2011

INDUSTRIAL TRAININGBHARAT HEAVY ELECTRICALS LIMITEDMANUFACTURING OF STATOR BAR OF 500 MW TURBO GENERATOR

SUBMITTED BY:-

SUBMITTED TO:Mr. A.K. Dhiman

DEEPAK KUMAR S.H.I.A.T.S ALLAHABAD

I take this opportunity with much pleasure to thank all the people who have helped me through the course of journey through producing this report. Firstly, I would like to say that I am highly obliged to the BHEL authorities which allowed me to do training at BHEL for the due course of time. I sincerely thank my thesis supervisor Mr. A.K. Dhiman for his guidance, help and motivation. I am also grateful to the workers and staff members of BHEL for providing me their invaluable knowledge in guiding various works during my training tenure.

DEEPAK KUMAR B.Tech EEE

BHEL- Corporate Profile

In the late fifties Bharat Heavy Electrical Established Limited , better known BHEL, is today the largest engineering and manufacturing enterprises of its kind in India . the first plant of BHEL was established nearly 47 years ago in August 1956 at Bhopal and was the genesis of heavy electrical equipment industry in India. The organization is engaged in engineering, development and manufacture of a wide variety of electrical and mechanical equipments for generation, tansmission and utilization of energy and electric power. The company provides product, system and services for the energy sector as well as for industry and transportation. It has a well recognized track record of performance, making profit continuously since 1971-72. It achieved a sales turnover of Rs. 5625 crores 1999-2000 and NAV per share Rs. 135. A vast reservoir of manufacturing skills the 80000- strong BHEL family comprises a formidable team of engineers, scientists, managers, and trained technicians. In the world power scene BHEL ranks among the top 12 manufacturers. It is the largest engineering and manufacturing enterprises of its kind in India. It has a well recognized track record of performance making profit continuously since 1971-72. It offers services from project feasibility studies trough after sales services, thus meeting all customer requirements. More than 456 countries ranging from USA and USSR in the west to Australia and New Zealand in the east are BHELs customers. Its operations are spread over 14 manufacturing units, 4 power sectors regional centers,

over 150 project sites and service centers, and 15 regional offices, which enable the company to be closer to its customer and provide them with suitable products, system and services at competitive prices. Having attained ISO 14001 and TQM (total quality management) BHEL is now on its journey towards ISO 18001 (OHSAS).

1. Heavy Electrical Equipment Plant & Central Foundry Forge PlantHaridwar. 2. Heavy Electrical Plant-Bhopal. 3. High Pressure Boiler Plant & Seamless & Steel tubes plant Tirichi. 4. Heavy Power Equipments Plant Hyderabad. 5. Boiler Auxillaries Plant Ranipet. 6. Electronics Division & Electro Porcelains Division - Bangalore. 7. Industrial Valves Plant Goindwal. 8. Transformer Plant Jhansi. 9. Component Fabrication Plant Rudrapur. Today, BHEL has a growing presence in the variety of areas besides the power sector. They are:

Industry Transportation Oil & gas Non Conventional Energy Sources

 Telecommunications
BHEL offers a variety of transportation systems to meet the growing needs of the country. 65% of the railways are equipped with BHEL manufactured traction equipment. Indias first underground rail Metro runs on drives and controls supplied by BHEL. For pollution free transportation, BHEL offers battery-operated passenger vans and electric trolleybus systems. Equipment for oil gas exploration and transportation is manufactured by BHEL. Range covers super-deep drill rigs, mobile and desert rigs with matching draw-works and hoisting equipments, also Christmas-tree valves and well head assemblies. BHEL has supplied several water heating systems, windmills, biogas generators and photovoltaic systems. BHEL has entered the field of telecommunications with electronic PABX systems based on indigenous technology from C-DOT. BHEL has collaboration with following companies:

Combustion Engineering Inc. U.S.A. Sludge Brothers, Switzerland. International general electrical co. Inc., U.S.A. Creset loire, France. Nuoveo pignore S.P.A., Italy. Svenska Flaktabrites, Sweden. Siemens Ag., W.Germany. Enlish Electro Co., U.k.

 Pronum Ashenport, U.S.S.R. Weir Pumps Ltd., U.K.

