Microsoft word b h e l training report

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 useful in 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 constructional features 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 particular desire, types of Blades, Operations
performed on Blades, their New Blade Shop less with Advance Technology like CNC Shaping
Machine.
I would like to express my deep sense of Gratitude and thanks to MR. JAIKESH KUMAR
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).

SR NO TOPIC PAGE NO.
1. INTERODUCTION
2. BHEL-AN
OVERVEIW
3. STEAM TURBINE
4. TYPES OF STEAM
TURBINE
5. BHEL UNITS
6. BHEL HARIDWAR
7. TURBINE PARTS
8. MANUFACTURING
PROCESS
9. BLADE SHOP
10. CONCLUSION

INTRODUCTION
BHEL is the largest engineering and manufacturing enterprise in
India in the energy relatedinfrastructure sector today. BHEL was
established more than 40
in Bhopal ushering in the indigenous Heavy Electrical Equipm
Industry in India a dream which has been more than realized with
a well recognized track record of performance it
has been earning profits continuously since1971
BHEL caters to core sectors of the Indian Economy viz., Powe
Generation's & Transmission,
Telecommunication, Renewable Energy, Defense, etc. The wide
network of BHEL's 14 manufacturing division, four power Sec
regional centers, over 150
18 regional offices, e
customers and provide them with suitable products, syst
services – efficiently
attained ISO 9000 certification for quality
14001certification for environment management.
inherent potential coupled with its strong pe
one of the “NAVRATNAS”, which is supported by the government
in their endeavor to become future
INTRODUCTION
established more than 40 years ago when its first plant
in Bhopal ushering in the indigenous Heavy Electrical Equipm
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., Powe
Transmission, Industry, Transportation,
network of BHEL's 14 manufacturing division, four power Sec
regional centers, over 150 project sites, eight service centers and
enables the Company to promptly
customers and provide them with suitable products, syst
efficiently and at competitive prices. BHEL has already
9000 certification for quality management, and ISO
n for environment management. The company’s
inherent potential coupled with its strong performance make this
“NAVRATNAS”, which is supported by the government
heir endeavor to become future global players
years ago when its first plant was setup
in Bhopal ushering in the indigenous Heavy Electrical Equipment
72.
BHEL caters to core sectors of the Indian Economy viz., Power
Industry, Transportation,
network of BHEL's 14 manufacturing division, four power Sector
project sites, eight service centers and
nables the Company to promptly serve its
customers and provide them with suitable products, systems and
and at competitive prices. BHEL has already
management, and ISO
The company’s
rformance make this
“NAVRATNAS”, which is supported by the government

B.H.E.L- An Overview
BHEL or the Bharat Heavy Engineering Limited is one of the
largest engineering and manufacturing organizations in the
country and theBHEL, Haridwar is their gift to Uttaranchal. With
two large manufacturing plants, BHEL in Haridwar is among the
leading industrial organizations in the state. 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, gas turbines
and huge steams. The Central Foundry Forge Plant in Haridwar
deals withsteel 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. Situate in
Ranipur near Haridwar, the Bharat Heavy Engineering Limited
employs over 8,000 people.
BHEL is an integrated power plant equipment manufacturer and
oneof the largest engineering and manufacturing companies in
India in terms of turnover. BHEL was established in 1964,
ushering in the indigenous Heavy Electrical Equipment industry in
India - a dream that has been more than realized with a well-
recognized track record of performance. The company has been
earning profits continuously since 1971-72 and paying dividends
since 1976-77 .BHEL is engaged in the design, engineering,
manufacture, construction,testing, commissioning and servicing of
a wide range of products andservices for the core sectors of the
economy, viz. Power,Transmission, Industry, Transportation,
Renewable Energy, Oil & Gasand Defence.BHEL has 15
manufacturing divisions, two repair units,four regional offices,
eight service centres, eight overseas offices and

Principle of Operation and Design
An ideal steam turbine is considered to be an isentropic process, or
constant entropy process, in which the entropy of the steam entering the
turbine is equal to the entropy of the steam leaving the turbine. No steam
turbine is truly “isentropic”, however, with typical isentropic efficiencies
ranging from 20%- 90% based on the application of the turbine. The interior
of a turbine comprises several sets of blades, or “buckets” as they are more
commonly referred to. One set of stationary blades is connected to the
casing and one set of rotating blades is connected to the shaft. The sets
intermesh with certain minimum clearances, with the size and configuration
of sets varying to efficiently exploit the expansion of steam at each stage.
Turbine Efficiency
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.
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.
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 thenchanges direction and increases its speed relative to the speed
of the blades. Apressure 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.
DIFFERENCES BETWEEN IMPULSE
AND REACTION TURBINE

