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1. AN INDUSTRIAL TRAINING REPORT
ON
TURBINE MANUFACTURING at B.H.E.L., Haridwar
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR
THE AWARD OF THE DEGREE OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
By
SHIVAM TEOTIA
Submitted To
SH. PARMANAND PANDIT (DY. MANAGER)
DEPARTMENT OF MECHANICAL ENGINEERING
G L BAJAJ INST. OF TECH. & MGMT.
GREATER NOIDA-201306

2. ACKNOWLEDGEMENT
We take this opportunity to thank the Industrial Training Co-Ordinator of Mechanical
Engineering Department for allowing us to work on such an interesting & informative topic.
We are highly indebted to our project guide DY. Manager SH. PARMANAND PANDIT Sir
for his guidance & words of wisdom. He always showed us the right direction during the
course of this project work. We are duly thankful to him to referring us to sites like science
direct, open pdf & providing many research papers which had some research work.
Success in such comprehensive report can’t be achieved single handed. It is the team
effort that sail the ship to the coast. So, I would like to express my sincere thanks to my
mentor SH. PARMANAND PANDIT Sir.
I am also grateful to the management of Bharat Heavy Electricals Limited (B.H.E.L.),
Haridwar for permitting me to have training during 1
st
June to 30
th
June, 2018.
We worked as a team and saw ups and downs as we are part of any project work team.
But in the end, it was their Guidance and my team work which made this project
possible. Last but not the least we would also like to thank all our teachers & friends for
their constructive criticism given in right spirit.
SHIVAM TEOTIA (1519240214)
7th
Semester, B.Tech.
Department of Mechanical Engineering
G L Bajaj Institute of Technology & Management,
Greater Noida

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 useful in 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
equipment 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 SH. PARMANAND
PANDIT (DY. MANAGER) us 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. INDEX
ABSTRACT i
ACKNOWLEDGEMENT ii
CERTIFICATE iii
Sr. No. Topic Page no.
INTRODUCTION 1
1. BHEL 2-3
1.1 OVERVIEW 3
1.2 WORKING AREAS 3
1.2.1 POWER GENERATION 3
1.2.2 POWER TRANSMISSION & DISTRIBUTION 3-4
1.2.3 INDUSTRIES 4
1.2.4 TRANSPORTATION 4-5
1.2.5 TELECOMMUNICATION 5
1.2.6 RENEWABLE ENERGY 5
1.2.7 INTERNATIONAL OPERATIONS 5-6
1.3 TECHNOLOGY UPGRADATION AND RESEARCH AND 6
DEVELOPMENT
1.3.1 HUMAN RESOURCE DEVELOPMENT INSTITUTE 6
1.4 HEALTH SAFETY AND ENVIRONMENT MANAGEMENT 7
1.4.1 ENVIRONMENTAL POLICY 7
1.4.2 OCCUPATIONAL HEALTH AND SAFETY POLICY 7-8
1.4.3 PRINCIPLE OF THE “GLOBAL COMPACT” 8
1.5 BHEL UNITS 9
1.6 BHEL HARIDWAR 10
1.6.1 LOCATION 10
1.6.2 ADDRESS 10
1.6.3 AREA 10
1.6.4 UNITS 10

5. Sr. No. Topic Page no.
1.6.5 HEEP PRODUCT PROFILE 12-13
2. STEAM TURBINE 14
2.1 INTRODUCTION 14-15
2.2 ADVANTAGES 16
2.3 DISADVANTAGES 16
2.4 STEAM TURBINE THE MAINSATY OF BHEL 16
3. TYPES OF STEAM TURBINE 17
3.1 THE IMPULSE TURBINE 17
3.2 THE IMPULSE TUBINE PRINCIPLE 17
3.3 THE REACTION PRINCIPLE 18
3.4 IMPULSE TURBINE STAGING 18
4. TURBINE PARTS 18
4.1 TURBINE BLADES 18-19
4.2 TURBINE CASING 19
4.3 TURBINE ROTORS 19-20
5. CONSTRUCTIONAL FEATURES OF BLADE 20
5.1 H.P. BLADE PROFILES 20-21
5.2 CLASSIFICATION OF PROFILES 21-22
5.3 H.P. BLADE ROOTS 22-23
5.4 L.P. BLADE PROFIES 23
5.5 L.P. BLADE ROOTS 23
5.6 DYNAMICS OF BLADE 23-25
5.7 BLADING MATERIALS 25
6. MANUFACTURING PROCESSES 26
6.1 INTRODUCTION 26
6.2 CLASSIFICATION OF MANUFACTURING 26
PROCESSES
6.2.1 PRIMARY SHAPING PROCESSES 27
6.2.2 SECONDARY OR MACHINING PROCESSES 27-28
7. BLOCK-3 LAYOUT 28
8. CLASSIFICATION OF BLOCK-3 29-31
9. BLADE SHOP 32
9.1 TYPES OF BLADES 32
9.2 OPERATIONS PERFORMED ON BLADES 33

