BHEL was established in 1956 ushering in the heavy electrical equipment industry in India. Heavy Electricals (India) Limited was merged with BHEL in 1974.[4] When it was set up in 1956, BHEL was envisaged as a plain manufacturing PSU, with technological help from the Soviet Union.[5] In 1980's it was cutting edge in thyristor technology.[6] In 1991, BHEL was converted into a public company. Over time, it developed the capability to produce a variety of electrical, electronic, and mechanical equipment for various sectors, including transmission, transportation, oil and gas, and other allied industries.[4] However, the bulk of the company's revenue is still derived from the sale of power generation equipment such as turbines and boilers. As of 2017, equipment supplied by BHEL constituted around 55% of the total installed power generation capacity in India.[7] The company also supplies electric locomotives to the Indian Railways and defence equipment such as the Super Rapid Gun Mount (SRGM) naval guns manufactured in partnership with the Ordnance Factory Board and simulators to the Indian Armed Forces.[4][8]
It also has been exporting its power and industry segment products and services for over 40 years. BHEL's global references are spread across over 76 countries across all the six continents of the world. The cumulative overseas installed capacity of BHEL manufactured power plants exceeds 9,000 MW across 21 countries including Malaysia, Oman, Iraq, UAE, Bhutan, Egypt, and New Zealand. Their physical exports range from turnkey projects to after sales services.[9]
Operations
BHEL WAG7 freight trainTwo-seat training monoplane Bharat Swati built by BHELSuper Rapid Gun Mount (SRGM) 76/62 naval gun built by BHELKolkata metro 1000 series coaches built between 1984 and 1988 by BHEL
BHEL is engaged in the design, engineering, manufacturing, construction, testing, commissioning and servicing of a wide range of products, systems and services for the core sectors of the economy, viz. power, transmission, industry, transportation, renewable energy, oil & gas, and defence.
It has a network of 16 manufacturing units, two repair units, four regional offices, eight service centres, eight overseas offices, 15 regional centres, seven joint ventures, and infrastructure allowing it to execute more than 150 projects at sites across India and abroad. The company has established the capability to deliver 20,000 MW p.a. of power equipment to address the growing demand for power generation equipment.[10]
BHEL has retained its market leadership position during 2015–16 with 74% market share in the Power Sector. An improved focus on project execution enabled BHEL record its highest ever commissioning/synchronization of 15059 MW of power plants in domestic and international markets in 2015–16, marking a 59% increase over 2014–15. With the all-time high commissioning of 15000 MW in a single year FY2015-16, BHEL has exceeded 170 GW installed base of power generating equipments.[11]
BHEL has been catering to the nation's Nuclear Programme since 1976 by way of design, manufacture, testing and supply of critical nuclear components like Reactor Headers, Steam Generators, Steam Turbine Generators, other Heat Exchangers and Pressure Vessels.[12]
It also has been exporting its power and industry segment products and services for over 40 years. BHEL's global references are spread across over 76 countries across all the six continents of the world. The cumulative overseas installed capacity of BHEL manufactured power plants exceeds 9,000 MW across 21 countries including Malaysia, Oman, Iraq, UAE, Bhutan, Egypt, and New Zealand. Their physical exports range from turnkey projects to after sales services.[9]
Bharat Heavy Electricals Limited has a total of 2406 patents globally, out of which 1326 have been granted. Of these 16833 patents, more than 78% patents are active. India is where Bharat Heavy Electricals Limited has filed the maximum number of patents, followed by USA and Europe.Bharat Heavy Electricals Ltd (BHEL) on an average applied for more than one patent or copyright every working day in FY-2011.[13][14]
Initiatives
The first 3-phase Ethernet-based AC MEMU train equipped with BHEL manufactured electrics
BHEL's investment in R&D is amongst the largest in the corporate sector in India.
