Liberalisation of industrial policies and deregulation of controls have led to greater competition for the domestic industry from both the domestic as well as international companies. The has reinforced the need for technology upgradation to attain international levels of competitiveness and to be able to offer contemporary levels of technology. The demands of the user sectors play an important role in selection of technologies and introduction of new products. In orders to meet these objectives, the development efforts is being pursued by entering , the suitable alliances with reputed foreign manufacturers, in –house R&D efforts and through interaction with various research organizations.

In the past , five national level institutes have been set up with UNIDO/UNDP assistance for research in newer technologies. These are the Fluid Control Research Institute (FCRI), Pollution Control Research Institute (PCRI), Centre for Electric Transportation Technology (CET), Ceramic Technological Institute (CTI), and Welding Research Institute (WRI).

The Fluid Control Research Institute (FCRI), set up as an independent national center for developing a frame of reference/ standardization inflow control/ metering with precision, provides infrastructural facilities for applied engineering research projects in the area of fluid flow. It also acts as a national certifying authority for testing and calibration for all kinds of flow products. It has helped many organization in obtaining ISO 9000 certification by calibrating their reference/master instruments with traceability to national standard and by imparting training as laid down in the ISO 9000 system requirements. It has set up 20 bar HP air flow calibration and testing facility to enable the petroleum companies to have the tests carried out in India.

Pollution Control Research Institute (PCRI) has been set up by Department of Heavy Industry with Bharat Heavy Electricals Ltd. (BHEL) as the lead agency under United Nations Devlopment Programme (UNDP). The development objective of PCRI project is to evolve industrial pollution control technologies with respect to air, water houses and solid wastes to avoid unitended side effects of economic growth. The Institute provides services industries and Thermal Power Stations on a regular basis.

The Project for development of Electric Transportation Technology was approved by the Government of India and UNDP in July 1988. The capabilities in the Centre have been developed to analyse and test all aspects of electrically powered vehicle designs to improve their performance, reliability and efficiency. The Centre is also able to conduct both computers and physical simulations of vehicles’ performance under all foreseeable operating conditions.

The developmental objective of this project is to support the Indian Ceramic Industry in modernising its technology and to develop new products of advanced ceramics. Many ceramic products required for the industry have been developed and a few of them commercialized. Test and evaluation services have been offered to more than 50 organisations.

Welding Research Institutes (WRI), the only one of its kind in the country, was set up at Tiruchy under the aegies of BHEL with funding and technical assistance from UNDP/UNIDO and Government of India. WRI is equipped with state of art welding research facilities like electron and laser beam, flasbutt, friction and plasma welding in addition to facilities for conventional arc welding. Further, it has advanced testing facilities for fatigue testing Residual stress measurement, Residual life estimation, etc. WRI has entered into an agreement with GTZ Germany for undertaking cooperative research projects in welding in the IInd phase of the Project.

It has been recognized that in the liberalised regime, the country will have to become a leader in some technology areas where India has comparative advantages. Efforts are being made in this direction and proposals for following projects are under active consideration.

IGCC is combined cycle power plant wherein the fuel gas for gas turbine is generated by the gasification of coal (or any other carbonaceous fuels like refinery residues; such as coke, visbreaker tar etc.) The selection of the coal gasification process and its efficiency integration with a suitably designed gas turbine is of paramount importance in achieving higher overall efficiency of IGCC plant. There are three basic generic type of coal gasification processes viz.

(a) moving bed

(b) entrained bed and

(c) fluidized bed

The project will result in better utilization of ‘high ash Indian Coal besides improving the efficiency of power generation and reducing pollution. The project is proposed to be taken up with the active participation of the various agencies in the power sector viz. Department of power, CEA, NTPC, BHEL, Department of Heavy Industry etc.

In India rapid industrialsation and consequent requirement for mobility of goods and passengers have led to high growth of vehicle population in recent years. A large number of automobile majors of the world have set up production facilities in India taking the installed capacity to 7.2 million vehicles per annum involving an investment of about Rs. 50,000 crore Simultaneously, emergence of statutory regulations on emission and safety has necessitated independent and comprehensive testing of vehicles and their major assemblies and sub-asssemblies being manufactured and imported into the country. In order to bring about conformity into international safety and emission standards, it is proposed to set up testing facilities as also undertake upgradation of existing facilities at 6-7 different centers in the country to cater to the emerging needs of the auto sector. Some of the programmes of technology upgradation and R&D efforts of the public sector enterprises under thes Department of Heavy Industry are detailed below:-