6. Sr. No. Topic Page no.
9.3 MACHINING OF BLADES 33
9.4 NEW BLADE SHOP 34
10. CONCLUSION 35
FIGURE INDEX
Sr. No. Topic Page no.
1. SECTIONAL VIEW OF STEAM TURBINE 14
2. FLOW DIAGRAM OF A STEAM TURBINE 15
3. HIGH PRESSURE BLADE PROFILE 20
4. OVERSPEED AND VACCUM BALANCING WHEEL 29
5. STEAM TURBINE CASING AND ROTORS IN ASSEMBLING 31
AREA
6. CNC ROTOR TURNING LATHE 31
7. TYPES OF BLADES 32
8. SCHMETIC DIAGRAM OF A CNC MACHINE 33
9. CNC SHAPING MACHINE 34
TABLE INDEX
Sr. No. Topic Page no.
1. BHEL UNITS 9
2. BLOCKS IN HEEP 11
3. SECTIONS IN CFFP 11
4. BLADE ROOTS 22-23
5. LAYOUT OF BLOCK-3 28

7. INTRODUCTION
BHEL is the largest engineering and manufacturing enterprise in India in the energy related
infrastructure sector today. BHEL was established more than 40 years ago when its first
plant was setup in Bhopal ushering in the indigenous Heavy Electrical Equipment 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 since1971-72.
BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission,
Industry, Transportation, Telecommunication, Renewable Energy, Defence, etc. The wide
network of BHEL's 14 manufacturing division, four power Sector regional centres, over 150
project sites, eight service centres 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 by the government in their endeavour to
become future global players.

8. B.H.E.L.
1.1.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, Defence and many more.
Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the
area of Scientific, Technical and 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.
Overall it has installed power equipment for over 90,000 MW.
BHEL's Investment in R&D is amongst the largest in the corporate sector in 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-Sector Undertakings or PSUs, known as
the NAVRATNAS or 'The Nine Jewels’.
The power plant equipment manufactured by BHEL is based on contemporary
technology comparable to the best in the world.
The wide network of BHEL's 14 manufacturing divisions, 4 Power Sector regional
centre, over 100 project sites, 8 Service Centre and 18 regional offices, enables
the Company to promptly serve its customers and provide them with suitable
products, systems and services efficiently.

9. 1.2. WORKING AREAS
1.2.1. 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 the technology 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 technology comparable to the best in the world and is also
internationally competitive.
The Company has proven expertise in Plant Performance Improvement through renovation
modernization and upgrading of a variety of power plant equipment besides specialized
know how of residual life assessment, health diagnostics and life extension of plants.
1.2.2. POWER TRANSMISSION & DISTRIBUTION (T & D)
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
transfer capacity of transmission lines and improving system stability 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.

10. 1.2.3. INDUSTRIES
BHEL is a major contributor of 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(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) 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 producer of large-size thruster devices. It also supplies digital
distributed control systems for process industries, and control & instrumentation
systems for power plant and industrial applications. BHEL is the only company in India
with the capability to make simulators for power plants, defence and other applications.
The Company has commenced manufacture of large desalination plants to help
augment the supply of drinking water to people.
1.2.4. TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production, installation,
and maintenance and after-sales service of Rolling Stock and 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 stock for special applications viz., overhead equipment cars, Special well
wagons, Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use,
BHEL manufactures traction propulsion systems for other rolling stock producers 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.