BHARAT HEAVY ELECTICALS LIMITED

The product profile of BHEL is very vast and includes following equipments and services: Thermal Sets:

Turbine generator sets along with all Auxillaries of thermal

power plant of the utilities are supplied for rating of 30, 60, 110, 120, 200, 210 & 500 MW capacities. Hydro Sets:

Custom built conventional hydro-turbines of Kaplan, Francis

and Peloton type with matching generators.

Pump turbines with matching motor generators. Mini/ micro hydro sets such as horizontal tubular turbines. Spherical, butterfly & rotary valves and Auxillaries for hydro
stations.

Governors (Mechanical and Electro-hydraulic type), drainage

and dewatering systems, compressed air systems, centralized grease lubrication system and other control and protection systems. Equipments for Nuclear Power Plant:

Turbines and Generators. Steam generators. Re-heaters/ separators.

 Heat exchangers & condensers.

Heat Exchangers:

Surface condensers. Low pressure heaters for re-generative feed heating systems. High pressure heaters. Chimney and gland steam-condensers for all operating
conditions.

Coolers, condensers, separators and seal oil regulators, tanks,

for upto 300 atm on channel sides of any material.

Try type de-areators for TG sets. Steam operated air ejectors.

Boiler Auxiliaries:

Fans-Axial reaction fans of single stage and double stage for

clean air application with capacity ranging from 25m^3/sec to 800m^3/sec with pressure ranging from 120 to 1480 meters of gas column. Axial impulse fans single and double suction radial fans etc are also.

Air heaters-Ljungstrong regenerative air-heaters for boiler and

process furnaces in a broad range of size and capacities.

Gravimetric feeders. Pulverizes- slow and medium speed coal pulverizes upto a
capacity of 100 tones/ hour.

Electro static precipitators- of any capacity with efficiency upto

99.5% for fly ash removal in power plants.

Mechanical separators.

Boiler & Pressure Vessels:

Steam generators for utilities; range- 30MW to 500MW using

coal, oil, natural gas or a combination of these fuels.

Steam generators for industrial applications; range6tonnes/hour to 300tonnes/hour using coal, oil, natural gas, industrial gases, wood, bio gases or a combination of these fuels.

Waste heat recovery boilers. Recovery boilers for paper industry; range- 100tonnes/day to
1000 tons/day of dry solids.

Pressure vessels. Fluidized bed boilers.

Pumps:

Boiler feed pumps (motor or steam turbine driven). Condensate booster pumps. Boiler feed booster pumps. Condensate pumps. Circulating water pumps. Emergency oil pumps. Lubricating oil pumps. Standby oil pumps.
Power station Electronic equipments:

Static excitation equipment. Data acquisition systems. Micro-processors based distributed digital control. Automatic voltage regulators.

 Electro-hydraulic governor control. Controls for HP / LP bypass valves. Turbine supervisory system and controls. Static shunt compensator. Station and industrial turbo-sets. Equipments for thermal, hydro, nuclear power. Controls for electrostatic precipitators.
Oil field equipments:

Diesel electric oil rigs for onshore drilling for depths upto
9000m complete with matching draw-works and hoisting equipments.

Christmas tree valve and well head assembly.

Compressors:

Centrifugal compressors of varying size for industrial

applications range covers MCL series (pressure upto 40kg/cm^2 and capacity upto 350,000NM^3/hr) amd BCL series (pressure upto 800kg/cm^2 and capacity upto 50,000 NM^3 /hr) and package SRL series (pressure ratio upto 40 and capacity upto 240,000 NM^3/hr). Transformers:

Power transformers for voltage upto 400KV. HVDC transformer and reactors. Series and shunt reactors upto 400KV. Instrument transformers: current transformers upto 400KV,
electromagnetic voltage transformer upto 220KV and capacitor voltage transformer upto 400KV.

Electrical Machines:

DC general purpose and rolling mill machines. DC auxiliaries mill motors. AC induction motors- squirrel cage and slip ring motor from
150KW to 15000KW.

AC synchronous motors- from 400KW to 15000KW. AC alternators- from 500KW to 25000KW. Synchronous condensers- from 2200KVAr to 100,000KVAr.
Insulators:

Disc/ suspension insulator for ac/dc applications; range- 45KN

to 160KN electro mechanical strength for clean and polluted atmospheres.

Pin and post insulator upto 33KV. Bushings upto 220KV. Solid core insulator of 25KV rating for railways. Special ceramics including ceramic liners for process industry.
Seamless steel tubes:

Hot finished and cold drawn seamless steel tubes with a range
varying from outer diameter of 14mm to 159mm and wall thickness 12.5mm in carbon steel and low alloy steels to suit ASTM/AP and other international specifications.

