BHE.L PPT.....ABOUT TRAINING

1. INDUSTRIAL VACATIONAL TRAINING
Submitted to: Submitted by :
Mr. Dinesh Chauhan S Parveen singh(151340104026)
Institute Of Technology
Gopeshwar

2. BHARAT HEAVY
ELECTRICALS
LIMITED,
Haridwar
Industrial Training
On BLOCK-3
BLADE SHOP

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. Electronics Division and Electro Porcelain Division,
Bangalore(Karnataka
7. Jagdishpur (Uttar Pradesh)
8. Rudrapur (Uttarakhand)
9. Industrial Valves Plant, 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. 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

6. Block-3: Turbine Manufacturing Shop
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 HYDRAULIC TESTING
GOVERNING SECTION

7. CONTENT
 INTRODUCTION
 Manufacturing Plant
 Major Products of BHEL, Haridwar
 General Details
 TURBINE SHOP
 BLADE SHOP
 MACHINE SHOP
 DESCRIPTION OF MACHINES
 REFERENCES

8. BHARAT HEAVEY ELECTRICAL LIMITED (BHEL)
INTRODUCTION
 The First plant of BHEL was set up at Bhopal in 1956.
 In the sixties, three more major plants were set up at Haridwar, Hyderabad
and Tiruchirapalli.
 It developed the capability to produce a variety of Electrical, Electronic and
Mechanical equipments for all sectors.
 BHEL has already attained ISO 9000 certification for quality management &
ISO 14001 certification foe environment management.

9. Manufacturing Plant
 BHEL Haridwar has two manufacturing plants:-
 Heavy Electrical Equipment Plant (HEEP) & Central
Foundry Forge Plant (CFFP).
 HEEP includes design and manufacture of large steam
and gas turbines, turbo generators, hydro turbines and
generators, hydro turbines and generators, large AC/DC
motors and so on.
 CFFP is engaged in manufacture of Steel Castings : Up to
50 Tons Per Piece Wt & Steel Forgings: Up to 55Tons Per
Piece Wt.

10. General Details
 Steam Turbines, Gas Turbines and Turbines Blades.
 Special Tooling for all products in the Tool Room located in the same block.
 Consists of four Bays, namely, Bay-I and II of size 36x378 meters and 36x400 meters
respectively and Bay-III and IV of size 24x402meters and 24x381 meters respectively.

11. STEAM TURBINE
 The Steam turbine is an engine that convert fluid
energy into mechanical energy.
 The steam turbine depends on dynamic action of
steam.
 The steam turbine is steam driven rotary engine.

12. TYPES OF STEAM TURBINE MANUFACTRED IN BHEL
(1): High pressure turbine (HP)

13. (1): High pressure turbine (HP)
 Double shell casing
(i) Inner casing
(ii) Outer casing
 Main steam pressure 247 ATA
 Main steam temperature 565C
 Outlet steam pressure 54 ATA
 Power generation in HPT 197MW
 usually double flow Turbine

14. (2): Intermediate pressure turbine (IP)
Double flow.
Double shell casing
(i) Inner casing
(ii) Outer casing
Reheated steam pressure 54 ATA
Reheated steam temperature 593 C
Outlet steam pressure 6.08 ATA
Power generation in HPT 262MW

15. (3): Low pressure turbine (LP)
Single flow.
Double shell casing
(i) Inner casing
(ii) Outer casing
Inlet steam pressure 5.97 ATA
Inlet steam temperature 282.8 C
Outlet steam pressure .1047 ATA
Power generation in HPT 210MW

16. Blade Shop
 Turbine Blade Machining Shop is
located in Bay-IV of Block-III.
 According to motion blade two type
 1. stationary type
 2. rotary type

17. The Blade Fitting on Rotor are two type
(1) Radials Fitting
(2) circular Fitting

18.  Inradials fittingthe groovecutin radialdirection.
 The blade fit in radialdirection.
 The radial fittingusedfor a low pressure blade.
(1) Radials fitting

19. (2) Circular Fitting
 Incircular fitting the groove cut are circular on the rotor.
 The blade fit in circular direction.
 The radialfittingusedforahighpressureblade.

20. TYPES OF BLADE USE IN STEAM TURBINE
(1) Highpressureturbine blade
(2)Intermediate pressureturbineblade
(3)Lowpressure turbineblade

21. H.P turbine blades
•.Theblades are responsibleforextracting energy fromthehigh
temperature,highpressure steamproducedbythe boiler.

22. Intermediate pressure turbine blade
• The size of blades of I.P steam turbine is larger than H.P
steam turbine , but smaller than L.P steam turbine.

23. Low Pressure Turbine blade
.
•The size of low pressure turbine blade in larger than the HP
and IP because it resist a low pressure and temperature.

