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Industrial Training Report bhel haridwar.

This document provides an industrial training report on steam turbine manufacturing at Bharat Heavy Electricals Limited (BHEL) in Haridwar, India. It includes an acknowledgement, abstract, introduction to BHEL and its units including the Heavy Electrical Equipment Plant and Central Foundry Forge Plant in Haridwar. The document then discusses the manufacturing of steam turbines, including the principle of operation, advantages, disadvantages and design process. It also covers types of steam turbines, turbine parts, blade features, classifications of blocks in BHEL Haridwar, and the blade shop operations.

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1 AN INDUSTRIAL TRAINING REPORT ON General Awareness on Steam Turbine Manufacturing B.H.E.L., Haridwar SUBMITTED By RISHABH NISHAD DEPARTMENT OF MECHANICAL ENGINEERING KIET GROUP OF INSTITUTIONS, GHAZIABAD
2 ACKNOWLEDGEMENT I take this opportunity to thank the Industrial Training Co-Ordinator of Mechanical Engineering Department for allowing us to avail this great opportunity. I am also grateful to the management of Bharat Heavy Electricals Limited (B.H.E.L.), Haridwar for permitting me to have training during 9th June to 9th July 2018. Last but not the least I would also like to thank all our teachers & friends for their constructive criticism given in right spirit. Rishabh Nishad 7th Semester, B.Tech. Mechanical Engineering KIET GROUP OF INSTITUTIONS
3 ABSTRACT In my Industrial Training in B.H.E.L., Haridwar I have gone through all sections in Turbine Manufacturing. Also, I got to know about the history of industry, Area, Capacity, Machines installed & Facilities in the Industry. In power generation mostly steam turbine is used because of its greater thermal efficiency and higher power-to-weight ratio. Of all heat engines and prime movers, the steam turbine is nearest to the ideal and it is widely used in power plants and in all industries where power is needed for process. 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. Rotor is the heart of the steam turbine and it affects the efficiency of the steam turbine. In this report we have mainly discussed about the working process of a steam turbine. The thermal efficiency of a steam turbine is much higher than that of a steam engine. I learned about the Steam Turbine its types, parts like Blades, Casing, Rotor etc. Constructional features and procedure along with equipment used, material of blade, types of Blades, Operations performed on Blades, their New Blade Shop with Advance Technology like CNC Shaping Machine. I would like to express my deep sense of Gratitude and thanks to Mr. VIMAL KUMAR (DY. MANAGER) our in charge of training, Turbine Block-3,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 Page No. ACKNOWLEDGEMENT ABSTRACT 2 3 INTRODUCTION 6 1. BHEL 1.1 OVERVIEW 1.2 BHEL UNITS 1.3 BHEL HARIDWAR 1.3.1 LOCATION 1.3.2 ADDRESS 1.3.3 AREA 1.3.4 UNITS 1.3.5 HEEP PRODUCT PROFILE 9 2. MANUFACTURING OF STEAM TURBINE 2.1 INTRODUCTION 2.2 PRINCIPLE 2.3 ADVANTAGES 2.4 DISADVANTAGES 2.5 STEPS INVOLVED IN THE DESIGN OF STEAM TURBINES 16 3. TYPES OF STEAM TURBINE 3.1 COMPARISION BETWEEN IMPULSE AND REACTION TURBINE 19 4. TURBINE PARTS 4.1 NOZZLE 4.2 DIFFUSER 4.3 TURBINE BLADES 4.4 GUIDE BLADES 4.4 TURBINE CASING 4.5 SHAFT, ROTOR, SPINDLE 4.6 TURBINE GOVERNING SYSTEM 21 5. FEATURES OF BLADE 24
5 5.1 BLADE MATERIALS 5.2 H.P. BLADE PROFILES 5.3 CLASSIFICATION OF PROFILES 5.4 H.P. BLADE ROOTS 6. CLASSIFICATION OF BLOCK-3 6.1 BAY-1 6.2 BAY-2 6.3 BAY-3 6.4 BAY-4 27 7. BLADE SHOP 9.1 TYPES OF BLADES 9.2 OPERATIONS PERFORMED ON BLADES 9.3 MACHINING OF BLADES 9.4 NEW BLADE SHOP 32 9. END NOTE 36
6 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 since 1971-72. BHEL has a mammoth 20,000 MW per annum capability for manufacturing of power generation equipment. A widespread network of 17 manufacturing units, 2 repair units, 4 regional offices, 8 service centers, 1 subsidiary, 4 overseas offices, 6 joint ventures, 15 regional marketing centers and current project execution at more than 150 project sites across India and abroad corroborates the humongous scale and size of its operations. With key focus on project execution, the worldwide installed base of power generating equipment supplied by BHEL has exceeded 178 GW. BHEL’s 54% share in India’s total installed capacity and 58% share in the country’s total generation from thermal utility sets (coal based) as of March 31, 2017 stand a testimony to its valuable contribution towards nation building.