Capacitors: Power capacitors for industrial use from 2to 20KVAr at 400V. Capacitors for high voltage installation. Coupling/ CVT capacitors for high voltage upto 400KV.

 Electrolytic and paper capacitor for motor start and motor run
duties.

Transportation Equipments:

Traction motors. Traction generators/ alternators. Auxiliary machines. Field diverting inductive shunts. Eddy current clutches. Transformers/ rectifiers. Electronic control equipments. Diesel electric shunting locomotives (350 HP to 700 HP). Battery operated passenger vans. Electric trolley buses.
Castings & Forgings:

Sophisticated heavy castings and forgings of creep resistant

alloy steel and other grades of alloy steels and meeting stringent international specification. Thyristor Equipment:

Thyristor convertor equipment. Thyristor inverter equipment. Static ac variable speed drives systems. Thyristor valves for HVDC transmission upto 500KV.
Telecommunications:

Electronic PABX systems.

 Data transmission.
Non-Conventional Energy Systems:

Biogas operated engines. Windmills. Solar thermal pumps. Solar water heating systems.
Systems and Services:

Turnkey power stations. Combined- cycle power plants. Cogeneration systems. Modernization & rehabilitation of power stations. Sub- stations & switchyards. HVDC transmission systems. Shunt & series compensator systems. Traction systems. Industrial devices and control systems. Cathode protection systems. Consultancy services. Erection, commissioning, operation and maintenance services.

BHEL- Haridwar

B.H.E.L. (Ranipur), Haridwar is located against the picturesque shivalik foothills of the Himalayas. It has two manufacturing plants: > HEEP (Heavy Electrical Equipment Plant) and > CFFP (Central Foundry & Forge Plant) HEEP was set up in technical collaboration with M/S Prommashexport of USSR, for the manufacture of power plant equipments. AC/DC motors of various sizes were available with associated control equipment and started production in Jan 1976. In 1976 BHEL entered in to collaboration with M/S Kraftwerk Union A.G. of Germany for design, manufacture, erection and commissioning of large size steam turbines and turbo generators of unit rating upto 1000MW. CFFP established in technical collaboration with M/S Creusot Loire of France and became operational in 1976. It was established for production of highly sophisticated alloy steel castings and forgings. CFFP has produced international creep resistant steel , heat resistant steel , armour steel etc. it supplies casting for steam turbines , turbo generators press ring , hydro turbines coupling blades. Together, the two plants contribute significantly to the BHEL energy is generated from the power equipment supplied by BHEL Haridwar. The Pollution Control Research Institute has also been set up at BHEL Haridwar with the help of United Nations Development Program (UNDP). The main objective of the institute is to evolve industrial pollution control technologies with respect to air, water, noise, and solid waste in order to avoid unintended side effects of economic

growth of country. BHEL Haridwar possesses very strong engineering base, R&D infrastructure, very prcised CNC and conventional machine tools.

BHEL has the latest Hardware and computer software for design development:
Latest computational techniques for design analysis and
integrated manufacturing like CAD, FEM, and CAM etc, are used. Use of solid modeling, finite element modeling and further downstream applications for solution of design structure, heat transfer electromagnetic applications etc, for optimization. The computer software is also used for thermal network, solutions and ventilation system, which are vital parameters for large capacity machines.

Various unique facilities which are provided at BHEL, Haridwar are highlighted below:

 Over speed vacuum balancing turbine (for rotors

1300MW ST/TG) 16m length, 320T. Turbine blade shop with modern facilities. Over speed balancing Installation (non-magnetic) for large TG rotors upto 80MT, 4M, and 12M length. Central plant laboratory. Hydro turbine model testing laboratory. Machine tool maintenance, capital repair shops and CNC laboratory.

Tool Room:
Die and stamping shop. ICIM-39-270-270-20 mainframe computer along with
satellite micros & PCs CAD/CAE stations. Micalastic insulation systems. Large size turbo generators test bed (upto 500MW IG). Radio remote control for EOT cranes in certain areas. Service plants (oxygen, nitrogen, PGP Acetylene, compressed air, central refrigeration). Pollution control research institute. Generator research institute. Metal research and testing: Various types of modern inspection and quality control equipment/ devices and testing/ calibration facilities (NDT, outline inspection, scanning, electron microscope, spectroscope, electrical

insulation spectrograph/ spectrometer, industrial X ray/ gamma ray apparatus etc.

