The document provides an overview of Bharat Heavy Electricals Limited (BHEL), including its operations, products, contributions to different sectors, and facilities. Specifically: 1) BHEL is India's largest engineering and manufacturing company focused on power, industry, transportation and defense. It has over 50,000 employees across multiple manufacturing units. 2) The Haridwar facility includes the Heavy Electrical Equipment Plant (HEEP) and Central Foundry Forge Plant (CFFP), which manufacture products like steam turbines, gas turbines, and generators. 3) HEEP is divided into blocks focused on different manufacturing processes and products. It produces equipment for power, transportation, and other industries both in India and

1. 1
BHARAT HEAVY ELECTRICALS
LIMITED (BHEL) Haridwar
Vocational Training Report
New Turbine Shop -Block 15
Submitted by:
Anuj Gupta
4th
Year, B. Tech
Mechanical Engineering
Manav Rachna University

2. 2
Bharat Heavy Electricals Limited (BHEL) – An overview
BHEL today is the largest Engineering Enterprise of its kind in India with excellent track record
of performance, making profits continuously since 1971-72.
BHEL's vision is to become a world-class engineering enterprise, committed to enhancing
stakeholder value. The company is striving to give shape to its aspirations and fulfill the
expectations of the country to become a global player.
BHEL business operations cater to core sectors of Indian Economy.
• Power
• Industry
• Transportation
• Transmission
• Defenses
The greatest strength of BHEL is its highly skilled and committed 50,000 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.
BHEL Units in India
UNIT TYPE PRODUCT
1. Bhopal Heavy Electrical Part Steam Turbines, Turbo
Generators, Hydro Sets,
Switch Gear Controllers
2. Haridwar
HEEP
CFFP
Heavy Electrical Equipment
Plant
Central Foundry Forge Plant
Hydro Turbines, Steam
Turbines, Gas Turbines, Turbo
Generators, Heavy Castings
and Forging, Control Panels,
Electrical Machines.

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3. Hyderabad
HPEP
Heavy Power Equipment
Plant
Industrial Turbo-Sets,
Compressor Pumps and
Heaters, Bow Mills, Heat
Exchangers Oil Rings, Gas
Turbines, Switch Gears, Power
Generating Sets.
4. Trichy
HPBP
High Pressure Boiling Plant Seamless Steel Tubes, Spiral
Fin Welded Tubes.
5. Jhansi
TP
Transformer Plant Transformers, Diesel Shunt
Less AC locos and EC EMU.
6. Bangalore
EDN
EPD
Electronics Division
Electro Porcelains Division
Energy Meters, Watt Meters,
Control Equipement,
Capacitors, Photo Voltic
Panels, Simulator,
Telecommunication System,
Other Advanced
Microprocessor based
Control System
7. Ranipet
BAP
Boiler Auxilary Plant Electrostatic Precipitator, Air
Pre-Heater, Fans, Wind
Electric Generators,
Desalination Plants
8. Goindwal Industrial Valves Plant Industrial Valves &
Fabrication
9. Jagdishpur
IP
Insulator Plant High tension ceramic,
Insulation Plates and
Bushings
10. Rudrapur Component Fabrication Plant Windmill, Solar Water
Heating system
11. Gurgaon Amorphous Silicon Solar Cell
Plant.
Solar Photovoltaic Cells, Solar
Lanterns, Chargers ,Solar
clock

