VOCATIONAL TRAINING

REPORT
ON
WATER AND STEAM TURBINE
MANUFACTURING
Submitted by
Shubham Kumar Singh
(Token No.: VT/40/2019-436)
Under the guidance of

Mr. Abdul Samad

Deputy Manager, CMX Dept.

BHEL Bhopal

Training Period: 27/05/2019-22/06/2019

Department of Mechanical Engineering

National Institute of Technology, Patna

Patna-800005, Bihar (India)

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 CERTIFICATE
I am SHUBHAM KUMAR SINGH, student of 3rd year (6th semester) of Bachelor of
Technology Department of Mechanical Engineering, National Institute of Technology
Patna.

I here certify that this vocational training work carried out by me at Bharat Heavy
Electricals Limited, Bhopal and report submitted in partial fulfilment of the requirements
of the programme is an original work of mine under the guidance of the experienced
mentor MR. ABDUL SAMAD, DY. MANAGER, CMX DEPT., BHEL BHOPAL is not based
on or reproduced from any existing work of any other person or any earlier work
undertaken at any other time or for any other purpose, and has not been submitted
anywhere else at any time. And it is also based upon my individual observation and work
experience.

SHUBHAM KUMAR SINGH MR. ABDUL SAMAD

NIT PATNA DY. MANAGER, CMX DEPARTMENT

TOKEN NO.- VT/40/2019-436 B.H.E.L., BHOPAL

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 ACKNOWLEDGEMENT

I would like to express my gratitude for the people who were part of my
project report, directly or indirectly people who gave unending support right
from the stage the idea was conceived.
An engineer with only theoretical knowledge is not a complete engineer.
Practical knowledge is very important to develop and apply engineering skills.
It gives me a great pleasure to have an opportunity to acknowledge and to
express gratitude those who were associated with me during my training at
BHEL, Bhopal.
I take this opportunity to express my sincere gratitude to the people who have
been helpful in the successful completion of my Industrial training and this
project I would like to show my greatest appreciation to MR. ABDUL SAMAD,
DY. MANAGER, CMX DEPT., BHEL BHOPAL who granted me the permission of
industrial training in the BHEL, Bhopal. I would like to thanks to all those
people who directly or indirectly helped and guided us to complete my
training and this project including the following instructor technical staff and
supervisor of various section

SHUBHAM KUMAR SINGH

Page 3
CONTENTS
Certificate

Acknowledgement

Introduction

About BHEL

Main manufacturing unit

Product Profile

Block Detail

Hydro Turbines

Classification of Impulse and Reaction Turbine

Types of turbine

Hydro Turbine Governor

Spiral case and Stay Ring

Wicket Gate and Operating Mechanism

Construction of Runner Hub and Blade

Power of Water Turbine

Design and Application

Various manufacturing process

Stam Turbine

HP, IP, LP Turbine

Working of Steam Turbine

Reaction Blading

Rankine Cycle

Machining Shop Machines

Conclusion

References

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INTRODUCTION
BHEL OVERVIEW
BHEL was established more than 50 years ago when its first plant was setup in Bhopal ushering in
the indigenous Heavy Electrical Equipment Industry in India.

BHEL is largest engineering and manufacturing enterprise in India in the energy

related/infrastructure sector. BHEL was established more than four decades ago ushering in the
indigenous Heavy Electrical Equipment industry in India. BHEL has built over the years, a robust
domestic market position by becoming the largest supplier of power plant equipment in India, and
by developing strong market presence in select segment of the industry sector and the Railway.
Currently, 80% of the Nuclear power generation in the country is through BHEL sets.

A dream which has been more than realized with a well-recognized track record of
performance it has been earning profits continuously since 1971-72 and achieved a turnover of Rs
2,658 crore for the year 2007-08, showing a growth of 17 per cent . Bharat Heavy Electricals Limited
is country’s ‘Navratna’ company and has earned its place among very prestigious national and
international companies. It finds place among the top-class companies of the world for manufacture
of electrical equipment.

BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission,
Industry, Transportation, Telecommunication, Renewable Energy, Defence, etc. BHEL has already
attained ISO 9000 certification for quality management, and ISO 14001 certification for environment
management and OHSAS – 18001 certifications for Occupational Health and Safety Management
Systems. The Company today enjoys national and international presence featuring in the “Fortune
International -500” and is ranked among the top 10 companies in the world, manufacturing power
generation equipment. BHEL is the only PSU among the 12 Indian companies to figure in “Forbes
Asia Fabulous 50” list.

Probably the most significant aspect of BHEL’s growth has been its diversification. The
constant reorientation of the organization to meet the varied needs in time with a philosophy that
has led to total development of a total capability from concepts to commissioning not only in the
field of energy but also in industry and transportation.

In the world power scene BHEL ranks among the top ten manufacturers of power plant
equipment not only in spectrum of products and services offered, it is right on top. BHEL ‘s
technological excellence and turnkey capabilities have won it worldwide recognition. Over 40
countries in world over have placed orders with BHEL covering individual equipment to complete
power stations on turnkey basis

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BHEL has

➢ Installed equipment for over 90000MW of power generation-for utilities, captive and
industrial users.
➢ Supplied over 225000MW a transformer capacity and other equipment operating in
transmission and distribution network up to 400Kv (AC& DC).
➢ Supplied over 25000 motors with drive control system to power projects, Petro chemicals,
refineries, steel, aluminium, fertilizers, cement plants etc.
➢ Supplied traction electrics and AC/DC locos to power over 12000kms railway network.
➢ Supplied over one million valves to power plants and other industries.

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,
Telecommunication, Renewable Energy, etc. The wide network of BHEL's 14 manufacturing divisions,
four Power Sector regional centres, over 100 project sites, eight service centres and 18 regional
offices, 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 &
reliability of its products is due to the emphasis on design, engineering and manufacturing to
international standards by acquiring and adapting some of the best technologies from leading
companies in the world, together with technologies developed in its own R&D centres.

➢ BHEL has acquired certifications to Quality Management Systems (ISO 9001),

Environmental Management Systems (ISO 14001) and Occupational Health & Safety
Management Systems (OHSAS 18001) and is also well on its journey towards Total
Quality Management.

➢ BHEL vision is to become a world class engineering enterprise, committed to enhancing

stakeholder value. The company is striving to give shape to its aspiration and fulfil the
expectations of the country to become a global presence: -

Vision:

“A world class engineering enterprise committed to enhance stakeholder values.”

Mission:

“To be an Indian multinational engineering providing total business solution through quality
product system and services in the field of energy, transportation, industry, infrastructure and other
potential area.

Values:

➢ Ensure speed of response.

➢ Foster learning, creativity and team work.
➢ Respect for dignity and potential of individuals
➢ Loyalty and pride in company

Page 6
 ➢ Zeal for the change.
➢ Zeal to excel.
➢ Integrity and fairness in all matters.
➢ Strict adherence to commitments.

BUSINESS MISSION
To maintain a leading position as supplier of quality equipment, system and services in the
field of conversion, transmission, utilization, and conversation of energy for application in the area
of electric power, transportation oil and gas exploration and industries. To utilize company’s
capability and resources to expand busyness in to allied area a priority sector of economy like
defence, communication and electronics.

BHEL OBJECTIVES
A dynamic organization is one which keeps its aim high, adopts itself quickly to changing
environment, so we are in BHEL. The objectives of the company have been redefined in the
corporate plane for 90’s.

Growth

To ensure a steady growth by enhancing the competitive edge of BHEL in existing busyness,
new area and international market so as to fulfil national expectation from BHEL.

Profitability

To ensure a reasonable and adequate return on capital employed, primarily through

improvements in operation, efficiency, capacity utilization & productivity and to generate adequate
internal resources to finance the company’s growth.

Focus

To built a high degree of customer confidence by providing increased value of his money
through international standards of product quality performance and superior customer service.

People Orientation

To enable each employee to achieve his potential, improve his capabilities, understand is role
and responsibilities and participate and contribute to the growth and success of the company.

Technology

To achieve technological excellence in operation of indigenous technologies and efficient

absorption and adoption of imparted technologies to suit business.

Image

To fulfill the expectations, which stack holders like government as owner employee,
customer and the country at large have from BHEL.

Page 7
 BHEL BHOPAL PROFILE
Heavy Electrical Plant , Bhopal is the mother plant of Bharat Heavy Electricals
Limited, the largest engineering and manufacturing enterprise in India in the energy-related
and infrastructure sector, today. It is located at about 7 kms. from Bhopal Railway station,
about 5 kms. from Habibganj Railway station and about 18 kms. From Raja Bhoj Airport.
With technical assistance from Associated Electricals (India) Ltd., a UK based company, it
came into existence on 29th of August, 1956. Pt. Jawaharlal Nehru, first Prime minister of
India dedicated this plant to the nation on 6th of November, 1960.

BHEL, Bhopal with state-of-the-art facilities, manufactures wide range of electrical

equipment. Its product range includes Hydro, Steam, Marine & Nuclear Turbines, Heat
Exchangers, Hydro & Turbo Generators, Transformers, Switchgears, Control gears,
Transportation Equipment, Capacitors, Bushings, Electrical Motors, Rectifiers, Oil Drilling
Rig Equipment and Diesel Generating sets.

BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving
towards excellence by adopting TQM as per EFQM / CII model of Business Excellence. Heat
Exchanger Division is accredited with ASME ‘U’ Stamp. With the slogan of “ Kadam kadam
milana hai, grahak safal banana hai”, it is committed to the customers.

BHEL Bhopal has its own Laboratories for material testing and instrument calibration
which are accredited with ISO 17025 by NABL. The Hydro Laboratory, Ultra High Voltage
laboratory and Centre for Electric Transportation are the only laboratories of its in this part of
The world.

BHEL Bhopal's strength is its employees. The company continuously invests in

Human Resources and pays utmost attention to their needs. The plant's Township, well
known for its greenery is spread over an area of around 20 sq. kms. and provides all facilities
to the residents like, parks, community halls, library, shopping centres, banks, post offices
etc. Besides, free health services are extended to all the employees through 350 bedded
(inclusive of 50 floating beds) Kasturba Hospital and chain of dispensaries.

Page 8
 BHEL – BUSINESS AREAS

BHEL today is the largest Engineering Enterprise of its kind in India with excellent track
record of performance, making profits continuously since 1971-72.

BHEL's operations are organised around three business sectors, namely Power,
Industry - including Transmission, Transportation, Telecommunication & Renewable Energy
- and Overseas Business. This enables BHEL to have a strong customer orientation, to be
sensitive to his needs and respond quickly to the changes in the market.

➢ Power
➢ Industry
➢ Transportation
➢ Transmission
➢ Defences etc.

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 all these have engendered development of a committed and motivated
workforce setting new benchmarks in terms of productivity, quality and responsiveness.

POWER SECTOR

Power is the core sector of BHEL and comprises of thermal, nuclear gas, diesel and
hydro business. Today BHEL supplied sets, accounts for nearly 66 % of the total installed
capacity in the country as against nil till 1969-70.

BHEL manufactures boilers auxiliaries, TG sets and associate controls, piping and station C &
I up to 500 MW rating with technology and capability to go up to 1000 MW range. The auxiliary
products high value capital equipment like bowl and tube mills, pumps and heaters, electrostatic
precipitators, gravimetric feeders, fans, valves etc.

BHEL has contracted so far around 240 thermal sets of various ratings, which includes 14
power plants set up on turnkey basis. Nearly 85 % of World Bank tenders for thermal sets floated in
India have been won by the company against international competition.

BHEL has adopted the technology to the needs of the country and local conditions. This has led to
the development of several technologies in house. The fluidized bed boiler that uses low graded
high-ash abrasive Indian coal is an outcome of such an effort. With large-scale availability of natural
gas and the sudden increase in demand, BHEL began to manufacture gas turbines and now
possesses two streams of gas turbine technology.

It has the capability to manufacture gas turbines up to 200 MW rating and custom-built
combined cycle power plants. Nuclear steams generators, turbine generators, sets and related
equipment of 235 MW rating have been supplied to most of the nuclear power plants in India.
Production of 500 MW nuclear sets, for which orders have been received.