11. 1.2.5. TELECOMMUNICATION
BHEL also caters to Telecommunication sector by way of small, medium and large
switching system.
1.2.6. 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.
1.2.7. 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, centrifugal compressors, 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 company have been in Australia, Saudi Arabia, Libya,
Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan, Sri Lanka, Iraq etc.
The company has been successful in meeting demanding customer's requirements in terms of
complexity of the works as well as technological, quality and other requirements viz. extended
warrantees, associated O&M, financing packages etc. BHEL has proved its capability to
undertake projects on fast-track basis. The company has been successful in meeting varying
needs of the industry, be it captive power plants, utility power generation or for the oil sector
requirements. Executing of overseas projects has also provided BHEL the experience of
working with world renowned consulting organizations and inspection agencies.
In addition to demonstrated capability to undertake turnkey projects on its own, BHEL
possesses the requisite flexibility to interface and complement with international
companies for large projects by supplying complementary equipment and meeting their
production needs for intermediate as well as finished products.
The success in the area of rehabilitation and life extension of power projects has
established BHEL as a comparable alternative to the original equipment manufacturers
(OEM’S) for such plants.

12. 1.3. TECHNOLOGY UPGRADATION AND 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 to contemporary levels
through continuous in-house efforts as well as through acquisition of new technologies
from leading engineering organizations of the world.
The Corporate 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 centres at each of the manufacturing divisions play a complementary role.
BHEL's Investment in R&D is amongst the largest in the corporate sector in 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 products developed in-
house: low-NOx oil / gas burners, circulating fluidized bed combustion boilers, high-
efficiency Pelton 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 system for 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 super conducting materials in power generations and
industry, and fuel cells for distributed, environment-friendly power generation.
1.3.1 HUMAN RESOURCE DEVELOPMENT INSTITUTE
The most prized asset of BHEL is its employees. The Human Resource Development
Institute and other HRD centres 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 productivity and higher levels of quality.

13. 1.4. HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT
BHEL, as an integral part of business performance and in its endeavour of becoming a world-
class organization and sharing the growing global concern on issues related to Environment.
Occupational Health 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.
1.4.1. 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. BHEL will also assist and co-operate with the concerned Government
Agencies and Regulatory Bodies engaged in environmental activities, offering the
Company's capabilities is this field.
1.4.2. OCCUPATIONAL HEALTH AND SAFETY POLICY
Compliance with applicable Legislation and Regulations.
Setting objectives and targets to eliminate/control/minimize risks due to
Occupational and Safety Hazards.
Appropriate structured training of employees on Occupational Health 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, adequacy and 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 Occupational Health and
Safety Management System certification for all BHEL units.

14. In pursuit of these Policy requirements, BHEL will continuously strive to improve work particles
in the light of advances made in technology and new understandings in Occupational Health,
Safety and 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 labour and NGOs. It provides a forum for them to work
together and 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.
1.4.3. PRINCIPLES OF 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.
3. Eliminate discrimination.
4. The elimination of all form of forces and compulsory labour.
5. The effective abolition of child labour.
6. Eliminate discrimination.
ENVIRONMENT
7. Businesses should support a precautionary approach to environmental challenges.
8.Undertake initiatives to promote greater environmental responsibility and
9. Encourage the development and diffusion of environmentally friendly technologies.
By joining the "Global Compact", BHEL would get a unique opportunity of networking
with corporate and sharing experience relating to social responsibility on global basis.

15. 1.5 BHEL UNITS
UNIT TYPE PRODUCT
1.Bhopal Heavy Electrical Part Steam Turbines, Turbo Generators, Hydro
Sets,
Switch Gear Controllers
2.Haridwar Hydro Turbines, Steam Turbines, Gas
Turbines, Turbo Generators, Heavy Castings
HEEP Heavy Electrical Equipment and Forging, Control Panels, Light Aircrafts,
Plant Electrical Machines.
CFFP Central Foundry Forge Plant
3.Hyderabad Industrial Turbo-Sets, Compressor Pumps
and Heaters, Bow Mills, Heat Exchangers
HPEP Heavy Power Equipment Plant Oil Rings, Gas Turbines, Switch Gears,
Power Generating Sets.
4. Trichy
Seamless Steel Tubes, Spiral Fin Welded
HPBP High Pressure Boiling Plant Tubes.
5.Jhansi
Transformers, Diesel Shunt Less AC locos
TP Transformer Plant and EC EMU.
6.Bangalore Energy Meters, Watt Meters, Control
Equipment, Capacitors, Photo Voltic Panels,
EDN Electronics Division Simulator, Telecommunication System, Other
Advanced Microprocessor based Control
EPD Electro Porcelains Division System, Insulator and Bushing, Ceramic
Liners
7.Ranipet Electrostatic Precipitator, Air Pre-Heater,
Fans, Wind Electric Generators, Desalination
BAP Boiler Auxilary Plant Plants.
8.Goindwal Industrial Valves Plant Industrial Valves & Fabrication
9.Jagdishpur High tension ceramic, Insulation Plates and
IP Insulator Plant
Bushings
10. Rudrapur Component Fabrication Plant Windmill, Solar Water Heating system
11. Gurgaon Amorphous Silicon Solar Cell Solar Photovoltaic Cells, Solar Lanterns,
Plant. Chargers ,Solar clock
Table-1

