summer training report in bhel block 3 by DevendraKumar

1. SUMMERTRANINING
REPORT FILE
22 MAY 2015 – 5 JULY 2015
SUBMITED TO: SUBMITED BY:
SASHI SIR
DEVENDRA KUMAR
COORDINATOR
153862104646
III YEAR
ARYAVART INSTITUTE
OF

2. ACKNOWLEDGEMENT
I have gone through six week training at BHARAT HEAVY ELECTRICAL
LIMITED ,RANIPUR HARIDWAR UTTRAKHAND . FROM 22 may 2015 to
6 july 2015 . During this period I have learn many thing regarding heavy
electrical equipments and my branch MECHANICAL PRODUCTION Above
this I have learn many operational and control of some more field.
I am very grateful to ARYAVART INSTITUTE OF TECNOLOGY &
MANAGEMENT LUCKNOW for granting me permission and a level . I
would like to thanks Mr SANTOSH SINGH (Head Of Department) for giving
me such chance.
I also thankfulto whole staff of B.H.E.L HARIDWAR who helped us as
well as encouraged me through my work .I am thankful to Engineer ROHIT
AJMANI Sir and staff member of TMU BLOCK III (TUBINE
MANUFECTURING UNIT) and other for providing me an opportunityto
have practical exposure on steam turbine manufacturing.

3. ABSTRACT
In the era of Mechanical Engineering, Turbine, A Prime Mover ( Which
uses the Raw Energy of a substance and converts it to Mechanical Energy) is
a well known Machine most usefulin the the field of Power Generation. This
Mechanical energy is used in running an Electric Generator which is directly
coupled to the shaft of turbine. From this Electric Generator, we get electric
Power which can be transmitted over long distances by means of
transmission lines and transmission towers. In my Industrial Training in
B.H.E.L., Haridwar I go through all sections in Turbine Manufacturing.
First management team told me about the history of industry, Area,
Capacity, Machines installed & Facilities in the Industry. After that they told
about the Steam Turbine its types , parts like Blades, Casing, Rotor etc. Then
they told full explanation of constructionalfeatures and procedure along
with equipement used. Before telling about the machines used in
Manufacturing of Blade, they told about the safety precautions, Step by Step
arrangement of machines in the block with a well defined proper format.
They also told the material of blade for a particulardesire, types of Blades,
Operations performed on Blades, their New Blade Shop less with Advance
Technologylike CNC Shaping Machine.
I would like to express my deep sense of Gratitude and thanks to
Mr. ROHIT AJMANI our in charge of training in Turbine Block in B.H.E.L.,
Haridwar. Without the wise counsel and able guidance, it would have been
impossible to complete the report in this manner. Finally, I am indebted to
all who so ever have contributed in this report and friendly stay at Bharat
Heavy Electricals Limited (BHEL)

4. INTRODUCTION
BHEL is the largest engineering and manufacturing enterprise in India
in the energy related infrastructure sectortoday. BHEL was established more
than 40 years ago when its first plant was setup in Bhopal ushering in the
indigenous Heavy Electrical Equipment Industryin India a dream which has
been more than realized with a well recognized track record of performance
it has been earning profits continuously since1971-72.
BHEL caters to core sectors of the Indian Economy viz., Power
Generation's & Transmission, Industry, Transportation, Telecommunication,
Renewable Energy, Defense, etc. The wide network of BHEL's 14
manufacturing division, four power Sectorregional centers, over 150 project
sites, eight service centers 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. BHEL has
already attained ISO 9000 certification for quality management, and ISO
14001certification for environment management. The company’s inherent
potential coupled with its strong performance make this one of the
“NAVRATNAS”,which is supported bythe government in their endeavor to
become future global players.

5. OVERVIEW
• Bharat Heavy Electricals Limited (B.H.E.L.) is the largest engineering and
manufacturing enterprise in India. BHEL caters to core sectors of the Indian
Economy viz., Power Generation's & Transmission, Industry, Transportation,
Telecommunication, Renewable Energy, Defense and many more.
• Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in
the area of Scientific, Technicaland Industrial Cooperation.
• BHEL has its setup spread all over India namely New Delhi, Gurgaon,
Haridwar, Rudrapur, Jhansi, Bhopal, Hyderabad, Jagdishpur, Tiruchirapalli,
Bangalore and many more.
• Over 65% of power generated in India comes from BHEL-supplied
equipment.Overallit has installed power equipment for over 90,000 MW.
• BHEL's Investment in R&D is amongst the largest in the corporate sectorin
India. Net Profit of the company in the year 2011-2012 was recorded as
6868crore having a high of 21.2% in comparison to last year.
• BHEL has already attained ISO 9000 certification for quality management,
and ISO 14001 certification for environment management.
• It is one of India's nine largest Public SectorUndertakings or PSUs, known
as the NAVRATNAS or 'The Nine Jewels’.
• The power plant equipment manufactured by BHEL is based on
contemporary technologycomparable to the best in the work

6. WORKING AREAS
POWER GENERATION
Power generation sector comprises thermal, gas, hydro and nuclear power
plant business as of 31.03.2001, BHEL supplied sets account for nearly 64737
MW or 65% of the total installed capacity of 99,146 MW in the country, as
against nil till 1969-70. BHEL has proven turnkey capabilities for executing
power projects from concept to commissioning, it possesses thetechnology
and capability to produce thermal sets with super critical parameters up to
1000 MW unit rating and gas turbine generator sets of up to 240 MW unit
rating. Co-generation and combined-cycle plants have been introduced to
achieve higher plant efficiencies. to make efficient use of the high-ash-
content coal available in India, BHEL supplies circulating fluidized bed
combustion boilers to both thermal and combined cycle power plants. The
company manufactures 235 MW nuclear turbine generator sets and has
commenced production of 500 MW nuclear turbine generator sets. Custom
made hydro sets of Francis, Pelton and Kaplan types for different head
discharge combination are also engineering and manufactured by BHEL. In
all, orders for more than 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 technologycomparable to
the best in the world and is also internationally competitive..