Page 9
BHEL has developed expertise in renovation and maintenance of power plant equipment
besides specialized know how of residual life assessment, health diagnostic and life
extensions of plants. The four power sectors regional centers at New Delhi, Chennai, Kolkata
and Nagpur will play a major role in giving a thrust to this business and focus BHEL's efforts
in this area.
As part of India’s largest Solar Power-based Island Electrification Project in India, Bharat
Heavy Electricals Limited (BHEL) has successfully commissioned two Grid-Interactive Solar
Power Plants of 100 KW each in Lakshadweep.

With this, the company has commissioned a total of eleven Solar Power Plants in the
Lakshadweep islands, adding over 1 MW of Solar Power to the power generating capacity of
the coral islands in the Arabian Sea.

➢ BHEL has proven turnkey capabilities for executing power projects from concept
to commissioning and manufactures boilers, thermal turbine generator sets and
auxiliaries up to 500MW.
➢ It possesses the technology and capability to procure thermal power generation up
to 1000MW.
➢ Co- generation and combined cycle plants have also been introduced.
➢ For the efficient use of high ash content coal BHEL supplies circulating fluidized
boiler.
➢ BHEL manufacturers 235MW nuclear sets and has also commenced production of
500MW nuclear turbine generator sets.

Custom made hydro sets of Francis, Pelton and Keplan types for different head
discharge combination are also engineering and manufactured by BHEL.

In, all 700 utility sets of thermal, hydro, gas and nuclear have been placed on the
company as on date. The power plant equipment manufactured by BHEL is based on
contemporary technology comparable to the best in the world and is also internationally
competitive.

The Company has proven expertise in Plant Performance Improvement through

renovation modernization and up rating of variety of power plant equipment besides
specialized know how of residual life assessment, health diagnostics and life extension of
plants.

Page 10
 RESEARCH AND DEVELOPMENT(R&D)

To remain competitive and meet customers’ expectations, BHEL lays great emphasis
on the continuous up gradation of products and related technologies, and development of
new products. The company has upgraded its products to contemporary levels through
continuous in-house efforts as well as through acquisitions of new technologies from
leading engineering organizations of the world.

Research and product development centres at each of the manufacturing divisions play a
complementary role.

BHEL’s investment in R&D is amongst the largest in the corporate sector in India.
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
fulfil 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 – all these have engendered development of a
committed and motivated workforce setting new benchmarks in terms of productivity,
quality and responsiveness.
BHEL has a corporate R & D centre supported by R & D groups at each of the
manufacturing divisions. The dedicated effort of BHEL's R & D engineers have produced
several new products like automated storage retrieval system automated guide vehicles for
material transportation etc. Establishment of Asia's largest fuel evaluation test facility at
Trichy was high light of the year. This facility will enable evaluation of combustion, heat
transfer and pollution parameters in boilers.

Major R & D achievement include:

• Design manufacture and supply of countries first 17.2 MW industrial steam turbines.
• Development of 4700 HP AC / DC loco for Indian Railways.
• Development of largest capacitor voltage transformers of 8800 PF 400 KV rating.
• Development and application low cost ROBOTS for job loading/unloading.

According to ex- CMD Mr. R.K.D. Shah, "BHEL is spending Rs. 60 Crores on Research
and Development. Earning from product which has been commercialized has gone up 26 %
to Rs. 760 Crores."

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 PRODUCTS

Thermal Power Plants

• Steam turbines, boilers and generators of up to 800 MW capacity for utility and
combined-cycle applications; Capacity to manufacture boilers and steam turbines
with supercritical system cycle parameter and matching generator up to 1000 MW
unit size.
➢ Steam turbines, boilers and generators of CPP applications; capacity to manufacture
condensing, extraction, back pressure, injection or any combination of these types of
steam turbines.

Nuclear Power Plants

• Steam generator & Turbine generator up to 700 MW capacity.

Gas-Based Power Plants

• Gas turbines of up to 280 MW (ISO) advance class rating.

• Gas turbine-based co-generation and combined-cycle systems of industry and utility
applications.

There are other products given as follows

Hydro Power Plants, DG Power Plants, Industrial Sets, Boiler, Boiler Auxiliaries, Piping
System, Heat Exchangers and Pressure Vessels Pumps, Power Station Control Equipment,
Switchgear, Bus Ducts, Transformers, Insulators, Industrial and Special Ceramics, Capacitors,
Electrical Machines, Compressors, Control Gear, Silicon Rectifiers, Thyristor GTO/IGBT
Equipment , Power Devices, Transportation Equipment

Oil Field Equipment, Casting and Forgings, Seamless Steel Tubes, Distributed Power
Generation and Small Hydro Plants.

Page 12
 TECHNICAL COLLABORATIONS

PRODUCT COLLABORATIONS

# Thermal Sets, Hydro Sets, Motors & Prommash export

Control Gears. RUSSIA

# Bypass & Pressure Reducing Systems Sulzer Brother Ltd.

SWITZERLAND

# Electronic Automation System for Siemens AG.

Steam Turbine & Generators GERMANY

# Francis Type Hydro Turbines General Electric

CANADA

# Moisture Separator Reheaters Baloke Duerr

GERMANY

# Christmas Trees & Conventional Well National Oil Well

Head Assemblies, USA

# Steam Turbines , Generators and Axial Siemens AG.

Condensers GERMANY

# Cam Shaft Controllers and Tractions Siemens AG.

Current Control Units GERMANY

Page 13
 MAJOR CUSTOMERS OF B.H.E.L
➢ Supplied to all major utilities in India :
1. National Thermal Power Corporation (NTPC)
2. PGCIL
3. NJPC
4. NHPC
5. NLC
6. NPCIL
7. NEEPCO
8. APTRANSCO
9. APGENCO
10. JPPCL
11. ALL State Electricity Boards (SEBs)

➢ Abroad:
1. TNB, Malaysia
2. PPC, Greece
3. MEW, Oman
4. OCC, Oman
5. GECOL, Libya
6. Trinidad & Tobago
7. New Zealand
8. Tanzania etc

MAJOR COMPETITORS OF BHEL

1. Asea Brown Boueri Switzerland

2. Beehtel USA
3. Block & Neatch USA
4. CNMI & EC China
5. Costain U.K.
6. Electrim Poland
7. Energostio Russia
8. Electro Consult Italy
9. Franco Tosi France
10. Fuji Japan
11. GEC Alsthom U.K.
12. General Electric USA
13. Hitachi Japan
14. LMZ Russia
15. Mitsubishi Japan
16. Mitsui Japan
17. NEI U.K.
18. Raytheon USA
19. Rolls Royce Germany

Page 14
 DIVISIONS OF BHEL

There are 20 Divisions of BHEL, they are as follows:

▪ HPEP, Hyderabad
▪ HPBP, Trichy
▪ SSTP & MHD, Trichy
▪ CFFP, Haridwar
▪ BHEL, Jhansi
▪ BHEL, Bhopal
▪ EPD, Bangalore
▪ ISG, Bangalore
▪ ED, Bangalore
▪ BAP, Ranipet
▪ IP, Jagdishpur
▪ IOD, New Delhi
▪ COTT, Hyderabad
▪ IS, New Delhi
▪ CFP, Rudrapur
▪ HERP, Varanasi
▪ Regional Operations Division ARP, New Delhi
▪ TPG, Bhopal
▪ Power Group (Four Regions and PEM)
▪ HEEP, Haridwar

Page 15
 MANUFACTURING UNIT OF BHEL
First Generation Units

BHOPAL Heavy Electrical Plant

HARDWAR Heavy Electrical Equipment Plant

HYDERABAD Heavy Electrical Power Equipment Plant

TRICHY High Pressure Boiler Plant

Second Generation Units

JHANSI Transformer and Locomotive Plant

HARDWAR Central Foundry and Forge Plant

TRICHY Seamless Steel Tube Plant

Unit Through Acquisition and Merger

BANGALORE Electronic Division

Electro Porcelain Division

New Manufacturing Units

RANIPAT Boiler Auxiliaries Plant

JAGDISHPUR Insulator Plant

RUDRAPUR Component and Fabrication Plant

BANGALORE Industrial System Group

Page 16
PRODUCT PROFILE OF BHEL BHOPAL

Page 17
 PRODUCTS OF BHEL

• Thermal power Plants

• Nuclear power Plants
• Gas based power Plants
• Hydro power Plants
• DG power Plants
• Boilers (steam generator)
• Boiler Auxiliaries
• Gas generator
• Hydro generator
• Steam turbine
• Gas turbine
• Hydro turbine
• Transformer
• Switchgear
• Oil field equipment
• Boiler drum
• Piping System
• Soot Blowers
• Valves
• Seamless Steel Tubes
• Condenser s and Heat exchangers
• Pumps
• Desalination and Water treatment plants
• Automation and Control systems
• Power electronics
• Transmission system control
• Semiconductor devices
• Solar photo voltaic
• Software system solutions
• Bus ducts
• Insulators
• Control panels
• Capacitors
• Bushings

Page 18
 BLOCK DETAILS
Block (1A)

➢ PFM- pre fabrication manufacturing.

➢ SFM- start fabrication manufacturing.

BLOCK-1

➢ HCM-heat and condenser manufacturing.

➢ Hydro Turbine
o WTM- water turbine manufacturing.
o FBM- fabrication manufacturing.

BLOCK-2

➢ EM- electric manufacturing.

➢ LEM- large electric motor manufacturing.
➢ PLM- plant large motor.
➢ HRP- heavy rotor plant.
➢ IMM- industrial motor manufacturing.
➢ TAM- traction alternator motor
➢ TXM- traction motor.

BLOCK-3

➢ TCB-transformer capacitor and bushing.

BLOCK-4

➢ SCR- switch gear, control gear and rectifier.

BLOCK-5

➢ FYM- foundry manufacturing.

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BLOCK-6

➢ STM- steam turbine manufacturing.

BLOCK-7

➢ MOD & WEX – modernisation & work engineering

BLOCK-8

➢ CIM- coil & insulation manufacturing.

BLOCK-9

➢ TXM- traction motor & manufacturing.

BLOCK-10

➢ PRM- press shop manufacturing.

BLOCK-11

➢ TGM- tool & gauge manufacturing.

NEW TRANSFORMER BLOCK(1200 KV)

➢ In it heavy transformer are manufactured.

GOLDEN JUBLI- HYDRO BLOCK HYDRO TURBINE.

UHV- ultra high voltage. It is used for testing the turbine and and equipment
comes from all over Asia.

HLX- hydro turbine testing lab.

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Block 1

Hydro turbines

Hydraulic turbines may be defined as prime movers that transform the kinetic energy of the
falling water into mechanical energy of rotation and whose primary function is to drive an
electric generator.

Pelton Turbine
Francis Turbine
Kaplan Turbine
BHEL (hydro turbines)
A leading engineering enterprise which supplies all types of equipment for hydro
power generation.

A leading turbine manufacturer offering a wide range of Hydro Turbine, Valves,

Governors, Turbine and Station Auxiliary systems, Balance of plants for Hydro
Power Station and related Services.

Installed manufacturing capacity:2500 MW/annum.

BLOCK 2
PRODUCTS
Generator Motor

Vertical
Conventional vertical generators
Reversible generators motors for pumped storage plants

Horizontal
Mini Micro generators for low head installations
Bulb/Tubular generators

Page 21
 Generator Auxiliaries
H.S.Lubrication System
Fire Extinguishing System
Cooling System
Excitation System
Brake Dust Collection
Braking/Jacking System

Product Design
Electrical
Mechanical
Hydraulic
Thermal
Finite Element Method

FACILITIES
Fabrication facilities
Special types of welding
- Submerged Arc
- Electro slag
- Narrow Gap
- TIG
3000 T shell bending press
Electronic flame cutting machine
Stress relieving furnace
Shot blasting chamber
NDT test facilities

- Dye penetrant
- Magnetic particle
- Ultrasonic
- Radiographic
Machining facilities
➢ Rotating Column Vertical Borer: Max. Job dia 16
mtrs -Ht 4mtrs
➢ Vertical Borer (HOMMA): Max. job dia 9 mtrs - Ht
4mtrs
➢ Horizontal Ram Borer: Max. travel Vert. 4.15 mtrs. -
Horiz 19mtrs
➢ Horizontal Planning Machine: Bed Length 9 mtrs. -
Ht 3 mtrs.
➢ Centre Lathe: Max. Job dia 4 mtrs. -Length 15 mtrs
Blanking/Varnishing facilities
➢ 250T blanking line
➢ 1600T hydraulic press
➢ 500/300T hydraulic press
➢ Deburring machine
➢ Spot welding machine
Page 22
 ➢ Automatic varnishing plant
Coil manufacturing facilities
➢ Automatic cleaning and cutting machine
➢ Hydraulic coil pulling machine
➢ Hydraulic press for consolidation of stator coils
➢ 1000T press for consolidation of field coils
➢ Air-conditioned room for taping
Complete assembly of
generators

Testing

Performance test consisting of

- Characteristic curves
- Temperature rise efficiency
- 3-phase sudden short circuit test
- Ventilation
- Windage loss etc.