7 World of BHEL: 1. Did you know - ▪ BHEL is the single largest contributor to the country’s total installed electric utilities. ▪ All Indian satellites launched by ISRO are equipped with BHEL supplied solar panels since 2002 & batteries since 2005. ▪ World's largest ±800 kV, 6000 MW multiterminal HVDC NE-Agra transmission project under execution by BHEL. ▪ All the three ships of the Kolkata-class stealth guided missile destroyers equipped with BHEL’s 76/ 62 mm Super Rapid Gun Mount (SRGM) and Auxiliary Control System. ▪ 95% of hydroelectric generating capacity in Bhutan installed by BHEL. ▪ BHEL’s first power generating set was the 30 MW thermal power station installed at Basin bridge in Tamil Nadu, way back in 1969. ▪ All the states & six union territories of the country have power generating equipment installed by BHEL. 2. Innovation- ▪ Innovation R&D Expenditure >2.5% of Turnover-highest in Indian engineering field. ▪ Five research institutes. 14 Centres of Excellence. ▪ In-house R&D Centres of 12 Manufacturing units/Divisions recognized by DSIR 3. Unparalleled industrial experience- ▪ 570,000+ MVA transmission equipment supplied. ▪ 31,000+ AC machines- supplied, largest Indian manufacturer. ▪ >50% of Indian Railways rolling stock equipped with BHEL's traction equipment. ▪ 360 electric locos supplied to Indian Railways & other industries. ▪ 385+ compressors & 90 oil drilling rigs- supplied.
8 4. Energizing India- ▪ Major integrated power plant equipment manufacturer in the world with 20,000 MW p.a. manufacturing capacity. ▪ 178+ GW power generating equipment installed till date. ▪ 55% of India’s nuclear power generating capacity (conventional island) installed by BHEL. ▪ Commissioned country’s first 660 MW indigenously manufactured supercritical set at NTPC Barh-5, in 2013. ▪ 16,500+ MW Captive Power Plant installed. ▪ 350+ MW- cumulative shipments of PV cells, modules, and systems. • Financial Report BHEL (2016-17): - Figures are restated as per Ind AS
9 # Dividend for 2015-16* and 2016-17, includes Interim Dividend for the Current Year and Final Dividend for the Previous Year as per Ind AS 1. B.H.E.L. 1.1. OVERVIEW BHEL is one of the few companies in the world having the capability to manufacture the entire range of power plant equipment and has proven turnkey capabilities for executing power projects from concept-to commissioning. The power sector of the company comprises thermal, gas, hydro and nuclear power plants. BHEL: ▪ Has the capability to supply steam turbines, generators, boilers and their auxiliaries up to 800 MW with capability to supply up to 1000 MW. Currently executing projects on EPC (Engineering, procurement and construction) basis including supercritical sets of 660/700/800 MW ratings. ▪ Has the capability to supply hydro turbines and generators up to 400 MW. ▪ Has the capability to supply nuclear turbine generator sets including 220/235/540/550/ 700MWe. ▪ Has proven expertise in plant performance improvement through renovation, modernization and uprating of a variety of power plant equipment. ▪ Has special knowhow of residual life assessment, health diagnostics and life extension of plants. ▪ Has supplied thermal sets that have consistently exceeded national average availability and efficiency parameters.