HEEP
Heavy Electrical Equipment Plant of BHEL, Haridwar involves in the manufacturing of the power equipments such as turbines and AC/DC machines. It comprises of following main blocks: Electrical Machines Block (Block-I): It is designed to manufacture hydro-generator, turbo-generators and large & medium sized AC/DC electrical machines. There are number of selfpropelled electrically driven transfer trolleys for the inner bay movement of component/ assemblies. Fabrication Block (Block-II): It is the feeder block for various products- steam turbine, turbo generators, hydro generators, electrical machines, apparatus and control gears, aircraft and medical lines. This block has facilities for compressed air, oxygen, acetylene and carbondioxide gas pipelines. Turbine & Auxiliary Block (Block-III): It manufactures turbines, hydro turbine, and gas turbines and turbine blades. Special toolings for all products are also manufactured in the Tool Room located in the same block. The block is equipped with the facilities of EOT cranes, compressed air, steam, OSBT, indicating stands for steam turbine rotors, one test stand for testing 210MW steam turbine and two separate test stands for testing of governing assembly of steam and hydro turbine.

Feeder Block (Block IV): There are two feeder block other than the fabrication blocks to feed electric machines manufacturing by block-I via CIM (coil & insulation manufacturing) and ACM (apparatus & control-gear manufacturing). It is a feeder block for class F-windings for turbo generators, hydro generators and class F&H insulation components for TG, HG and motors. Fabrication & Forge Block (Block-V): Fabrication work been done in this section is of steam turbine parts like condenser , water box, assemblies for LPC , storage tanks etc and hydro turbine parts. Fabrication of hydro generators and motor assemblies and components are also carried out. Forging of carbon, alloy and stainless steel are manufactured in the forging sections. It is equipped with pneumatic hammer from 500Kg to 3tonnes capacity, gas fired furnace for heating of billets, blooms and for subsequent heat treatment for forging, hydraulic manipulators of various capacities are also used to handle the forgings on the hammer.

CIM (Coil & Insulation Manufacturing) ACM(Advanced Control Manufacturing)

BAY-I: Bar winding shop:- manufacturing of stator winding bars of generators. BAY-II:

Manufacturing of motor stator coil, DC armature coil

, main pole coil , inter pole coil , equalizer coil etc.

 Also manufacture heavy duty generator stator bar

with new CNC machines i.e. Robot bar center. BAY-III: Insulation detail shop:- Manufacturing of hard insulation and machining of hard insulation part (glass textile) such as packing, washer, insulation box, wedges etc. Bar: It is quite difficult to manufacture, handle and wind the coil in stator slot of generator of higher generation capacity because of its bigger size and heavy weight. That is why we make coil in two parts- bottom (lower) and top (upper) part.

Types of generators: The generators may be classified based on the cooling system used in the generators such as: THRI, TARI, THDD, THFF, and THW. T= Ist alphabet signifies the type of generator i.e. turbo or hydro generator. H/A=IInd alphabet stands for the cooling media used for the cooling of rotor i.e. hydrogen gas or air. R/D/F/I=IIIrd alphabet signifies the type of cooling of rotor e.g. radial, indirect, forced, direct, etc. I/D/F=last alphabet stands for the type of cooling of stator e.g. indirect, forced, direct, etc. W=cooling media used for cooling the stator coil e.g. water.

Resin Systems:

Rich resin is thermo reactive insulation system: in this type of insulation system the bond content in resin is 35 to 37 %. The raw materials are ready to use and requires reservation and working on temperature 20 to 25 C. Its shelf life is one year when kept at temp. 20 C which could be increased when kept at temperature of 5 C. resin or micalastic insulation system: In this type of insulation the bond content in the resin is 5 to 7 % and insulating material is prepared with accelerator treatment. The temperature control is not required. The insulating material is applied on job and then the same is impregnated (fully dipped).

