R&D and Technology upgradation is a continuous process in the companies of the Department. Liberalisation of industrial policies and deregulation of controls have led to greater competition from both the domestic as well as international companies. This 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 order to meet these objectives, the development effort is being pursued by entering into collaboration with reputed foreign manufacturers, forming joint ventures, in-house R&D efforts and through interaction with various research organisations.

In the past five 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), Center for Electric Transportation Technology (CET), Ceramic Technological Institute (CTI), and Welding Research Institute (WRI).

Fluid Control Research Institute, Palghat

The Fluid Control Research Institute (FCRI) has been set up an independent national center for providing the basic framework for technology development of low products not only in this country but also for South East Asia. Facilities have been set up for research and development, testing and evaluation and training of manpower for flow products in the industrial secure. The Institute also provides opportunities for joint research and development programs on behalf of the user and manufacturing industry to promote applied research.

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 Development Programme (UNDP).

The development objective of PCRI project is to evolve industrial pollution control technologies with respect to air, water, noise and solid wastes to avoid unintended side effects of economic growth.

The Institute provides services to various industries and Thermal Power Stations on a regular basis. A comprehensive study on Environmental Impact Assessment covering all the three seasons for Amarkantak TPS for MPEB-Madhya Pradesh was completed by PCRI.

Centre for Electric Transportation, Bhopal

The Project for development of Electric Transportation Technology was approved by the Govt. of India and UNDP in July 1988. The capabilities in the Center have been developed to analyse and test all aspects of electrically powered vehicle designs to improve their performance, reliability and efficiency. The Center will also be able to conduct both computer and physical simulations of these vehicles' performance under all foreseeable operating conditions. It would also assist in development of technology for Urban Mass Transit System (UMTS). The Institute is now fully operational.

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 both in high technology as well as other type of industries have been developed and a few of them commercialised. Test and evaluation services have been offered to more than 50 organisations.

Welding Research Institute (WRI), the only one of its kind in the country, was set up at Tiruchy under the aegis 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, flatboat, friction and plasma welding in addition to facilities for conventional arc welding. Further, it has advanced testing facilities for fatigue testing metallorgraphic studies, 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 2nd phase of the Project which is under implementation.

Some of the programes of technology upgradation and R&D effort of the Public Sector undertaking are detailed below:

In BHEL, during 1997-98, Rs.61 cr. were spent on in-house R&D programs, focusing on development of new products/systems, business enhancement, quality/reliability improvement and indigenisation. The turnover due to R&D efforts resulting in new or modified products was around Rs.760 cr. during the year.

New products designed and developed include; Hydrogen Recycle Compressors for Diesel Hydro Desulphurisation System (DHDS) units being set up by refineries; Spark Gaps for series compensation schemes for 400 KV transmission lines which have been successfully tested to International Standards at KEMA, Netherlands making BHEL one of the few companies in the world having this technology; Bull ring segments with super Ni-hard composition to increase life and reliability of Bowl type Coal mills; a modified 2 cylinder HP-IP steam turbine of 150 MW utility sets which has been supplied to Jindal Tractobel, GIPCL and will be supplied to Tata Jojobera; an Energy Management System has been supplied to Narmada Control Authority; a microprocessor based control system for HVDC is being supplied to NHVDC stage II: 210 KN Disc Insulators have passed all type tests and have been demonstrated at a few commercial sites; the largest synchronous motor of 3950 KW which so far were being imported has been manufactured and supplied to ONGC Santhal Project; a single shaft combined cycle system with gas turbine and steam turbine on a single shaft have been developed and is being offered commercially.

BHEL has also developed a highly efficient Terminal Automation System to accurately load pre-set quantity of Petrol into wagons/trucks. IOCL has placed an order worth Rs.1.5 cr. for this system marking BHEL's entry into a new line of business.

BHEL has also developed a higher power 207 KW traction motor for 25 KV single phase broad gauge AC-EMU operating in Indian Railways at Chennai; Delhi and Calcutta. Other developments include 282 KW rating traction motor for 3100 HP broad gauge diesel electric locos operating at maximum speed of 160 KMPH.

A new design of 700 HP meter gauge Diesel Electric Shunting loco has been developed for an export order to Malaysia and M/s Mitusibishi Japan who are the customers' consultants.

A 20 KWP grid interactive Solar Photovoltaic power plant has been designed, installed and commissioned at Electric Systems Division, Bangalore.