7. POWERTRANSMISSION& DISTRIBUTION
BHEL offer wide ranging products and systems for T & D applications.
Products manufactured include power transformers, instrument
transformers, dry type transformers, series and stunt reactor, capacitor
tanks, vacuum and SF circuit breakers gas insulated switch gears and
insulators. A strong engineering base enables the Company to undertake
turnkey delivery of electric substances up to 400 kV level series
compensation systems (for increasing power transfercapacity of
transmission lines and improving systemstability and voltage regulation),
shunt compensation systems (for power factor and voltage improvement)
and HVDC systems (for economic transfer of bulk power). BHEL has
indigenously developed the state-of-the-art controlled shunt reactor (for
reactive power management on long transmission lines). Presently a 400 kV
Facts (Flexible AC Transmission System) project under execution.

8. INDUSTRIES
BHEL is a major contributorof equipment and systems to industries.
Cement, sugar, fertilizer, refineries, petrochemicals, paper, oil and gas,
metallurgical and other process industries lines and improving system
stability and voltage regulation, shunt compensation systems (for power
factor and voltage improvement) and HVDC systems(foreconomic transfer
of bulk power) BHEL has indigenously developed the state-of-the-art
controlled shunt reactor (for reactive power management on long
transmission lines).Presentlya 400 kV FACTS (Flexible AC Transmission
System) projects is under execution. The range of system& equipment
supplied includes: captive power plants, co-generation plants DG power
plants, industrial steam turbines, industrial boilers and auxiliaries.
Water heat recovery boilers, gas turbines, heat exchangers and
pressure vessels, centrifugal compressors, electrical machines, pumps, valves,
seamless steel tubes, electrostatic precipitators, fabric filters, reactors,
fluidized bed combustion boilers, chemical recovery boilers and process
controls.
The Company is a major producerof large-size thrusterdevices. It
also supplies digital distributed controlsystems for process industries, and
control & instrumentation systems for power plant and industrial
applications. BHEL is the only company in India with the capabilityto make
simulators for power plants, defense and other applications. TheCompany
has commenced manufacture of large desalination plants to help augment
the supplyof drinking water to people

9. TRANSPORTATION
BHEL is involved in the development design, engineering, marketing,
production, installation, and maintenance and after-sales service of Rolling
Stockand traction propulsion systems. In the area of rolling stock, BHEL
manufactures electric locomotives up to 5000HP, diesel-electric locomotives
from 350 HP to 3100 HP, both for mainline and shunting duly applications.
BHEL is also producing rolling stockfor special applications viz., overhead
equipment cars, Specialwell wagons, Rail-cum-road vehicle etc., Besides
traction propulsion systems for in-house use, BHEL manufactures traction
propulsion systems for other rolling stockproducers of electric locomotives,
diesel-electric locomotives, electrical multiple units and metro cars. The
electric and diesel traction equipment on India Railways are largely powered
by electrical propulsion systems produced by BHEL. The company also
undertakes retooling and overhauling of rolling stock in the area of urban
transportation systems. BHEL is geared up to turnkey execution of electric
trolley bus systems, light rail systems etc. BHEL is also diversifying in the
area of port handing equipment and pipelines transportation system.
TELECOMMUNICATION
BHEL also caters to Telecommunication sectorby way of small, medium
and large switching system.

10. RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional
and renewable sources of energy include: wind electric generators, solar
photo voltaic systems, solar lanterns and battery-powered road vehicles. The
Company has taken up R&D efforts for development of multi-junction
amorphous silicon solar cells and fuel based systems.
INTERNATIONAL OPERATIONS
BHEL has, over the years, established its references in around 60 countries of
the world, ranging for the United States in the west to New Zealand in the
far east. These references encompass almost the entire product range of
BHEL, covering turnkey power projects of thermal, hydro and gas-based
types, substation projects, rehabilitation projects, besides a wide variety of
products, like transformers, insulators, switch gears, heat exchangers,
castings and forgings, valves, well-head equipment, centrifugalcompressors,
photo-voltaic equipment etc. apart from over 1110mw of boiler capacity
contributed in Malaysia, and execution of four prestigious power projects in
Oman, some of the other major successes achieved by the companyhave
been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt,
Bangladesh, Azerbaijan, Sri Lanka, Iraq etc.