BLOCK 3
TRANSFORMER
A transformer is an electrical device which, by the principles of electromagnetic induction,
transfers electrical energy from one electric circuit to another, without changing the
frequency. The energy transfer usually takes place with a change of voltage and current.
Transformers either increases or decreases AC voltage.
Transformers are used to meet a wide variety of needs. Some transformers can be several
stories high, like the type found at a generating station or small enough to hold in your
hand, which might be used with the charging cradle for a video camera. No matter what
the shape or size, a transformers purpose remains the same: transforming electrical power
from one type to another.
There are many different types of transformers in use today. This resource will take a
closer look at Power Transformers, Auto Transformers, Distribution Transformers,
Instrument Transformers, Isolation Transformers, Potential Transformers and Current
Transformers.

Page 23
Shop Transformers
How Transformers Work
It is important to remember that transformers do not generate electrical power; they
transfer electrical power from one AC circuit to another using magnetic coupling. The core
of the transformer is used to provide a controlled path for the magnetic flux generated in
the transformer by the current flowing through the windings, which are also known as
coils.
There are four primary parts to the basic transformer. The parts include the Input
Connection, the Output Connection, the Windings or Coils and the Core.

• Input Connections - The input side of a transformer is called the primary

side because the main electrical power to be changed is connected at this point.
• Output Connections - The output side or secondary side of the transformer is where
the electrical power is sent to the load. Depending on the requirement of the load, the
incoming electric power is either increased or decreased.
• Winding - Transformers have two windings, being the primary winding and the
secondary winding. The primary winding is the coil that draws power from the source.
The secondary winding is the coil that delivers the energy at the transformed or
changed voltage to the load. Usually, these two coils are subdivided into several coils
in order to reduce the creation of flux.
• Core - The transformer core is used to provide a controlled path for the magnetic flux
generated in the transformer. The core is generally not a solid bar of steel, rather a
construction of many thin laminated steel sheets or layers. This construction is used to
help eliminate and reduce heating.
Transformers generally have one of two types of cores: Core Type and Shell Type.
These two types are distinguished from each other by the manner in which the
primary and secondary coils are place around the steel core.
o Core type - With this type, the windings surround the laminated core.
o Shell type - With this type, the windings are surrounded by the laminated core.

When an input voltage is applied to the primary winding, alternating current starts to flow
in the primary winding. As the current flows, a changing magnetic field is set up in the
transformer core. As this magnetic field cuts across the secondary winding, alternating
voltage is produced in the secondary winding.

Page 24
The ratio between the number of actual turns of wire in each coil is the key in determining
the type of transformer and what the output voltage will be. The ratio between output
voltage and input voltage is the same as the ratio of the number of turns between the two
windings.
A transformers output voltage is greater than the input voltage if the secondary winding
has more turns of wire than the primary winding. The output voltage is stepped up, and
considered to be a "step-up transformer". If the secondary winding has fewer turns than
the primary winding, the output voltage is lower. This is a "step-down transformer".

Transformer Configurations
There are different configurations for both single-phase and three-phase systems.

• Single-phase Power - Single-phase transformers are often used to supply power for
residential lighting, receptacle, air-conditioning, and heating needs. Single phase
transformers can be made even more versatile by having both the primary winding
and secondary winding made in two equal parts. The two parts of either winding can
then be reconnected in series or parallel configurations.
• Three-phase Power - Power may be supplied through a three-phase circuit
containing transformers in which a set of three single-phase transformers is used, or
on three-phase transformer is used. When a considerable amount of power is involved
in the transformation of three-phase power, it is more economical to use a three-
phase transformer. The unique arrangement of the windings and core saves a lot of
iron.
• Three-phase Transformers - Three-phase transformers have six windings; three
primary and three secondary. The six windings are connected by the manufacturer as
either delta or wye. As previously stated, the primary windings and secondary
windings may each be connected in a delta or wye configuration. They do not have to
be connected in the same configuration in the same transformer. The actual
connection configurations used depend upon the application.

Page 25
Power Transformer
A power transformer is used
primarily to couple electrical
energy from a power supply line
to a circuit system, or to one or
more components of the
system. A power transformer
used with solid state circuits is
called a rectifier transformer. A
power transformer's rating is
given in terms of the
secondary's maximum voltage
and current-delivering capacity.
Distribution Transformer
A pole-type distribution transformer is used to supply relatively small amounts of power to
residences. It is used at the end of the electrical utility's delivery system.
Autotransformer
The autotransformer is a special type of power transformer. It consists of a single,
continuous winding that is tapped on one side to provide either a step-up or a step-down
function. This is different from a conventional two-winding transformer, which has the
primary and secondary completely isolated from each other, but magnetically linked by a
common core. The autotransformer's windings are both electrically and magnetically
interconnected.
An autotransformer is initially cheaper than a similarly-rated two-winding transformer. It
also has better regulation (smaller voltage drops), and greater efficiency. Furthermore, it
can be used to obtain the neutral wire of a three-wire 240/120-volt service, just like the
secondary of a two0winding transformer. The autotransformer is considered unsafe for use
on ordinary distribution circuits. This is because the high-voltage primary circuits are
connected directly to the low-voltage secondary circuit.

PRODUCTS
BUSHING AND CYLINDERS

• 52KV TO 525 KV OIP condenser Bushings up to 3150 amps. Rating

• 25 kV, up to 300 amps. Bushing for Indian Railways.
• Bushing for miscellaneous applications such as bushings, roof bushings, T.G.
bushings etc. To suit customer requirements.
• SRBP cylinders for transformer application up to 1400 mm I/D, up to 2400 mm long.

CAPACITORS

• Shunt Capacitor banks with all film dielectric impregnated with non PCB Impregnate
of desired ratings from 6.6 to 400 kV complete with manual / automatic control
equipment for Industrial and power system application.
• Pole mounted Capacitors for mounting in line with Rural Electrification scheme up to
11 KV

Page 26
 • Roof Capacitor in Traction Motor application: 4 microfarad, 2 KV DC
• Series capacitors for Reactive compensation and voltage regulation in power system
from 33kV to 400 KV
• Capacitor to improve power factor of traction substations suitable for Railway
Electrification.
• Surge Capacitor for protection of Rotating Machine and Generator transformers
winding 15 kV and 40 kV, 0.125 micro farad.
• AC filter Capacitor for Harmonic filtering suitable for HVDC application up to 500 kV.
• Coupling capacitors / CVT up to 800 kV class for Power line carrier communication
application, meeting and protection.

TRANSFORMERS

• Power Transformers upto 420kV class, 50/60 Hz 945 MVA, 3-phase Bank.
• Power Transformers upto 420kV class, 50/60 Hz 500 MVA, 3-phase Unit.
• HVDC Converter Transformers and Smoothing Reactors.
• 500 MVA, ± 500kVDC, 3 winding, 1- Phase. Convertor Transformer.
• 254 MVAR, 360mH, 1568A, ±500 kVDC 1 –Phase Smoothing Reactor.

INSTRUMENTS TRANSFORMERS

• Current transformers up to 400 kV.

• Capacitor voltage Transformer up to 1200 kV.

REACTORS

• Gapped core Shunt Reactors up to 420 kV class, 125 MVAR 3 Phase Unit.
• Series and Neutral Grounding Reactors.
• Controlled Shunt Reactor up to 420 kV class, 80 MVAR 3 Phase Unit.

ULTRA HIGH VOLTAGE LABORATORY

• The DC test plant is adequate for test levels suitable up to +800 kV HVDC
transmission.
• Suitability for testing AC equipments up to 1200KV class.

FOR POWER TRANSMISSION

• Control for protection Panels for substations up to 400 kV, distribution feeders and
capacitors banks.
• OLTC control panels.
• Controls for Nuclear Power Plants.

Page 27
BLOCK 4
SWITCH GEAR

In an electric power system, switchgear is the combination of electrical disconnect

switches, fuses or circuit breakers used to control, protect and isolate electrical equipment.
Switchgear is used both to de-energize equipment to allow work to be done and to
clear faults downstream. This type of equipment is directly linked to the reliability of
the electricity supply.

Functions

One of the basic functions of switchgear is protection, which is interruption of short-circuit and
overload fault currents while maintaining service to unaffected circuits. Switchgear also provides
isolation of circuits from power supplies. Switchgear is also used to enhance system availability by
allowing more than one source to feed a load.

Circuit breaker types

A switchgear may be a simple open-air isolator switch or it may be insulated by some other
substance. An effective although more costly form of switchgear is the gas-insulated switchgear
(GIS), where the conductors and contacts are insulated by pressurized sulfur
hexafluoride gas (SF6). Other common types are oil or vacuum insulated switchgear.

The combination of equipment within the switchgear enclosure allows them to interrupt fault
currents of thousands of amps. A circuit breaker (within a switchgear enclosure) is the primary
component that interrupts fault currents. The quenching of the arc when the circuit breaker pulls
apart the contacts (disconnects the circuit) requires careful design

Page 28
BHEL PRODUCTS

• Indoor Metal clad Vacuum Switchgear Type VM12

• SF6 Gas Insulated Vacuum Switchgear GVM36
• Pole Mounted Vacuum Auto Re-closure Type PMVN
• 25KVAC 50Hz Single Pole Outdoor loco VCB Type SBLB
• Spark Gap
• Indoor Metal Enclosed Vacuum Switchgear Type VM 24/VM36
• Outdoor Pole Mounted Capacitor Switch type PMVC
• Outdoor Pole Mounted Vacuum Sectionalizer PMVS
• Outdoor Metal clad Vacuum Switchgear Type VMN-12
• Outdoor Porcelain clad Vacuum Circuit Breaker Type PVN
• Outdoor Metal clad Vacuum Switchgear Type VN-12
• 25 KV AC 50Hz Single Pole Outdoor Vacuum Interrupter type PVTI
• 25 KV AC 50Hz Single Pole Outdoor Vacuum Circuit Breaker type PVTB

BLOCK 5
FOUNDARY

Foundry Definition
In simplified terms, a foundry is a factory where castings are produced by melting metal,
pouring liquid metal into a mould, then allowing it to solidify. Even if you have never been to
a foundry, or even know what one looks like, you are surrounded by the metal castings
they produce. There is a good chance that you are reading this less than 10 feet away from
one.

Foundries don’t just produce metal products for engine, railroad, or pipe components. They
also form components for machines that are required to make many of the essential
consumer products we depend on. 90 percent of all manufactured goods rely on metal
castings.

The Casting Process

In order to understand a foundry, you need to understand the casting process. The general
steps involved in casting are patternmaking, moulding, melting, pouring, ejection, cleaning,
fettling, and inspection.

Page 29
The final casting shape corresponds with the mould it is poured into, so moulds are
carefully shaped with a pattern – a wood or metal replica of the object to be cast. The most
common mould material is silica sand, but they can be produced from a number of different
materials depending on the casting metal and method being used.

A melting furnace is “charged” with metal and heated above the metal’s melting point. Once
the molten metal has reached a specific pouring temperature it is tapped from the furnace
through a spout into a refractory lined steel pouring ladle. Any slag or impurities are
skimmed from the top of the molten metal surface. The ladle is then tipped to pour molten
metal into a mould cavity.

The mould cools and the metal solidify, then the casting is ejected from the mould and
cleaned. The cleaned casting is finished with fettling, a process which removes excess
material from the casting to meet specified dimensions for the finished product. Depending
on the casting specifications, fettling can be quick and simple, or extremely detailed work.
Finished castings are then inspected by the foundry before being shipped.

Foundries don't just produce raw castings. They house a number of operations that often
include part design, tool building, prototyping, machining, assembly and other after-sales
services.

BLOCK 6
STEAM TURBINE
PRODUCTS
Turbines

1) Design, Manufacturing, Erection,

Commissioning and Services of :

• 30 MW, 120 MW Steam Turbines

• 236 MW Nuclear Turbines.
• 15000 SHP Marine Turbines
• 210 MW Steam Turbines.