• Development of an on-line vibration monitoring and analysis system for Boiler Feed Pumps for 210 MW Thermal Power Station (TPS). The system has been successfully field tested at Vijayawada TPS.

• Development of Duplex low pressure Heaters. The first LP Heater of this design has been supplied to Jindal Tractobel 2x130 MW units.

• Developed and supplied for the first time in India, a variable Frequency Drive (VFD) for Boiler Feed Pumps for 250 MW Kothagudam TPS (AP).

- Developed a water cooled Thyristor module for high current applications.

- Developed a single enclosure 3-phase bus bar module for 145 KV GIS.

• Developed a 'Hardware-in-loop' Simulator for shop floor testing of control systems for thermal power plants.

• Designed and manufactured the largest hydro-generator air coolers for 6x250 MW Nathpa Jhakri Hydro Electric Power Station.

Some R&D projects which are likely to be completed by March 1999 are: development of High Pressure Boiler for Circulating Fluidised Bed Combustion (CFBC) boiler; demonstration and testing of state of the art 200 KW Phosphoric Acid Fuel Cell (PAFC) power plant under Indian conditions; Installation and commissioning of Corex Gas Firing system for 130 MW boiler; Development of 3-phase induction motor type 6 FRA 6068 for AC Locos; Development of high speed BAPLON for control of Electrostatic precipitators; Development of 11 KV.2 MVAR controlled shunt reactor with technical Consultancy from St.Petersburg University, Russia and Development of efficient Francis runner profile for the head range 60-80 meters.

The Company has established its own R&D facilities for different products to meet its needs. The focus of R&D is to progressively achieve self-reliance in product technology. In Machine Tool Business Group, R&D activities were planned to meet the market needs with a focus on customer satisfaction. This resulted in many new and upgraded products which included turning centres, machining centres, grinding machines, special purpose machines and sub-systems.

R&D and Technology upgradation programs of various business groups of HMT are as under :

The company developed Horizontal Machining Centers : HMC 400 E: VCM 500 E. Vertical Machining Center VMC-55. Duel Spindle CNC Turning Center DTC-20, CNC Turning Center Stallion-200, CNC Lathe Autocomp CNC-55, CNC Chucker C-16, CNC Lathe Starturn, CNC double Disc Grinder GDS-22, CNC High Speed Gear Shaper WS1 CNC.

INDUSTRIAL MACHINERY GROUP - Four Colour Sheet fed Offset Printing Machine SOM 436 and Die Casting Machines with high capacity DC 1100 have been introduced.

WATCH BUSINESS GROUP - The following product developmental activities were carried out :

- Introduced shakti QAW 7 models.

- Introduced Lalit QAW 5 models.

- Developed Children watches.

• Introduced 4 new models in LHW Watches and 3 new models in ADD

Watches.

• 25 types of new models were developed and commercialised.

TRACTOR BUSINESS GROUP of HMT has been working to bring newer and better features in their Tractors apart from better quality and reliability such as Lower emissions, Lower noise level, Better Comfort safety energonomics, Better fuel efficiency, Synchromesh gear box, Higher and more number of speeds, power steering, Four Wheel drive and better aesthetics.

BHPV's R&D strategies involve selection of products involving sophisticated and hightech areas to keep pace with the latest technological advancements the world over. Some of the new technologies developed include technology for expansion engines for Helium Liquifier and technology for flexible super insulated Piping besides the following :

1. Integration of the Helium Liquidifier assembly, consisting of various sub-systems like Heat exchangers, Battery, Expansion Engines Sample Thempson Valves inter-connecting piping and instruments.

b) Fabrication of Oxygen concentrator made out of Aluminimum Alloy.

The company continued its efforts in Research and Development and Computerised the electrical, hydraulic and pneumatic activities with the introduction of latest software i.e. Autocad-R14, Mech Desktop & Promise and brought out new product to meet the specific demands of Ordnance Factories. A new CNC Precision Milling and Boring Machine Model 232 CNC brought out by incorporating a servo control spindle and three linear axes movement alongwith rotary attachment into the existing product range integrating it with latest Siemens 810 D Control. This is designed and developed to meet the growing demands for a higher capacity in this range and a Precision Vertical Head version in the range of CNC Machining Centers that is more suitable, economical and competitive.

AY & CO.

The company's in-house R&D efforts have been suitably geared up for improving/up-dating listing products/technology as well as absorption/assimilation of technology obtained from foreign collaborators. The company has commenced phased implementation of ISO 9000 standard at different units. While Belting Division and Tea Division has already been accredited with ISO 9002 certification, both Transformer and Switchgear and Brentford units have also achieved ISO 9001 Certification.

