BHEL is India's largest manufacturer of power generation equipment. It produces steam turbines through a multi-step manufacturing process in its heavy equipment plant involving machining, milling, grinding and assembly of components. Blades are a critical part of steam turbines and are manufactured to specifications using CNC machines with processes like cutting, profiling, tapering and polishing. The finished turbine components undergo quality checks and the assembled rotor is tested at high speeds in an overspeed balancing tunnel.
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.
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.
ppt on coil and insulation manufacturing block, BHEL, haridwar
manufacturing process of stator bar by bhel for practical training or industrial training.about bhel
This is my Summer Training Report in B.H.E.L., Haridwar on General Awareness Of Steam Turbine in Turbine Block-III in the period 17/06/13 to 31/07/13.
I would like to thank My Mentor Mr. Alok Shukla Sir, My Guide Asst. Prof. Mr. Anuj Dixit Sir. Without their guidance and efforts it was impossible to achieve.
ppt on coil and insulation manufacturing block, BHEL, haridwar
manufacturing process of stator bar by bhel for practical training or industrial training.about bhel
This is my Summer Training Report in B.H.E.L., Haridwar on General Awareness Of Steam Turbine in Turbine Block-III in the period 17/06/13 to 31/07/13.
I would like to thank My Mentor Mr. Alok Shukla Sir, My Guide Asst. Prof. Mr. Anuj Dixit Sir. Without their guidance and efforts it was impossible to achieve.
PROJECT REPORT ON BHEL BHOPAL FOR MECHANICALRohitsen21
This presentation is on vocational training that I have done between 12 july to 1 august, in BHEL BHOPAL I visited all the blocks and our training was sheduled to WTM block and traction motor block.
The aim of this project is to design a positive displacement rotary pump for small scale applications. The design is in such a way that it combines the advantages of both rotodynamic and positive displacement pumps. Currently available centrifugal pumps cannot attain high heads, and reciprocating pumps are less efficient and requires much space. When centrifugal pump is used as a jet pump, it delivers fluids at a high head, but in the expense of efficiency.
To overcome these negatives of currently available pumps, a new design of a rotary type positive displacement pump is developed. This design imitates the working of a normal reciprocating pump, but in a rotary action. This consumes less space compared to a reciprocating pump of same capacity. The main part of the pump is a cam which is mounted on a rotating shaft that rotates in a cylindrical casing. The cam is designed in such a way that it always maintains contact with the walls of the casing as it rotates. A spring loaded blade acts as the cam follower and moves in an accurately machined slot in the casing. The blade and the slot are of rectangular cross section. This blade separates suction and delivery sides of the pump. Inlet and outlet ports are placed on either sides of this blade. This pump does not require inlet and outlet valves. The discharge from the pump is continuous. It also eliminates the crank and connecting-rod mechanisms and delivers a smooth operation.
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Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
2. MANUFACTURING OF STEAM
TURBINE
Presented by: Sushil kumar
Roll no.-110106281
Sharda University
3. 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.
BHEL is one of India’s nine larger Public Sector Undertakings or
PSUs ,known as the NAVRATNAS or the nine jewels .
The wide network of BHEL's 14 manufacturing division, four
power Sector regional centre, over 150 project sites, eight service
centre and 18 regional offices.
BHEL has already attained ISO 9000 certification for quality
management, and ISO 14001 certification for environment
management
4. The power plant equipment manufactured by BHEL is based on
contemporary technology comparable to the best in the world and is
also internationally competitive.
BHEL is the only company in India with the capability to make
simultaneous for power plants, defense and other applications.
Supplied traction electrics and AC/DC locos to power over
12000kms railway network.
Supplied over one million valves to power plants and other
industries.
7. STEAM TURBINE:
Turbine is an engine that converts energy of fluid into mechanical
energy .
Steam turbine depends completely upon the dynamic action of the
steam.
Steam turbine is steam driven rotary engine.
8. TYPE OF STEAM TURBINE
Impulse turbine
Reaction turbine
9. IMPULSE TURBINE
The basic idea of an impulse turbine is that a jet of
steam from a fixed nozzle pushes against the rotor
blades and impels them forward.
The velocity of steam is twice as fast as the velocity
of blade.
Pressure drops take place in the fixed blade
(nozzle).
10. SINGLE STAGE IMPULSE TURBINE
The turbine consists of a single rotor to which
impulse blades are attached.
The steam is fed through one or several
convergent nozzles.If high velocity of steam is
allowed to flow through one row of moving
blades.
It produces a rotor speed of about 30000 rpm
which is too high for practical use.
11. REACTION TURBINE
A reaction turbine utilizes a jet of steam that
flows from a nozzle on the rotor.
Actually, the steam is directed into the moving
blades by fixed blades designed to expand the
steam.
The result is a small increase in velocity over
that of the moving blades.
13. PROBLEM IN STEAM TURBINE
Stress corrosion
Corrosion fatigue
Pitting
Oil lubrication
imbalance of the rotor can lead to vibration
misalignment
Thermal fatigue
15. WORKING OF STEAM TURBINE:
Impulse Turbine:-
• steam is expanded only in nozzles.
• Blade passage of constant cross-section
area.
Reaction Turbine:-
• Pressure drop in fixed & moving blade.
• Blade passage of varying cross-section
area.