2) Supply of Spares and Repairs of above

Steam Turbines.

Page 30
 3) R & M and Life assessment studies of BHEL & Non BHEL TG sets.

4) Repair and Supply of Spares of 210 MW and 500 MW KWU Turbines.

5) Repair and supply of Spares for Non BHEL TG Sets.

BLOCK 7
WINDING AND FORMATION OF MOULD
Transformers are very versatile devices. The basic concept of energy transfer between
mutual inductors is useful enough between a single primary and single secondary coil,
but transformers don’t have to be made with just two sets of windings. Consider this
transformer circuit: (Figure below)

Transformer with multiple secondaries provides multiple output voltages.

Here, three inductor coils share a common magnetic core, magnetically “coupling” or
“linking” them together. The relationship of winding turn ratios and voltage ratios seen
with a single pair of mutual inductors still holds true here for multiple pairs of coils. It is
entirely possible to assemble a transformer such as the one above (one primary winding,
two secondary windings) in which one secondary winding is a step-down and the other is
a step-up. In fact, this design of transformer was quite common in vacuum tube power
supply circuits, which were required to supply low voltage for the tubes’ filaments
(typically 6 or 12 volts) and high voltage for the tubes’ plates (several hundred volts) from
a nominal primary voltage of 110 volts AC. Not only are voltages and currents of
completely different magnitudes possible with such a transformer, but all circuits are
electrically isolated from one another.

Different Types of Transformer Winding

Core and Windings of Three Phase Core Type Transformer
There are different types of windings used for different kinds of applications
and arrangements. Windings are the conductors wrapped in various forms like

Page 31
helical, disc, cylindrical, crossover which generates mmf that is carried by the
core to other windings for having the different level of voltages. Mainly there are
two types of transformer:

1. Core type transformer

2. Shell type transformer
In core type, we wrap the primary, and the secondary winding on the outside
limbs and in shell type we place the primary and secondary windings on the inner
limbs.

We use concentric type windings in core type transformer. We place low voltage
winding near to the core. However, to reduce leakage reactance, windings can
be interlaced. Winding for core type depends on many factors like current rating,
short circuit withstand capacity, limit of temperature rise, impedance, surge
voltage, transport facilities, etc.

Types of Winding used for Core Type Transformer

Cylindrical Windings
These windings are layered type and uses rectangular or round conductor shown
in Fig.(a) and (b). The conductors are wound on flat sides shown in Fig.(c) and
wound on the rib side in Fig.(d).

Uses of Cylindrical Windings

Cylindrical windings are low voltage windings used up to 6.6 kV for kVA up to
600-750, and current rating between 10 to 600 A. We often use cylindrical
windings in its multi-layer forms. We use rectangular conductors in two-layered
type because it is easy to secure the lead-out ends. Oil ducts separate the layers
of the windings this arrangement facilitates the cooling through oil circulation in

Page 32
the winding. In multi-
layered cylindrical windings, we use circular conductors, wound on vertical strips
to improve cooling conditions. The arrangement creates oil ducts to facilitate
better cooling. We use this type of winding for high voltage ratings up to 33 kV,
800 kVA and current ratings up to 80 A. The maximum diameter we use for a
bare conductor is 4 mm.

Helical Windings
We use helical windings low voltage, high capacity transformers, where current
is higher, at the same time windings turns are lesser. The output of transformer
varies from 160 - 1000 kVA from 0.23-15 kV. To secure adequate mechanical
strength the cross-sectional area of the strip not made less than 75-100 mm
square. The maximum number of strips used in parallel to make up a conductor
is 16.

There are three types:

• Single Helical Winding

• Double Helical Winding
• Disc-Helical Winding
Single Helical Windings consist of winding in an axial direction along a screw
line with an inclination. There is only one layer of turns in each winding. The
advantage of Double Helical Winding is that it reduces eddy current loss in
conductors. This is on account of the reduced number of parallel conductors
situated in the radial direction.

Page 33
 In Disc-Helical Windings,
the parallel connected strips are placed side by side in a radial direction to

occupy total radial depth of winding.

Multi-layer Helical Winding

We use it commonly for high voltage ratings for 110 kV and above. These types
of winding consist of several cylindrical layers concentrically wound and

connected in series. We make the outer

layers shorter than inner layers to distribute capacitance uniformly. These
windings primarily improve the surge behaviour of transformers.

Crossover Winding
We use these windings for high voltage windings of small transformers. The
conductors are paper covered round wires or strips. The windings are divided
into a number of coils in order to reduce voltage between adjacent layers. These
Page 34
coils are axially separated by a distance of 0.5 to 1 mm. The voltages between
adjacent coils should not be more than 800 to 1000 V.

The inside end of a coil is

connected to the output side end of the adjacent one as shown in above figure.
The actual axial length of each coil is about 50 mm while the spacing between
two coils is about 6 mm to accommodate blocks of insulating material. The width
of the coil is 25 to 50 mm. The crossover winding has a higher strength than
cylindrical winding under normal condition. However, the crossover has lover
impulse strength than the cylindrical one. This type also consumes more labour
cost.

Disc and Continuous Disc Winding

Primarily used for a high capacity transformer. The winding consist of a number
of flat coils or discs in series or parallel. The coils are formed with rectangular
strips wound spirally from the centre outwards in the radial direction as shown in

the figure below. The conductor

can be a single strip or multiple strips in a parallel wound on the flat side. This
makes robust construction for this type of windings. Discs are separated from
each other with press-board sectors attached to vertical strips. The vertical and
horizontal spacers provide radial and axial ducts for free circulation of oil which
comes in contact with every turn. The area of the conductor varies from 4 to 50
mm square and limits for current are 12 - 600 A. The minimum width of oil duct is
6 mm for 35 kV. The advantage of the disc and continuous windings is their
greater mechanical axial strength and cheapness.

Windings for Shell Type Transformer

Sandwich Type Winding
Allow easy control over the reactance the nearer two coils are together on the

Page 35
same magnetic axis, the greater is the proportion of mutual flux and the less is
the leakage flux. Leakage can be reduced by subdividing the low and high
voltages sections. The end low voltages sections contain half the turns of the
normal low voltage sections called half coils.

In order to balance the magnetomotive forces of adjacent sections, each normal

section whether high or low voltage carries the same number of ampere-turns.
The higher the degree of subdivision, the smaller is the reactance.

Advantages of Shell Type Windings in Transformers

• High short-circuit withstand capability
• High mechanical strength
• High dielectric strength
• Excellent control of leakage magnetic flux
• Efficient cooling capability
• Flexible design
• Compact size.
• Highly Reliable Design

BLOCK 8
GEAR
A gear or cogwheel is a rotating machine part having cut like teeth, or cogs, which mesh
with another toothed part to transmit torque. Geared devices can change the speed,
torque, and direction of a power source. Gears almost always produce a change in torque,
creating a mechanical advantage, through their gear ratio, and thus may be considered
a simple machine. The teeth on the two meshing gears all have the same shape.[1] Two or

Page 36
more meshing gears, working in a sequence, are called a gear train or a transmission. A
gear can mesh with a linear toothed part, called a rack, producing translation instead of
rotation.
The gears in a transmission are analogous to the wheels in a crossed, belt pulley system.
An advantage of gears is that the teeth of a gear prevent slippage.
When two gears mesh, if one gear is bigger than the other, a mechanical advantage is
produced, with the rotational speeds, and the torques, of the two gears differing in
proportion to their diameters.
In transmissions with multiple gear ratios—such as bicycles, motorcycles, and cars—the
term "gear" as in "first gear" refers to a gear ratio rather than an actual physical gear. The
term describes similar devices, even when the gear ratio is continuous rather than discrete,
or when the device does not actually contain gears, as in a continuously variable
transmission.

BLOCK 9
MOTOR AND TRANSFORMER TESTING
Traction motor refers to a type of electric motor. A traction motor is used to make
rotation torque on a machine. It is usually changed into a straight line motion.
Traction motors are used in electrically powered rail vehicles such as electric multiple
units and electric locomotives. They are also used in electric vehicles, such as electric milk
floats, elevators, and conveyors. Vehicles with electrical transmission systems such
as Diesel-electric locomotives, electric hybrid vehicles and battery powered electric
vehicles.
AC Motors & Alternators

BHEL is a leading AC Machines manufacturer and in the last four decades have supplied
more than 20000 HT & LT A.C. Machines for various applications to Indian as well as
Export market. The applications include Power Plants, Nuclear Energy, Petrochemicals,
Fertilizers, Refineries, Cement & Steel Industries, Irrigation Projects, Pipelines, etc.

The manufacturing plant in Bhopal was established in technical collaboration with AEI UK.
Commercial production of A.C. Machines commenced in the year 1963. Technology was
upgraded by collaborating with Siemens AG, Germany from 1980-1990 and subsequently
from 1996-2006. Motors are offered both in standard as well as tailor made designs to
meet customer's specific needs. High performance is achieved through optimum utilization
of the active materials and components.

BHEL A.C. Machines offer high efficiency, exceptional reliability, quick installation and

Page 37
minimal maintenance costs.
SQUIRREL CAGE INDUCTION MOTORS
➢ SLIPRING INDUCTION MOTORS
➢ SYNCHRONOUS MOTORS
➢ INDUSTRIAL ALTERNATORS
➢ VARIABLE FREQUENCY DRIVE MOTORS
➢ PRESSURISED MOTORS
➢ FLAME PROOF MOTORS
➢ INDUCTION GENERATORS
➢ WIND ELECTRIC GENERATOR
➢ H Compact
➢ Squirrel cage
➢ S Ring
➢ Bearing Assembly Antifriction Bearing_TETV Motor
➢ Bearing Assembly Sleeve Bearing_TETV Motor

Special Features of BHEL AC Machines

• Machines conform to the requirements of IEC 60034 and relevant Indian

standards.
• Modular system with standard frames for different degree of protection and
type of cooling requirements.
• Robust construction and vibrato-stable frames.
• Compact construction requiring small floor area
• Low shaft centre heights
• Uniform Cooling.
• Machines shipped completely assembled for quick and easy installations.
• Field-proven MICALASTIC Insulation System with both Resin rich for medium
range and Resin poor with vacuum pressure impregnation technology for
large range.
• Low Vibrations and Noise levels.

Recent Developments in AC Machines

➢ 20500kW, 11kV, 4P SCIM for BFP application for M/s Raichur Power Corporation
Ltd. For 2 X 800MW Yeramarus TPS.
➢ 17500kW, 11kV, 4P SCIM for BFP application for M/s NTPC Barh.
➢ 6000kW, 6.6kV, 4P vertical SCIM for Primary Coolant Pump (PCP) application for
M/s NPCIL.
➢ 5200kW, 11kV, 22P vertical SCIM for CWP application for M/s KBL for Mundra.
➢ 3600kW, 3.15kV, 10P variable speed vertical induction motor for SSP application for
fast breeder reactor for M/s NPCIL.
➢ 12.5MW, 11kV, 4P synchronous motor in Line-F construction with on-line brush
changing facility.
➢ 2150kW, 6.6kV, 4P constant torque SCIM for M/s Essar construction.
➢ 4575kW, 2X4.0kV, 10P VFD synchronous motor with top mounted cooler.

Page 38
Images / Photographs of Various Types of AC Machines

Totally Enclosed Tube Ventilated Sq. Cage Induction Motor

Vertical Sq. Cage Induction Motor

Vertical CACW Sq. Cage Induction Motor for Nuclear Applications

Flame Proof (Exd) Sq. Cage Induction Motor for Zone-1 Hazardous Areas

Page 39
Cyl. Rotor Syn. Machine

TRANSFORMER TESTS
• Insulation resistance Test.
• Winding resistance Test.
• Turns Ration / Voltage ratio Test
• Polarity / Vector group Test.
• No-load losses and current Test.
• Short-circuit impedance and load loss Test.
• Continuity Test.
• Magnetizing Current Test.
• Magnetic Balance Test.
• High Voltage Test.
• Dielectric tests (Separate source AC voltage/ Induced overvoltage/ Lightning
impulse tests).
• Test on On-load tap changers, where appropriate.

Type tests
Type tests are tests made on a transformer which is representative of other transformers
to demonstrate that they comply with specified requirements not covered by routine tests:

• Temperature rise test (IEC 60076-2).

• Dielectric type tests (IEC 60076-3).

Special tests
Special tests are tests, other than routine or type tests, agreed between manufacturer and
purchaser.