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BHEL Contributions in Different Sectors
• POWER SECTOR: Power sector comprises thermal, nuclear, gas & hydro power plant
business. Today, BHEL supplied sets account for nearly 56,318 MW or 65% of the total
installed capacity of 86,636 MW in as against nit till 1969-1970. BHEL has proven turnkey
capabilities for executing power projects from concept to commissioning. It possess the
technology and capability to produce thermal power plant equipments up to 1000MW
rating and gas turbine generator sets up to a unit rating of 240 MW. To make efficient use
of the high ash content coal available in India, BHEL supplies circulating fluidized bed
boilers to thermal and combined cycle power plants. BHEL manufacturers 235 MW
nuclear turbine generator sets and has commenced production of 500 MW nuclear
turbine generator sets. Custom-made hydro sets of Francis, Pelt on and Kaplan types for
different head-discharge combinations are also engineered and manufactured by BHEL is
based upon contemporary technology comparable to the best in the world & is also
internationally competitive.
• Transmission: BHEL also supplies a wide range of transmission products and systems up
to 400 KV Class. These include high voltage power and distribution transformers,
instrument transformers, dry type transformers, SF6 switchgear, capacitors, and
insulators etc. For economic transmission bulk power over long distances, High Voltage
Direct Current (HVDC) systems are supplied. Series and Shunt Compensation Systems
have also been developed and introduced to minimize transmission losses.
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).
• Transportation: A high percentage of trains operated by Indian Railways are equipped
with BHEL’s traction and traction control equipment including the metro at Calcutta. The
company supplies broad gauge electrical locomotives to Indian Railways and diesel
shunting locomotives to various industries.5000/6000 hp AC/DC locomotives developed
and manufactured by BHEL have been leased to Indian Railways. Battery powered road
vehicles are also manufactured by the company.

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• International Operations: BHEL’s products, services and projects have been exported to
over 50 countries ranging from United States in the west to New Zealand in Far East. The
cumulative capacity of power generating equipment supplied by BHEL outside India is
over 3000MW. The company’s overseas presence includes projects in various countries.
A few notable ones are: 150 MW (ISOI) gas turbine to Germany, utility boilers and open
cycle gas turbine plants to Malaysia, Tripoli-west, power station in Libya executed on
turnkey basis, thermal power plant equipment to Malta and Cyprus, Hydro generators to
New Zealand and hydro power plant equipment to Thailand. BHEL has recently executed
major gas-based power projects in Saudi Arabia and Oman, a Boiler contract in Egypt and
several Transformer contracts in Malaysia and Greece
• Renewable Energy: Technologies offered by BHEL for non-conventional and renewable
sources of energy include: wind electric generators, solar photovoltaic system, stand
alone and grid-interactive solar power plants, solar heating systems, solar lanterns and
battery-powered road vehicles. The company has taken up R&D efforts for development
of multi-junction amorphous solar cells and fuel cells based systems.
• INDUSTRIES: BHEL is a major contributor of equipment and systems to industries:
cement, sugar, fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and
process industries. The company is a major producer of large-size thyristor devices. It also
supplies digital distributed control system for process industries and control &
instrumentation systems for power plant and industrial application. 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, defense and other applications.

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BHEL – Haridwar
At Haridwar, against the picturesque background of Shivalik Hills, 2 important manufacturing
units of BHEL are located viz. Heavy Electrical Equipment Plant (HEEP) & Central Foundry Forge
Plant (CFFP). The hum of the construction machinery working started under Shivalik Hills during
early 60s and sowed the seeds of one of the greatest symbol of Indo Soviet Collaboration –
Heavy Electrical Equipment Plant.
Consequent upon the technical collaboration between India and USSR in 1959, BHEL’s
prestigious unit, Heavy Electrical Equipment plant (HEEP), was established in October, 1963, at
Hardwar. It started manufacturing thermal sets in 1967 and now thermal sets of 210, 250 and
500 MW, including steam turbines, turbo-generators, condensers and all associated
equipments, are being manufactured. This unit is capable of manufacturing thermal sets up to
1000 MW. HEEP-manufactured gas turbines, hydro turbines and generators, etc., are not only
successfully generating electrical energy within and outside the country, but have also
achieved a historic record of the best operational availability.
POWER & WATER SUPPLY SYSTEM:
- 40 MVA sanctioned Electric Power connection from Grid (132 KV / 11KV / 6.6 KV)
(Connected load – around 185 MVA)
- 26 deep submersible Tube Wells with O.H. Tanks for watersupply.
- A 12 MW captive thermal power station is located in the factory premises.
MAIN PRODUCTS:
- Steam Turbines
- Gas Turbines
- Turbo Generators
- Heat Exchangers
BHEL – Haridwar is broadly divided into 2 PLANTS
A. CFFP – Central Foundry Forge Plant B. HEEP – Heavy Electrical Equipment Plant