10 1.2. BHEL UNITS: UNIT TYPE PRODUCT 1. Bhopal Heavy Electrical Part Steam Turbines, Turbo Generators, Hydro Sets, Switch Gear Controllers 2. Haridwar Hydro Turbines, Steam Turbines, Gas Turbines, Turbo Generators, Heavy Castings HEEP Heavy Electrical Equipment and Forging, Control Panels, Light Aircrafts, Plant Electrical Machines. CFFP Central Foundry Forge Plant 3. Hyderabad Industrial Turbo-Sets, Compressor Pumps and Heaters, Bow Mills, Heat Exchangers HPEP Heavy Power Equipment Plant Oil Rings, Gas Turbines, Switch Gears, Power Generating Sets. 4. Trichy Seamless Steel Tubes, Spiral Fin Welded HPBP High Pressure Boiling Plant Tubes. 5. Jhansi Transformers, Diesel Shunt Less AC locos TP Transformer Plant and EC EMU. 6. Bangalore Energy Meters, Watt Meters, Control Equipment, Capacitors, Photo Voltaic Panels, EDN Electronics Division Simulator, Telecommunication System, Other Advanced Microprocessor based Control EPD Electro Porcelains Division System, Insulator and Bushing, Ceramic Liners
11 7. Ranipet Electrostatic Precipitator, Air Pre-Heater, Fans, Wind Electric Generators, Desalination BAP Boiler Auxiliary Plant Plants. 8. Goindwal Industrial Valves Plant Industrial Valves & Fabrication 9. Jagdishpur High tension ceramic, Insulation Plates and IP Insulator Plant Bushings 10. Rudrapur Component Fabrication Plant Windmill, Solar Water Heating system 11. Gurgaon Amorphous Silicon Solar Cell Solar Photovoltaic Cells, Solar Lanterns, Plant. Chargers, Solar clock Table-1 1.3. BHEL HARIDWAR 1.3.1. LOCATION It is situated in the foot hills of Shivalik range in Haridwar. The main administrative building is at about 8 km from Haridwar. 1.3.2. ADDRESS Bharat Heavy Electrical Limited (BHEL) Ranipur, Haridwar PIN- 249403 1.3.3. AREA BHEL Haridwar consists of two manufacturing units, namely Heavy Electrical Equipment Plant
12 (HEEP) and Central Foundry Forge Plant (CFFP), having area HEEP area: - 8.45 sq. km CFFP area: - 1.0 sq. km The Heavy Electricals Equipment Plant (HEEP) located in Haridwar, is one of the major manufacturing plants of BHEL. The core business of HEEP includes design and manufacture of large steam and gas turbines, turbo generators, hydro turbines and generators, large AC/DC motors and so on. Central Foundry Forge Plant (CFFP) is engaged in manufacture of Steel Castings: Up to 50 Tons per Piece Wt. & Steel Forgings: Up to 55 Tons per Piece Wt. 1.3.4. UNITS There are two units in BHEL Haridwar as followed: 1) Heavy Electrical Equipment Plant (HEEP) 2) Central Foundry Forge Plant (CFFP) There are 8 Blocks in HEEP: Blocks Work Performed in Block I) Electrical Machine Turbo Generator, Generator Exciter, Motor (AC and DC)
13 II) Fabrication Large Size Fabricated Assemblies or Components III) Turbines & Auxiliary Steam, Hydro Turbines, Gas turbines, Turbine Blade, Special Tooling. IV) Feeder Winding of Turbo, Hydro Generators, Insulation for AC & DC Motors V) Fabrication Fabricated Parts of Steam Turbine, Water Boxes, Storage Tank, Hydro Turbine Parts VI) Fabrication Fabricated Oil Tanks, Hollow Guide Blades, Rings, Stator Frames and Stamping & Die Manufacturing Rotor Spindle, All Dies, Stamping for Generators and Motor VII) Wood Working Wooden Packing, Spacers VIII) Heaters & LP heaters, Ejectors, Glands, Steam and Oil Coolers, Oil Tank, Bearing Coolers Covers Table-2 There are 3 Sections in CFFP: Blocks Work Performed in Block 1. Foundry Casting of Turbine Rotor, Casing and Francis Runner 2. Forging Forging of Small Rotor Parts 3. Machine Shop Turning, Boring, parting off, Drilling etc. Table -3