During the year 2000-2001, a turnover of Rs. 546.63 crore was achieved by commercializing products and systems through in-houses R&D/technology developments. An amount of Rs. 86.28 crore was spent on R&D programms, focusing on new product/systems development, product improvements in terms of reliability/quality/cost and import substitution. Some of the achievements made and programmes undertaken for R&D and technology upgradation are as under :-

1. BHEL commissioned an eco-friendly phosphoric acid fuel cell power pack (PAFC) suitable for distributed power generation in remotes areas. A joint venture project between BHEL, MNES and Sree Rayalseema Alkalies & Allied Chemicals Ltd. (SRAAC), the 50 kW PAFC power pack, has been installed at SRAAC's works at Kurnool in Andhra Pradesh. BHEL is also actively involved in a study sponsored by MNES & UNDP on the ‘Feasibility of introduction of fuel Cell Buses in India.
2. To improve power tranfser capability of transmission lines, reduce system losses and improve power system stability, BHEL developed a 400 KV, 3 phase, 50 MVAr controlled shunt reactor for application in high voltage transmission lines. The complete system is under trial at PGCIL’s 400 KV substation at Itarsi.
3. BHEL has developed a cost effective, efficient and low noise 12MW, 11 KV, 1500 rpm generator. With a special double wall enclosures design, the noises level has been reduced below the permissible level have been supplied and commissioned at Jawahar Sugars, Kolhapur.
4. A microprocessor based control systems for 110 kV switchyard of 108 MW Kovikalappal Combined Cycles Power Plant has been designed manufactured and commissioned and control enhanced reliability and can monitor and control the switchyard through a PC based SCADA system.
5. For the first times in India, Electronics Load Control Modules (ELCM) for 1400 HP DEMU have been successfully developed, manufactured, type tested and cleared by Railways. The design of ELCM is based on diodes logic replacing the relay based logic in earlier systems which was prone to failure and required frequent setting.
6. BHEL has developed double junction amorphous silicon photovoltaic modules of 1ft x 3ft and 1ft x 1ft. Double junction modules are the standard globally dues to their higher efficiency and lower degradation after exposure to light. The 1ft x 3ft modules, with an output of 16 watt, can be used for lantern charging, street lighting and building integrated PV systems.
7. BHEL has jointly developed a 400kV, 50Ar Controlled Shunt Reactor (CSR) with technical consultancy from Prof. GN Alexandrove, St. Petersburg Univsersity, Russia. The CSR is an improvement over the fixed shunt reactor used at present . It enhances power transfer capacity of transmission lines, improves power system stability and helps reduce losses. The CSR has been successfully installed and commissioned at the 400 kV substation of PGCIL at Itarsi. The technology developed has been patented. Marketing will be taken up after completion of field trials.
8. BHEL has developed a Francis Hydro turbine model suitable for 170 m head. The hydraulic design of the runner was carried out using Computational Fluid Dynamics to optimize the performance and achieve cost reduction . S The model has been manufactured and tested in accordance with international standards. The maximum efficiency obtained is about 95.6% which is an improvement of 2.6% over the earlier design available with BHEL. This level of efficiency is comparable to the best in the world currently. S The model will be suitable for the forthcoming. 3x125 MW KOL Dam project of NTPC and other project with a similar head.
9. BHEL has designed and manufactured a 4kV, 7.5 MW Static Frequency Converter (SFC) for use in the lift irrigation project at Srisailam Left Bank Canal. The SFC is designed for sequentially starting four 18MW, 11 kV synchronous motors, These motors drive the pumps that lift water from the Krishna River to a reservoir, from where a canal takes the water to drought affected areas of Nalgonda District in Andhra Pradesh. The system has been installed and commissioned and has been working satisfactorily.

Some of the other projects expected to be completed during the year 2001-2002 are as under.

• Development of 420 kV SF6 Gas Insulated Bus Duct.
• Establishment of successful operation of India’s largest 165t/hr.steam capacity coal fired AFBC boiler.
• - Development of integrated control panel for medium size turbo generators.
• Certification testing of 145 kV insulated nozzle type SF^ circuit breaker with modified spring operation mechanism.
• Demonstration & Field trial of 100 kw grid interactive
• Solar PV system at AP TRANSCO Hyderabad.
• Development & testing of 33 kV, 2 MVAr Phase shifting Transformer for Transmission line application.
• Development of 20 KVA HVDC capacitor units for filter bank applications.
• Testing & evaluation of automatic plan start up and shut down (APS) scheme for thermal & combined cycle plants.

R&D activities are undertaken in each of its subsidiary companies for upgradation of product technology, quality, reliability and price competitiveness with particular reference to customer needs. Upgrading the existing products with additional features, design optimization and improvement in aethetics are the major thrust areas. This approach has resulted in many new products and also upgradation of existing products. Some of the efforts in the product ranges of HMT are as under:-

The tractors Unit introduced new models likes HMT 4922 with a 49 HP power and HMT 7511 which is the first to be introduced in the country. 

