An Industrial Training Presentation on

General Awareness in steam

Turbine Manufacturing

Presented by:
Presented to:
Sakshyam Rai
Mr. Nilesh Sonawane
1403040093
Faculty in charge
Contents:

 Introduction to BHEL, overview and product range

 BHEL Haridwar
 Steam turbines- components and types
 Manufacturing of components- operations
 Few Heavy Duty Machines
 Conclusion
BHARAT HEAVY
ELECTRICALS
LIMITED
Overview of BHEL
BHEL was established in 1964.

BHEL is one of the only 7 PSUs of India clubbed under the

esteemed 'Maharatna' status. (1st February 2013).

BHEL is engaged in the design, engineering, manufacture,

construction, testing, commissioning and servicing of a wide
range of products and services for the core sectors of the
economy, viz. Power, Transmission, Industry, Transportation
(Railway), Oil & Gas and defence.

BHEL has 15 manufacturing divisions, two repair units, four

regional offices, eight service centers and 15 regional centers
Main Manufacturing Units
1. BHEL Bhopal (Madhya Pradesh )
2. BHEL Ramachandrapuram, Hyderabad (Andhra Pradesh)
3. Transformer Plant, BHEL Jhansi(Uttar Pradesh)
4. High Pressure Boiler Plant and Seamless Steel Tube Plant,
Tiruchirapalli(Tamil Nadu)
5. Boiler Auxiliaries Plant, Ranipet (Tamil Nadu)
6. ElectronicsDivision and Electro Porcelain
Division, Bangalore(Karnataka
7. Jagdishpur (Uttar Pradesh)
8. Rudrapur (Uttrakhand)
9. Industrial ValvesPlant, Goindwal (Punjab)
10. BHEL Ranipur, Haridwar (Uttarakhand)
11. Bharat Heavy Plates and Vessels Limited(Vizag)
 Product Range
 Boiler(stream generator)
 Gas Generator
 Hydro Generator
 Steam turbine
 Gas turbine
 Hydro turbine
 Transportation Equipments
 Traction Machines
 Transformer
 Switchgear
 Oil field equipments OFE
 Boiler drum
 Water wall panel
 Wind mill
 Valve
 BHEL HARIDWAR Unit
 BHEL is one of the largest engineering and manufacturing
organizations in the country and the BHEL, Haridwar is their
gift to UTTARAKHAND With two large manufacturing plants. It
has established a Heavy Electrical Equipment Plant or HEEP
and a Central Foundry Forge Plant or CFFP in Haridwar.
 The Heavy Electrical Equipment Plant in Haridwar designs and
manufactures turbo generators, AC and DC motors, STEAM
turbines, heat exchangers.
 The Central Foundry Forge Plant in Haridwar deals with steel
castings and manufacturing of steel forgings.
 The BHEL plants in Haridwar have earned the ISO - 9001 and
9002 certificates for its high quality and maintenance. These two
units have also earned the ISO - 14001 certificates.
 Situated in Ranipur near Haridwar, the Bharat Heavy Engineering
Limited employs over 8,000 people.
Heavy Electrical Equipment
Plant(HEEP)

1. BLOCK-1: Electrical Machine Shop

2. BLOCK-2: Heavy Fabrication Shop
3. BLOCK-3: Turbine Manufacturing Shop
4. BLOCK-4: CIM (Coils & Insulation Manuf.)
5. BLOCK-5: Condenser Fabrication & Forge Shop
6. BLOCK-6: Fabrication Shop & Die Shop
7. BLOCK-7: Carpentry & Heat Treatment Shop
8. BLOCK-8: Heat Exchanger Shop
Block-3: Turbine Manufacturing Shop
Steam Turbine

 Turbine is an engine that converts energy of fluid into mechanical

energy .
 Steam turbine depends completely upon the dynamic action of the
steam.
 Steam turbine is steam driven rotary engine.
Working Principle:
 A steam turbine is a device that extracts thermal energy
from pressurized steam and uses it to do mechanical work on
a rotating output shaft.
 An ideal steam turbine is considered to be an isentropic process,
in which the entropy of the steam entering the turbine is equal to
the entropy of the steam leaving the turbine.