11. TECHNOLOGY UPGRADATIONAND RESEARCH
& DEVELOPMENT
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 tocontemporary levels through continuous in house
efforts as well as through acquisition of new technologies from leading
engineering organizations of the world. TheCorporate R&D Division at
Hyderabad, spread over a 140 acre complex, leads BHEL's research efforts in
a number of areas of importance to BHEL's product range. Research and
product development centers at each of the manufacturing divisions play a
complementary role. BHEL's Investment in R&D is amongst the largest in
the corporate sectorin India. Products developed in-house during the last
five years contributed about 8.6% to the revenues in 2000- 2001. BHEL has
introduced, in the recent past, several state-of-the-art productsdeveloped
in-house: low-NOx oil / gas burners, circulating fluidized bed combustion
boilers, high-efficiencyPelton hydro turbines, petroleum depot automation
systems, 36kV gas-insulated sub-stations,etc. The Company has also
transferred a few technologies developed in-house to other Indian
companies for commercialization. Some of the on-going development &
demonstration projects include: Smart wall blowing systemfor cleaning
boiler soot deposits, and micro-controller based governor for diesel-electric
locomotives. The company is also engaged in research in futuristic areas,
such as application of superconducting materials in power generations and
industry, and fuel cells for distributed, environment-friendlypower
generation.

12. HUMAN RESOURCE DEVELOPMENT INSTITUTE
The most prized asset of BHEL is its employees. The Human Resource
Development Institute and other HRD centers of the Company help in not
only keeping their skills updated and finely honed but also in adding new
skills, whenever required .Continuous training and retraining, positive, a
positive work culture and participative style of management, have
engendered development of a committed and motivated workforce leading
to enhanced productivityand higher levels of quality.
HEALTH, SAFETY AND ENVIRONMENT
MANAGEMENT
BHEL, as an integral part of business performance and in its endeavor of
becoming a world-class organization and sharing the growing global concern
on issues related to Environment. OccupationalHealth and Safety, is
committed to protecting Environment in and around its own establishment,
and to providing safe and healthy working environment to all its employees.
For fulfilling these obligations, Corporate Policies have been formulated as.
ENVIRONMENTAL POLICY
• Compliance with applicable Environmental Legislation/Regulation.
• Continual Improvement in Environment Management Systems to protect
our natural environment and Control Pollution.
• Promotion of activities for conservation of resources by Environmental
Management.
• Enhancement of Environmental awareness amongst employees, customers
and suppliers.

13. OCCUPATIONAL HEALTH AND SAFETY POLICY
• Compliance with applicable Legislation and Regulations.
• Setting objectives and targets to eliminate/control/minimize risks due to
Occupationaland Safety Hazards.
• Appropriate structured training of employees on OccupationalHealth and
Safety (OH&S) aspects.
• Formulation and maintenance of OH&S Management programs for
continual improvement.
• Periodic review of OH&S Management System to ensure its continuing
suitability, adequacyand effectiveness.
• Communication of OH&S Policy to all employees and interested parties.
The major units of BHEL have already acquired ISO 14001 Environmental
Management System Certification, and other units are in advanced stages of
acquiring the same. Action plan has been prepared to acquire OHSAS 18001
OccupationalHealth and Safety Management System certification for all
BHEL units.
1. . In pursuit of these Policy requirements, BHEL will continuouslystrive
to improve work particles in the light of advances made in technology and
new understandings in OccupationalHealth, Safetyand Environmental
Science Participation in the "Global Compact" of the United Nations. The
"Global Compact" is a partnership between the United Nations, the business
community, international labor and NGOs. It provides a forum for them to
work togetherand improve corporate practices through co-operation rather
than confrontation. BHEL has joined the "Global Compact" of United
Nations and has committed to support it and the set of core values
enshrined in its nine principles.

14. PRINCIPLESOF THE "GLOBAL COMPACT"
• HUMAN RIGHTS
1. Business should support and respect the protection of internationally
proclaimed human rights and.
2. Make sure they are not complicit in human rights abuses.
• LABOUR STANDARDS
1. Business should uphold the freedom of association and the effective
recognition of the right to collective bargaining.
2. Eliminate discrimination.
3. The elimination of all form of forces and compulsory labour. 4. The
effective abolition of child labour.
5. Eliminate discrimination.
• ENVIRONMENT
1. Businesses should support a precautionaryapproach to environmental
challenges .
2. Undertake initiatives to promote greater environmental responsibility
and
3. Encourage the development and diffusion of environmentally friendly
technologies. By joining the "Global Compact", BHEL would get a unique
opportunityof networking with corporate and sharing experience relating to
social responsibility on global basis.

15. BHEL HARIDWAR
LOCATION
It is situated in the foot hills of Shivalik range in Haridwar. The main
administrative building is at a distance of about 8 km from Haridwar.
ADDRESS
Bharat Heavy Electrical Limited (BHEL) Ranipur, Haridwar PIN- 249403
AREA
BHEL Haridwar consists of two manufacturing units, namely Heavy
Electrical Equipment Plant (HEEP) and Central Foundry Forge Plant (CFFP),
having area HEEP area:- 8.45 sq km CFFParea:- 1.0 sq km
The Heavy Electricals Equipment Plant (HEEP) located in Haridwar, is one
of the major manufacturing plants of BHEL. The core business of HEEP
includes design and manufacture of large steam and gas turbines, turbo
generators, hydro turbines and generators, large AC/DC motors and so on.
Central Foundry Forge Plant (CFFP) is engaged in manufacture of Steel
Castings:Up to50 Tons per Piece Wt & Steel Forgings: Up to 55 Tons per
Piece Wt. 1.6.4.
UNITS
There are two units in BHEL Haridwar as followed:
1) Heavy Electrical Equipment Plant (HEEP)
2) Central Foundry Forge Plant (CFFP)