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A. CFFP is divided in to following shops:
• Forge Shop
• Machine Shop
• Steel Melting Shop (SMS)
• Steel Foundry
• Pattern Shop
• Cast Iron (CI) Foundry
B. HEEP is divided into following blocks:
• BLOCK-1: Turbo Generators, Assembly
• BLOCK-2: Fabrication (Steam, Hydro & gas Turbine)
• BLOCK-3: Gas & Steam Turbine
• BLOCK-4: CIM (Coil & Insulation Manufacturing) & ACG (Apparatus control Gear)
• BLOCK-5: Heat exchangers, Forging and Fabrication
• BLOCK-6: Stamping Shop
• BLOCK-7: Wooden Packing works
• BLOCK-8: Heat exchanger Shop
• BLOCK-11: Defense Block
• BLOCK-12: New Blade Shop
• BLOCK-14: Apparatus Controlled Gear Manufacturing
• BLOCK-15: New turbine Shop

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Detailed Organization/Production Tree of HEEP PLANT of BHEL
– Haridwar
BHEL – Haridwar is divided into various sections/blocks for effective organization and
management. Each block manufactures a specific set of machinery and equipments,
which are described as below:
Sr. No. Block Major Facilities Products
1. Block –I
(Electrical Machines) Machine Shop, Stator Winding
[THRI & LSTG], Rotor Winding [THRI
& LSTG], Core Assembly, Exciter
Section, over speed balancing, Test
Bed, babbiting, Micalastic
impregnation [LSTG & THRI]
Turbo Generator,
Brushless Exciters
2. Block – II
(Fabrication
Block)
Stator Frame [THRI & LSTG],
Markings, welding, Cutting,
straightening, gas cutting press,
, Grinding, assembly, heat
treatment, cleaning & Shot blasting,
machining, fabrication of pipe
coolers, painting
Large size
fabricated
assemblies/
components for
power
Equipments
3. Block –III
(Turbines & Auxiliary
Block)
Machining, facing wax melting,
broaching, assembly
preservation & packing, test stands/
station, painting grinding, milling,
polishing etc.
Stem turbines,
Hydro turbines,
Gas turbines, turbine
bladders, special
tooling.
4. Block –IV
(Feeder Block)
1. ACM
Rotor Bar Manufacturing
[THRI & LSTG]
Rotor Bars
[Field Bars]
2. CIM Stator Bar Manufaturing
Exciter Rotor Bar Manufacturing
Stator Bars and
Exciter Bars
[Armature Bars]

9. 9
5. Block – V Fabrication, pneumatic hammer for
forgings, gas fired furnaces,
hydraulic manipulators
Fabricated parts of
steam turbine, water
box,
Storage tank
hydro turbine
Parts, hydro
turbines assemble
6. Block – VI
(Fabrication)
Welding, drilling, shot blasting, CNC
flame cutting, CNC deep drilling,
Shot basting, sheet metal work,
assembly
Fabricated parts of
steam turbine water
box,
Stronger tanks,
Hydro turbine
Parts, Hydro
turbines assemblies
7. Block – VI
(Stamping & Die
Manufacturing)
Machining, turning, grinding, jig
boring stamping presses, de
varnishing, degreasing & de rusting,
varnishing sport welding, painting.
Wooden packing,
spacers etc.
8. Block – VII (wood
working)
Wood Cutting, machines,
grinding, packing
Wooden packing,
spacers etc.
9. Block – VIII Drilling, turning, saw, cutting,
welding, tig welding
LP Heater
ejectors glad, steam
cooler oil coolers,
ACG collers, oil tanks,
bearing covers.
CFFP PLANT of BHEL
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.

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STEAM TURBINE
Fig 1. VIEW OF 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 (invented by
Thomas Newcomen and greatly improved by James Watt) 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 6
multiple stages in the expansion of the steam, which results in a closer approach to the ideal
reversible process.
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.

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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. 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. 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.

