BHEL is one of India's largest engineering companies that designs and manufactures heavy machinery including steam turbines. It has several manufacturing units across India including one in Haridwar, Uttarakhand. The Haridwar unit has a Turbine Manufacturing Shop that produces steam turbines using CNC machines. The turbine production process involves machining components like casings from steel and casting blades from alloys using various machines and operations.

1. BHARAT HEAVY
ELECTRICALS
LIMITED,
HARIDWAR
Presentation By:-
ANIL KUMAR GUPTA
1202940031
Industrial Training
on NEW
TURBINE SHOP

2. 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.

3. 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)

4. 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

5. 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.

6. 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

7. BLOCK 3
TURBINE SHOP
BAY 1 BAY 2 BAY 3
HEAVY MACHINE
SHOP(HMS)
BEARING SECTION BLADE SHOP
ASSEMBLY SECTION TURNING SECTION TURNING SECTION
ASSEMBLY SECTION HEAT TREATMENT
SHOP
GOVERNING SECTION
Block-3: Turbine Manufacturing Shop

8. 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.

9. 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)

10. 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

11. HIGH PRESSURE TURBINE

12. H.P turbine blades
 .The blades are responsible for extracting energy from the
high temperature, high pressure steam produced by
the boiler.

13. 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.

14. IP TURBINE

15. 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.

16. 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.

17. LP TURBINE

18. Low Pressure Turbine

19. 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.

21. 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

22. 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

23. Tacchi heavy duty CNC lathe:

24. 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.

25. CASING SHELL OR
CYLINDER

26.  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 Materials

28. Casing

29.  Lower half  Upper half

30. 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

32.  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

33. Hydraulic coping m/c or CNC
Coping m/c

34. Template (checking for external
profile)

35. 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).

36. RUSSIAN DESIGN
BLADE
GERMAN DESIGN
BLADE

37. 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.