN form so
that authorized users can only add to the database. And there will be no
mishandling of the centralized oracle database.
For any reasons if the administrator need to have some modifications he has
provided with the original VB code.
The code is so well written that if a new type if design comes the
administrator can add the new type within few minutes along with the
previous 16 types.

9.REFERENCES
 AVEVA PDMS MANUALS

o catalogues and specifications user guide
o catalogues and specifications reference manual
o design conventions for catalogues and specifications
o introduction to templates user guide
 WIKIPEDIA
 BEGINNING SQL BY PAUL WILTON ,JOHN COLBY,
PUBLISHER- WILEY DREAMTECH
 PML
 BHEL WEBSITE AND MAGAZINES
 VISUAL BASIC 6 PROGRAMMING IN 2 AND HALF
DAYS BY RICHARD MANSFIELD,PUBLISHER-
HUNGRY MINDS
 LEARN MICRO SOFT VISUAL BASIC 6.0 NOW BY
MICHAEL HALVORSON ,PUBLISHER-PRENTICE HALL
OF INDIA PVT.LTD
 VISUAL BASIC 6 : THE COMPLETE REFERENE BY
NOEL JERKE ,, PUBLISHER- TATA MC-GRAW HILL
PUBLISHING COMPANY LIMITED

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CENTRALISED STRUCTURAL CATALOGUE MANAGEMENT

BHARAT HEAVY ELECTRICALS LIMITED

A Practice School – I station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE,

IT Solutions & Services Page 1

Prepared in partial fulfillment of the

BHARAT HEAVY ELECTRICALS LIMITED

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE,

IT Solutions & Services Page 2

I would like to express my gratitude to Mr. A.V. Krishnan, Executive

I wish to thank Mr. K. Chandrasekaran, AGM – HRDC and coordinator

I would like to express my sincere gratitude to Mr. M. S. Ramesh, SDGM,

I am in debt to express my gratitude to Mr. Tamilsevan.T, Assistant

Lastly, I would like to thank Dr. P. Srinivasan, PS instructor at BHEL,

IT Solutions & Services Page 3

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

Practice School Division

Station: Bharat Heavy Electricals Ltd. Centre: Tiruchirapalli

E.kisan 2008A4PS394G B.E.(Hons)MechanicalEngg.

Name of PS Faculty: Dr. P. Srinivasan

Key Words: PDMS, SQL, VISUAL BASIC, CATALOGUE

Abstract: A brief overview of BHEL, and its various departments. A

Signature of Student Signature of PS Faculty

Date: 16/07/2010 Date: 16/07/2010

IT Solutions & Services Page 4

IT Solutions & Services Page 5

1.BHARAT HEAVY ELECTRICALS LTD (BHEL)

Bharat Heavy Electricals Limited (BHEL) is largest engineering and

IT Solutions & Services Page 6

For power generation applications, BHEL designs, engineers, manufactures,

IT Solutions & Services Page 7

type steam generators in addition to conventional natural and controlled

BHEL supplies steam generators of rating up to 450 ton/hr for industrial

BHEL manufactures state-of-the-art Circulating Fluidised Bed Combustion

 Simplified fuel preparation equipment eliminating sophisticated and

IT Solutions & Services Page 8

BHEL is the pioneer in Atmospheric Fluidised Bed Combustion (AFBC)

BHEL's AFBC Boilers - Unique Design Features

 Specially developed fuel feeders and feeding system to handle even

HeRECOVERY STEAM GENERATORS

IT Solutions & Services Page 9

ADVANCE TECHNOLOGY PRODUCTS

Advanced Technology Products Department in BHEL, Tiruchy is

Advanced Technology Products Department in BHEL, Tiruchy is

IT Solutions & Services Page 10

3. SEAMLESS STEEL TUBE PLANT

BHEL – SSTP manufactures Seamless Steel Tubes of world standards, catering

An additional range of specialized applications...

Towards ever shorter delivery periods

Meeting International Specifications…

IT Solutions & Services Page 11

A WIDE RANGE OF APPLICATIONS

SEAMLESS STEEL TUBES AND PIPES (APPLICABLE

Specification Grade Title

ASME SA A,B,C Seamless carbon steel pipes for high

SA 179 Seamless cold drawn low carbon steel

SA 192 Seamless carbon steel boiler tubes for

SA210 A1,C Seamless medium carbon steel boiler and

SA209 T1 Seamless carbon-molybdenum alloy steel

IT Solutions & Services Page 12

SA213 T2, T5, Seamless ferritic and austenitic alloy

SA333 1,6 Seamless and welded steel tubes for low

SA334 1,6 Seamless and welded carbon alloy steel