17. There are 8 Blocks in HEEP:
Blocks Work Performed In Block
I) Electrical Machine TurboGenerator, Generator Exciter
, Motor (AC and DC)
II) Fabrication Large Size Fabricated Assemblies or
Components
III) Turbines & Auxilary Auxilary Steam, Hydro Turbines,
Gas turbines, Turbine Blade, Special
Tooling.
IV) Feeder Winding of Turbo,Hydro
Generators, Insulation for AC & DC
Motors
V) Fabrication Winding of Turbo,Hydro
Generators, Insulation for AC & DC
Motors
VI) Fabrication Stamping & Die
Manufacturing
Fabricated Oil Tanks, Hollow Guide
Blades, Rings, Stator Frames and
Rotor Spindle, All Dies, Stamping
for Generators and Motor
VII) Wood Working Wooden Packing, Spacers
VIII) Heaters & Coolers LP heaters, Ejectors, Glands, Steam
and Oil Coolers, Oil Tank, Bearing
Covers

18. There are 3 Sections in CFFP:
Blocks Work Performed In Block
1. Foundry Casting of Turbine Rotor, Casing
and Francis Runner
2. Forging Forging of Small Rotor Parts
3. Machine Shop Turning, Boring, Parting off, Drilling
etc.
HEEP PRODUCT PROFILE
1. THERMAL SETS:
• Steam turbines and generators up to 500 MW capacityfor utility and
combined cycle applications
• Capability to manufacture up to 1000 MW unit cycle.
2. GAS TURBINES:
• Gas turbines for industryand utility application range 3 to 200 MW (ISO).
• Gas turbines based co-generation and combined cycle system.
3. HYDRO SETS:
• Custom– built conventional hydro turbine of Kaplan, Francis and Pelton
with matching generators up to 250 MW unit size.
• Pump turbines with matching motor-generators.
• Mini / micro hydro sets.
• Spherical butterflyand rotary valves and auxiliaries for hydro station.

19. 4. EQUIPMENT FOR NUCLEAR POWER PLANTS:
• Turbines and generators up to 500MW unit size.
• Steamgenerator up to 500MW unit size.
• Re-heaters / Separators.
• Heat exchangers and pressure vessels.
5. ELECTRICAL MACHINES:
• DC general purpose and rolling mill machines from 100 to 19000KW
suitable for operation on voltage up to 1200V. These are provided with STDP,
totally enclosed and duct ventilated enclosures.
• DC auxiliary mill motors.
6. CONTROL PANEL:
Control panel for voltage up to 400KW and control desks for generating
stations and EMV sub–stations.
7. CASTING AND FORGINGS:
• Sophisticated heavycasting and forging of creep resistant alloy steels,
stainless steel and other grades of alloy meeting stringent international
specifications.
8. DEFENCE:
• Naval guns with collaboration of Italy.

20. STEAM TURBINE
INTRODUCTION
A turbine is a device that converts chemical energy into mechanical energy,
specifically when a rotor of multiple blades or vanes is driven by the
movement of a fluid or gas. In the case of a steam turbine, the pressure and
flow of newly condensed steam rapidly turns the rotor. This movement is
possible because the water to steam conversion results in a rapidly
expanding gas. As the turbine’s rotor turns, the rotating shaft can work to
accomplish numerous applications, often electricity generation.
STEAM TURBINE
Sectional View Of A Steam Turbine In a steam turbine, the steam’s energy is
extracted through the turbine and the steam leaves the turbine at a lower
energy state. High pressure and temperature fluid at the inlet of the turbine
exit as lower pressure and temperature fluid. The difference is energy
converted by the turbine to mechanical rotational energy, less any

21. aerodynamic and mechanical inefficiencies incurred in the process. Since the
fluid is at a lower pressure at the exit of the turbine than at the inlet, it is
common to say the fluid has been “expanded” across the turbine. Because of
the expanding flow, higher volumetric flow occurs at the turbine exit (at
least for compressible fluids) leading to the need for larger turbine exit areas
than at the inlet.
2.21. The generic symbol for a turbine used in a flow diagram is shown in
Figure below. The symbol diverges with a larger area at the exit than at the
inlet. This is how one can tell a turbine symbol from a compressor symbol. In
Figure, the graphic is colored to indicate the general trend of temperature
drop through a turbine. In a turbine with a high inlet pressure, the turbine
blades convert this pressure energy into velocity or kinetic energy, which
causes the blades to rotate. Many green cycles use a turbine in this fashion,
although the inlet conditions may not be the same as for a conventional high
pressure and temperature steam turbine. Bottoming cycles, for instance,
extract fluid energy that is at a lower pressure and temperature than a
turbine in a conventional power plant. A bottoming cycle might be used to
extract energy from the exhaust gases of a large diesel engine, but the fluid
in a bottoming cycle still has sufficient energy to be extracted across a
turbine, with the energy converted into rotational energy.
Flow of steam

22. Flow Diagram Of A Steam Turbine Turbines also extract energy in fluid flow
where the pressure is not high but where the fluid has sufficient fluid kinetic
energy. The classic example is a wind turbine, which converts the wind’s
kinetic energy to rotational energy. This type of kinetic energy conversion is
common in green energy cycles for applications ranging from larger wind
turbines to smaller hydrokinetic turbines currentlybeing designed for and
demonstrated in river and tidal applications. Turbines can be designed to
work well in a variety of fluids, including gases and liquids, where they are
used not only to drive generators, but also to drive compressors or pumps.
One common (and somewhat misleading) use of the word “turbine” is “gas
turbine,” as in a gas turbine engine. A gas turbine engine is more than just a
turbine and typically includes a compressor, combustorand turbine
combined to be a self-contained unit used to provide shaft or thrust power.
The turbine component inside the gas turbine still provides power, but a
compressor and combustorare required to make a self-contained system
that needs only the fuel to burn in the combustor. An additional use for
turbines in industrial applications that may also be applicable in some green
energy systems is to cool a fluid. As previously mentioned, when a turbine
extracts energy from a fluid, the fluid temperature is reduced.