16. ROTOR AND CASING OF STEAM
TURBINE:
HP (High Pressure)
IP (Intermediate Pressure)
LP (Low Pressure)
17.
18. Manufactured blade according to specifications with the
help of CNC 3AXIS MACHINE.
In order to meet the increasing demand to manufacture complicated
components of high accuracy in large quantities, sophisticated technological
equipment and machinery have been developed.
•The design and construction of Computer Numerically Controlled (CNC)
machines differs greatly from that of conventional machine tools. This
difference arises from the requirements of higher performance levels.
•The control of a machine tool by means of stored information through the
computer is known as Computer Numerically Controlled. The information
stored in the computer can be read by automatic means and converted into
electrical signals, which operate the electrically controlled servo systems.
•Computer Numerically Control can be applied to milling machines ,Lathe
machines, Grinding machines, Boring machines, Flame cutters, Drilling
machines
19. BLADE MANUFACTURING
Operations Performed On Blades:
Inspection
Cutting
Milling
Grinding on both the surface
Machining Of Blades:
Horizontal milling machine
Central lathe machine
CNC machine
Vertical boring machine
20. MANUFACTURING OF BLADE
PROCESS
The different processes followed in the
manufacture of steam turbine blade on cnc 3axis
machine as follows
1. RAW MATERIAL PROCUREMENT:
The steam turbine blade material is procured as
per the design specification. The material is
inspected dimensionally
21. CONT.
2.LENGTH CUTTING:
The material is cut to length by keeping
machining allowance at both ends either by Band
Saw or by Power Hack Saw.
3. THICKNESS MILLING
The material is clamped in a vice or fixture and
thickness is milled on both sides by keeping n
allowance of 0.5mm on both sides for grinding.
This operation is done either by horizontal
milling machining or by vertical milling machine.
22. CONT.
4.THICKNESS GRINDING:
The milled bars are debarred and kept on a
magnetic chuck of the segmental surface
grinding machine. 5 to 10 blades are kept each
time depending on the size and ground each side
to maintain the dimension.
5. RHOMBOID MILLING:
The ground blade bars are milled to rhomboid
shape with an angle given in the process by
clamping in a fixture on both sides with an
allowance of 0.5mm on both side. This is done on
the horizontal milling machines.
23. CONT.
6. RHOMBOID GRINDING:
The milled bars are debarred and kept on
magnetic chuck of the surface grinder and
grinding is done on both sides.
7. FACING AND SIZE MILLING:
The ground blades are faced on the root side to
maintain perpendicularity. This is very
important as the blade is held on this face while
in assembly.
24. CONT.
ROOT MILLING:
Clamp the blade in a vice or fixture and machine
the root on both sides as per drawing keeping an
allowance for root radius. Do not machine 2 blade
as these are used for locking purpose. This
operation is done on horizontal milling machine.
9. ROOT RADIUS MILLING:
Clamp the blade in a vice or fixture and machine
the root radius as per drawing by CNC M aching
centre. This operation is done on CNC Vertical
machining centre by CNC Program.
25. CONT.
10. WIDTH MILLING:
The profile width is done on both sides on
horizontal milling machine as per the drawing.
11. CONVEX MILLING:
The milling is done on convex side by aCNC
machining center. The CNC Program is
developed based on the profile coordinates and
then loaded into the CNC system of the machine.
26. CONT.
12. CONCAVE MILLING:
The profile milling is done on concave side by a
CNC machining center. The CNC Program is
developed based on the profile coordinate and
then loaded in to the CNC system of the
machine.
13. TAPER MILLING:
The taper milling is done on a horizontal milling
machine by putting in a fixture specially made.
The taper is calculated from sine values and
machined accordingly.
27. CONT.
14. TAPER GRINDING:
The taper grinding is done on a surface grinding
machine and ensure the angle with in the given
tolerance in the diagram. Also surface finish
must be with in 8 microns.
15. FITTING AND POLISHING:
The blades are debarred and rounded off on the
inlet side and then polished on blade polishing
machine.
28. CONCLUSION ON BLADE
MANUFACTURING
As we understood that the efficiency and
reliability of a steam turbine depends on the
proper design of blades.
•The reliability of moving blades is to be ensured
upon proper design selection of material.
•In blade profile where as in impulse the entire
heats drop occurs in stationary blades.
•The fork root has higher load carrying capacity
than T‐root.
•Different milling cutters are used to finish the
operation on the blade.
•The growth for the steam turbines are very high
and demand for blades is growing.
29. Mostly 500MW turbine blades are manufactured in this shop.
Basically the design of blades is classified according to the stages of
turbine.
The size of LP Turbine blades is generally greater than of HP
Turbine blades.
30. OVER SPEED BALANCING
TUNNEL:
Features:
max. thickness of tunnel : 2500mm
tunnel diameter : 9000mm
min. vibration limit : 1micron
over speed limit : 2500 to 4500 rpm
rotor balancing of max. : 600Mw
rating
type of pedestal : DH 90/ DH 12
31. CONCLUSION:-
BHEL is the largest engineering and manufacturing enterprise in
India .
The company manufactures 235 MW nuclear turbine generator sets
and in future it will 500 MW.
BHEL is a major contributor of equipment and systems to
industries.
At the all, till now BHEL is best in supply and manufacturing
products.