14 1.3.5. HEEP PRODUCT PROFILE 1. THERMAL SETS: • Steam turbines and generators up to 1000 MW capacity for utility and combined cycle applications. • Capability to manufacture up to 1000 MW unit cycle. 2. GAS TURBINES: • Gas turbines for industry and utility application range 3 to 200 MW (ISO). • Gas turbines based co-generation and combined cycle system. 3. HYDRO SETS: • Custom– built conventional hydro turbine of Kaplan, Francis and Pelton with matching generators up to 250 MW unit size. • Pump turbines with matching motor-generators. Mini / micro hydro sets. • Spherical butterfly and rotary valves and auxiliaries for hydro station. 4. EQUIPMENT FOR NUCLEAR POWER PLANTS: • Turbines and generators up to 500MW unit size. • Steam generator up to 500MW unit size. • Re-heaters / Separators. • Heat exchangers and pressure vessels.
15 5. ELECTRICAL MACHINES: • DC general purpose and rolling mill machines from 100 to 19000KW suitable for operation on voltage up to 1200V. These are provided with STDP, totally enclosed and duct ventilated enclosures. • DC auxiliary mill motors. 6. CONTROL PANEL: Control panel for voltage up to 400KW and control desks for generating stations and EMV sub–stations. 7. CASTING AND FORGINGS: • Sophisticated heavy casting and forging of creep resistant alloy steels, stainless steel and other grades of alloy meeting stringent international specifications. 8. DEFENCE: • Naval guns with collaboration of Italy.
16 2. MANUFACTURING OF STEAM TURBINE 2.1. INTRODUCTION: A steam turbine is a mechanical device that converts thermal energy in pressurized steam into useful mechanical work. The steam turbine derives much of its better thermodynamic efficiency because of the use of multiple stages in the expansion of the steam. A turbine is a rotary engine that extracts energy from a fluid flow and converts it into useful work. The simplest turbines have one moving part, a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades, or the blades react to the flow, so that they move and impart rotational energy to the rotor. Fig.1 Sectional View of a Steam Turbine
17 2.2. PRINCIPLE: The steam energy is converted mechanical work by expansion through the turbine. The expansion takes place through a series of fixed blades (nozzles) and moving blades each row of fixed blades and moving blades is called a stage. The moving blades rotate on the central turbine rotor and the fixed blades are concentrically arranged within the circular turbine casing which is substantially designed to withstand the steam pressure. Since the fluid is at a lower pressure at the exit of the turbine than at the inlet, it is common to say the fluid has been “expanded” across the turbine. Because of the expanding flow, higher volumetric flow occurs at the turbine exit (at least for compressible fluids) leading to the need for larger turbine exit areas than at the inlet. Fig.2 Flow Diagram of a Steam Turbine Also note that turbines in high inlet-pressure applications are sometimes called expanders. The terms “turbine” and “expander” can be used interchangeably for most applications, but expander is not used when referring to kinetic energy applications, as the fluid does not go through significant expansion.
18 2.3. ADVANTAGES: • Ability to utilize high pressure and high temperature steam. • High efficiency. • High rotational speed. • High capacity/weight ratio. • Smooth, nearly vibration-free operation. • No internal lubrication. • Oil free exhausts steam. 2.4. 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. 2.5. STEPS INVOLVED IN THE DESIGN OF STEAM TURBINES: - 1. Perform thermodynamic and axial thrust calculations to decide diameters and axial length of blading. 2. Perform rotor dynamic calculation and suggest any change of lengths and diameters to repeat step one. 3. Select suitable turbine extensions and diameters to meet above blading geometry. 4. Select suitable materials to meet steam parameters. 5. Select suitable governing system and protection system. 6. Prepare ordering / manufacturing documents incorporating above selections.