23. 2.2. ADVANTAGES:-
• Ability to utilize high pressure and high temperature steam.
• High efficiency.
• High rotational speed.
• High capacity/weightratio.
• Smooth, nearly vibration-free operation.
• No internal lubrication.
• Oil free exhausts steam.
2.3 DISADVANTAGES:-
For slow speed application reduction gears are required. The steam turbine
cannot be made reversible. The efficiency of small simple steam turbines is
poor.
2.4 STEAM TURBINES THE MAINSTAY OF BHEL:-
• BHEL has the capability to design, manufacture and commission steam
turbines of up to 1000 MW rating for steam parameters ranging from 30 bars
to 300 bars pressure and initial & reheat temperatures up to 600ºC.
• Turbines are built on the building block system, consisting of modules
suitable for a range of output and steam parameters.
• For a desired output and steam parameters appropriate turbine blocks can
be selected.

24. 4. TYPES OF STEAM TURBINE
.
IMPULSE TURBINE
The principle of the impulse steam turbine consists of a casing containing
stationary steam nozzles and a rotor with moving or rotating buckets. The
steam passes through the stationary nozzles and is directed at high velocity
against rotor buckets causing the rotor to rotate at high speed. The following
events take place in the nozzles:
1. The steam pressure decreases.
2. The enthalpy of the steam decreases.
3. The steam velocity increases.
4. The volume of the steam increases.
5. There is a conversion of heat energy to kinetic energy as the heat energy
from the decrease in steam enthalpy is converted into kinetic energy by the
increased steam velocity.
THE IMPULSE PRINCIPLE
If steam at high pressure is allowed to expand through stationarynozzles,
the result will be a drop in the steam pressure and an increase in steam
velocity. In fact, the steam will issue from the nozzle in the form of a high-
speed jet. If this high steam is applied to a properly shaped turbine blade, it
will change in direction due to the shape of the blade. The effect of this
change in direction of the steam flow will be to produce an impulse force, on
the blade causing it to move. If the blade is attached to the rotor of a turbine,
then the rotor will revolve. Force applied to the blade is developed by
causing the steam to change direction of flow (Newton’s 2nd Law – change
of momentum). Thechange of momentum produces the impulse force. The
fact that the pressure does not drop across the moving blades is the
distinguishing feature of the impulse turbine. The pressure at the inlet to the
moving blades is the same as the pressure at the outlet from the moving
blades.

25. REACTION PRINCIPLE
A reaction turbine has rows of fixed blades alternating with rows of moving
blades. The steam expands first in the stationary or fixed blades where it
gains some velocity as it drops in pressure. It then enters the moving blades
where its direction of flow is changed thus producing an impulse force on
the moving blades. In addition, however, the steam upon passing through
the moving blades again expands and further drops in pressure giving a
reaction force to the blades. This sequence is repeated as the steampasses
through additional rows of fixed and moving blades.
IMPULSE TURBINE STAGING
In order for the steam to give up all its kinetic energy to the moving blades
in an impulse turbine, it should leave the blades at zero absolute velocity.
This condition will exist if the blade velocity is equalto one half of the steam
velocity. Therefore, for good efficiency the blade velocity should be about
one half of steam velocity. In order to reduce steam velocity and blade
velocity, the following methods may be used:
1.Pressure compounding.
2.Velocity compounding.
3.Pressure-velocitycompounding.
4.Pressure Compounding.

26. TURBINE PARTS
TURBINE BLADES
• Cylindrical reaction blades for HP, IP and LP Turbines
• 3-DS blades, in initial stages of HP and IP Turbine, to reduce secondary
losses.
• Twisted blade with integral shroud, in last stages of HP, IP and initial
stages of LP turbines, to reduce profile and Tip leakage losses o Free
standing LP moving blades Tip sections with supersonic design. o Fir-tree
root o Flame hardening of the leading edge o Banana type hollow guide
blade
Tapered and forward leaning for optimized mass flow distribution o Suction
slits for moisture removal

27. TURBINE CASING
Casings or cylinders are of the horizontal split type. This is not ideal, as the
heavy flanges of the joints are slow to follow the temperature changes of the
cylinder walls. However, for assembling and inspection purposes there is no
other solution. The casing is heavy in order to withstand the high pressures
and temperatures. It is general practice to let the thickness of walls and
flanges decrease from inlet- to exhaust-end. Thecasing joints are made
steam tight, without the use of gaskets, by matching the flange faces very
exactly and very smoothly. The bolt holes in the flanges are drilled for
smoothly fitting bolts, but dowel pins are often added to secure exact
alignment of the flange joint. Double casings are used for very high steam
pressures. Thehigh pressure is applied to the inner casing, which is open at
the exhaust end, letting the turbine exhaust to the outer casings.