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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, reflecting the work performed in the
driving of the rotor.
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.
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.
STEAM 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.
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

13. 13
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.
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

14. 14
impulse or reaction turbines. Most modern steam turbines are a combination of the reaction and
impulse design. Typically, higher pressure sections are impulse type and lower pressure stages
are reaction type.
Impulse Turbines
An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets
contain significant kinetic energy, which the rotor blades, shaped like buckets, convert into shaft
rotation as the steam jet changes direction. A pressure drop occurs across only the stationary
blades, with a net increase in steam velocity across the stage.
Reaction Turbines
In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles.
This type of turbine makes use of the reaction force produced as the steam accelerates through
the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator.
It leaves the stator as a jet that fills the entire circumference of the rotor. The steam 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.

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TURBINE BLADE
1.TURBINE 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
• Free standing LP moving blades Tip sections with supersonic design.
• Fir-tree root
• Flame hardening of the leading edge
• Banana type hollow guide blade
• Tapered and forward leaning for optimized mass flow distribution
• Suction slits for moisture removal
2.TURBINE 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.
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 the haft. This construction
requires a disc rotor. Basically there are two types of rotor:

16. 16
1.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.
2.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.
3.CONSTRUCTIONAL FEATURES OF A BLADE
The blade can be divided into 3 parts:
1. The profile, which converts the thermal energy of steam into kinetic energy, with a
certain efficiency depending upon the profile shape.
2. 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.
3. 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.
1.1 H.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.
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

17. 17
setting angle. Pitch of a blade is the circumferential distance between any point on the profile
and an identical point on the next blade.
Fig 2. HIGH PRESSURE BLADE AIRFOIL PROFILE

18. 18
1.2 CLASSIFICATION OF PROFILES
There are two basic types of profiles - Impulse and Reaction. In the impulse type of profiles, the
entire heat drop of the stage occurs only in the stationary blades. In the reaction type of blades,
the heat drop of the stage is distributed almost equally between the guide and moving blades.
Though the theoretical impulse blades have zero pressure drop in the moving blades, practically,
for the flow to take place across the moving blades, there must be a small pressure drop across
the moving blades also. Therefore, the impulse stages in practice have a small degree of reaction.
These stages are therefore more accurately, though less widely, described as low-reaction stages.
The presently used reaction profiles are more efficient than the impulse profiles at part loads.
This is because of the more rounded inlet edge for reaction profiles. Due to this, even if the inlet
angle of the steam is not tangential to the pressure-side profile of the blade, the losses are low.
However, the impulse profiles have one advantage. The impulse profiles can take a large heat
drop across a single stage, and the same heat drop would require a greater number of stages if
reaction profiles are used, thereby increasing the turbine length. The Steam turbines use the
impulse profiles for the control stage (1st stage), and the reaction profiles for subsequent stages.
There are four reasons for using impulse profile for the first stage:
a) Most of the turbines are partial arc admission turbines. If the first stage is are action stage, the
lower half of the moving blades do not have any inlet steam, and would ventilate. Therefore,
most of the stage heat drop should occur in the guide blades.
b) The heat drop across the first stage should be high, so that the wheel chamber of the outer
casing is not exposed to the high inlet parameters. In case of -4turbines, the inner casing parting
plane strength becomes the limitation, and therefore requires a large heat drop across the 1st
stage.
c) Nozzle control gives better efficiency at part loads than throttle control.
d) The number of stages in the turbine should not be too high, as this will increase the length of
the turbine.
There are exceptions to the rule. Turbines used for CCPs, and BFP drive turbines do not have a
control stage. They are throttle-governed machines. Such designs are used when the inlet
pressure slides. Such machines only have reaction stages. However, the inlet passages of such
turbines must be so designed that the inlet steam to the first reaction stage is properly mixed,
and
occupies the entire 360 degrees. There are also cases of controlled extraction turbines where the
L.P. control stage is an impulse stage. This is either to reduce the number of stages to make the
turbine short, or to increase the part load efficiency by using nozzle control, which minimizes
throttle losses.