16. 1.6. BHEL HARIDWAR
1.6.1. 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.
1.6.2. ADDRESS
Bharat Heavy Electrical Limited (BHEL)
Ranipur, Haridwar PIN- 249403
1.6.3. 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.
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 Turbo Generator, Generator Exciter , Motor (AC and DC)
II) Fabrication Large Size Fabricated Assemblies or Components
III) Turbines & Steam , Hydro Turbines, Gas turbines, Turbine Blade, Special Tooling.
Auxilary
IV) Feeder Winding of Turbo ,Hydro Generators, Insulation for AC & DC Motors
V) Fabrication Fabricated Parts of Steam Turbine, Water Boxes, Storage Tank, Hydro
Turbine Parts
VI) Fabrication Fabricated Oil Tanks, Hollow Guide Blades, Rings, Stator Frames and
Stamping & Die Rotor Spindle, All Dies, Stamping for Generators and Motor
Manufacturing
VII) Wood Working Wooden Packing, Spacers
VIII) Heaters & LP heaters, Ejectors, Glands, Steam and Oil Coolers, Oil Tank, Bearing
Coolers Covers
Table-2
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.
Table -3

18. 1.6.5. HEEP PRODUCT PROFILE
1. THERMAL SETS:
Steam turbines and generators up to 500 MW capacity for utility and combined
cycle applications
Capability to manufacture up to 1000 MW unit cycle.
2. GAS TURBINES:
Gas turbines for industry and 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 butterfly and rotary valves and auxiliaries for hydro station.
4. EQUIPMENT FOR NUCLEAR POWER PLANTS:
Turbines and generators up to 500MW unit
size. Steam generator 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.

19. 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 heavy casting 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. 2. STEAM TURBINE
2.1 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.
Fig.1 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 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.

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.
Fig.2 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
currently being 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, combustor and 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 combustor are 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. Some industries, such as the gas processing industry, use
turbines as sources of refrigeration, dropping the temperature of the gas going

22. through the turbine. In other words, the primary purpose of the turbine is to reduce the
temperature of the working fluid as opposed to providing power. Generally speaking, the
higher the pressure ratio across a turbine, the greater the expansion and the greater the
temperature drop. Even where turbines are used to cool fluids, the turbines still produce
power and must be connected to a power absorbing device that is part of an overall system.
Also note that turbines in high inlet-pressure applications are sometimes called
expanders. The terms “turbine” and “expander” can be used interchangeably for most
applications, but expander is not used when referring to kinetic energy applications, as
the fluid does not go through significant expansion.
2.2.ADVANTAGES:-
Ability to utilize high pressure and high temperature
steam. High efficiency.
High rotational speed.
High capacity/weight ratio.
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.
2.4STEAM 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.

23. 3. TYPES OF STEAM TURBINE
There are complicated methods to properly harness steam power that give rise to the
two primary turbine designs: impulse and reaction turbines. These different designs
engage the steam in a different method so as to turn the rotor
3.1 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.
3.2 THE IMPULSE PRINCIPLE
If steam at high pressure is allowed to expand through stationary nozzles, 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). The change 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.

24. 3.3 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 steam passes through additional rows of fixed and moving blades.
3.4 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 equal to 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-velocity compounding.
4.Pressure Compounding.
4. TURBINE PARTS
4.1TURBINE 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

25. o Tapered and forward leaning for optimized mass flow distribution
o Suction slits for moisture removal
4.2TURBINE 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. The casing 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. The high pressure is applied to the inner casing, which is open
at the exhaust end, letting the turbine exhaust to the outer casings.
4.3 TURBINE ROTORS
The design of a turbine rotor depends on the operating principle of the turbine. The impulse
turbine with pressure drop across the stationary blades 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:
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. The bore 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.