• Dielectric special tests.

• Zero-sequence impedance on three-phase transformers.
• Short-circuit test.
• Harmonics on the no-load current.
• Power taken by fan and oil-pump motors.

Page 40
 • Determination of sound levels.
• Determination of capacitances between windings and earth, and between windings.
• Determination of transient voltage transfer between windings.
• Tests intended to be repeated in the field to confirm no damage during shipment, for
example Frequency Response Analysis.

Pre commissioning Tests

The Test performed before commissioning the transformer at site is called pre
commissioning test of transformer. These tests are done to assess the condition of
transformer after installation and compare the test results of all the low voltage tests with
the factory test reports. All transformers are subjected to the following Pre commissioning
tests:

• IR value of transformer and cables

• Winding Resistance
• Transformer Turns Ratio
• Polarity Test
• Magnetizing Current
• Vector Group
• Magnetic Balance
• Bushing & Winding Tan Delta (HV)
• Protective relay testing
• Transformer oil testing
• Hipot test.

Routine Tests of Transformer Insulation Resistance Test

Test Purpose
Insulation resistance test of transformer is essential to ensure the healthiness of overall
insulation of an electrical power transformer.
Test Instruments
LT System: 500V / 1000V Megger. & MV / HV System: 2500V / 5000V Megger.

Page 41
BLOCK 10
PRESS SHOP

Machine press

General-purpose hydraulic shop press

A forming press, commonly shortened to press, is a machine tool that changes the shape
of a work piece by the application of pressure. Presses can be classified according to

• their mechanism: hydraulic, mechanical, pneumatic;

• Their function: forging presses, stamping presses, press brakes, punch press, etc.

Page 42
• their structure, e.g. Knuckle-joint press, screw press
• their controllability: conventional vs. servo-presses
Typically consisting of a simple rectangular frame, often fabricated from C-channel or
tubing, containing a bottle jack or hydraulic cylinder to apply pressure via a ram to a work
piece. Often used for general-purpose forming work in the auto mechanic shop, machine
shop, garage or basement shops, etc. Typical shop presses are capable of applying
between 1- and 30-tons pressure, depending on size and construction. Lighter-duty
versions are often called Arbor presses.
A shop press is commonly used to press interference fit parts together, such as gears onto
shafts or bearings into housings.

Other presses by application

• A press brake is a special type of machine press that bends sheet metal into shape. A
good example of the type of work a press brake can do is the back plate of a computer
case. Other examples include brackets, frame pieces and electronic enclosures. Some
press brakes have CNC controls and can form parts with accuracy to a fraction of a
millimetre. Bending forces can range up to 3,000 tons.
• A punch press is used to form holes.
• A screw press is also known as a fly press.
• A stamping press is a machine press used to shape or cut metal by deforming it with
a die. It generally consists of a press frame, a bolster plate, and a ram.
• Capping presses form caps from rolls of aluminium foil at up to 660 per minute.

Types of presses
The press style used is in direct correlation to the end product. Press types are straight
side, BG (back geared), geared, gap, OBI (open back inclinable) and OBS (open back
stationary). Hydraulic and mechanical presses are classified by the frame the moving
elements are mounted on. The most common are the gap-frame, also known as C-frame,
and the straight side press. A straight side press has vertical columns on either side of the
machine and eliminates angular deflection. A C-frame allows easy access to the die area
on three sides and requires less floor space. A type of gap-frame, the OBI pivots the frame
for easier scrap or part discharge. The OBS timed air blasts, devices or conveyor for scrap
or part discharge.

Page 43
 WTM BLOCK
Water turbine manufacturing block (block-1) is one of the biggest blocks in the BHEL
complex. Hydro turbine and its associated components are machined and
manufactured here.

The entire block is divided into different bays.

BAY-1

It houses the following machines:

➢ Deep drilling machine - Used to drill holes in the shaft.

➢ CNC lathe– Computer Numerically Controlled Lathes

Page 44
➢ Planning machine-uses linear relative motion between the work
piece and a single-point cutting tool to machine a linear tool path.

➢ Horizontal floor boring machine-bores holes in

horizontal direction.

➢ Vertical boring machine- work piece rotates around a vertical

axis.

Page 45
➢ CNC vertical boring machine- Computer Numerically Controlled
vertical boring machine.

➢ Radial drilling machines-are known for their precision, accuracy

and efficiency. These are designed to meet the most exacting
requirements of engineering and allied operations and utility. They
ensure smooth rotation of column and avoid angular deflection of
spindle axis.

➢ Slotting machine- for perfect slotting and planning of materials.

Page 46
Components machined: -

• Shaft
• Log for lever
• Sleeve
• Bush housing
• Guide bent stock
• Hexagonal screw head
• Guiding piece
• Bush housing

BAY-2

It houses the following machines:

• Vertical boring machine
• Table planning machine
• Lathe machine
• CNC end milling machine
• CNC horizontal table borer
➢ Make-Craven
➢ Boring spindle diameter-130mm
➢ Maximum load capacity-12 tons
• Horizontal boring machine
➢ Spindle diameter-88.9mm
➢ Swivelling table size-1067*1067mm
➢ Sliding table size-1676*1067mm
➢ Maximum facing head mill face-1219mm
• CNC lathe machine
Components machined:
• Rubber seal clamping ring
•Bottom cover plate
• Bush
• Guide vane
• Extension tube
•Deflector

GOVERNOR ASSEMBLY-Bay 2 also houses the governor assembly area.

Governor Assembly WTM

Components Manufactured:
➢ Guide Bearing

Page 47
➢ MIV Servo Motor

➢ Nozzle Assembly- Nozzle tip

➢ Anti-Vacuum Valve

➢ Pressure Receiver

➢ By pass valve

Page 48
 BAY-3

It houses the following machines:

Vertical boring machine

• Table diameter-6705mm
• Maximum job diameter-7696mm
• Maximum capacity-90 tons
CNC vertical boring machine

Runner blade turning machine

➢ Maximum length of work-8000mm
➢ Maximum diameter that can be turned-4000mm
➢ Length of job that can be done-7200mm
Column boring machine
➢ Table diameter-5523mm
➢ Maximum external diameter that can be machined-9000mm
➢ Stroke of RAM-3353mm
➢ Maximum capacity-100 tons

Components machined:

· Top cover
· Inner turbine housing
· Spacer flange
· Pivoted ring cover
· Sealing flange
· Stay ring
· Runner blade

BAY-4

It houses the following machines:

•Lathe machine
• CNC lathe machine
• Table planning machine
• End milling machine
➢ Distance between columns-4242mm
➢ Maximum underbridge movement-3276mm
➢ Maximum length of machines-9144mm
➢ Maximum height up to vertical head-3200mm
➢ Maximum capacity-100 tons
Page 49
• Horizontal boring and milling machine
➢ Spindle diameter-203mm
➢ Traverse X-8992mm, Y-4500mm, Z-1981mm
➢ Minimum height of spindle centre to bed-760mm
• Break lathe machine
➢ Sliding bed and centre height-1422mm
➢ Base plate and centre height-2108mm
➢ Saddles rotation over sliding bed-2286mm
➢ Distance between centre-7621mm
➢ Length of sliding bed-9905mm
➢ Diameter of face plate-2438mm
➢ Weight capacity-50 tons

• Vertical milling machine

➢ Height between spindle nose and table-660mm
➢ Spindle to face column-559mm
• Slotting machine
➢ Maximum stroke -530mm
➢ Minimum stroke -190mm
• Radial drilling machine
• Vertical boring machine
• CNC horizontal floor borer
➢ Boring spindle diameter-200mm
➢ Column guide way-1050mm
➢ Headstock vertical movement-5000mm
➢ Spindle / rack movement-2000/1600mm
➢ Rotary table size-3150*3150mm

Components machined:
•Trunnion
• Sleeve screw
• Bottom sleeve
• Top cover

Page 50
 FABRICATION SHOP

BAY-5

It is the place where degreasing and fabrication work takes place. It houses the
following machines:

• Electro slag welding machine

➢ Job completed in one pass
➢ for job of thickness 40-110mm single nose is used
➢ for job of thickness greater than 110mm double nose is used
➢ lesser defects as compared to manual arc welding

•Oven
➢ heating fuel-LPG
➢ Maximum heating temperature-150 degree Celsius
➢ Maximum size-W-5250mm
➢ Transformer tank assembly-H-5000mm

Components fabricated:
•Distributor
• Pivot ring
• Transformer tank

Page 51
 BAY-6

It houses the following machines and equipment:

• Manual arc welding

• Manual grinding

• Submerged arc welding

BAY-7

It houses the following machines:

• Submerged arc welding
• Robotic arm welding

• Shot blast plant-Used for treating corroded parts

• Paint shop-Used to paint shot blasted components
Components fabricated:
• Transformer tank
• Spacer flange

Page 52
 Bay-8

It houses the heat exchanger and cooler assembly. Following machines are situated
in this bay:
• Lahar deep gun drilling machine
• Radial drilling machine
• Arboga CNC drilling machine
• Multi-spindle drilling machine
➢ Traverse x-7000mm y-8500mm z-350mm
➢ No. of spindles-8
➢ Min. pitch-100mm
➢ Max.pitch-200mm
➢ per spindle drilling capacity-40mm
➢ Spindle speed-71-1400 RPM
➢ Spindle feed-10-1000 mm/min
➢ No. of drilling motors-2
• Lathe machine

Components machined:

• Buffel
• Tube plate
• Sleeve

Page 53
WATER TURBINE
MFG. DIVISION
Water turbine
A water turbine is a rotary engine that
converts kinetic and potential energy of
water into mechanical work.

Water turbines were developed in the 19th century and were widely used for
industrial power prior to electrical grids. Now they are mostly used for electric
power generation. Water turbines are mostly found in dams to generate electric
power from water kinetic energy.

Theory of operation

Flowing water is directed on to the blades of a turbine runner, creating a force

on the blades. Since the runner is spinning, the force acts through a distance
(force acting through a distance is the definition of work). In this way, energy is
transferred from the water flow to the turbine

Impulse turbine:
- Pelton turbine
Reaction turbine:
- Francis turbine
- Kaplan and Propeller turbine
Propeller turbines are mainly Kaplan turbines but Moody, nagler and Bell
turbines may be found in market. The main difference between Kaplan and
other type of propeller turbines is that the former has adjusted runner blades.

FRANCIS TURBINE-
➢ These are inward flow reaction turbine.
➢ Used when operating head is in the range of 30-500m.
➢ These are medium pressure turbine.
➢ Total machines -190
➢ Megawatt capacity-5-165 MW
➢ Runner radius-1050-5250mm

Page 54
 FRANCIS TURBINES

The Francis turbine is a type of water turbine that was developed by James B.
Francis in Lowell, Massachusetts. It is an inward-flow reaction turbine that combines
radial and axial flow concepts.

The Francis turbine is a reaction turbine, which means that the working fluid changes
pressure as it moves through the turbine, giving up its energy. A casement is needed
to contain the water flow. The turbine is located between the high-pressure water
source and the low-pressure water exit, usually at the base of a dam.
The inlet is spiral shaped. Guide vanes direct the water tangentially to the turbine
wheel, known as a runner. This radial flow acts on the runner's vanes, causing the
runner to spin. The guide vanes (or wicket gate) may be adjustable to allow efficient
turbine operation for a range of water flow conditions.

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As the water moves through the runner, it’s spinning radius decreases, further acting
on the runner. For an analogy, imagine swinging a ball on a string around in a circle; if
the string is pulled short, the ball spins faster due to the conservation of angular
momentum. This property, in addition to the water's pressure, helps Francis and other
inward-flow turbines harness water energy efficiently.
At the exit, water acts on cup-shaped runner features, leaving with no swirl and very
little kinetic or potential energy. The turbine's exit tube is shaped to help decelerate
the water flow and recover the pressure.

MAIN COMPONENTS OF FRANCIS TURBINE:

1. SPIRAL CASING: in order to distribute the water around the guide ring
evenly the scroll casing is designed with a cross sectional area reducing
uniformly around the circumference, maximum at the entrance and nearly
zero at tip. This gives spiral shape and hence is named as spiral casing.
These are also provided with inspection holes and also with pressure gauge
connection.

2. GUIDE MECHANISM: these have a cross sectional area of aero foil section.
This particular cross section allows water to pass over them without
forming eddies and with minimum frictional losses. It is mounted on a ring
which is connected to generator shaft by means of a regulating shaft

Page 56
 depending upon load, speed of turbine is controlled by a governor which
basically deals with the guide vane opening.