19 3. TYPES OF STEAM TURBINE Steam turbines may be classified into different categories depending on their construction, the process by which heat drop is achieved, the initial and final conditions of steam used and their industrial usage. Most of the industrial steam turbines are high speed turbines for the power output range of 1- 30MW with speed reduction by turbo gears which in turn means smaller sizes and higher efficiency for the turbine for the output of 30MW and above the turbine speed is 3000rpm. • Impulse turbines. • Axial Reaction turbines. • Radial reaction turbines without any stationary guide blades. • Radial reaction turbines having stationary guide blades. • Single – stage turbines with one or more velocity stages usually of small power capacities, mostly used for driving centrifugal compressors, blowers and other similar machinery. • Multistage impulse and Reaction turbines, made in a wide range of power capacities varying from small to large. There are complicated methods to properly harness steam power that give rise to the two primary turbine designs: impulse and reaction turbines. 3.1 Comparison Between Impulse and Reaction Turbine: • In impulse turbine the pressure of steam remains constant during its flow through the moving blades. But in reaction turbine, the pressure of steam reduces during its flow through the moving blades. • In impulse turbine the steam flows through the nozzle and strikes on the moving blades. In reaction turbine steam first flows through the guide mechanism and then flows through the moving blades.
20 • In impulses turbine, steam strikes on the moving blades with kinetic energy only. But in the reaction turbine, the steam which glides over the moving blades possesses both pressure and kinetic energy.
21 4. TURBINE PARTS 4.1 NOZZLE: The nozzle expands steam of comparatively low velocity and high static pressure within considerable increase in velocity. The nozzle is so positioned as to direct the flow of steam into the rotor passage. 4.2 DIFFUSER: It is a mechanical device that is designed to control the characteristics of steam at the entrance to a thermodynamic open system. Diffusers are used to slow the steam's velocity and to enhance its mixing into the surrounding steam. 4.3 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. o Free standing LP moving blades Tip sections with supersonic design. o Fir-tree root o Flame hardening of the leading edge. 4.4 GUIDE BLADES: Often a turbine is arranged with a series of rotor flow passages. Intervening between the blades comprising the rotor passages are rows of stationary guide blades. The purpose of this guide is to reverse the direction of steam leaving the preceding moving blade row so that general direction of steam leaving the preceding moving blade rows is similar. If guide blades were not
22 provided, opposing force would be exerted on the rotor which would largely negate each other. 4.5. TURBINE CASING: The turbine enclosure is generally called the casing although the other two names are in common use. The nozzle and guide are fixed on casing, which in addition to confining the steam serves as support for the bearings. 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 to withstand the high pressures and temperatures. It is general practice to let the thickness of walls and flanges decrease from inlet- to exhaust-end. The casing joints are made steam tight, without the use of gaskets, by matching the flange faces very exactly and very smoothly. The bolt holes in the flanges are drilled for smoothly fitting bolts, but dowel pins are often added to secure exact alignment of the flange joint. Double casings are used for very high steam pressures. The high pressure is applied to the inner casing, which is open at the exhaust end, letting the turbine exhaust to the outer casings. 4.6. SHAFT, ROTOR, SPINDLE: These terms are applied to the rotating assembly which carries the blades.
23 4.7 TURBINE GOVERNING SYSTEM: Mechanical governor: The purpose of a mechanical governor is to maintain the speed of the turbine at a desired value when the generator is disconnected from the power supply. Main parts of mechanical governor: Flyweights Bracket Spring etc. Mechanism: When the turbine shaft rotates, the governor flyweights respond to the centrifugal forces created by the rotations. As turbine speed increases, the centrifugal force increases, causing the flyweights to move outward, overcoming the tension of the spring.