19. 19
1.3 H.P. BLADE ROOTS
The root is a part of the blade that fixes the blade to the rotor or stator. Its design depends upon
the centrifugal and steam bending forces of the blade. It should be designed such that the
material in the blade root as well as the rotor / stator claw and any fixing element are in the safe
limits to avoid failure. The roots are T-root and Fork-root. The fork root has a higher 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
2 L.P. BLADE PROFILES
The LP blade profiles of moving blades are twisted and tapered. These blades are used when
blade height-to-mean stage diameter ratio (h/Dm) exceeds 0.2.
2.1 LP BLADE ROOTS
The roots of LP blades are as follows:
• 2 Blading:
a. The roots of both the LP stages in –2 type of LP Blading are T-roots.
• 3 Blading:
a. The last stage LP blade of HK, SK and LK blades have a fork-root. SK blades
have4-fork roots for all sizes. HK blades have 4-fork roots up to 56 size, where
modified profiles are used. Beyond this size, HK blades have 3 fork roots. LK
blades have 3-forkroots for all sizes. The roots of the LP blades of preceding
stages are of T-roots.
2.2 DYNAMICS IN BLADE
The excitation of any blade comes from different sources. They are
• Nozzle-passing excitation: As the blades pass the nozzles of the stage, they encounter
flow disturbances due to the pressure variations across the guide blade passage. They
also encounter disturbances due to the wakes and eddies in the flow path. These are
sufficient to cause excitation in the moving blades. The excitation gets repeated at
every pitch of the blade. This is called nozzle-passing frequency excitation. The order
of this frequency =no. of guide blades x speed of the machine. Multiples of this
frequency are considered for checking for resonance.

20. 20
• Excitation due to non-uniformities in guide-blades around the periphery. These can
occur due to manufacturing inaccuracies, like pitch errors, setting angle variations,
inlet and outlet edge variations, etc.
For HP blades, due to the thick and cylindrical cross-sections and short blade heights, the natural
frequencies are very high. Nozzle-passing frequencies are therefore necessarily considered, since
resonance with the lower natural frequencies occurs only with these orders of excitation.
In LP blades, since the blades are thin and long, the natural frequencies are low. The excitation
frequencies to be considered are therefore the first few multiples of speed, since the 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 ranges. The entire design range of operating speed of the LP blades cannot be outside
the resonance ranges. 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.

21. 21
The damping in any blade can be of any of the following types:
a) Material damping: This type of damping is because of the inherent damping properties of the
material which makes up the component.
b) Aerodynamic damping: This is due to the damping of the fluid which surrounds the
component in operation.
c) Friction damping: This is due to the rubbing friction between the component under
consideration with any other object.
Out of these damping mechanisms, the material and aerodynamic types of damping are very
small in magnitude. Friction damping is enormous as compared to the other two types of
damping. Because of this reason, the damping elements in blades generally incorporate a feature
by which the vibrational energy is dissipated as frictional heat. The frictional damping has a
particular characteristic. When the frictional force between the rubbing surfaces is very small as
compared to the excitation force, the surfaces slip, resulting in friction damping. However, when
the excitation force is small when compared to the frictional force, the surfaces do not slip,
resulting in locking of the surfaces. This condition gives zero friction damping, and only the
material and aerodynamic damping exists. In a periodically varying excitation force, it may
frequently happen that the force is less than the friction force.
During this phase, the damping is very less. At the same time, due to the locking of the rubbing
surfaces, the overall stiffness increases and the natural frequency shifts drastically away from the
individual value. The response therefore also changes in the locked condition. The resonant
response of a system therefore depends upon the amount of damping in the system (which is
determined by the relative duration of slip and stick in the system, i.e., the relative magnitude of
excitation and friction forces) and the natural frequency of the system (which alters between the
individual values and the locked condition value, depending upon the slip or stick condition).
2.3 BLADING MATERIALS
Among the different materials typically used for blading are 403 stainless steel, 422 stainless
steel, A-286, and Haynes Satellites Alloy Number 31 and titanium alloy. The403 stainless steel is
essentially the industry’s standard blade material and, on impulse steam turbines, it is probably
found on over 90 percent of all the stages. It is used because of its high yield strength, endurance
limit, ductility, toughness, erosion and corrosion resistance, and damping. It is used within a
Brinell hardness range of 207 to 248 to maximize its damping and corrosion resistance. The 422
stainless steel material is applied only on high temperature stages (between 700 and 900°F or
371 and 482°C), where its higher yield, endurance, creep and rupture strengths are needed.
The A-286 material is a nickel-based super alloy that is generally used in hot gas expanders with
stage temperatures between 900 and 1150°F (482 and 621°C). The Haynes Satellites Alloy
Number 31 is a cobalt-based super alloy and is used on jet expanders when precision cast blades
are needed. The Haynes Satellite Number 31 is used at stage temperatures between 900 and
1200°F (482 and 649°C). Another blade material is titanium. Its high strength, low density, and