BHEL HARIDWAR
1. 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.
2. ADDRESS
Bharat Heavy Electrical Limited (BHEL)
Ranipur, Haridwar PIN- 249403
3. 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
CFFP area:- 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 to 50 Tons
per Piece Wt& Steel Forgings: Up to 55 Tons per Piece Wt.
4. UNITS
There are two units in BHEL Haridwar as followed:
1) Heavy Electrical Equipment Plant (HEEP)
2) Central Foundry Forge Plant (CFFP)

1.2 CLASSIFICATION OF PROFILES
There are two basic types of profiles - Impulse and Reaction. In the impulse type of profiles, the
entire heat drop of the stage occurs only in the stationary blades. In the reaction type of blades,
the heat drop of the stage is distributed almost equally between the guide and moving blades.
Though the theoretical impulse blades have zero pressure drop in the moving blades, practically,
for the flow to take place across the moving blades, there must be a small pressure drop across
the moving blades also. Therefore, the impulse stages in practice have a small degree of reaction.
These stages are therefore more accurately, though less widely, described as low-reaction stages.
The presently used reaction profiles are more efficient than the impulse profiles at part loads.
This is because of the more rounded inlet edge for reaction profiles. Due to this, even if the inlet
angle of the steam is not tangential to the pressure-side profile of the blade, the losses are low.
However, the impulse profiles have one advantage. The impulse profiles can take a large heat
drop across a single stage, and the same heat drop would require a greater number of stages if
reaction profiles are used, thereby increasing the turbine length. The Steam turbines use the
impulse profiles for the control stage (1st stage), and the reaction profiles for subsequent stages.
There are four reasons for using impulse profile for the first stage:
a) Most of the turbines are partial arc admission turbines. If the first stage is are action stage, the
lower half of the moving blades do not have any inlet steam, and would ventilate. Therefore,
most of the stage heat drop should occur in the guide blades.
b) The heat drop across the first stage should be high, so that the wheel chamber of the outer
casing is not exposed to the high inlet parameters. In case of -4turbines, the inner casing parting
plane strength becomes the limitation, and therefore requires a large heat drop across the 1st
stage.
c) Nozzle control gives better efficiency at part loads than throttle control.
d) The number of stages in the turbine should not be too high, as this will increase the length of
the turbine.
There are exceptions to the rule. Turbines used for CCPs, and BFP drive turbines do not have a
control stage. They are throttle-governed machines. Such designs are used when the inlet
pressure slides. Such machines only have reaction stages. However, the inlet passages of such
turbines must be so designed that the inlet steam to the first reaction stage is properly mixed, and
occupies the entire 360 degrees. There are also cases of controlled extraction turbines where the
L.P. control stage is an impulse stage. This is either to reduce the number of stages to make the
turbine short, or to increase the part load efficiency by using nozzle control, which minimizes
throttle losses.
1.3 H.P. BLADE ROOTS
The root is a part of the blade that fixes the blade to the rotor or stator. Its design depends upon
the centrifugal and steam bending forces of the blade. It should be designed such that the
material in the blade root as well as the rotor / stator claw and any fixing element are in the safe
limits to avoid failure. The roots are T-root and Fork-root. The fork root has a higher
loadcarrying
capacity than the T-root. It was found that machining this T-root with side grip is more

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
turbineapplications are
1) T-ROOT
2) T-ROOT WITH SIDE GRIP
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 encounter
flow disturbances due to the pressure variations across the guide blade passage. They
also encounter disturbances due to the wakes and eddies in the flow path. These are
sufficient to cause excitation in the moving blades. The excitation 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
frequency are considered for checking for resonance.
Excitation due to non-uniformities in guide-blades around the periphery. These can
occur due to manufacturing inaccuracies, like pitch errors, setting angle variations,
inlet and outlet edge variations, etc.
For HP blades, due to the thick and cylindrical cross-sections and short blade heights, the natural
frequencies are very high. Nozzle-passing frequencies are therefore necessarily considered, since
resonance with the lower natural frequencies occurs only with these orders of excitation.
In LP blades, since the blades are thin and long, the natural frequencies are low. The excitation
frequencies to be considered are therefore the first few multiples of speed, since the
nozzlepassing
frequencies only give resonance with very high modes, where the vibration stresses are
low.
The HP moving blades experience relatively low vibration amplitudes due to their thicker

