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BHARAT HEAVY
ELECTRICALS
LIMITED,
HARIDWAR
Presentation By:-
ISHANT GAUTAM
B.TECH (M.E)
ROLL N0. 1232140025
TITM, MEERUT
VOCATIONAL TRAINING
At
NTS (NEW TURBINE
SHOP)
BHEL, HARIDWAR
(BLOCK-3)
 BHEL was established in 1964.
 BHEL is one of the only 7 Public Sector Undertakings (PSUs) of India
clubbed under the esteemed 'Maharatna' status . On 1st February
2013, the Government of India granted Maharatna status to BHEL.
 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 (Railway), Renewable
Energy, Oil & Gas and defence.
 BHEL has 15 manufacturing divisions, two repair units, four regional
offices, eight service centers and 15 regional centers.
OVERVIEW OF BHEL
1. BHEL Bhopal (Madhya Pradesh )
2. BHEL Ramachandrapuram, Hyderabad (Andhra Pradesh)
3. Transformer Plant, BHEL Jhansi(Uttar Pradesh)
4. High Pressure Boiler Plant and Seamless Steel Tube Plant,
Tiruchirapalli(Tamil Nadu)
5. Boiler Auxiliaries Plant, Ranipet (Tamil Nadu)
6. ElectronicsDivision and Electro Porcelain Division,Bangalore(Karnataka)
7. Jagdishpur (Uttar Pradesh)
8. Rudrapur (Uttrakhand)
9. Industrial ValvesPlant, Goindwal (Punjab)
10. BHEL Ranipur, Haridwar (Uttarakhand)
11. Bharat Heavy Plates and Vessels Limited(Vizag)
MAIN MANUFACTURING UNITS
 Boiler(stream generator)
 Gas Generator
 Hydro Generator
 Steam turbine
 Gas turbine
 Hydro turbine
 Transportation Equipments
 Traction Machines
 Transformer
 Switchgear
 Oil field equipments OFE
 Boiler drum
 Water wall panel
 Wind mill
 Valve
PRODUCTS RANGE
 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. 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, STEAM turbines, heat exchangers.
 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.
 Situated in Ranipur near Haridwar, the Bharat Heavy Engineering Limited employs over
8,000 people.
BHEL HARIDWAR UNIT
1. BLOCK-1: Electrical Machine Shop
2. BLOCK-2: Heavy Fabrication Shop
3. BLOCK-3: Turbine Manufacturing Shop
4. BLOCK-4: CIM (Coils & Insulation Manuf.)
5. BLOCK-5: Condenser Fabrication & Forge Shop
6. BLOCK-6: Fabrication Shop & Die Shop
7. BLOCK-7: Carpentry & Heat Treatment Shop
8. BLOCK-8: Heat Exchanger Shop
HEAVY ELECTRICAL EQUIPMENT
PLANT (HEEP)
BLOCK 3
TURBINE SHOP
BAY 1 BAY 2 BAY 3
HEAVY MACHINE
SHOP(HMS)
BEARING SECTION BLADE SHOP
ASSEMBLY SECTION TURNING SECTION TURNING SECTION
ASSEMBLY SECTION HEAT TREATMENT SHOP
GOVERNING SECTION
Block-3: TURBINE
MANUFACTURING SHOP
 A steam turbine works on the principle
of conversion of High pressure & temperature steam into high
Kinetic energy , thereby giving torque to a moving rotor.
STEAM TURBINE
1.High pressure turbine (H.P. Turbine)
2.Intermediate pressure turbine (I.P. Turbine)
3.Low pressure turbine (L.P. Turbine)
TYPES OF STEAM TURBINE
• High pressure and temperature fluid at the inlet of the turbine exit as lower
pressure and temperature fluid.
Specification of HP Turbine(500 MW)
Main Steam Temp- 537˚C
main steam pressure- 170 kg/cm2
Reheat steam temp- 537˚C
Length of Rotor - 4.61m
Height -2.15m
Weight -86400kg
HIGH PRESSURE TURBINE
(H.P. Turbine)
HIGH PRESSURE TURBINE
 Thebladesareresponsibleforextractingenergyfromthehigh
temperature,highpressuresteamproducedbythe boiler.
H.P TURBINE BLADES
 Intermediate pressure turbine having more pressure then L.P
turbine and lass than the high pressure turbine(H.P) . Its blade
is larger than high pressure turbine.
INTERMEDIATE PRESSURE
TURBINE
 The size of blades of I.P steam turbine is larger than H.P
steam turbine , but smaller than L.P steam turbine.
BLADE OF I.P TURBINE
 LP turbine is designed to be a dual flow turbine. Steam enters the centre of the
turbine from the crossover pipe and flows across the reaction blading in two
opposite directions. This configuration reduces axial thrust on the turbine and allows
for a smaller turbine installation.