During 2012–2013, the company invested about ₹1,252 Crore on R&D efforts, which corresponds to nearly 2.50% of the turnover of the company, focusing on new product and system developments and improvements in existing products. The IPR (Intellectual Property Rights) capital of BHEL grew by 21.5% in the year, taking the total to 2170.
The corporate R&D division at Hyderabad leads BHEL's research efforts in a number of areas of importance to BHEL's product range. Research & product development (RPD) groups for each product group at the manufacturing divisions play a complementary role. BHEL has established Centres of Excellence for Simulators, Computational Fluid Dynamics, Permanent Magnet Machines, Surface Engineering, Machine Dynamics, Centre for Intelligent Machines and Robotics, Compressors & Pumps, Centre for Nano Technology, Ultra High Voltage Laboratory at Corporate R&D; Centre of Excellence for Hydro Machines at Bhopal; Power Electronics and IGBT & Controller Technology at Electronics Division, Bengaluru, and Advanced Fabrication Technology and Coal Research Centre at Tiruchirappalli.
BHEL has established four specialized institutes, viz., Welding Research Institute (WRI) at Tiruchirappalli, Ceramic Technological Institute (CTI) at Bangalore, Centre for Electric Traction (CET) at Bhopal and Pollution Control Research Institute (PCRI) at Haridwar. Amorphous Silicon Solar Cell plant at Gurgaon pursues R&D in Photo Voltaic applications.[15]
Bharat Heavy Electricals Limited (BHEL) has achieved the unique milestone of supplying its 100th Space-grade battery to ISRO for its very important and critical mission, Chandrayaan 3.These are manufactured at the Electronic Systems Division (ESD) of BHEL in Bengaluru, These batteries use various types of chemistry, including Nickel-Cadmium, Nickel-Hydrogen and Lithium-Ion.[16]
BHEL-supplied equipment at Kaiga power plant creates world record for continuous operation.[17] BHEL and NPCIL collaborated to develop 220-MW Kaiga 1 nuclear power plant, an indigenously designed pressurized heavy water reactor (PHWR), On 31 Dec 2019 Kaiga 1 became a world record holder for running 962 unbroken days.[18]
BHEL is one of the only four Indian companies and the only Indian public sector enterprise figuring in 'The Global Innovation 1000' of Booz & Co., a list of 1,000 publicly traded companies which are the biggest spenders on R&D in the world.[19]
In 2011, Bharat Heavy Electricals Ltd has been ranked 9th most innovative company in the world by US business magazine Forbes.It filed 303 patents and copyrights during the year.Its intellectual capital has gone up to 1,438 patents and copyrights.[20]
Its R&D breakthroughs include 100 KW permanent magnet motors for India's submarine programme, which significantly reduce the size of the submarines for greater mobility.
The insulated-gate bipolar transistor-based inverter for railway locomotives. This propulsion system, which allows locomotives to use power more efficiently, helped BHEL bag a Rs 400 crore order from the Indian Railways, beating international rivals.
its R&D developed the high temperature superconducting (HTSC) transformer, which is more efficient, smaller in size, weight and volume, and can withstand twice the capacity overload without insulation damage or loss of product life.