Poor

Manufacturing Process of 500MW TG Stator Bar

1. Conductor Draw from Store

In this process the conductor drown from store & the size of the conductor is given below :-

Copper conductor 8*28mm[solid, for lower bar] Hallow Copper conductor 8*4.6*1.5mm Copper Conductor 8*1.3mm[solid, for upper bar]

2. Conductor Cutting
This process is done by automatic CNC machine. In this process the pre insulated copper conductor is cut in to number of pieces of required length. Insulation is removed from both ends of the copper conductor cut. LOWER BARS:

Solid conductors length 10,200mm(10 no.s)- 1 bar Hollow conductors length 10,200mm(10 no.s)
UPPER BARS:

Solid conductors length 10050mm( 20 no.s)- 1 bar Hollow conductors length 10050mm( 10 no.s)
We have to clean both sides of ends 500mm.

CNC (Computerized Numeric Control)

Conductor Cutting Machine:
1. Copper storage 2. Bobbin ready to use 3. Tool rack 4. Bobbin revolving machine 5. Tension device 6. Conductor cutting 7. Drum for plastic waste 8. Control panel 9. Operator control desk 10. Waste glass dust collection 11. Conductor shifting table

3. Transposition of Conductor & Assembly of all conductor to be used in stator bars

Transposition means changing/shifting of position of each conductor in active core (slot) part. After cutting the required number of conductors, the conductors are arranged on the comb and in staggered manner and the bends are given to the conductors with the help of bending die at required distance.

Then the conductors are taken cut from, the comb and die and placed with their ends in a line and transposition is carried out. This process is repeated for making another half of the bar which would be mirror image of the first half. The two halves of the bar are overlapped over each other and a spacer is placed between the two halves.

Requirement: The main reason of doing transposition is to

generate equal emf in each bar. Also, it is done so that average distance of each bar from the rotor is same so they cut same amount of flux and thereby producing equal emf. If transposition is not done then the conductors nearer to the rotor generates more emf and therefore, its life is reduced and after sometimes nearly half of the conductors get damaged due to heating.

LOWER BARS:
COMB OF SETTING: Die 1st Die 2nd 2200.2mm 3735.3mm Die 3rd 6586.2mm

UPPER BARS:
COMB OF SETTING: Die 1st Die 2nd 2109mm 3602.2mm Die 3rd 6496.2mm

4. Cross over insulation

The pre insulation of the copper conductor may get damaged due to mechanical bending in die during transposition, hence the insulating spacers are provided at the crossover portion of the conductors. A filter material (insulating putty of molding

micanite) is provided along the height of the bar to maintain the rectangular shape and to cover the difference of level of conductors.

SPACER SIZE: 1ST Band 146mm 2nd Band 219mm 3rd Band 292mm

Fix the insulation in cross portion & fix MICA bonded spacer in light portion.

5. Pressing or Stack Consolidation

The core part of the bar stack is pressed in press (closed box). Under pressure (varies from product to product) and temperature of 160 degree Celsius for a given period. The consolidated stack is withdrawn from the press and the dimensions are checked.

Half bar press (Tapped with transparent file pressed on machine-4 no.) Remove the transparent film & calibrate the 4 no.s of bars and cleaning with sand paper, spirit, searchbrite.

6. Inter Strand Short Test

The consolidated bar stack is tested for the short circuit between any two conductors in the bar, if found then it has to be rectified. 300V is applied for both THRI & TG generators. For IST testing

Series Testing Lamb Machine is used. This 300V is applied between two conductors one by one to all conductors, if the conductors are short then the bulb glows.

IInd Pressing
Attach full slots separator between two half bar with NOMEX paper and tapped with transparent film. After pressing remove the transparent film and calibrate sand etc. Radius Milling In slot portion, corner of bar should be cleaned by Radius Miling Machine.

The straight bar stack is formed as per overhang profile( as per design). The overhang portion is consolidated after forming.

7. 0 Pickling of E/S &T/S End

Pickling is the process of cleaning of component by chemical like: PICKLING SOLUTION:-

Water- 100 parts by weight Sulphuric acid -10 parts by weight Phosphoric acid-5 parts by weight Hydrogen per oxide-5 parts by weight

140 Kg 14Kg 7 Kg 7 Kg

These chemicals are heated upto 50-60 degree Celsius.

Dip the components in solution. 10-15 min after that, clean the component with brass brush and water. Dip Ammonia solution for neutralization of acidic property. Ammonia solution is the combination of liquid Ammonia 10 parts by weight with 100 parts by weight and clean with water and then dipping in Ethyl Alcohol. After this dry the solution with nitrogen pressure before pickling all types of components like bar, contact sleeves, bottom and top part of water box, wedge plane and profile etc.

