B.H.E.L.HARIDWAR BLOCK 3

1. INDUSTRIAL TRAINING REPORT
(JUNE – JULY 2016)
On
General Awareness of Steam Turbine Manufacturing
Submitted in partial fulfilment of the requirements
Of the degree of
Bachelor of Technology
In
Mechanical Engineering
By
(ASHUTOSH SHARMA)
(1301440010)
(Shri Ram Murti Smarak College of Engineering and Technology)
Bareilly, 243202.

2. ACKNOWLEDGEMENT
“An engineer with only theoretical knowledge is not a complete Engineer.
Practical knowledge is very important to develop and apply engineering skills”.
It gives me a great pleasure to have an opportunity to
acknowledge and to express gratitude to those who were associated with me during
my training at BHEL.
I am very grateful to Mr. VIMAL KUMAR for providing me with an opportunity
to undergo training under his able guidance.
Last, but not the least, I would also like to acknowledge the support of my college
friends, who pursued their training with me. We shared some unforgettable
moments together.
I express my sincere thanks and gratitude to BHEL authorities for allowing me to
undergo the training in this prestigious organization.
I will always remain indebted to them for their constant interest and excellent
guidance in my training work, moreover for providing me with an opportunity to
work and gain experience.
THANK YOU

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 Assembly. 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. Step by Step arrangement of machines in the block
with a well-defined proper format.
I would like to express my deep sense of Gratitude and thanks to MR. VIMAL
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).

4. INDEX
SR. NO. TOPIC
1. INTRODUCTION
2. BHEL-AN OVERVEIW
3. STEAM TURBINE
4. TYPES OF STEAM TURBINE
5. BHEL UNITS
6. BHEL HARIDWAR
7. MANUFACTURING PROCESS
8. HEAVY DUTY MACHINES
9. FUTURE SCOPE
10. CONCLUSION.

5. 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,
Defense, etc. The wide network of BHEL's 14 manufacturing division, four
power Sector regional centers, over 150 project sites, eight service centers and 18
regional offices, enables the Company to promptly serve its customers and provide
them with suitable products, systems and services – efficiently and at competitive
prices. BHEL has already attained ISO 9000 certification for quality management,
and ISO 14001certification for environment management. The company’s inherent
potential coupled with its strong performance make this one of the
“NAVRATNAS”, which is supported by the government in their endeavor to
become future global players

6. 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 the BHEL, Haridwar is their
gift to Uttarakhand. 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 with steel castings and manufacturing of
steel forgings.
The BHEL plants in Haridwar have earned the ISO - 9001 and 9002 certificates for
its high quality and maintenance. These two units have also earned the ISO - 14001
certificates. Situate in Ranipur near Haridwar, the Bharat Heavy Engineering
Limited employs over 8,000 people.
BHEL is an integrated power plant equipment manufacturer and one of 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 and services for the core sectors of the
economy, viz. Power, Transmission, Industry, Transportation, Renewable Energy,
Oil & Gas and Defense. BHEL has 15 manufacturing divisions, two repair units,
four regional offices, eight service centers, eight overseas offices and 15 regional
centers and currently operate at more than 150 projects sites across India and
abroad. BHEL places strong emphasis on innovation and creative development of
new technologies. Our research and development (R&D) efforts are aimed not only
at improving the performance and efficiency of our existing products, but also at
using state-of-the-art technologies and processes to develop new products.

7. This enables us to have a strong customer orientation, to be sensitive to their needs
and respond quickly to the changes in the market.
The high level of quality & reliability of our products is due to adherence to
international standards by acquiring and adapting some of the best technologies
from leading companies in the world including General Electric Company, Alstom
SA, Siemens AG and Mitsubishi Heavy Industries Ltd., together with technologies
developed in our own R&D centers. Most of our manufacturing units and other
entities have been accredited to Quality Management Systems (ISO 9001:2008),
Environmental Management Systems (ISO 14001:2004) and Occupational Health
& Safety Management Systems (OHSAS 18001:2007).
BHEL has a share of around 59% in India's total installed generating capacity
contributing 69% (approx.) to the total power generated from utility sets
(excluding non-conventional capacity) as of March 31, 2012. We have been
exporting our power and industry segment products and services for approximately
40 years. We have exported our products and services to more than 70 countries.
We had cumulatively installed capacity of over 8,500 MW outside of India in 21
countries, including Malaysia, Iraq, the UAE, Egypt and New Zealand. Our
physical exports range from turnkey projects to after sales services.
BHEL work with a vision of becoming a world-class engineering enterprise,
committed to enhancing stakeholder value. Our greatest strength is our highly
skilled and committed workforce of over 49,000 employees. Every employee is
given an equal opportunity to develop himself and grow in his career. Continuous
training and retraining, career planning, a positive work culture and participative
style of management - all these have engendered development of a committed and
motivated workforce setting new benchmarks in terms of productivity, quality and
responsiveness.

8. STEAM TURBINE
A steam turbine is a mechanical device that extracts thermal energy from
pressurized steam, and converts it into rotary motion. Its modern manifestation was
invented by Sir Charles Parsons in 1884. It has almost completely replaced the
reciprocating piston steam engine primarily because of its greater thermal
efficiency and higher power-to-weight ratio. Because the turbine generates rotary
motion, it is particularly suited to be used to drive an electrical generator – about
80% of all electricity generation in the world is by use of steam turbines. The
steam turbine is a form of heat engine that derives much of its improvement in
thermodynamic efficiency through the use of multiple stages in the expansion of
the steam, which results in a closer approach to the ideal reversible process.