Specification of LP Turbine(500 MW)
Main Steam Temp- 320˚C
Main steam pressure- 8 kg/cm2
Reheat steam temp- 320˚C
Length of Rotor - 8.71m
Height -10.7m
Weight-345000kg.
Low Pressure Turbine
LP TURBINE
Low Pressure Turbine
Titanium alloys offer high strength to intermediate
temperatures at a density almost half that of steel and nickel-
based super alloys. As a result, they have been adopted widely
in the fan and compressor stages of the gas turbine for both
disc and blade applications..
 LP blade is larger than HP & IP.
L.P TURBINE BLADES
HEAVY DUTY MACHINES
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
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
TACCHI HEAVY DUTY CNC LATHE:
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.
CASING SHELL OR
CYLINDER
 ASTM A 356 Grade 1 for
cast carbon steel
 Nodular Cast Iron G40
 The reason is that cast
carbon steel is weld
repairable(LP turbine inner
casing rings,)
 1-2 Cr Mo steels –low
temperature steam
 Cast 9 Cr 1 –Mo- V –Nb
alloys
 9-12-cr Martensite /ferrite
steel
Casing Materials
CASING
 LOWER HALF (L/H)  UPPER HALF (U/H)
 Various operations consist in manufacturing of blades
of steam turbine.
 Check the raw material(Stainless Steel / Titanium
Alloy)
 Blanking-by blank saw m/c
 MILLING- width and thickness are maintained
 Mill Rhomboid –Rhomboid shape is provided by
Duplex milling machine
 Blanking of Rhomboid shape
BLADE SHOP
 Rhomboid grinding-by CH-BACH M/c
 Right angle-by Horizontal milling M/C
 External profiling-by Hydraulic coping m/c or CNC Coping m/c
• Internal profiling
HYDRAULIC COPING M/C or CNC
COPING M/C
Template (checking for external
profile)
T –ROOT profiling is done by NC M/c at various station
 STATION 1- Clamping the w/p on NC m/c .
 STATION 2- Rough Tapering
 STATION 3- T-ROOT Cutting, Chamfering
 STATION 4- Stepping
 STATION 5- Smoothing o/p(final milling).
RUSSIAN DESIGN BLADE
GERMAN DESIGN
BLADE
Summer Training gives the idea of ‘general awareness in
steam turbine manufacturing’, & its process. Its provides
practical idea to manufacturing several components of
turbine.
CONCLUSION
Bhel hrd nts_ishant_me_titm

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Bhel hrd nts_ishant_me_titm

  • 1. BHARAT HEAVY ELECTRICALS LIMITED, HARIDWAR Presentation By:- ISHANT GAUTAM B.TECH (M.E) ROLL N0. 1232140025 TITM, MEERUT VOCATIONAL TRAINING At NTS (NEW TURBINE SHOP) BHEL, HARIDWAR (BLOCK-3)
  • 2.  BHEL was established in 1964.  BHEL is one of the only 7 Public Sector Undertakings (PSUs) of India clubbed under the esteemed 'Maharatna' status . On 1st February 2013, the Government of India granted Maharatna status to BHEL.  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 (Railway), Renewable Energy, Oil & Gas and defence.  BHEL has 15 manufacturing divisions, two repair units, four regional offices, eight service centers and 15 regional centers. OVERVIEW OF BHEL
  • 3. 1. BHEL Bhopal (Madhya Pradesh ) 2. BHEL Ramachandrapuram, Hyderabad (Andhra Pradesh) 3. Transformer Plant, BHEL Jhansi(Uttar Pradesh) 4. High Pressure Boiler Plant and Seamless Steel Tube Plant, Tiruchirapalli(Tamil Nadu) 5. Boiler Auxiliaries Plant, Ranipet (Tamil Nadu) 6. ElectronicsDivision and Electro Porcelain Division,Bangalore(Karnataka) 7. Jagdishpur (Uttar Pradesh) 8. Rudrapur (Uttrakhand) 9. Industrial ValvesPlant, Goindwal (Punjab) 10. BHEL Ranipur, Haridwar (Uttarakhand) 11. Bharat Heavy Plates and Vessels Limited(Vizag) MAIN MANUFACTURING UNITS
  • 4.  Boiler(stream generator)  Gas Generator  Hydro Generator  Steam turbine  Gas turbine  Hydro turbine  Transportation Equipments  Traction Machines  Transformer  Switchgear  Oil field equipments OFE  Boiler drum  Water wall panel  Wind mill  Valve PRODUCTS RANGE
  • 5.  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. 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, STEAM turbines, heat exchangers.  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.  Situated in Ranipur near Haridwar, the Bharat Heavy Engineering Limited employs over 8,000 people. BHEL HARIDWAR UNIT