28. TURBINE ROTORS
The design of a turbine rotor depends on the operating principle of the
turbine. The impulse turbine with pressure drop across the stationaryblades
must have seals between stationary blades and the rotor. The smaller the
sealing area, the smaller the leakage; therefore the stationary blades are
mounted in diaphragms with labyrinth seals around thes haft. This
construction requires a disc rotor.Basically there are two types of rotor:
1 . DISC ROTORS
All larger disc rotors are now machined out of a solid forging of nickel steel;
this should give the strongest rotor and a fully balanced rotor. It is rather
expensive, as the weight of the final rotor is approximately 50% of the initial
forging. Older or smaller disc rotors have shaft and discs made in separate
pieces with the discs shrunk on the shaft. Thebore of the discs is made 0.1%
smaller in diameter than the shaft. The discs are then heated until they easily
are slid along the shaft and located in the correct position on the shaft and
shaft key. A small clearance between the discs prevents thermal stress in the
shaft.
2. DRUM ROTORS
The first reaction turbines had solid forged drum rotors. They were strong,
generally well balanced as they were machined over the total surface. With
the increasing size of turbines the solid rotors got too heavy pieces. For good
balance the drum must be machined both outside and inside and the drum
must be open at one end. The second part of the rotor is the drum end cover
with shaf.

29. 1. CONSTRUCTIONAL FEATURES OF A BLADE
2. The blade can be divided into 3 parts:
3. The profile, which converts the thermal energy of steam into kinetic
energy, with a certain efficiency depending upon the profile shape. The
root, which fixes the blade to the turbine rotor, giving a proper anchor to
the blade, and transmitting the kinetic energy of the blade to the rotor.
The damping element, which reduces the vibrations which necessarily
occur in the blades due to the steam flowing through the blades. These
damping elements may be integral with blades, or they may be separate
elements mounted between the blades. Each of these elements will be
separately dealt with in the following sections
1. 1.1 H.P. BLADE PROFILES
HIGH PRESSURE BLADE AIRFOIL PROFILE

30. CLASSIFICATION OF PROFILES
There are two basic types of profiles –
Impulse and Reaction.
1. 1.3 H.P. BLADE ROOTS
2. 19. of a problem. It has to be machined by broaching, and the
broaching machine available could not handle the sizes of the root. The
typical roots used for the HP moving blades for various steam turbine
applications are 1) T-ROOT 2) T-ROOT WITH SIDE GRIP

31. 2 L.P. BLADE PROFILES
The LP blade profiles of moving blades are twisted and tapered. These
blades are used when blade height-to-mean stage diameter ratio (h/Dm)
exceeds 0.2.
2.1 LP BLADE ROOTS The roots of LP blades are as follows:
1) 2 Blading : a. The roots of both the LP stages in –2 type of LP Blading are
T-roots.
2) 3 Blading: a. The last stage LP blade of HK, SK and LK blades have a fork-
root. SK blades have4-fork roots for all sizes. HK blades have 4-fork roots up
to 56 size, where modified profiles are used. Beyond this size, HK blades
have 3 fork roots. LK blades have 3-forkroots for all sizes. The roots of the LP
blades of preceding stages are of T-roots.
2.2 DYNAMICS IN BLADE The excitation of any blade comes from
different sources. They are Nozzle-passing excitation: As the blades pass the
nozzles of the stage, they encounterflow disturbances due to the pressure
variations across the guide blade passage. Theyalso encounter disturbances
due to the wakes and eddies in the flow path. Theexcitation gets repeated at
every pitch of the blade. This is called nozzle-passing frequency excitation.
The order of this frequency=no. of guide blades x speed of the machine.
Multiples of this frequencyare considered for checking for resonance.

32. BLADING MATERIALS
Among the different materials typically used for blading are 403 stainless
steel, 422 stainless steel, A-286, and Haynes Satellites Alloy Number 31 and
titanium alloy.
The403 stainless steel is essentially the industry’s standard blade material
and, on impulse steamturbines, it is probably found on over 90 percent of
all the stages. It is used because of its high yield strength, endurance limit,
ductility, toughness, erosion and corrosion resistance, and damping. It is
used within a Brinell hardness range of 207 to 248 to maximize its damping
and corrosion resistance.
The 422 stainless steel material is applied only on high temperature stages
(between 700 and 900°F or 371 and 482°C), where its higher yield, endurance,
creep and rupture strengths are needed. TheA-286 material is a nickel-based
superalloy that is generally used in hot gas expanders with stage
temperatures between 900 and 1150°F (482 and 621°C).
The Haynes Satellites Alloy Number 31 is a cobalt-based superalloy and is
used on jet expanders when precision cast blades are needed. The Haynes
Satellite Number 31 is used at stage temperatures between 900 and 1200°F
(482 and 649°C).
Another blade material is titanium. Its high strength, low density,
and good erosion resistance make it a good candidate for high speed or long-
last stage blading.