22. 22
good erosion resistance make it a good candidate for high speed or long-last stage blading.
3. MANUFACTURING PROCESS
3.1 INTRODUCTION
Manufacturing process is that part of the production process which is directly concerned with
the change of form or dimensions of the part being produced. It does not include the
transportation, handling or storage of parts, as they are not directly concerned with the changes
into the form or dimensions of the part produced. Manufacturing is the backbone of any
industrialized nation.
Manufacturing and technical staff in industry must know the various manufacturing processes,
materials being processed, tools and equipments for manufacturing different components or
products with optimal process plan using proper precautions and specified safety rules to avoid
accidents. Beside above, all kinds of the future engineers must know the basic requirements of
workshop activities in term of man, machine, material, methods, money and other infrastructure
facilities needed to be positioned properly for optimal shop layouts or plant layout and other
support services effectively adjusted or located in the industry or plant within a well planned
manufacturing organization. Today’s competitive manufacturing era of high industrial
development and research, is being called the age of mechanization, automation and computer
integrated manufacturing. Due to new researches in the manufacturing field, the advancement
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.
3.2 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

23. 23
• Processes effecting change in properties
3.2.1 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
3.2.2 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

24. 24
• Planning
• Shaping
• 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.

25. 25
4. BLOCK 15 LAY-OUT

26. 26
5. CLASSIFICATION OF BLOCK 15 – NEW TURBINE SHOP
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.
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.

27. 27
Fig 3. 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.
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.

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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.
Fig 4. 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 5. CNC Rotor Turning Lathe

29. 29
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.
4. BLADE SHOP
Blade shop is an important shop of Block 3. Blades of all the stages of turbine are made in this
shop only. They have a variety of centre lathe and CNC machines to perform the complete
operation of blades. The designs of the blades are sent to the shop and the Respective job is
distributed to the operators. Operators perform their job in a fixed interval of time.
5. TYPES OF BLADES
Basically the design of blades is classified according to the stages of turbine. The size of LP
TURBINE BLADES is generally greater than that of HP TURBINE BLADES. At the first T1,
T2, T3 & T4 kinds of blades were used, these were 2nd generation blades. Then it was replaced
by TX, BDS (for HP TURBINE) & F shaped blades. The most modern blades are F & Z shaped
blades.
Cylindrical Profile
TX Blade
HP/IP Intermediate stages & LP Initial 3 Dimesional 3DS Blade
HP/IP Initial Stages Twisted Profile F Blade
HP/IP Rear Stages
Fig. 6 Types of Blades

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5.2 OPERATIONS PERFORMED ON BLADES
Some of the important operations performed on blade manufacturing are: -
• Milling
• Blank Cutting
• Grinding of both the surfaces
• Cutting
• Root milling
5.3 MACHINING OF BLADES
Machining of blades is done with the help of Lathe & CNC machines. Some of the machines
Are: -
• Centre lathe machine
• Vertical Boring machine
• Vertical Milling machine
• CNC lathe machine

31. 31
5.4 NEW BLADE SHOP
A new blade shop is being in operation, mostly 500mw turbine blades are manufactured in this
shop. This is a highly hi-tech shop where complete manufacturing of blades is done using single
advanced CNC machines. Complete blades are finished using modernized CNC machines. Some
of the machines are: -
• Pama CNC ram boring machine.
• Wotum horizontal machine with 6 axis CNC control.
• CNC shaping machine.
Fig 7. CNC Shaping Machine

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Conclusion
Gone through rigorous 6 Weeks training under the guidance of capable engineers
and workers of BHEL Haridwar in Block-15 “THE NEW TURBINE SHOP” headed by
Senior Engineer of department Mr. SUSHIL KUMAR RAWAT situated in 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.
Overall, the Vocational training has been quite an experience and provided me the
platform to purse my dreams in a rightful manner.