24 5. FEATURES OF A BLADE Blades are the heart of a turbine, as they are the principal elements that convert the energy of working fluid into kinetic energy. Efficiency of the turbine depends on the following parameters. • Inlet and outlet angle of the blade • Surface finishing of the blade • Profile of the blade The blade can be divided into 3 parts: • The profile, which converts the thermal energy of steam into kinetic energy, with a certain efficiency depending upon the profile shape. • The root, which fixes the blade to the turbine rotor, giving a proper anchor to the blade, and transmitting the kinetic energy of the blade to the rotor. • The damping element, which reduces the vibrations which necessarily occur in the blades due to the steam flowing through the blades. These damping elements may be integral with blades, or they may be separate elements mounted between the blades. 5.1. Blade Material: - Among the different materials typically used for blading are 403 stainless steel, 422 stainless steel, A286, and and titanium alloy. The 403 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.
25 The 422 stainless steel material is applied only on high temperature stages (between 370 and 480°C), where its higher yield, endurance, creep and rupture strengths are needed. Another blade material is titanium. Its high strength, low density, and good erosion resistance make it a good candidate for high speed or long-last stage blading. Blades are made of alloy steel which mainly contains carbon, chromium, nickel, molybdenum. 5.2. H.P. BLADE PROFILES 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 setting angle. Pitch of a blade is the circumferential distance between any point on the profile and an identical point on the next blade.
26 5.3. 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. The Steam turbines use the impulse profiles for the control stage (1st stage), and the reaction profiles for subsequent stages. 5.4. 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. The roots are T-root and Fork-root. The fork root has a higher load-carrying capacity than the T-root the typical roots used for the HP moving blades for various steam turbine applications are shown in the following figure: T-ROOT T-ROOT WITH SIDE GRIP
27 BLOCK 3 LAY-OUT 6. CLASSIFICATION OF BLOCK 3 6.1. 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.
28 2. Assembly Section (of hydro turbines) In this section assembly of hydro turbines are done. Blades of turbine are1st assemble on the rotor & after it this rotor is transported to balancing tunnel where the balancing is done. After balancing the rotor, rotor &casings both internal & external are transported to the customer. Total assembly of turbine is done in the company which purchased it by B.H.E.L. 3. OSBT (Over Speed Balancing Tunnel) In this section, rotors of all type of turbines like LP (low pressure), HP (high pressure) & IP (Intermediate pressure) rotors of Steam turbine, rotors of Gas & Hydro turbine are balanced. In a large tunnel, Vacuum of 2 torr is created with the help of pumps & after that rotor is placed on pedestal and rotted with speed of 2500-4500 rpm. After it in a computer control room the axis of rotation of rotor is seen with help of computer & then balance the rotor by inserting the small balancing weight in the grooves cut on rotor. Fig 4: Over speed & Vacuum Balancing Tunnel For balancing and over speed testing of rotors up to 320 tons in weight, 1800 mm in length and 6900 mm diameter under vacuum conditions of 1 Torr.
29 6.2. 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. 6.3. 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.
30 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. 6.4. 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 5. Steam Turbine Casing & Rotors in Assembly Area
31 2. Turning Section Same as the turning section in Bay-3, there are several small Machine- like lathes machines, milling, boring, grinding machines etc. Fig 6. CNC Rotor Turning Lathe 3. Heat Treatment Shop In this shop there are several tests performed for checking the Hardness of different components. Tests performed are Sereliting, Nitriding, DP Test.
32 7. 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 center 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. 7.1. TYPES OF BLADES • HP BLADES (high pressure blades) • IP BLADES (intermediate pressure blades) • LP BLADES (low pressure blades) Constructional Features of Blades: High pressure blades are mainly divided into three parts: a) Profile: The profile which converts thermal energy of steam into kinetic energy and with certain efficiency depending on the shape of profile. b) Root: The root which fixes into the turbine rotor which gives the proper anchor to the blade and transmitting the kinetic energy of blade to the rotor. Different kinds of roots of blades used are • T-root • Double T-root • Fork root • Firtree root • Dove tail root c) Shroud: The dampening element which reduces the vibration the vibration occurs in the blade which forms due to the flowing of high pressure steam
33 through the blades. This dampening element may be integral with the blade or that may be separate element mounted between the blades. 3 Dimensional Cylindrical Profile Twisted Profile 3DS Blade TX Blade F Blade HP/IP Initial Stages HP/IP Intermediate stages HP/IP Rear Stages & LP Initial Fig. 7 Types of Blades 7.2. OPERATIONS PERFORMED ON BLADES Some of the important operations performed on blade manufacturing are: - • Blank Cutting. (length cutting o/p) • Width Milling o/p. • Surface Grinding o/p. • Angular/Orbital/Rhomboid Milling o/p. (angular shape) • Angular/Orbital/Rhomboid Grinding. • Profile Cutting. • Root making.