33. MANUFACTURINGPROCESS
INTRODUCTION
Manufacturing process is that part of the production process which is
directly concerned with the change of form or dimensions of the part being
produced. It does not include the transportation, handling or storage of
parts, as they are not directly concerned with the changes into the form or
dimensions of the part produced.
Manufacturing is the backbone of any industrialized nation.
Manufacturing and technicalstaff in industry must know the various
manufacturing processes, materials being processed, tools and equipments
for manufacturing different components or products with optimal process
plan using proper precautions and specified safetyrules to avoid accidents.
Beside above, all kinds of the future engineers must know the basic
requirements of workshop activities in term of man, machine, material,
methods, money and other infrastructure facilities needed to be positioned
properly for optimal shop layouts or plant layout and other support services
effectively adjusted or located in the industryor plant within a well planned
manufacturing organization.
Today’s competitive manufacturing era of high industrial
development and research, is being called the age of mechanization,
automation and computerintegrated manufacturing. Due to new researches
in the manufacturing field, the advancement has come to this extent that
every different aspect of this technologyhas become a full- fledged
fundamentaland advanced studyin itself. This has led to introduction of
optimized design and manufacturing of new products. New developments in
manufacturing areas are deciding to transfermore skill to the machines for
considerablyreduction of manual labor.

34. CLASSIFICATIONOF MANUFACTURING
PROCESSES
For producing of products materials are needed. It is therefore important to
know the characteristics of the available engineering materials. Raw
materials used manufacturing of products, tools, machines and equipments
in factories or industries are for providing commercial castings, called ingots.
Such ingots are then processed in rolling mills to obtain market form of
material supplyin form of bloom, billets, slabs and rods. These forms of
material supplyare further subjected tovarious manufacturing processes for
getting usable metal products of different shapes and sizes in various
manufacturing shops. All these processes used in manufacturing concern for
changing the ingots into usable products may be classified into six major
groups as Primary shaping processes Secondarymachining processes Metal
forming processes Joining processes Surface finishing processes and
Processes effecting change in properties
PRIMARY SHAPING PROCESSES
Primary shaping processes are manufacturing of a product from an
amorphous material. Some processes produces finish products or articles
into its usualform whereas others do not, and require furtherworking to
finish component to the desired shape and size. The parts produced
through these processes may or may not require to undergofurther
operations.
Some of the important primary shaping processes are:
Casting
Powder metallurgy
Plastic technology
Gas cutting
Bending
Forging

35. SECONDARY OR MACHINING PROCESSES
As large number of components require further processing afterthe primary
processes. These components are subjected to one or more number of
machining operations in machine shops, to obtain the desired shape and
dimensional accuracyon flat and cylindrical jobs. Thus, the jobs undergoing
these operations are the roughly finished products received through primary
shaping processes.
The process of removing the undesired or unwanted material from the
work-piece or job or component to produce a required shape using a cutting
tool is known as machining.
This can be done by a manual process or by using a machine called machine
tool (traditional machines namely lathe, milling machine, drilling, shaper,
planner, slotter).
In many cases these operations are performed on rods, bars and flat surfaces
in machine shops. These secondaryprocesses are mainly required for
achieving dimensional accuracyand a very high degree of surface finish.
The secondaryprocesses require the use of one or more machine tools,
various single or multi-point cutting tools (cutters), jobholding devices,
marking and measuring instruments, testing devices and gauges etc.
forgetting desired dimensional control and required degree of surface finish
on the work-pieces.
The example of parts produced by machining processes includes hand tools
machine tools instruments, automobile parts, nuts, bolts and gears etc.

36. Lot of material is wasted as scrap in the secondary or machining process.
Some of the common secondaryor machining processes are:
Turning
Threading
Knurling
Milling
Drilling
Boring
Planning
Shaping
Slotting
Sawing
Broaching
Hobbing
Grinding
Gear Cutting
Thread cutting
and Unconventional machining processes namely machining with
Numerical control (NC) machines tools or
Computer Numerical Control (CNC) machine tool using ECM, LBM, AJM,
USM setups.

37. BLOCK 3 LAY-OUT Lay-out of Block 3
CLASSIFICATIONOF BLOCK
BAY-1
IS FURTHER DIVIDED INTO THREE PARTS
1. HMS (HEAVY MACHINE SHOP)
In this shop heavy machine work is done with the help of different NC &
CNC machines such as center lathes, vertical and horizontal boring &
milling machines. Asia’s largest vertical boring machine is installed here
and CNC horizontal boring milling machines from Skoda of
Czechoslovakia.
CNC LATHE CNC VERTICAL BORING CNC HORINJENTAL BORING
2. Assembly Section (of hydro turbines)
In this section assemblyof hydro turbines are done. Blades of turbine
are1st assemble on the rotor & after it this rotor is transported to
balancing tunnel where the balancing is done. After balancing the rotor,
rotor &casings both internal & external are transported to the customer.
Total assembly of turbine is done in the company which purchased it by
B.H.E.L
.

38. 3. OSBT (Over Speed Balancing Tunnel)
In this section, rotors of all type of turbines like LP(low pressure), HP(high
pressure) & IP(Intermediate pressure) rotors of Steam turbine ,rotors of Gas
& Hydro turbine are balanced .In a large tunnel, Vacuumof 2 torr is created
with the help of pumps & after that rotor is placed on pedestaland rotted
with speed of 2500-4500 rpm. After it in a computer control room the axis of
rotation of rotor is seen with help of computer& then balance the rotor by
inserting the small balancing weight in the grooves cut on rotor. : Over
speed & VacuumBalancing Tunnel For balancing and over speed testing of
rotors up to 320 tons in weight, 1800 mm in length and 6900 mm diameter
under vacuum conditions of 1 Torr.
BAY –2 IS DIVIDED IN TO 2 PARTS:
HMS In this shop several components of steam turbine like LP, HP & IP
rotors, Internal & external casing are manufactured with the help of different
operations carried out through different NC & CNC machines like grinding,
drilling,
vertical & horizontal milling and boring machines,
center lathes,
planer,
Kopp milling machine.