8. Brazing of Coil Lugs

For water cooled generator bars, the electrical connection contact and water box for inlet and outlet of water are brazed. LUG MOUNTING: 1. Stand by bars for setting of lug. 2. Set up the conductors in each row as per drawing. 3. Insert contact sleeve with the setting of plane row wise wedge then tapper wedge fix up for tightening with copper thin strip as per marking. MAIN BRAZING: 1. Stand by bars of setting for brazing used Resistone for that area which will not braze.

2. Heating the lug joint by two inductors at 65 C use brazing alloy L Ag-15P by 4 persons. 3. Then cooled with air and water.

9. Milling & Debarring

20 no.s of hollow conductors should be deveered in lug braze with the help of special machine. After deveering water flow is checked, whether all hollow conductors are allowing equal amount of water or if not, then may be due to improper hammering during lug brazing, then the bar has to be repaired.

10. Nitrogen Leak Test

The bar is tested for water flow test, nitrogen leak test & pressure test for given duration.

11. Thermal Shock Test

The cycle of hot (80 degree celsius) & cold (30 degree celsius) water are flown through the bar to ensure the thermal expansion and contraction of the joints. Then we apply vacuum tubes for 1 hr so that all the moisture is absorbed.

12. Helium Leak Test

After thermal shock test bar is tested for any leakage with the help of helium gas at 12 Kg/cm^2 pressure hr 11min. For helium testing Mass Spectrometer machine is used.

13. Insulation
The bar is insulated with the given no. of layers to build the wall thickness of insulation subjected to the generating voltage of the machine.

14. Impregnation and Baking

Thermo reactive system: In case of rich resin insulation the bar is pressed in closed box in heated condition and baked under pressure and temp. as per requirement for given period. Micalastic system : in case of poor resin system the insulated bar are heated under vacuum and the impregnated (dipped) in heated resin so that all the air gaps are filled , layer by layer , with resin . Then the extra resin is drained out and bars are fixture. VPI MICALASTIC SYSTEM:- The bars already laid in closed fixture and full fixture is impregnated in resin and then fixture with box is baked under given temp. for given duration.

VIP MICALASTIC SYSTEM:- The individual (separate) bar is heated in vacuum and impregnated in resin . Then bar is taken out and pressed in closed box fixture and then baked at given temp. for given duration.

15. Finishing
The baked and dimensionally correct bars are sanded of to smoothen the edges and the surfaces is calibrated, if require, for the dimension.

16. Conducting Varnish Coating

OCP (Outer Corona Protection) Coating:- The black semiconducting varnish coating is applied on the bar surface on the core length. ECP (End Corona Protection) Coating:- The Grey semiconducting varnish coating is applied at the bend outside core end of the bars in gradient to prevent from discharge in minimize the end corona.

17. Testing
Tan test: - This test is carried out to ensure the healthiness of dielectric (insulation) i.e. dense or rare and measure the capacitance loss.

 HV test: - Each bar is tested momentarily at high voltage increased gradually to 3 times higher than rated voltage. FORMULA USED: Hv = 1.5(2un + 1) Up = 2Un + 1 Un = working voltage

18. Dispatched for winding

The bar preserved with polythene sleeves to protect from dust, dirt, oil, rain, etc are send for winding.

CONCLUSION
Modernization and regular Upgradation / up gradation of facilities and other infrastructure is a continuous endeavor at HEEP, BHEL. After initial setting up of the plant during the year 1964-72, in collaboration with the Soviet Union, the plant facilities and infrastructures have since been continuously upgraded under various investment projects vise, Stamping Unit Project, LSTG Project, Motor Project, Governing Components Project, TG Facilities Modernizations, TG Facilities Augmentation, Quality Facilities Augmentation, EDP projects, Gas Turbine Project, Facilities have also been added and establishments have been created for new projects in Defense and Aviation Project. Additionally, R &D facilities have also been created under Generators Research Institute, Pollution Control Research Institute, HTL modernization and other such schemes.

Today the Plant has unique manufacturing and testing facilities, computerized numerically controlled machine-tools, Blade shop, heavy duty lathes, milling machines, boring machines, machining centers and many more. The Over Speed Vacuum Balancing Tunnel created for rotors up to 1300 MW (32T, 6.9 M dia bladed rotor, 6 rpm up to 4500 rpm) is one of the 8 of its kind in the entire world.