3. DRAFT TUBE: It is a conduit which connects the runner exit to the

Tailrace. A tube should be drowned approx. below the lowest tail race level.
It basically increases the workable head of turbine by an amount equal to
the height of the runner outlet, thus making it possible to install the turbine
above the tail race level without loss of head.

APPLICATION OF FRANCIS TURBINES

Francis turbines may be designed for a wide range of heads and flows. This, along with
their high efficiency, has made them the most widely used turbine in the world.
Francis type units cover a head range from 20 to 700 meters, and their output power
varies from just a few kilowatts up to one Gigawatt. Large Francis turbines are
individually designed for each site to operate at the highest possible efficiency,
typically over 90%.
In addition to electrical production, they may also be used for pumped storage, where
a reservoir is filled by the turbine (acting as a pump) during low power demand, and
then reversed and used to generate power during peak demand.

Construction of spherical valve

Valve disc of spherical valve Spherical valve with dismantling joint

Spherical valve under pressure test Construction of spherical valve

Page 57
 PELTON TURBINE

➢ These are impulse turbines which extract energy from the

impulse(momentum)of moving water.
➢ These are high pressure turbines
➢ Total machines-46
➢ Head limit-245-1025m
➢ Megawatt limit-1.5-200 MW

The Pelton wheel is an impulse turbine which is among the most efficient types
of water turbines. It was invented by Lester Allan Pelton in the 1870s. The Pelton
wheel extracts energy from the impulse (momentum) of moving water, as opposed to
its weight like traditional overshot water wheel. Pelton's paddle geometry was
designed so that when the rim runs at ½ the speed of the water jet, the water leaves
the wheel with very little speed, extracting almost all of its energy, and allowing for a
very efficient turbine.

The water flows along the tangent to the path of the runner. Nozzles direct forceful
streams of water against a series of spoon-shaped buckets mounted around the edge of
a wheel. As water flows into the bucket, the direction of the water velocity changes to
follow the contour of the bucket. When the water-jet contacts the bucket, the water
exerts pressure on the bucket and the water is decelerated as it does a "U-turn" and

Page 58
flows out the other side of the bucket at low velocity. In the process, the water's
momentum is transferred to the turbine. This "impulse" does work on the turbine. For
maximum power and efficiency, the turbine system is designed such that the water-jet
velocity is twice the velocity of the bucket. A very small percentage of the water's
original kinetic energy will still remain in the water; however, this allows the bucket to
be emptied at the same rate it is filled, (see conservation of mass), thus allowing the
water flow to continue uninterrupted. Often two buckets are mounted side-by-side,
thus splitting the water jet in half (see photo). This balances the side-load forces on
the wheel, and helps to ensure smooth, efficient momentum transfer of the fluid jet to
the turbine wheel.
Because water and most liquids are nearly incompressible, almost all of the available
energy is extracted in the first stage of the hydraulic turbine. Therefore, Pelton wheels
have only one turbine stage, unlike gas turbines that operate with compressible fluid.

PARTS OF PELTON TURBINE:

1. Guide mechanism: this mechanism controls the quality of water passing

through the nozzle and striking the bucket thus meeting the variable
demand of power. It maintains the speed constant of wheel, when head
varies.

2. Bucket and runner: Each bucket is divided vertically into two parts by
splitter, which is the sharp edge at centre giving the shape of double
hemispherical cup (in BHEL, the edge of splitter is cut to increase efficiency
and to reduce the impact force of the impinging jet which otherwise will
decrease the life of bucket).

3. Casing: it does not have any hydraulic function taper form. It is necessary
only to prevent splashing and to lead the water to tail race, and also further
safe guard against accidents.

4. Hydraulic brakes: After shutting down the inlet valve of turbine, the large
capacity of runner will go on revolving or a considerable period, due to
inertia. This has necessitated the development of brakes to bring the
turbine to a standstill in a shortest possible time.

APPLICATION OF PELTON WHEEL

Pelton wheels are the preferred turbine for hydro-power, when the available water
source has relatively high hydraulic head at low flow rates. Pelton wheels are made in
all sizes. There exist multi-ton Pelton wheels mounted on vertical oil pad bearings in
hydroelectric plants. The largest units can be up to 200 megawatts. The smallest
Pelton wheels are only a few inches across, and can be used to tap power from
mountain streams having flows of a few gallons per minute. Some of these systems
utilize household plumbing fixtures for water delivery. These small units are

Page 59
recommended for use with thirty meters or more of head, in order to generate
significant power levels. Depending on water flow and design, Pelton wheels operate
best with heads from 15 meters to 1,800 meters, although there is no theoretical limit.
The Pelton wheel is most efficient in high head applications (see the "Design Rules"
section). Thus, more power can be extracted from a water source with high-pressure
and low-flow than from a source with low-pressure and high-flow, even when the two
flows theoretically contain the same power. Also, a comparable amount of pipe
material is required for each of the two sources, one requiring a long thin pipe, and
the other a short wide pipe.

KAPLAN TURBINE-

➢ The Kaplan turbine is a propeller-type water turbine which has adjustable

blades.
➢ These are reaction turbines
➢ The head ranges from 10-70 meters
➢ Output from 5 to 120 MW
➢ Runner diameters are between 2 and 8 meters
➢ Used in high-flow, low-head power production

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The Kaplan turbine is a propeller-type water turbine which has adjustable blades. It
was developed in 1913 by the Austrian professor Viktor Kaplan, who combined
automatically adjusted propeller blades with automatically adjusted wicket gates to
achieve efficiency over a wide range of flow and water level.

Its invention allowed efficient power production in low-head applications that was
not possible with Francis turbines. The head ranges from 10-70 meters and the output
from 5 to 120 MW. Runner diameters are between 2 and 8 meters. The range of the
turbine is from 79 to 429 rpm. Kaplan turbines are now widely used throughout the
world in high-flow, low-head power production.

APPLICATION OF KAPLAN
Kaplan turbines are widely used throughout the world for electrical power production.
They cover the lowest head hydro sites and are especially suited for high flow
conditions.
HYDRO TURBINE GOVERNOR

➢ Used to govern the speed of rotation of the runner such that the frequency of
power generated is 50 Hz.
➢ This is done by controlling the opening of guide vanes.

SPIRAL CASE AND STAY RING

Spiral case for turbine with 411m head Stay ring for turbine with 146m head

Page 61
 WICKET GATES AND OPERATING MECHANISM

Wicket gates for a low head turbine Wicket gates for a high head turbine

Wicket gates operating linkage Self-lubricated bearing for wicket gate stem

CONSTRUCTION OF RUNNER HUB AND BLADE

The runner blades are operated to smoothly adjust their blade angles by a link
mechanism. Their mechanism is installed inside the runner hub, containing the
runner blade and stem, the link crosshead and so on. A high-quality lubricating oil is
filled inside the runner hub to lubricate the mechanism interior.

Shop assembly of runner Runner blade under machining

Page 62
 MAIN SHAFT

The main shaft for the turbine is made of high-grade forged carbon steel. When the
size of the main shaft exceeds the limitation of forging capacity or transportation or it
is economical, the main shaft is formed by welding steel plates or a combination of
forged steel and steel plates.
The main shaft is connected to the generator shaft or the intermediate shaft by a
flange coupling. The shaft surface passing through the shaft seal is protected with a
stainless-steel shaft sleeve to prevent the main shaft
from wearing.

Forged shaft Fabricated shaft

Power of Water Turbine

The power available in a stream of water is;

where:
➢ P = power (J/s or watts)
➢ η = turbine efficiency
➢ ρ = density of water (kg/m³)
➢ g = acceleration of gravity (9.81 m/s²)
➢ h = Potential head (m). For still water, this is the difference in height between
the inlet and outlet surfaces. Moving water has an additional component added
to account for the kinetic energy of the flow. The total head equals the pressure
head plus velocity head.
➢ = flow rate (m³/s)

Page 63
 DESIGN AND APPLICATION
Turbine selection is based mostly on the available water head, and less so on the
available flow rate. In general, impulse turbines are used for high head sites, and
reaction turbines are used for low head sites. Kaplan turbines with adjustable blade
pitch are well-adapted to wide ranges of flow or head conditions, since their peak
efficiency can be achieved over a wide range of flow conditions.

Small turbines (mostly fewer than 10 MW) may have horizontal shafts and even fairly
large bulb-type turbines up to 100 MW or so may be horizontal. Very large Francis and
Kaplan machines usually have vertical shafts because this makes best use of the
available head, and makes installation of a generator more economical. Pelton wheels
may be either vertical or horizontal shaft machines because the size of the machine is
so much less than the available head. Some impulse turbines use multiple water jets
per runner to increase specific speed and balance shaft thrust.
Typical range of heads

• Hydraulic wheel turbine 0.2 < H < 4

• Archimedes' screw turbine 1 < H < 10
• Kaplan 2 < H < 40
• Francis 10 < H < 350
• Pelton 50 < H < 1300
• Turgo 50 < H < 250
Specific speed
The specific speed ns of a turbine characterize the turbine's shape in a way that is not
related to its size. This allows a new turbine design to be scaled from an existing
design of known performance. The specific speed is also the main criteria for matching
a specific hydro site with the correct turbine type.

Page 64
The specific speed is the speed with which the turbine turns for a particular discharge
Q, with unit head and thereby is able to produce unit power.

Affinity laws
Affinity Laws allow the output of a turbine to be predicted based on model tests. A
miniature replica of a proposed design, about one foot (0.3 m) in diameter, can be
tested and the laboratory measurements applied to the final application with high
confidence. Affinity laws are derived by requiring
similitude between the test model and the application. Flow through the turbine is
controlled either by a large valve or by wicket gates arranged around the outside of the
turbine runner. Differential head and flow can be plotted for a number of different
values of gate opening, producing a hill diagram used to show the efficiency of the
turbine at varying conditions.
Runaway speed
The runaway speed of a water turbine is its speed at full flow, and no shaft load. The
turbine will be designed to survive the mechanical forces of this speed. The
manufacturer will supply the runaway speed rating.

VARIOUS MANUFACTURING PROCESSES

Milling: Introduction

Milling is as fundamental as drilling among powered metal cutting processes.

Milling is versatile for a basic machining process, but because the milling set up has so
many degrees of freedom, milling is usually less accurate than turning or grinding
unless especially rigid fixturing is implemented.

For manual machining, milling is essential to fabricate any object that is not axially
symmetric. There is a wide range of different milling machines, ranging from manual
light-duty Bridgeports™ to huge CNC machines for milling parts hundreds of feet long.
Below is illustrated the process at the cutting area.

Page 65
 Milling: Column-and-Knee Manual Mill

Below is illustrated a typical column-and-knee type manual mill. Such manual mills
are common in job shops that specialize in parts that are low volume and quickly
fabricated. Such job shops are often termed "model shops" because of the prototyping
nature of the work.

The parts of the manual mill are separated below. The knee moves up and down the
column on guideways in the column. The table can move in x and y on the knee, and
the milling head can move up and down.

Page 66
 Grinding: Introduction

Grinding is a finishing process used to improve surface finish, abrade hard materials,
and tighten the tolerance on flat and cylindrical surfaces by removing a small amount
of material. Information in this section is organized according to the subcategory links
in the menu bar to the left.

In grinding, an abrasive material rubs against the metal part and removes tiny pieces
of material. The abrasive material is typically on the surface of a wheel or belt and
abrades material in a way similar to sanding. On a microscopic scale, the chip
formation in grinding is the same as that found in other machining processes. The
abrasive action of grinding generates excessive heat so that flooding of the cutting area
with fluid is necessary.

Reasons for Grinding

Reasons for grinding are:

• The material is too hard to be machined economically. (The material may

have been hardened in order to produce a low-wear finish, such as that in a
bearing raceway.)

• Tolerances required preclude machining. Grinding can produce flatness

tolerances of less than ±0.0025 mm (±0.0001 in) on a 127 x 127 mm (5 x 5 in)
steel surface if the surface is adequately supported.

• Machining removes excessive material.

Drilling: Introduction

Drilling is easily the most common machining process. One estimate is that 75% of all
metal-cutting material removed comes from drilling operations.