In 2011, World's first 1200 kV Ultra High Voltage Alternating Current (UHVAC) Transformer of 333 MVA rating.The Transformer has been developed, manufactured and successfully tested by BHEL entirely through in-house know-how.[23] India’s PowerGrid beats global peers in high-voltage game with the help of BHEL.[24]
World's First DC Electric Train Engine With Regenerative Braking. the concept involving the energy-efficient regeneration system was put into shape by BHEL in a 5,000 HP WAG-7 electric locomotive. The technology is meant to be an upgrade to the existing dynamic braking system used presently in the locomotives.[25]
In 2002, The Bharat Heavy Electricals has successfully developed a first-of-its-kind in the world device for improving power transfer capability and reducing transmission losses in the country's highest rating (400 kV) transmission lines. The device, called Controlled Shunt Reactor[26][27]
BHEL has commissioned the world’s first ±800 kV multi-terminal HVDC project from North-East to Agra.[28]
BHEL successfully demonstrates World's first indigenous High Ash Coal Gasification Plant which converts Coal to Methanol.[29][30]
BHEL commissions 250 MW lignite power plant in Gujarat based on eco-friendly Circulating Fluidized Bed Combustion (CFBC) technology, using low grade coal (lignite) as the primary fuel.[31]
Bharat Heavy Electricals has developed a high velocity oxy fuel thermal spray process for preventing silt erosion in components of hydro turbines in hydro electric power stations.HVOF coatings were applied to turbine needles at Shanan project and to guide vanes, top cover and lower ring at Bairasiul project.It was found that the coated components showed negligible erosion.[32]
BHEL implements innovative boiler cleaning process in coal-fired thermal units.The boiler commissioning cycle will reduce from 100 days to 80 days by successfully completing the main 'Boiler Acid cleaning' without its light-up, by using an Auxiliary Boiler.[33]
BHEL with collaboration with IIT Madras developed Solid Waste Combustor, This indigenous Pilot Plant, based on a first-of-its-kind ‘Rotary Furnace’ to efficiently incinerate unsegregated Municipal Solid Waste generated in India.[34]
In 2022, Bharat Heavy Electricals Ltd. (BHEL) has produced a Bus Potential Transformer Module, first of its kind to be developed by an Indian manufacturer. In the existing design, a separate Potential Transformer(PT) panel was provided, having the same size, weight and cost as a regular feeder panel. Cost-savings of 57% can be achieved by the new development. In addition, panel size and weight are reduced by 80%, compared to conventional PT panels. The new PT Module for 33 kV Gas Insulated Switchgear (GIS) was successfully developed, installed and commissioned at a substation site (HVPNL, Sector – 107 Gurugram, Haryana).[35][36]
In 2009, has developed a new state-of-the-art 1,200 kV class Ultra High Voltage (UHV) transformer manufacturing facility at BHEL, Bhopal in Madhya Pradesh.The new UHV transformer block has a dust free and controlled atmosphere, air conditioned bays for winding works, pressurised bay for core building and final assembly, EOT cranes for lifting loads up to 450 tonne, isostatic pressing device for windings, air cushion transport system for movement of equipment & machinery and attached UHV laboratory for testing transformers.[37]
BHEL Jhansi, is a factory and township in Uttar Pradesh, India. It was founded on 9 January 1974 and is one of the 17 manufacturing units including FSIP Jagdishpur. BHEL Jhansi started production of transformers in 1976. BHEL Jhansi has two product groups: transformers and locomotives.
Test facilities
BHEL collaborated with National High Power Test Laboratory Pvt. Ltd. (NHPTL) to test auto transformer at NHPTL facilities.[38]
BHEL to establish the India’s first High Temperature Spin Test Rig for coal based thermal power plants.The efficiency enhancement of coal-based thermal power plants depends on the use of nickel-based superalloy materials as against chrome-based steels widely used now. Advanced Ultra Super Critical (AUSC) consortium selected the nickel-based Alloy 617M.[39]
In 2019, BHEL and Libcoin are in talks to form a consortium to initially build a 1GWh lithium-ion battery plant in India.The plant's capacity will be scaled up to 30GWh in due course.[40]
In 2022, BHEL and Titagarh Wagons formed a consortium and participated in a tender by Government of India. The consortium emerged the second lowest bidder and will be supplying 80 Vande Bharat Trains at the rate of 120 crore per train to Indian Railways.[41][42] BHEL will supply propulsion system i.e. IGBT based traction converter-inverter, auxiliary converter, train control management system, motors, transformers and mechanical bogies.[43]