34 7.3. 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. 7.4. 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 horizontal boring machine with 6 axis CNC control. • CNC shaping machine.
35 8. BHEL in year 2016-17 at a glance.
36 9. END NOTE. Gone through rigorous 4 Weeks training under the guidance of capable engineers and workers of BHEL Haridwar in Block-3 “TURBINE MANUFACTURING” 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 and machining processes which was shown on heavy to medium machines. 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.
37 10. REFRENCES: - ▪ BHEL Annual Report. (2016-17, 2015-16) ▪ BHEL Official Website. ▪ International Refereed Journal of Engineering and Science (IRJES)
38

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Industrial Training Report bhel haridwar.

  • 1.
    1 AN INDUSTRIAL TRAININGREPORT ON General Awareness on Steam Turbine Manufacturing B.H.E.L., Haridwar SUBMITTED By RISHABH NISHAD DEPARTMENT OF MECHANICAL ENGINEERING KIET GROUP OF INSTITUTIONS, GHAZIABAD
  • 2.
    2 ACKNOWLEDGEMENT I take thisopportunity to thank the Industrial Training Co-Ordinator of Mechanical Engineering Department for allowing us to avail this great opportunity. I am also grateful to the management of Bharat Heavy Electricals Limited (B.H.E.L.), Haridwar for permitting me to have training during 9th June to 9th July 2018. Last but not the least I would also like to thank all our teachers & friends for their constructive criticism given in right spirit. Rishabh Nishad 7th Semester, B.Tech. Mechanical Engineering KIET GROUP OF INSTITUTIONS
  • 3.
    3 ABSTRACT In my IndustrialTraining in B.H.E.L., Haridwar I have gone through all sections in Turbine Manufacturing. Also, I got to know about the history of industry, Area, Capacity, Machines installed & Facilities in the Industry. In power generation mostly steam turbine is used because of its greater thermal efficiency and higher power-to-weight ratio. Of all heat engines and prime movers, the steam turbine is nearest to the ideal and it is widely used in power plants and in all industries where power is needed for process. 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. Rotor is the heart of the steam turbine and it affects the efficiency of the steam turbine. In this report we have mainly discussed about the working process of a steam turbine. The thermal efficiency of a steam turbine is much higher than that of a steam engine. I learned about the Steam Turbine its types, parts like Blades, Casing, Rotor etc. Constructional features and procedure along with equipment used, material of blade, types of Blades, Operations performed on Blades, their New Blade Shop with Advance Technology like CNC Shaping Machine. I would like to express my deep sense of Gratitude and thanks to Mr. VIMAL KUMAR (DY. MANAGER) our in charge of training, Turbine Block-3,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.
    4 INDEX: Sr. No. TopicPage No. ACKNOWLEDGEMENT ABSTRACT 2 3 INTRODUCTION 6 1. BHEL 1.1 OVERVIEW 1.2 BHEL UNITS 1.3 BHEL HARIDWAR 1.3.1 LOCATION 1.3.2 ADDRESS 1.3.3 AREA 1.3.4 UNITS 1.3.5 HEEP PRODUCT PROFILE 9 2. MANUFACTURING OF STEAM TURBINE 2.1 INTRODUCTION 2.2 PRINCIPLE 2.3 ADVANTAGES 2.4 DISADVANTAGES 2.5 STEPS INVOLVED IN THE DESIGN OF STEAM TURBINES 16 3. TYPES OF STEAM TURBINE 3.1 COMPARISION BETWEEN IMPULSE AND REACTION TURBINE 19 4. TURBINE PARTS 4.1 NOZZLE 4.2 DIFFUSER 4.3 TURBINE BLADES 4.4 GUIDE BLADES 4.4 TURBINE CASING 4.5 SHAFT, ROTOR, SPINDLE 4.6 TURBINE GOVERNING SYSTEM 21 5. FEATURES OF BLADE 24
  • 5.