Page 67
Drilling involves the creation of holes that are right circular cylinders. This is
accomplished most typically by using a twist drill, something most readers will have
seen before. The figure below illustrates a cross section of a hole being cut by a
common twist drill:

The chips must exit through the flutes to the outside of the tool. As can be seen in the
figure, the cutting front is embedded within the workpiece, making cooling difficult.
The cutting area can be flooded, coolant spray mist can be applied, or coolant can be
delivered through the drill bit shaft. For an overview of the chip-formation process,
see the Chip Formation Section.

Selection of Drilling Machines

Normal pillar drilling machines (Drill Press) are specified basically by the size of hole
the machine can drill in Mild Steel i.e. a 16mm machine can drill holes up to and
including 16mm dia in mild steel. The speed range of a drilling machine is related to
the size e.g. machines for small holes down to 1mm can have speed ranges up to
8000rpm. Larger drilling machines more suited for drilling holes. up to 25mm will
have a more limited range. A machine which is used to drill larger holes ( >15mm) is
not generally suitable for drilling small diameter holes (< 1 mm). Smaller machines are
provided with permanent chucks whilst larger machines generally include Morse
tapers for fixing the drills.

Most pillar drills are manually fed using a rotating lever driving the vertical motion of
the spindle. Larger machines can have power drives feeds.

Page 68
A belt driven spindle is often a convenient low-cost option but there is a tendency in
modern times to use geared /inverter drives.

When drilling holes in a material a number of factors should be considered including

Material being drilled

• Hole size
• Hole quality.
• Speed /Feed required
• Depth of hole
• Through or Blind Hole
• Need for coolant
• Capacity of drilling machine
• Method of work holding. Hand held, vice, clamped
• Orientation of drill (horizontal, vertical drilling, angle
• Swarf control
Shaping Machine Tools

Introduction

The shaping process was used in the early days of machine tools. Shaping machines
are not widely used now. Shaping produces flat surfaces by moving a single point
cutting tool in a reciprocating motion. The forward stroke is the cutting stroke the
backward movement is completed at a faster velocity and includes the sideways feed
motion.

The shaping machine is a versatile machine able to produce flat surfaces, grooves, T-
Slots, dovetails, and may be used to produce curved surfaces.

The size of components that may be machined is normally limited by the length of the
stroke of the shaping machine which can vary up to a maximum of about 1500mm.
(750mm is normally the maximum stroke. The shaping machine is not generally used
as a production tool because of its slow cutting speed and the unproductive return
stroke.

Page 69
 SHAPING MACHINE

Turing process

Turning process produces solids of revolution which can be adjusted because of the
specialized nature of the operation. This machining is done on a machine called a
lathe in which the tool is stationary and the part is rotated. When turning, a
cylindrical piece of material, made of wood, metal, etc. is rotated. The cutting tool
moves along two axes of motion, thereby producing precise depths and diameters.
Turning is done either on the inside of the cylinder or outside to produce tubular
components to various measurements.

Page 70
 STEAM TURBINE MFG. DIVISION

A steam turbine is a mechanical device that extracts thermal energy from

pressurized steam, and converts it into rotary motion. Its modern manifestation was
invented by Sir Charles Parsons in 1884. It has almost completely replaced
the reciprocating piston steam engine (invented by Thomas Newcomen and greatly
improved by James Watt) primarily because of its greater thermal efficiency and
higher power-to-weight ratio. Because the turbine generates rotary motion, it is
particularly suited to be used to drive an electrical generator – about 80% of all
electricity generation in the world is by use of steam turbines. The steam turbine is a
form of heat engine that derives much of its improvement in thermodynamic
efficiency through the use of multiple stages in the expansion of the steam, which
results in a closer approach to the ideal reversible process.

History
The first device that may be classified as a reaction steam turbine was little more than
a toy, the classic Aeolipile, described in the 1st century by Hero of
Alexandria in Roman Egypt. A thousand years later, the first impact steam turbine
with practical applications was invented in 1551 by Taqi al-Din in Ottoman Egypt, who
described it as a prime mover for rotating a spit. Similar smoke jacks were later
described by John Wilkins in 1648 and Samuel Pepys in 1660. Another steam turbine
device was created by Italian Giovanni Branca in 1629.

The modern steam turbine was invented in 1884 by the Englishman Sir Charles
Parsons, whose first model was connected to a dynamo that generated 7.5 kW of
electricity. Parson's steam turbine, making cheap and plentiful electricity possible and
revolutionising marine transport and naval warfare, the world would never be the
same again.. His patent was licensed and the turbine scaled-up shortly after by an
American, George Westinghouse. A number of other variations of turbines have been
developed that work effectively with steam. The de Laval turbine (invented by Gustaf
de Laval) accelerated the steam to full speed before running it against a turbine blade.
This was good, because the turbine is simpler, less expensive and does not need to be
pressure-proof. It can operate with any pressure of steam. It is also, however,
considerably less efficient. The Parson's turbine also turned out to be relatively easy to
scale-up. Parsons had the satisfaction of seeing his invention adopted for all major
world power stations. The size of his generators had increased from his first 7.5 kW set
up to units of 50,000 kW capacity. He knew that the total output from turbo-
generators constructed by his firm C._A._Parsons_and_Company and by their
licensees, for land purposes alone, had exceeded thirty million horse-power.. Within
Parson's lifetime the generating capacity of a unit was scaled-up by about 10,000 times.

Page 71
Types
Steam turbines are made in a variety of sizes ranging from small 1 hp (0.75 kW) units
(rare) used as mechanical drives for pumps, compressors and other shaft driven
equipment, to 2,000,000 hp (1,500,000 kW) turbines used to generate electricity.
There are several classifications for modern steam turbines.

Steam Supply and Exhaust Conditions

These types include condensing, noncondensing, reheat, extraction and induction.

Noncondensing or backpressure turbines are most widely used for process steam
applications. The exhaust pressure is controlled by a regulating valve to suit the needs
of the process steam pressure. These are commonly found at refineries, district heating
units, pulp and paper plants, and desalination facilities where large amounts of low
pressure process steam are available.

Condensing turbines are most commonly found in electrical power plants. These
turbines exhaust steam in a partially condensed state, typically of a quality near 90%,
at a pressure well below atmospheric to a condenser.

Reheat turbines are also used almost exclusively in electrical power plants. In a reheat
turbine, steam flow exits from a high pressure section of the turbine and is returned to
the boiler where additional superheat is added. The steam then goes back into an
intermediate pressure section of the turbine and continues its expansion.

Extracting type turbines are common in all applications. In an extracting type turbine,
steam is released from various stages of the turbine, and used for industrial process

Page 72
needs or sent to boiler feedwater heaters to improve overall cycle efficiency. Extraction
flows may be controlled with a valve, or left uncontrolled.

Induction turbines introduce low pressure steam at an intermediate stage to produce

additional power.

Casing or Shaft Arrangements

These arrangements include single casing, tandem compound and cross compound
turbines. Single casing units are the most basic style where a single casing and shaft
are coupled to a generator. Tandem compound are used where two or more casings
are directly coupled together to drive a single generator. A cross compound turbine
arrangement features two or more shafts not in line driving two or more generators
that often operate at different speeds. A cross compound turbine is typically used for
many large applications.

Turbine Efficiency

Schematic diagram outlining the difference between an impulse and a reaction

turbine

To maximize turbine efficiency, the steam is expanded, generating work, in a number

of stages. These stages are characterized by how the energy is extracted from them and
are known as impulse or reaction turbines. Most modern steam turbines are a
combination of the reaction and impulse design. Typically, higher pressure sections
are impulse type and lower pressure stages are reaction type.

Page 73
Impulse Turbines
An impulse turbine has fixed nozzles that orient the steam flow into high speed jets.
These jets contain significant kinetic energy, which the rotor blades, shaped like
buckets, convert into shaft rotation as the steam jet changes direction. A pressure
drop occurs across only the stationary blades, with a net increase in steam velocity
across the stage.

As the steam flows through the nozzle its pressure falls from steam chest pressure to
condenser pressure (or atmosphere pressure). Due to this relatively higher ratio of
expansion of steam in the nozzle the steam leaves the nozzle with a very high velocity.
The steam leaving the moving blades is a large portion of the maximum velocity of the
steam when leaving the nozzle. The loss of energy due to this higher exit velocity is
commonly called the "carry over velocity" or "leaving loss".

Reaction Turbines
In the reaction turbine, the rotor blades themselves are arranged to form convergent
nozzles. This type of turbine makes use of the reaction force produced as the steam
accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor
by the fixed vanes of the stator. It leaves the stator as a jet that fills the entire
circumference of the rotor. The steam then changes direction and increases its speed
relative to the speed of the blades. A pressure drop occurs across both the stator and
the rotor, with steam accelerating through the stator and decelerating through the
rotor, with no net change in steam velocity across the stage but with a decrease in
both pressure and temperature, reflecting the work performed in the driving of the
rotor.

Page 74
 Steam Turbine description: Construction, STEAM
FLOW
The Turbine is a tandem compound machine with separate HP, OP and LP sections.
The HP section being a single flow cylinder and IP and LP sections double flow
cylinders. The Turbine Rotors and the generator rotors are connected by rigid
couplings.

The HP turbine is throttle controlled. The Initial steam is admitted ahead of the
blading via 2 main stop and control valve combinations. A swing check valve is
installed in the line leading from HP turbine exhaust to the reheater to prevent hot
steam from reheater flowing back into HP turbine.

The Steam coming from reheater is passed to the IP turbine via 2 reheat stop and
control valve combinations. Cross around pipes connect IP and LP cylinders.
Connections are provided at several points of the turbine for feedwater extraction
purposes.

HP TURBINE, BARREL TYPE CASING

The outer casing of the HP turbine is of the barrel type and has neither an axial nor
radial flange. This prevents mass concentration which would have caused high
thermal stresses. The Inner Casing is axially split and supported so as to be free to
move in response of thermal expansion. The Barrel Type casing permits flexibility of
operation in the form of short start-up times and a high rate of change of load even at
initial steam conditions.

IP TURBINE
The IP turbine section is of single construction with horizontal split casings. The inner
casing carries the stationary blading. The Reheated steam enters the inner casing from
top and bottom. The provision of an Inner Casing confines high steam inlet conditions
to the admission section of this casing.

LP TURBINE
The Casing of double-flow LP cylinder is of three shell design. The shells are
horizontally split and are of rigid welded construction. The innermost shell, which
carries the first rows of stationary blades, is supported so as to allow thermal
expansion within the intermediate shell. Guide blade carriers, carrying the stationary
blade rows are also attached to the intermediate shell.

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BEARINGS
The HP rotor is supported on two bearings, a journal bearing at its front end, and a
combined journal and thrust bearing immediately next to the coupling to the IP rotor.
The IP and LP rotors have a journal b earing each at rear end. The combined journal
and thrust bearing incorporate a journal and a thrust bearing which takes up residual
thrust from both directions.

The Bearing pedestals are anchored to the foundation by means of anchor bolts and
are fixed by position,

The HP and IP turbines rest with their lateral support horns on the bearing pedestals
at the turbine centreline level.

The Axial position of HP and IP casings is fixed at the support brackets on HP-IP
bearing pedestals.

The Following components forms the fixed points for the turbine:

1.The HP, IP and LP turbine bearing pedestals

2.The horn supports of the HP and IP turbine at HP-IP Pedestals

3.At the middle of longitudinal girder of the LP Turbine

4.The Thrust Bearing in the HP turbine rear bearing pedestals

CASING EXPANSION
Centring of LP outer casing is provided by guides which run in recesses in the
foundation cross beam. Axial movement of casings is unrestrained.

Hence, when there is temperature rise, the outer casing of the HP turbine expand
from their from their fixed points towards front pedestals. Casing of IP Turbine
expand from its fixed point towards the generator.

LP Casing expands from its fixed point at front end, towards the generator.

ROTOR EXPANSION
The HP turbine rotor expands from the thrust bearing towards the front bearing
pedestal of the HP turbine and the Ip turbine Rotor from the thrust bearing towards
the generator.

The LP turbine rotor is displaced towards the generator by the expansion of the shaft
assembly, originating from the thrust bearing.

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DIFFERENTIAL EXPANSION
Differential expansion between rotors and casings results from the difference between
the expansion of rotor and casing originating from the HP-IP pedestal.

Differential expansion between rotor and casing of the IP turbine results from the
difference between the expansion of the shaft assembly, originating from thrust
bearing and casing expansion, which originates from the fixed points on the LP
turbine longitudinal beams.