The machines tools subsidiary has introduced many new products which were exhibited in IMTEX 2001 and also won awards, Some new products introduced are:-

1. High speed Machining centre- HSM
2. CNC Drilling and Tapping centre –DT 40
3. CNC Drilling and Tapping M/C centre –Blitz 40
4. CNC Surface Grrinder Machine – SG CNC
5. CNC Vertical Tool room milling machine – CNC TRM
6. CNC High turning machine – Stallion HS
7. CNC Hard turning machine – Vajra
8. CNC Turning Centre – Pushkar
9. CNC Internal Grinding machine – GI 100 CNC
10. CNC Automat – A16 CNC

 Watches

1. Vikram 750D with water cooled engine developed and introduced in the market
2. Vikram 450D with steering wheel developed.
3. Load carrier and Safari version of Vikram EV developed for varied application of electric vehicle.
4. CNG operated Vikram 410 G is under development.
5. LPG operated Vikram 410G is under development.
6. 3 Seater Auto rickshaw version of electric vehicle is under development.

1. Vikram –750D with water cooled engine being upgraded for provision of alternator and starter motor in place of dynastarter.
2. Chassis has been modified based on FEA study improving its life and load bearing capacity.
3. New leaf spring has been designed and developed for Vikram.750D.
4. Front suspension has been redesigned to reduce field failures.
5. New differential system has been designed to reduce noise and improve life. The system is under durability test.

Some of the efforts made by HEC for technology upgradation/R&D during the year have been as under:-

1. Development of fabricated Body/Disc with integral rings for Hot Blast Valve dia 1100 mm of Bakro Steel Ltd. This improvement will increase the life 3 times.
2. Design modified for use of cheaper conventional spherical bearing in place of costly existing split bearing for Drive Roller Assembly for segments of Continuous Casting Machine (CCM) for BSL.
3. Development of EOT Crane (200/30 T) for ISRO having lift of 72M with unique feature having Rope Drum Dia 2700 mm, Emergency Brake Drum Dia2700mm Emergency Brake Drum Dia 3400 mm , and Planetary Gear Box of high torque with a facility of single motor operation in case of failure of other motors.
4. Development of Hydraulically operated Door Frame Cleaning Mechanism for 4.3M Coke Pusher for Bokaro Steel Plant (BSP).
5. 15 CDV6 Blooms for Pressure Vessels , Vikram Saranhai Space Centre (VSSC), Trivandrum.
6. Castings of Casnub- 22 HLB Bogie for Railways have been successfully produced with required quality.
7. Centrifugal Casting facility to cast pipes (length upto 3M length & weight upto 8T) by centrifugal casting has been created which will give better surface finish and desired wall thickness. This will also help in production of non- ferrous liners for propeller as well as stainless steel sleeves.
8. Design and Development of complete new CNC Centre Lathe model LC 140N with hydraulic feeding of tailstock sleeve, hydraulic 4 jaw chuck, automatic tool monitoring system, guide ways with hardened strip, boring bar holder for diameter 100mm.
9. Design and development of vertical column drilling machine model DCV –75 with fixed column, drilling capacity 75 mm in steel.
10. Design and development of Swing Feeder Gear box for Patratu Thermal Power Station.

HCL’s R&D Cesntre continued its efforts on standardisation of new and cheaper basic raw materials for jelly Filled Cables and Optical Fibre Cables. It has carried out successful trial for reduction in thickness and which of polyal and black polythene tapes. It has carried out improvement in production process thereby increasing the productivity of PIJF Cables of upto 20 pairs. Testing and standardising various joint closures in association with TEC is being done regularly. R&D Centre is extending test facilities to other organisation and meeting their requirements on charge basis. R&D Centre, Naini, Allahabad is providing customer service for PDH Transmission Systems supplied to BSNL.

At HSL installation of 300 TPA capacity Glass Tower bromine Plant at Kharaghoda based on new technology (i.e. Glass Stripping Tower) has been completed . The plant is working satisfactorily. Experiments for utilisation of brine coming out from the Rock Salt Deposits at Mandi Unit have been carried out.

HPC’s efforts in the aarea of R&D include:

• Implement in pulping and breaching process by adopting eco-friendly technology.
• Further reduction in Energy consumption.
• Further reduction of pollution load and treatment of Effluent.

• Better quality of pulp.
• Reduced cost on energy and water
• Better environment –improved quality

• Continuous efforts on waste minimization.
• Further efforts for energy consumption reduction.