sections and shorter heights. They also have integral shrouds. These shrouds of adjacent blades
butt against each other forming a continuous ring. This ring serves two purposes – it acts as a
steam seal, and it acts as a damper for the vibrations. When vibrations occur, the vibration
energy
is dissipated as friction between shrouds of adjacent blades.
For HP guide blades of Wesel design, the shroud is not integral, but a shroud band is riveted to a
number of guide blades together. The function of this shroud band is mainly to seat the steam. In
some designs HP guide blades may have integral shrouds like moving blades. The primary
function remains steam sealing.
In industrial turbines, in LP blades, the resonant vibrations have high amplitudes due to the thin
sections of the blades, and the large lengths. It may also not always be possible to avoid
resonance at all operating conditions. This is because of two reasons. Firstly, the LP blades are
standardized for certain ranges of speeds, and turbines may be selected to operate anywhere in
the speed range. The entire design range of operating speed of the LP blades cannot be outside
the resonance range. It is, of course, possible to design a new LP blade for each application, but
this involves a lot of design efforts and manufacturing cycle time. However, with the present-day
computer packages and manufacturing methods, it has become feasible to do so. Secondly, the
driven machine may be a variable speed machine like a compressor or a boiler-feed-pump. In
this case also, it is not possible to avoid resonance. In such cases, where it is not possible to
avoid resonance, a damping element is to be used in the LP blades to reduce the dynamic
stresses, so that the blades can operate continuously under resonance also. There may be blades
which are not adequately damped due to manufacturing inaccuracies. The need fora damping
element is therefore eliminated. In case the frequencies of the blades tend towards resonance due
to manufacturing inaccuracies, tuning is to be done on the blades to correct the frequency. This
tuning is done by grinding off material at the tip (which reduces the inertia more than the
stiffness) to increase the frequency, and by grinding off material at the base of the profile (which
reduces the stiffness more than the inertia) to reduce the natural frequency.
The damping in any blade can be of any of the following types:
a) Material damping: This type of damping is because of the inherent damping properties of the
material which makes up the component.
b) Aerodynamic damping: This is due to the damping of the fluid which surrounds the
component in operation.
c) Friction damping: This is due to the rubbing friction between the component under
consideration with any other object.
Out of these damping mechanisms, the material and aerodynamic types of damping are very
small in magnitude. Friction damping is enormous as compared to the other two types of
damping. Because of this reason, the damping elements in blades generally incorporate a feature
by which the vibrational energy is dissipated as frictional heat. The frictional damping has a
particular characteristic. When the frictional force between the rubbing surfaces is very small as
compared to the excitation force, the surfaces slip, resulting in friction damping. However, when
the excitation force is small when compared to the frictional force, the surfaces do not slip,
resulting in locking of the surfaces. This condition gives zero friction damping, and only the

material and aerodynamic damping exists. In a periodically varying excitation force, it may
frequently happen that the force is less than the friction force.
During this phase, the damping is very less. At the same time, due to the locking of the rubbing
surfaces, the overall stiffness increases and the natural frequency shifts drastically away from the
individual value. The response therefore also changes in the locked condition. The resonant
response of a system therefore depends upon the amount of damping in the system (which is
determined by the relative duration of slip and stick in the system, i.e., the relative magnitude of
excitation and friction forces) and the natural frequency of the system (which alters between the
individual values and the locked condition value, depending upon the slip or stick condition).
2.3 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 steam turbines, 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.
The A-286 material is a nickel-based super alloy 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 super alloy 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.
3. MANUFACTURING PROCESS
3.1 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 technical staff 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 safety rules 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 industry or 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 computer
integrated manufacturing. Due to new researches in the manufacturing field, the advancement

Fig 5. 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.
Fig 6. CNC Rotor Turning Lathe
3. 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.
5. BLADE SHOP
Blade shop is an important shop of Block 3. 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 to the operators. Operators perform their job in a fixed interval of time.
5.1 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
Fig. 7 Types Of Blades
5.2 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

5.3 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
Fig 8. Schmetic Diagram of a CNC Machine
5.4 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.
Fig 9. CNC Shaping Machine

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