In 2023, Nuclear Power Corporation of India Limited (NPCIL) and Bharat Heavy Electricals Limited (BHEL) have entered into an MoU to jointly pursue business opportunities in the area of nuclear power plants based on Pressurized Heavy Water Reactor (PHWR) technology. BHEL is the company to be actively associated with all the three stages of the Indian Nuclear Programme (1st Stage PHWR, 2nd Stage FBR and 3rd Stage AHWR).[44]
In May 2023, Bharat Heavy Electricals Limited (BHEL), stated that the Indian Railways has set very ambitious targets and kept aggressive targets for upgradation.One of the significant goals set by the Indian Railways is the complete overhaul of signaling systems.As technology upgrades, BHEL will also upgrade and participate in the modernization process of the signaling system.[45]
Criticism
BHEL is selected to construct 1340-megawatt Rampal coal power plant in Rampal Upazila, Bangladesh, which is close to the Sundarbans mangrove forest. The power plant is set up by Bangladesh-India Friendship Power Company Pvt. Limited — a joint venture between NTPC Limited and Bangladesh Power Development Board.[46] The project has faced criticism for the environmental impact and the potential harm to the largest mangrove forest in the world.[47][48][49] In 2017 Norway's sovereign wealth fund removed BHEL from its investment portfolio over concerns about the Rampal coal plant.[50][51]
The Nuclear Power Corporation of India Limited (NPCIL) is an Indian public sector undertaking based in Mumbai, Maharashtra. It is wholly owned by the Government of India and is responsible for the generation of electricity from nuclear power. NPCIL is administered by the Department of Atomic Energy (DAE).
Kaiga Generating Station is a nuclear power generating station situated at Kaiga, near the river Kali, in Uttara Kannada district of Karnataka, India. The plant has been in operation since March 2000 and is operated by the Nuclear Power Corporation of India.
Madras Atomic Power Station (MAPS) located at Kalpakkam about 80 kilometres (50 mi) south of Chennai, India, is a comprehensive nuclear power production, fuel reprocessing, and waste treatment facility that includes plutonium fuel fabrication for fast breeder reactors (FBRs). It is also India's first fully indigenously constructed nuclear power station, with two units each generating 220 MW of electricity. The first and second units of the station went critical in 1983 and 1985, respectively. The station has reactors housed in a reactor building with double shell containment improving protection also in the case of a loss-of-coolant accident. An Interim Storage Facility (ISF) is also located in Kalpakkam.
Kudankulam Nuclear Power Plant is the largest nuclear power station in India, situated in Kudankulam in the Tirunelveli district of the southern Indian state of Tamil Nadu. Construction on the plant began on 31 March 2002, but faced several delays due to opposition from local fishermen. KKNPP is scheduled to have six VVER-1000 reactors built in collaboration with Atomstroyexport, the Russian state company and Nuclear Power Corporation of India Limited (NPCIL), with an installed capacity of 6,000 MW of electricity.
Shanghai Electric is a Chinese multinational power generation and electrical equipment manufacturing company headquartered in Shanghai. The company traces its roots to 1880.
BGR Energy Systems Limited is a company headquartered in Chennai, operating in the utility industry, offering services ranging from product manufacturing to project execution. The company operates in two segments: capital goods and construction and engineering procurement construction (EPC) Contracts.
Panki Thermal Power Station is located at Panki in Kanpur, Uttar Pradesh. Its first stage was commissioned in 1967 by the then Prime Minister, Indira Gandhi. It has an installed capacity of 660 Mega Watts. The power plant is owned and operated by Uttar Pradesh Rajya Vidyut Utpadan Nigam. It has a 275 Metres high chimney which is one of the tallest structures in India
Harduaganj Thermal Power Station is located at Qasimpur Power House Colony which is 1 km distance from Harduaganj railway station at Harduaganj in Aligarh district in the Indian state of Uttar Pradesh, about 18 km from Aligarh and 105 km from Agra. It is the new electric power station established in Aligarh district; the old one is Sumera Hydroelectric Power Plant located in Jawan Sikandarpur of Aligarh district.