24. MATERIALS USE IN BLADE
• 403 Stainless steel.
• Nickel based super alloy.
• Titanium based alloy.

25. HYDRAULIC TESTING
In Hydraulic testing process check a casting defects in outer and
inner casing Of turbine.
PROCESS:
Firstly the turbine but on the testing base vertical direction
without rotor and closed all holes And produced a high pressure
water in the base side through a small pipe connected, if defect is
available so produce a leakage and check a defect.

26. OVER SPEED BALANCING TUNNEL
 OSBT is used to turbine rotor balancing , blade fitting
testing , vibration.
 The rotor with blade take place a pedestal and create a
vacuum is 2 torr With the help of pump in the tunnel .
 The rotor is rotate with speed of 2500-4500 rpm.
 In the computer control room the axis of rotation
of rotor is seen with help
 Of computer.

27. Three type rotor test in this tunnel.
(i) high pressure rotor
(ii) intermediate pressure rotor
(iii) low pressure rotor

28. Introduction: Gas Turbine
The important components are compressor and combustion chamber.
The mass of gas turbine per kw developed is less.
The starting of a gas turbine is very easy and quick.
It can be driven at a very high speed.
The pressure used are very low(about 5bar).

29. Brayton cycle:
The ideal cycle that the working fluid undergoes in
the close loop in the Brayton cycle. It is made up of
four internally reversible process.
1-2 Isentropic compression;
2-3 Constant pressure heat addition;
3-4 Isentropic expansion;
4-1 Constant pressure heat
rejection.

30. Working principle of gas turbine:
 A simple gas turbine is comprised of three main section a compressor, a combustor and a power
turbine.
 The gas turbine operates of the brayton cycle where the compressed air is mixed with fuel and
burn under constant pressure condition.

31. Classification:
1.According to the path of the working substance:
 Close cycle gas turbine
 Open cycle gas turbine
 Semi-close gas turbine
2.According to the process of heat absorption:
 Constant pressure gas turbine
 Constant volume gas turbine

32. Working of Close cycle gas turbine:
A closed cycle gas turbine works on joule’s or
Brayton’s cycle.
A closed cycle gas turbine consists of a compressor,
heating chamber, gas turbine which drives the
generator and compressor and the cooling chamber.

33. Working of Open cycle gas turbine:
It’s also works on joule’s cycle.
Open cycle gas turbine consists of a compressor,
combustion chamber and a gas turbine which
drives the generator and compressor.
Open cycle gas turbine also called a continuous
gas turbine as the combustion of fuel takes place
continuously.

34. Advantages
Very high power to weight ratio.
Less vibration.
Low lubricant oil cost and consumption.
High operation speed.
Disadvantages:
Machine operation are also more complex.
Less efficient.
High cost compare to the reciprocating engine.
Less regular pattern of use then tank, helicopters,
large boats.

35. MACHINE SHOP
Operations Performed
 Turning
 Drilling
 Boring
 Facing
 Milling

36. TURNING
Turning is a form of machining, a material removal process, which is used to create
rotational parts by cutting away unwanted material. The turning process requires a
turning machine or lathe, work piece, fixture, and cutting tool.

37. DRILLING
 The operation of making round holes in metal pieces is known as
drilling. It is done with the help of drilling

38. BORING
In machining, boring is the process of enlarging a hole that has already been
drilled (or cast) by means of a single-point cutting tool (or of a boring head
containing several such tools), such as in boring a gun barrel or an engine cylinder.
Boring is drilling a hole, tunnel, or well in the earth.

39. FACING
 Facing is the process of removing metal from the end
of a work piece to produce a flat surface.
 In machining, facing is the act of cutting a face, which is
a planar surface, onto the work piece

40. MILLING
Milling (grinding), the process of grinding grain or other materials in a mill.
Milling machine, a cutting and shaping equipment removing asphalt
pavement with a milling machine Photochemical milling (disambiguation)
a part of the leather crusting process.

41. Vertical Boring Machine
Max diameter of work piece accommodated :10000mm
Max height of work piece :5000mm
Diameter of table :8750mm
Max travel of vertical tool head RAM slides :3200mm
Max travel of vertical tool heads from centre of table :5250mm
Max weight of work piece :200 T
Diameter of boring spindle of combined head :160mm

42. CNC Machines: CNC refers to Computer Numerical
Control, and is responsible for the automation of machine tools.
there are mainly 2 type of CNC Machines
1. CNC Turning
2. CNC Milling

43. CNC Turning
CNC turning is used to create objects with round or
tubular shapes that are created from larger pieces of
material

44. CNC Milling
CNC Milling are used for making the
complex shaping of metal. CNC milling
machines are controlled in one of two ways:
by computer or via manual override.
Computer programming allows the machine
to make the precise cuts required

45. CONCLUSION
Summer training gives the idea of general awareness in steam
turbine manufacturing & its process. Its provide practical idea to
manufacturing several component of turbine.

46. REFERENCES
1-www.bhelhwr.co.in
2-Material science by John Willey
3-Workshop technology by S.k.Garg

47. THANK YOU