BHARAT HEAVY

ELECTRICALS
LIMITED,
HARIDWAR

Industrial Training
on NEW Presentation By:-
TURBINE SHOP ANIL KUMAR GUPTA
1202940031
Overview of BHEL
 BHEL was established in 1964.
 BHEL is one of the only 7 Public Sector Undertakings (PSUs) of India
clubbed under the esteemed 'Maharatna' status . On 1st February 2013,
the Government of India granted Maharatna status to BHEL.
 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), Renewable Energy, 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
 Electro-static Precipitator
sR & D products
 BHEL HARIDWAR Unit
 BHEL or the Bharat Heavy Engineering Limited 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

BLOCK 3
TURBINE SHOP
BAY 1 BAY 2 BAY 3
HEAVY MACHINE BEARING SECTION BLADE SHOP
SHOP(HMS)
ASSEMBLY SECTION TURNING SECTION TURNING SECTION
ASSEMBLY SECTION HEAT TREATMENT
SHOP
GOVERNING SECTION
 STEAM TURBINE
A steam turbine works on the principle
of conversion of High pressure & temperature steam into
high Kinetic energy , thereby giving torque to a moving
rotor.
Types of steam turbine

1.High pressure turbine (H.P. Turbine)

2.Intermediate pressure turbine (I.P. Turbine)
3.Low pressure turbine (L.P. Turbine)
High pressure turbine (H.P. 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
HIGH PRESSURE TURBINE
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 lass than the high pressure turbine(H.P) .
Its blade is larger than high pressure turbine.
IP 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.
LP TURBINE
Low Pressure Turbine
Low Pressure Turbine blade
Titanium alloys offer high strength to intermediate
temperatures at a density almost half that of steel and
nickel-based super alloys. As a result, they have been
adopted widely in the fan and compressor stages of the
gas turbine for both disc and blade applications..
LP blade is larger than HP & IP. 
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
Tacchi heavy duty CNC lathe:
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.
CASING SHELL OR
CYLINDER
Casing Materials
ASTM A 356 Grade 1 for
cast carbon steel
 Nodular Cast Iron G40
The reason is that cast
carbon steel is weld
repairable(LP turbine
inner casing rings,)
1-2 Cr Mo steels –low
temperature steam
Cast 9 Cr 1 –Mo- V –Nb
alloys
9-12-cr Martensite /ferrite
steel
Casing
Lower half Upper half
 BLADE SHOP
Various operations consist in manufacturing of blades of
steam turbine.
 Check the raw material(Stainless Steel / Titanium Alloy)
 Blanking-by blank saw m/c
 MILLING- width and thickness are maintained
 Mill Rhomboid –Rhomboid shape is provided by Duplex
milling machine
 Blanking of Rhomboid shape
 Rhomboid grinding-by CH-BACH M/c

 Right angle-by Horizontal milling m/c

 External profiling-by Hydraulic coping m/c or CNC

Coping m/c
• Internal profiling
Hydraulic coping m/c or CNC Coping m/c
Template (checking for external profile)
T-ROOT PROFILE OF BLADE
T –ROOT profiling is done by NC M/c at various station
STATION 1- Clamping the w/p on NC m/c .

STATION 2- Rough Tapering

STATION 3- T-ROOT Cutting, Chamfering

STATION 4- Stepping

STATION 5- Smoothing o/p(final milling).

 RUSSIAN DESIGN
BLADE
 CONCLUSION
Summer Training gives the idea of ‘general awareness in steam
turbine manufacturing’, & its process. Its provides practical
idea to manufacturing several components of turbine.