  • 6. 1. BLOCK-1: Electrical Machine Shop 2. BLOCK-2: Heavy Fabrication Shop 3. BLOCK-3: Turbine Manufacturing Shop 4. BLOCK-4: CIM (Coils & Insulation Manuf.) 5. BLOCK-5: Condenser Fabrication & Forge Shop 6. BLOCK-6: Fabrication Shop & Die Shop 7. BLOCK-7: Carpentry & Heat Treatment Shop 8. BLOCK-8: Heat Exchanger Shop HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)
  • 7. BLOCK 3 TURBINE SHOP BAY 1 BAY 2 BAY 3 HEAVY MACHINE SHOP(HMS) BEARING SECTION BLADE SHOP ASSEMBLY SECTION TURNING SECTION TURNING SECTION ASSEMBLY SECTION HEAT TREATMENT SHOP GOVERNING SECTION Block-3: TURBINE MANUFACTURING SHOP
  • 8.  A steam turbine works on the principle of conversion of High pressure & temperature steam into high Kinetic energy , thereby giving torque to a moving rotor. STEAM TURBINE
  • 9. 1.High pressure turbine (H.P. Turbine) 2.Intermediate pressure turbine (I.P. Turbine) 3.Low pressure turbine (L.P. Turbine) TYPES OF STEAM TURBINE
  • 10. • High pressure and temperature fluid at the inlet of the turbine exit as lower pressure and temperature fluid. Specification of HP Turbine(500 MW) Main Steam Temp- 537˚C main steam pressure- 170 kg/cm2 Reheat steam temp- 537˚C Length of Rotor - 4.61m Height -2.15m Weight -86400kg HIGH PRESSURE TURBINE (H.P. Turbine)
  • 13.  Intermediate pressure turbine having more pressure then L.P turbine and lass than the high pressure turbine(H.P) . Its blade is larger than high pressure turbine. INTERMEDIATE PRESSURE TURBINE
  • 14.  The size of blades of I.P steam turbine is larger than H.P steam turbine , but smaller than L.P steam turbine. BLADE OF I.P TURBINE
  • 15.  LP turbine is designed to be a dual flow turbine. Steam enters the centre of the turbine from the crossover pipe and flows across the reaction blading in two opposite directions. This configuration reduces axial thrust on the turbine and allows for a smaller turbine installation. Specification of LP Turbine(500 MW) Main Steam Temp- 320˚C Main steam pressure- 8 kg/cm2 Reheat steam temp- 320˚C Length of Rotor - 8.71m Height -10.7m Weight-345000kg. Low Pressure Turbine
  • 18. Titanium alloys offer high strength to intermediate temperatures at a density almost half that of steel and nickel- based super alloys. As a result, they have been adopted widely in the fan and compressor stages of the gas turbine for both disc and blade applications..  LP blade is larger than HP & IP. L.P TURBINE BLADES
  • 20. 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
  • 21. 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. TACCHI HEAVY DUTY CNC LATHE:
  • 23. 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.
  • 25.  ASTM A 356 Grade 1 for cast carbon steel  Nodular Cast Iron G40  The reason is that cast carbon steel is weld repairable(LP turbine inner casing rings,)  1-2 Cr Mo steels –low temperature steam  Cast 9 Cr 1 –Mo- V –Nb alloys  9-12-cr Martensite /ferrite steel Casing Materials
  • 26.
  • 28.  LOWER HALF (L/H)  UPPER HALF (U/H)
  • 29.  Various operations consist in manufacturing of blades of steam turbine.  Check the raw material(Stainless Steel / Titanium Alloy)  Blanking-by blank saw m/c  MILLING- width and thickness are maintained  Mill Rhomboid –Rhomboid shape is provided by Duplex milling machine  Blanking of Rhomboid shape BLADE SHOP
  • 30.
  • 31.  Rhomboid grinding-by CH-BACH M/c  Right angle-by Horizontal milling M/C  External profiling-by Hydraulic coping m/c or CNC Coping m/c • Internal profiling
  • 32. HYDRAULIC COPING M/C or CNC COPING M/C
  • 33. Template (checking for external profile)
  • 34. T –ROOT profiling is done by NC M/c at various station  STATION 1- Clamping the w/p on NC m/c .  STATION 2- Rough Tapering  STATION 3- T-ROOT Cutting, Chamfering  STATION 4- Stepping  STATION 5- Smoothing o/p(final milling).
  • 36. Summer Training gives the idea of ‘general awareness in steam turbine manufacturing’, & its process. Its provides practical idea to manufacturing several components of turbine. CONCLUSION