NTPC Ramagundam, a part of National Thermal Power Corporation, is a 2,600 megawatt (MW) Super thermal power station situated at Ramagundam in Peddapalli district in Telangana, India. It is the current largest power station in South India. It is the first ISO 14001 certified "Super Thermal Power Station" in India.
Ador Welding Limited is an industrial manufacturing company headquartered in Mumbai, India. The flagship company of the Ador Group, Ador Welding produces a variety of welding products, industry applications, and technology services, including welding consumables as well as welding and cutting equipment. It has over 30% market share in the organized welding market and is considered one of the major players in the Indian welding industry. Ador PEB is the company's project engineering division. PEB is based in Pune and has provided services to the Indian Government's Bharat Nirman Program in the field of combustion and thermal engineering technologies.
Bihar State Power Holding Company Limited (BSPHCL), formerly Bihar State Electricity Board (BSEB) is a state-owned electricity regulation board operating within the state of Bihar in India. BSEB was established in 1958 as a statutory corporation under the Electricity (Supply) Act, 1948. As of November 2012, BSEB has nearly 1,700 officers and 14,850 employees. The derated capacity comes to just 530 MW. The BSEB was unbundled on 2 August 2011. Power Finance Corporation was the main consultant for BSEB's restructuring.
The Gorakhpur Nuclear Power Plant or the Gorakhpur Haryana Anu Vidyut Pariyojana (GHAVP) is a proposed nuclear power plant to be built on a 560 hectares area west of Gorakhpur village of Fatehabad district of Haryana.
Vallur Thermal Power Station is a power plant located in Vallur, Thiruvallur district, India. The power plant is operated by NTPC Tamil Nadu Energy Company Limited, a joint venture between NTPC Limited and TANGEDCO and has three units with 500 MW each.
Jindal Tanmar Thermal Power Plant is a coal-based thermal power plant located in Tamnar village near Raigarh town in Raigarh district in the Indian state of Chhattisgarh. The power plant is operated by the Jindal Power Limited which is a subsidiary of Jindal Steel and Power.
Angul Thermal Power Station is a coal based thermal power project located at Derang village in Angul district in Indian state of Odisha. The power plant is one of the coal based power plants of Jindal India Thermal Power Limited.
Darlipali Super Thermal Power Station at Darlipali village in Sundargarh district in Indian state of Odisha. The power plant is one of the coal based power plants of NTPC Limited. Coal will be obtained from Dulanga and Pakri Barwadih Coal Block and water supply will be sourced from the Hirakund Reservoir on the Mahanadi River through a pipeline at over a distance of about 30.0 km from project site. Plant is under construction by Bharat Heavy Electrical Limited (BHEL), L&T Power.
Yermarus Thermal Power Station is a coal-based thermal power plant located in Yermarus village in Raichur district, Karnataka. The power plant is owned by the Karnataka Power Corporation. This is India's first 800MW super critical thermal power plant and Bharat Heavy Electricals is the EPC contractor for this power project.
MPCL Thermal Power Project is located near Angul in Odisha. The power plant is one of the coal based power plants of Monnet Power Company Limited.
The IPHWR-700 is an Indian pressurized heavy-water reactor designed by the NPCIL. It is a Generation III reactor developed from earlier CANDU based 220 MW and 540 MW designs. It can generate 700 MW of electricity. Currently there is two unit operational, 6 units under construction and 8 more units planned, at a cost of ₹1.05 lakh crore (US$13 billion).
The IPHWR is a class of Indian pressurized heavy-water reactors designed by the Bhabha Atomic Research Centre. The baseline 220 MWe design was developed from the CANDU based RAPS-1 and RAPS-2 reactors built at Rawatbhata, Rajasthan. Later the design was based on VVER technology which was scaled to 540 MW and 700 MW designs. Currently there are 17 units of various types operational at various locations in India.
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₹24,439 crore (US$3.1 billion) (2024) [1] 
₹243 crore (US$30 million) (2024) [1] 