39. 4. Assembly Section
In this section assemblyof steam turbines up to 1000 MWIs assembled. 1st
moving blades are inserted in the grooves cut on circumferences of rotor,
then rotor is balanced in balancing tunnel in bay-1.Afteris done in which
guide blades are assembled inside the internal casing & then rotor is fitted
inside this casing. After it this internal casing with rotor is inserted into the
external.
BAY 3 IS DIVIDED INTO 3 PARTS:
1. Bearing Section In this section Journal bearings are manufactured which
are used in turbines to overcome the vibration & rolling friction by providing
the proper lubrication.
2. Turning Section In this section small lathe machines, milling & boring
machines, grinding machines & drilling machines are installed. In this
section small jobs are manufactured like rings, studs, disks etc.
3. Governing Section In this section governors are manufactured. These
governors are used in turbines for controlling the speed of rotor within the
certain limits. 1st all components of governor are made by different
operations then these all parts are treated in heat treatment shop for
providing the hardness. Then these all components are assembled into
casing. There are more than 1000 components of Governor.

40. BAY-4 IS DIVIDED INTO 3 PARTS:
TBM (Turbine Blade Manufacturing) Shop In this shop solid blade of both
steam & gas turbine are manufactured. Several CNC & NC machines are
installed here such as
Copying machine,
Grinding machine,
Rhomboid milling machine,
Duplex milling machine,
T- root machine center,
Horizontal tooling center,
Vertical & horizontal boring machine etc.
Steam Turbine Casing & Rotors in Assembly
Area 2. Turning Section Same as the turning section in Bay-3, there are
several small Machine like
lathes machines,
milling,
boring,
grinding machines etc
. NC Rotor Turning Lathe Rotors in Assembly

41. Heat Treatment Shop
In this shop there are several tests performed for checking the Hardness of
different components.
Tests performed are
Sereliting,
Nitriding,
DP Test.
BLADE SHOP
Blade shop is an important shop of Block
Blades of all the stages of turbine are made in this shop only. They have a
variety of centre lathe and CNC machines to perform the complete operation
of blades. The designs of the blades are sent to the shop and the Respective
job is distributed tothe operators. Operators perform their job in a fixed
interval of time.
TYPES OF BLADES
Basically the design of blades is classified according to the stages of turbine.
The size of LP TURBINE BLADES is generally greater than that of HP
TURBINE BLADES. At the first T1, T2, T3 & T4 kinds of blades were used,
these were 2nd generation blades. Then it was replaced by TX, BDS (for HP
TURBINE) & F shaped blades. The most modern blades are F & Z shaped
blades. Cylindrical Profile TX Blade HP/IP Intermediate stages & LP Initial 3
Dimesional 3DS Blade HP/IP Initial Stages Twisted Profile F Blade HP/IP
Rear Stages

42. OPERATIONS PERFORMED ON BLADES
Some of the important operations performed on blade manufacturing are:-
Milling
Blank
Cutting
Grinding of both the surfaces Cutting Root milling
MACHINING OF BLADES
Machining of blades is done with the help of Lathe& CNC machines. Some
of the machines are:-
Centre lathe machine
Vertical Boring machine
Vertical Milling machine
CNC lathe machine
NEW BLADE SHOP
CNC TRIPLE SPINDLE 5 AXES MACHINE

43. IN NEW BLADE SHOP
A new blade shop is being in operation, mostly 500mw turbine blades are
manufactured in this shop. This is a highly hi tech shop where complete
manufacturing of blades is done using single advanced CNC machines.
Complete blades are finished using modernized CNC machines. Some of the
machines are:-
Pama CNC ram boring machine
.
Wotum horizontal machine with 6 axis
CNC control.
CNC shaping machine.

44. CONCLUSION
Gone through 1 month training under the guidance of capable engineers and
workers of BHEL Haridwar in Block-3 “TURBINEMANUFACTURING”
headed by Engineer of department MR ROHIT AJMANI situated in Ranipur,
Haridwar,(Uttarakhand). Thetraining was specified under the Turbine
Manufacturing Department. Working under the department I came to know
about the basic grinding, scaling and machining processes which was shown
on heavy to medium machines. Duty lathes were planted in the same line
where the specified work was undertaken. The training brought to my
knowledge the various machining and fabrication processes went not only in
the manufacturing of blades but other parts of the turbine.

45. INDEX
S NO TOPIC
1 INTRODUCTION
2 OVER VIEW
3 WORKING AREA
4 INDUSTRY
5 BHEL HARIDWAR
6 BLOCK LAYOUT
7 HEEP PRODUCT PROFILE
8 STEAM TURBINE
9 TURBINE PARTS
1 TURBINE BLADE
2 TURBINE CASING
3 TURBINE ROTOR
10 MATERIAL
11 MANUFECTURING PROCESS
12 CLASSIFICATION OF MANUFACTURING PROCESSES
1. PRIMARY PROCESS
2. SECONDARY PROCESS
13 BLOCK DESCRIPTION
1. BAY 1 HMS
2. BAY 2 HMS
3. BAY 3 TURNING & MILLING
4. BAY 4 BLADE SHOP
14 CONCLUSION