SHAFT SEAL and BLADE TIP SEALING

All shaft seals, which seal the steam in the casing against atmosphere, are axial-flow
type. They consist of a large number of thin seal strips which, in the HP and Ip
turbines are caulked alternately into grooves in the shafts and the surrounding seal
rings.

VALVES
The HP turbine is fitted with2 main stop and control valves. The main stop valves are
spring action single seated valves, the control valves, also of single seat design; the
control valves; also, of single-seat design, have diffusers to reduce pressure losses.

The Ip turbine has 2 reheat stop and control valves. The reheat stop valves are spring
action single stop valves. The control valves; also, spring loaded, have diffusers.

The reheat stop and control valves are supported free to move in response tto thermal
expansion on the foundation cover plate below the operating floor and in front of the
turbine generator unit.

TURBINE CONTROL SYSTEM

The Turbine has an electrohydraulic control system. An electric system measures
speed and output and controls them by controlling the control valve hydraulically via
an electrohydraulic converter.

The linear power frequency droop characteristic can be adjusted in fine steps even
when the turbine is running

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TURBINE MONITORING SYSTEM
In addition to measuring and display instruments for pressure, temperatures, valve
lifts and speed, the monitoring system also includes following parameters :

1.Rotor expansion measured at the rear bearing pedestal of LP turbine.

2.Axial Shift measured at the HP-IP pedestal

3.Bearing pedestal vibration

4.Shaft vibration measured at all turbine bearings.

OIL SUPPLY SYSTEM

A common oil supply system lubricates and cools the bearings. The main oil pump is
driven by the turbine shaft and draws oil from the main oil tank. Auxiliary oil pumps
maintain the oil supply on start-up and shutdown, during turning gear operation and
when the main oil supply is faulted.

A jack oil pump forces high pressure oil under the shaft journals to prevent boundary
lubrication during turning gear operation. The Lubricating and cooling oil is passed
through oil coolers before entering the bearings.

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Working Of STEAM TURBINE:
Introduction
A steam turbine is a mechanical device that converts thermal energy in pressurised
steam into useful mechanical work. The original steam engine which largely powered
the industrial revolution in the UK was based on reciprocating pistons. This has now
been almost totally replaced by the steam turbine because the steam turbine has a
higher thermodynamic efficiency and a lower power-to-weight ratio and the steam
turbine is ideal for the very large power configurations used in power stations. The
steam turbine derives much of its better thermodynamic efficiency because of the use
of multiple stages in the expansion of the steam. This results in a closer approach to
the ideal reversible process.

Steam turbines are made in a variety of sizes ranging from small 0.75 kW units used as
mechanical drives for pumps, compressors and other shaft driven equipment, to
1,500,000kW turbines used to generate electricity. Steam turbines are widely used for
marine applications for vessel propulsion systems. In recent times gas turbines, as
developed for aerospace applications, are being used more and more in the field of
power generation once dominated by steam turbines.

Steam Turbine Principle

The steam energy is converted mechanical work by expansion through the turbine.
Th expansion takes place through a series of fixed blades (nozzles) and moving blades
each row of fixed blades and moving blades is called a stage. The moving blades
rotate on the central turbine rotor and the fixed blades are concentrically arranged
within the circular turbine casing which is substantially designed to withstand the
steam pressure.

On large output turbines the duty too large for one turbine and a number of turbine
casing/rotor units are combined to achieve the duty. These are generally arranged on
a common centre line (tandem mounted) but parallel systems can be used called cross
compound systems.

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Impulse Blading
The impulse blading principle is that the steam is directed at the blades and the
impact of the steam on the blades drives them round. The day to day example of this
principle is the Pelton wheel Turbines.

In this type of turbine, the whole of the stage pressure drop takes place in the fixed
blade (nozzle) and the steam jet acts on the moving blade by impinging on the blades.

Blades of an impulse turbine

Velocity diagram impulse turbine stage

z represents the blade speed, V r represents the relative velocity, V wa & V wb- represents
the tangential component of the absolute steam in and steam out velocities

The power developed per stage = Tangential force on blade x blade

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Reaction Blading
The reaction blading principle depends on the blade diverting the steam flow and
gaining kinetic energy by the reaction. The Catherine wheel (firework) is an example
of this principle. For this turbine principle the steam pressure drop is divide between
the fixed and moving blades.

Velocity diagram reaction turbine stage

z represents the blade speed , V r represents the relative velocity, V wa & V wb-
represents the tangential component of the absolute steam in and steam out
velocities

The power developed per stage = Tangential force on blade x blade speed.

Power /stage= (V w a - V wb).z/1000 kW per kg/s of steam

The blade speed z is limited by the mechanical design and material constraints of the
blades.

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Rankine Cycle
The Rankine cycle is a steam cycle for a steam plant operating under the best
theoretical conditions for most efficient operation. This is an ideal imaginary cycle
against which all other real steam working cycles can be compared.

The theoretic cycle can be considered with reference to the figure below. There will
no losses of energy by radiation, leakage of steam, or frictional losses in the
mechanical components. The condenser cooling will condense the steam to water
with only sensible heat (saturated water). The feed pump will add no energy to the
water. The chimney gases would be at the same pressure as the atmosphere.

Within the turbine the work done would be equal to the energy entering the turbine
as steam (h1) minus the energy leaving the turbine as steam after perfect expansion
(h2) this being isentropic (reversible adiabatic) i.e. (h1- h2). The energy supplied by
the steam by heat transfer from the combustion and flue gases in the furnace to the
water and steam in the boiler will be the difference in the enthalpy of the steam
leaving the boiler and the water entering the boiler = (h1 - h3).

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 Basic Rankine Cycle
The ratio output work / Input by heat transfer is the thermal efficiency of the Rankine
cycle.

Although the theoretical best efficiency for any cycle is the Carnot Cycle the Rankine
cycle provides a more practical ideal cycle for the comparison of steam power cycles (
and similar cycles ). The efficiencies of working steam plant are determined by use of
the Rankine cycle by use of the relative efficiency or efficiency ratio as below:

The various energy streams flowing in a simple steam turbine system as indicated in
the diagram below. It is clear that the working fluid is in a closed circuit apart from
the free surface of the hot well. Every time the working fluid flows at a uniform rate
around the circuit it experiences a series of processes making up a thermodynamic
cycle.

The complete plant is enclosed in an outer boundary and the working fluid crosses
inner boundaries (control surfaces).. The inner boundaries defines a flow process.

The various identifiers represent the various energy flows per unit mass flowing along
the steady-flow streams and crossing the boundaries. This allows energy equations to
be developed for the individual units and the whole plant...

When the turbine system is operating under steady state conditions the law of
conservation of energy dictates that the energy per unit mass of working agent **
entering any system boundary must be equal to the rate of energy leaving the system
boundary.

**It is acceptable to consider rates per unit mass or unit time whichever is most
convenient

Steam Cycle
on Temp-
Enthalpy
Diagram

Page 83
Steady Flow Energy Equations

Boiler

The energy streams entering and leaving the boiler unit are as follows:

F + A + h d = h 1 + G + hl b hence F + A = G + h 1 - h d + hl b

Turbine

The energy streams entering and leaving the boiler unit are as follows:

h 1 = T + h 2 + hl t hence 0 = T - h 1 + h 2 + hl t

Condenser Unit

The energy streams entering and leaving the boiler unit are as follows:

W i + h 2 = W o + h w + hl c hence W i = W o + h w - h 2 + hl c

Feed Water System

The energy streams entering and leaving the Feed Water System are as follows:

h w + d e + d f= h d + hl f hence d e + d f = - h w + h d + hl

The four equations on the right can be arranged to give the energy equation for the whole
turbine system enclosed by the outer boundary

That is ..per unit mass the of working agent (water) the energy of the fuel (F) is equal to the
sum of

- the mechanical energy available from the turbine less that used to drive the pumps
(T - (d e+ d f)

- the energy leaving the exhaust [G - A] using the air temperature as the datum.

- the energy gained by the water circulating through the condenser [W o - W i]

- the energy gained by the atmosphere surrounding the plant Σ hl

The overall thermal efficiency of a steam turbine plant can be represented by the
ratio of the net mechanical energy available to the energy within the fuel supplied.
as indicated in the expressions below...

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Turbine Vapour Cycle on T-h Diagram

This cycle shows the stages of operation in a turbine plant. The enthalpy reduction
in the turbine is represented by A -> B . The reversible process for an ideal isentropic
(reversible adiabatic) is represented by A->B'. This enthalpy loss would be (h g1 - h 2 )
in the reversible case this would be (h g1 - h 2s ).

The heat loss by heat transfer in the condenser is shown as B->C and results in a
loss of enthalpy of (h 2- h f2) or in the idealised reversible process it is shown by B'->
C with a loss of enthalpy of (h 2s- h f2).

The work done on the water in extracting it from the condenser and feeding it to the
boiler during adiabatic compression C-> D is (h d - h f2 ) = length M

The energy added to the working agent by heat transfer across the heat transfer
surfaces in the boiler is (h g1 - h d ) which is approx.( h g1 - h f2 )

The Rankine efficiency of the Rankine Cycle AB'CDEA is

The efficiency of the Real Cycle is

Page 85
Following were Some of the machines used for the manufacturing
of the steam turbine parts

Craven Lathe machine

No .20/A/30

Speed: .5-51 rpm

Distance from the centre: 7620 mm

Maximum swing over 1676 mm

Head stock Face Plate diameter: 1524 mm

Face Plate gripping Capacity: 203-1270mm

Load :90 tons

Horizontal Boring Machine:

No. 20/A/2111

Spindle diameter: 127mm

Fending head:1524 mm

Width of table =1524 mm

Maximum diameter of boring bar = 158.80 mm

Feeds=129- 38 mm

Morando Boring Machine:

No: 20/A/2012

Speed :1.5- 200 rpm

Feed: .5-2000 mm/min

Centre Height: 770 mm

Distance between centres :6000 mm

On Swing Bed: 1520 mm

Max Weight on Centre= 30 Tons

Max Weight on face plate= 60 Tons

Page 86
Richard Vertical Boring and Turning Machine:

No : 20/A/11

Speed : .48- 13 rpm

Feed: .501 – 102.51 mm/min

Dia: 4877 mm

Max Turning Diameter: 4955 mm

Page 87
 MACHINING SHOP
➢ HYDRAULIC PRESS MACHINE
• The hydraulic press is a kind of machine which uses the liquid as a working
medium to transfer energy based on PASCAL’s principle to realize various
technique.
• Hydraulic press machine (also known as hydraulic oil press) is a machine that
makes use of the static pressure of the liquid to process metal, plastic, rubber,
wood, powder products.
• It is often used in pressing and pressing forming processes, such as forging
press, stamping, cold extrusion, straightening, bending, flanging,
sheet drawing, powder metallurgy, pressing, etc

Types of Hydraulic Press

Machine
According to the structural form, the hydraulic press machine is mainly divided into:
• Four-column hydraulic press
• Single column hydraulic press (C type)
• Horizontal hydraulic press
• Vertical frame hydraulic press
• Universal hydraulic press

If classified by tonnage, the hydraulic press can be divided into:

Page 88
 • 63T hydraulic press machine
• 100T hydraulic press machine
• 150T hydraulic press machine
• 200T hydraulic press machine
• 250T hydraulic press machine
• 300T hydraulic press machine
• 315T hydraulic press machine
• 500T hydraulic press machine
• 630T hydraulic press machine
• 800T hydraulic press machine
According to the applications, it is mainly divided into metal forming, bending, stretching,
punching, powder (metal, non-metal) forming, pressing, extrusion and so on.

Page 89
Page 90
Page 91
 CONCLUSION

The Vocational training at BHEL Bhopal helped me in

improving my practical knowledge and understanding of
Hydro turbine, its manufacturing and types to a large extent.
Here I came to know about the technology and material used
in manufacturing of hydro turbine and steam turbine. Besides
this, I also visualized the parts involved and equipment that
were used during the manufacturing process of these turbines
and the mechanical machines used in machining shop. In all it
was a truly learning experience for me. As a mechanical
engineering student, I hope that the training I got here would
help me in coming future. I hereby thank all the authorities
at BHEL for their kind cooperation and guidance.

Page 92
REFERENCES:
• www.wikipedia.org
• www.electrical4u.com
• www.bhelbhopal.co.in
• Daily Report Diary.
• Text book on fluid machinery by R.K. Bansal

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