26. 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 shaft.
5. CONSTRUCTIONAL FEATURES OF A BLADE
The blade can be divided into 3 parts:
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.
5.1H.P. BLADE PROFILES
In order to understand the further explanation, a familiarity of the terminology used is
required. The following terminology is used in the subsequent sections.

27. If circles are drawn tangential to the suction side and pressure side profiles of a blade, and
their centers are joined by a curve, this curve is called the camber line. This camber line
intersects the profile at two points A and B. The line joining these points is called chord, and
the length of this line is called the chord length. A line which is tangential to the inlet and
outlet edges is called the bitangent line. The angle which this line makes with the
circumferential direction is called the setting angle. Pitch of a blade is the circumferential
distance between any point on the profile and an identical point on the next blade.
5.2 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.

28. 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.
5.3 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
load-carrying 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 turbine applications are shown in the following figure:
T-ROOT
T-ROOT WITH SIDE GRIP

29. FORK ROOT
Table 4 Blade Roots
5.4 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.
5.5 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.
5.6DYNAMICS 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.

30. 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 nozzle-passing 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.

31. 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).
5.7 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.

32. 6. MANUFACTURING PROCESS
6.1 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
has come to this extent that every different aspect of this technology has become a full-fledged
fundamental and advanced study in itself. This has led to introduction of optimized design and
manufacturing of new products. New developments in manufacturing areas are deciding to
transfer more skill to the machines for considerably reduction of manual labor.
6.2 CLASSIFICATION OF 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 supply in form of bloom, billets, slabs and
rods. These forms of material supply are further subjected to various 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
Secondary machining processes
Metal forming processes
Joining processes
Surface finishing processes and
Processes effecting change in properties

33. 6.2.1 PRIMARY SHAPING PROCESSES
Primary shaping processes are manufacturing of a product from an amorphous
material. Some processes produces finish products or articles into its usual form
whereas others do not, and require further working to finish component to the desired
shape and size. The parts produced through these processes may or may not require to
undergo further operations. Some of the important primary shaping processes are:
Casting
Powder metallurgy
Plastic technology
Gas cutting
Bending and
Forging
6.2.2 SECONDARY OR MACHINING PROCESSES
As large number of components require further processing after the primary processes. These
components are subjected to one or more number of machining operations in machine shops, to
obtain the desired shape and dimensional accuracy on 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 secondary processes are mainly required for achieving dimensional accuracy and
a very high degree of surface finish. The secondary processes 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. Lot of material is wasted as scrap in the secondary or
machining process. Some of the common secondary or machining processes are:
Turning
Threading
Knurling
Milling
Drilling
Boring
Planning
Shaping

34. 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.
7. BLOCK 3 LAY-OUT
Table 5: Lay-out of Block 3

35. 8. CLASSIFICATION OF BLOCK 3
BAY-1 IS FURTHER DIVIDED INTO THREE PARTS
1. HMS
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.
2. Assembly Section (of hydro turbines)
In this section assembly of 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.
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, Vacuum of 2 torr is created with the help of pumps & after that
rotor is placed on pedestal and 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.
Fig 4: Over speed & Vacuum Balancing 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.

36. BAY –2 IS DIVIDED IN TO 2 PARTS:
1. 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.
2. Assembly Section
In this section assembly of 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.After is 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.
BAY-4 IS DIVIDED INTO 3 PARTS:
1. 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.

37. 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.

38. 9. 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.
9.1 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.
3 Dimesional Cylindrical Profile Twisted Profile
3DS Blade TX Blade F Blade
HP/IP Initial Stages HP/IP Intermediate stages HP/IP Rear Stages
& LP Initial
Fig. 7 Types Of Blades

39. 9.2 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
9.3MACHINING 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

40. 9.4 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

41. 10. CONCLUSION
Gone through rigorous 6 Weeks training under the guidance of capable engineers and
workers of BHEL Haridwar in Block-3 “TURBINE MANUFACTURING” headed by Senior
Engineer of department Mr. ALOK SHUKLA situated in Ranipur, Haridwar,(Uttarakhand).
The training 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.