9. ADVANTAGES:-
-free operation.
usts steam.
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.

10. STEAM TURBINES THE MAINSTAY OF BHEL:-
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.
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.
Types
These arrangements include single casing, tandem compound and cross Compound
turbines. Single casing units are the most basic style where a single casing and
shaft are coupled to a generator. Tandem compound are used where two or more
casings are directly coupled together to drive a single generator. A cross compound
Steam turbines are made in a variety of sizes ranging from small 1 hp (0.75 kW)
units (rare) used as mechanical drives for pumps, compressors and other shaft
driven equipment, to 2,000,000 hp (1,500,000 kW) turbines used to generate
electricity. There are several classifications for modern steam turbines.
Steam Supply and Exhaust Conditions
These types include condensing, non-condensing, reheat, extraction and Induction.
Non-condensing or backpressure turbines are most widely used for process steam
applications. The exhaust pressure is controlled by a regulating valve to suit the
needs of the process steam pressure. These are commonly found at refineries,
district heating units, pulp and paper plants, and desalination facilities where large
amounts of low pressure process steam are available. Condensing turbines are most
commonly found in electrical power plants. These turbines exhaust steam in a
partially condensed state, typically of a quality near 90%, at a pressure well below
atmospheric to a condenser.

11. Reheat turbines are also used almost exclusively in electrical power plants. In a
reheat turbine, steam flow exits from a high pressure section of the turbine and is
returned to the boiler where additional superheat is added. The steam then goes
back into an intermediate pressure section of the turbine and continues its
expansion.
Casing or Shaft Arrangements
Turbine arrangement features two or more shafts not in line driving two or more
generators that often operate at different speeds. A cross compound Turbine is
typically used for many large applications.
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.

12. 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 then changes direction and
increases its speed relative to the speed of the blades. A pressure 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.

14. 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
4. UNITS
There are two units in BHEL Haridwar as followed:
1) Heavy Electrical Equipment Plant (HEEP)
2) Central Foundry Forge Plant (CFFP)

15. LAYOUT OF BLOCK 3

17. MANUFACTURING PROCESS
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 equipment’s 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.

18. 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 equipment 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
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 undergoing further operations. Some of the important primary shaping
processes is:
Casting
Powder metallurgy
Plastic technology
Gas cutting
Bending and
Forging

19. 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.
Some of the common secondary or machining processes are:
Turning
Threading
Knurling
Milling
Drilling
Boring
Planning
Shaping
Slotting
Sawing
Broaching
Hobbing
Grinding
Gear Cutting
Thread cutting and

20. BLOCK 3 (BAY-1)
BAY-1 IS 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.

21. HEAVY DUTY MACHINES
1) SINUMERIK CNC lathe
 Swing over carriage:3500mm
 Centre distance :9000mm
 Weight capacity:120 T
 Spindle power:196KW
 External chucking range:250-2000mm
 Max spindle rpm:200
 CNC system 840D:SINUMERIK
2) INNSE Horizontal CNC machine :
 Boring spindle diameter:160mm
 Headstock vertical travel:3000mm
 Longitudinal RAM travel:700mm
 Longitudinal spindle travel:1000mm
 Column cross travel:10m
 Rotary table travel:3000mm
 Table load:40 T

22. 3) Tacchi heavy duty CNC lathe:
4) Skoda Vertical CNC lathe
 Finishing machining casings including guide blade grooves are carried out in
vertical position on this lathe. The machine is provided with 840-C CNC
system.

23. Research and development
BHEL's investment in R&D is amongst the largest in the corporate sector in India.
During the year 2012-13, the company invested about Rs. 1,252 Crore on R&D
efforts, which corresponds to nearly 2.50% of the turnover of the company,
focusing on new product and system developments and improvements in existing
products for cost competitiveness, higher reliability, efficiency, availability and
quality etc. To meet customer expectations, 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 IPR (Intellectual Property Rights) capital of BHEL grew by 21.5% in
the year, taking the total to 2170.
The Corporate R&D division at Hyderabad leads BHEL’s research efforts in a
number of areas of importance to BHEL’s product range. Research & product
development (RPD) Groups for each product group at the manufacturing divisions
play a complementary role. BHEL has established Centers of Excellence for
Simulators, Computational Fluid Dynamics, Permanent Magnet Machines, Surface
Engineering, Machine Dynamics, Centre for Intelligent Machines and Robotics,
Compressors & Pumps, Centre for Nano Technology, Ultra High Voltage
Laboratory at Corporate R&D; Centre of Excellence for Hydro Machines at
Bhopal; Power Electronics and IGBT & Controller Technology at Electronics
Division, Bengaluru, and Advanced Fabrication Technology and Coal Research
Centre at Tiruchirappalli.
BHEL has established four specialized institutes, viz., Welding Research Institute
(WRI) at Tiruchirappalli, Ceramic Technological Institute (CTI) at Bangalore,
Centre for Electric Traction (CET) at Bhopal and Pollution Control Research
Institute (PCRI) at Haridwar. Amorphous Silicon Solar Cell plant
at Gurugram pursues R&D in Photo Voltaic applications.
Significantly, BHEL is one of the only four Indian companies and the only Indian
Public Sector Enterprise figuring in 'The Global Innovation 1000' of Booz & Co., a
list of 1,000 publicly traded companies which are the biggest spenders on R&D in
the world.

24. Criticism
BHEL is to construct 1,320-megawatt coal power plant in Rampal which is close
to the Sundarban mangrove forest for Bangladesh-India Friendship Power
Company(Pvt.) Limited(joint venture between NTPC Limited and Bangladesh
Power Development Board). The project has faced criticism for the environmental
impact and the potential harm to the largest mangrove forest in the world.
CONCLUSION
Gone through 1 month training under the guidance of capable engineers and
workers of BHEL Haridwar in Block-3 “TURBINE MANUFACTURING” headed
by Senior Engineer of department Mr. VIMAL KUMAR 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.