E= KE+P+T

Total ∆E= ∆KE+ ∆H

Degree of Reaction= ∆H/(∆KE+ ∆H)

DOR = 0 : Impulse Turbine

= 1 : Reaction Turbine
Components of Steam Turbine
 Rotor
 Blades
 Casings
 Control valves
 Coupling
 Bearing steam ejector
 Gland
Types of steam turbine
 Impulse turbine
 Reaction turbine

And depending upon pressure:

• High pressure turbine (H.P. Turbine)

• Intermediate pressure turbine (I.P. Turbine)
• Low pressure turbine (L.P. Turbine)
Reaction and Impulse turbine

Impulse Turbine:-
• Steam is expanded only
in nozzles.
• Blade passage of
constant cross-section
area.
• Only velocity changes
across the blades.

Reaction Turbine:-
• Pressure drop in fixed &
moving blade.
• Blade passage of varying
cross-section
area.
Degree of Reaction= ∆H/(∆KE+ ∆H)
 High pressure turbine
High pressure and temperature fluid at the inlet of the turbine, exit as
lower pressure and temperature fluid.

Specification of HP
Turbine(500 MW):

Main Steam Temp- 537˚C

Main steam pressure- 170
kg/cm2
Reheat steam temp- 537˚C
Length of Rotor - 4.61m
Height -2.15m
Weight -86400kg
H.P turbine blades

 The blades are responsible for extracting energy from the high
temperature, high pressure steam produced by the boiler.
INTERMEDIATE PRESSURE
TURBINE

 Intermediate pressure turbine having more pressure then L.P

turbine and less than the high pressure turbine(H.P) . Its blade
is larger than high pressure turbine
Blade of intermediate pressure turbine

The size of blades of

I.P steam turbine is
larger than H.P steam
turbine , but smaller
than L.P steam turbine.
 Low Pressure Turbine
LP turbine is designed to be a dual flow turbine. Steam enters the centre of
the turbine from the crossover pipe and flows across the reaction blading in
two opposite directions. This configuration reduces axial thrust on the turbine
and allows for a smaller turbine installation.

Specification of LP Turbine(500 MW)

Main Steam Temp- 320˚C

Main steam pressure- 8 kg/cm2
Reheat steam temp- 320˚C
Length of Rotor - 8.71m
Height -10.7m
Weight-345000kg
Low Pressure Turbine blade
 LP blade is larger than HP & IP.
 BLADE SHOP
 As we understood that the efficiency and reliability of a steam
turbine depends on the proper design of blades, e.g. in
impulse turbine, the entire heats drop occurs in stationary
blades.

 Operations Performed On Blades:

Inspection
Cutting
Milling
Grinding on both the surface

Machining Of Blades:
Horizontal milling machine
Central lathe machine
CNC machine
Vertical boring machine
 Manufacturing of blade process
Processes followed:

 Raw material (Stainless Steel / Titanium Alloy) procurement

and inspection.
 Length cutting
 Blanking-by blank saw m/c
 Thickness MILLING and GRINDING
 Rhomboid MILLING and GRINDING- Rhomboid shape is provided
by Duplex milling machine
 Facing and size milling
 Root Milling (horizontal CNC)
 Root radius milling (vertical milling)
 Width milling
 Convex and concave milling
 Taper milling and grinding
 Fitting and polishing
FEW HEAVY DUTY
MACHINES
SINUMERIK CNC lathe

 Swing over
carriage:3500mm
 Centre distance :9000mm
 Weight capacity:120 T
 Spindle power:196KW
 External chucking
range:250-2000mm
 Max spindle rpm:200
 CNC system
840D:SINUMERIK
INNSE Horizontal CNC machine

 Boring spindle
diameter:160mm
 Headstock vertical
travel:3000mm
 Longitudinal RAM
travel:700mm
 Longitudinal spindle
travel:1000mm
 Column cross travel:10m
 Rotary table travel:3000mm
 Table load:40 T
 Skoda Vertical CNC lathe

 Finishing machining
casings including guide
blade grooves are
carried out in vertical
position on this lathe.
The machine is
provided with 840-C
CNC system.
 Conclusions:
Summer Training gives the idea of ‘general awareness in steam turbine
manufacturing’ & its processes. It provides practical idea of manufacturing
several components of turbine.

Also:
 BHEL is the largest engineering and manufacturing enterprise in India .
 The company manufactures 235 MW nuclear turbine generator sets and in
future it will 500 MW.
 BHEL is a major contributor of equipment and systems to industries.
Thank You
!