The company's R&D set up has been recognised by the Department of Scientific & Industrial Research. Some of the R&D activities of the company's various Units are detailed below :

1. Switchgear unit under electrical Division has stabilised 11 KV porcelain

Clad Breaker.

6. Engineering Division has developed higher capacity Fluid Bed Drier with Dust Collector & Efficiency Heater.

The Company has been working on quality improvement of existing products i.e. Vikram 750 D & Vikram 410 (D). Vikram 750 D: Upgraded through ARAI to conform to CMV Rules. Features like Wiring harness with connectors, Piano type switches, ergonomic driver's seat, floor mounted gear shifting, Tandem master cylinder have been incorporated in the vehicle. Projects for noise and vibration reduction, fitment of smoke scrubber unit has been taken up.

In addition new Test Rigs, Finite Element Study of Vehicle Chassis, development of improved transmission/suspension systems is being developed in association with IIT, Kanpur. Center for CAD system is under implementation.

The company is vigorously pursuing for achieving emission norms. In this regard, the following product developments have taken place.

• New models of vehicles being developed using 4-stroke petrol engines of different makes like Greaves and Briggs & Stratton.

In-house Research & Development activities have resulted in the development of the following :

- Dust Extraction System (Dry type) was developed for O.B. Drill -250.

- CNC Roll Turning Lathe model LRT-100 N was designed and developed.

H N L

Laboratory scale experiments were carried out in the following areas :

d) Use of 2.3% CPSF in furnish improved the tearing strength of newsprint.

An Economy grade newsprint was produced and because of its low production cost, it is found suitable for medium level price sensitive newspapers and publishers. This grade of paper was manufactured using 100% partially de-inked pulp. This partial de-inking process is developed by modification in existing pulping units like pulper, cleaners, Screens, Wasters, etc.

In addition, for quality sensitive customers and to compete with better quality imported newsprint, the de-inked pulp was bleached and blended with imported mechanical fibers and comparable quality newsprint has been produced with more brightness in different varieties such as Deluxe, Prime, Superior and Cream Wove.

In order to maintain company's competitive position, R & D activities in following areas continued to be pursued with great vigor.

a) POL depots and terminals.

b) Water Treatment Plants.

c) Furnaces and Heaters.

d) Fuel Oil diversification in power Plants.

e) Marine Berth construction.

Following Developmental Work was carried out by In-house effort at MAMC:

- Import Substitution item like Hinge Plan for imported Bridge Stage Loader used in Underground Mining - Design Documentation have been completed and Prototype Development under progress.

- Design & Development of Three Non-standard Gear Box with Long Center Distance and Low Height for Direct Haulage - Design Development completed and Prototype manufacture is in process.

- Gear Box for Endless Haulage with Double Helical Pair in the First Stage and straight Spur Pair in 2nd stage to suit specific requirement of the customer. Design and Development completed and 2 Nos. already supplied.

- Development of latest generation Gear Box with Hardened and Ground Gear Teeth are being continued on a regular basis for complete absorption of Imported Know-How.

• Bio-technical enrichment of Magnesite Ore from BSCL Salem Mines through Dump Leaching –

• Laboratory trials at Calcutta University (CU) has yielded encouraging results. Two field trials of 5 MT/batch carried out at Salem Works have also yielded encouraging results. Further field trials are being arranged after MOU was signed between BSCL & CU. Parallel work with different processes are being carried out at CGCRI Laboratory.

- Electric power generation, Combustible gas generation and Production high NPK Manure from Municipal Solid Waste (MSW) - Two numbers Captive Power Plants are running successfully in continuation of follow up work order from Government of Tripura, which is being considered by them for 300 KW power using 20 MT/day of MSW. Company have in the meanwhile put up Project proposal for Rs.36 lakhs on 'Bio-Energy from MSW with high T.S. (Total Solids) Management' for economic viability towards commercialization to DSIR.

- Ergonomics design for Arc Welding electrode savings - Shop floor trial runs have been completed at Howrah Works. Feedback corrections are being worked out towards Shop floor introduction.

- High Power Magnetic Separation of Silica from Magnesite ore having Silica content greater than 10% - Laboratory evaluation of magnetic moment with microwave irradiation has been done for pure MgO & pure SiO2 for di-electric constants, results on which are encouraging to formulate further irradiation of Composite ore powder. Temperature sensing for hazardous microwave radiation zone are being worked out.