    5 5.1 BLADE MATERIALS 5.2H.P. BLADE PROFILES 5.3 CLASSIFICATION OF PROFILES 5.4 H.P. BLADE ROOTS 6. CLASSIFICATION OF BLOCK-3 6.1 BAY-1 6.2 BAY-2 6.3 BAY-3 6.4 BAY-4 27 7. BLADE SHOP 9.1 TYPES OF BLADES 9.2 OPERATIONS PERFORMED ON BLADES 9.3 MACHINING OF BLADES 9.4 NEW BLADE SHOP 32 9. END NOTE 36
  • 6.
    6 INTRODUCTION BHEL is thelargest 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 since 1971-72. BHEL has a mammoth 20,000 MW per annum capability for manufacturing of power generation equipment. A widespread network of 17 manufacturing units, 2 repair units, 4 regional offices, 8 service centers, 1 subsidiary, 4 overseas offices, 6 joint ventures, 15 regional marketing centers and current project execution at more than 150 project sites across India and abroad corroborates the humongous scale and size of its operations. With key focus on project execution, the worldwide installed base of power generating equipment supplied by BHEL has exceeded 178 GW. BHEL’s 54% share in India’s total installed capacity and 58% share in the country’s total generation from thermal utility sets (coal based) as of March 31, 2017 stand a testimony to its valuable contribution towards nation building.
  • 7.
    7 World of BHEL: 1.Did you know - ▪ BHEL is the single largest contributor to the country’s total installed electric utilities. ▪ All Indian satellites launched by ISRO are equipped with BHEL supplied solar panels since 2002 & batteries since 2005. ▪ World's largest ±800 kV, 6000 MW multiterminal HVDC NE-Agra transmission project under execution by BHEL. ▪ All the three ships of the Kolkata-class stealth guided missile destroyers equipped with BHEL’s 76/ 62 mm Super Rapid Gun Mount (SRGM) and Auxiliary Control System. ▪ 95% of hydroelectric generating capacity in Bhutan installed by BHEL. ▪ BHEL’s first power generating set was the 30 MW thermal power station installed at Basin bridge in Tamil Nadu, way back in 1969. ▪ All the states & six union territories of the country have power generating equipment installed by BHEL. 2. Innovation- ▪ Innovation R&D Expenditure >2.5% of Turnover-highest in Indian engineering field. ▪ Five research institutes. 14 Centres of Excellence. ▪ In-house R&D Centres of 12 Manufacturing units/Divisions recognized by DSIR 3. Unparalleled industrial experience- ▪ 570,000+ MVA transmission equipment supplied. ▪ 31,000+ AC machines- supplied, largest Indian manufacturer. ▪ >50% of Indian Railways rolling stock equipped with BHEL's traction equipment. ▪ 360 electric locos supplied to Indian Railways & other industries. ▪ 385+ compressors & 90 oil drilling rigs- supplied.
  • 8.
    8 4. Energizing India- ▪Major integrated power plant equipment manufacturer in the world with 20,000 MW p.a. manufacturing capacity. ▪ 178+ GW power generating equipment installed till date. ▪ 55% of India’s nuclear power generating capacity (conventional island) installed by BHEL. ▪ Commissioned country’s first 660 MW indigenously manufactured supercritical set at NTPC Barh-5, in 2013. ▪ 16,500+ MW Captive Power Plant installed. ▪ 350+ MW- cumulative shipments of PV cells, modules, and systems. • Financial Report BHEL (2016-17): - Figures are restated as per Ind AS
  • 9.
    9 # Dividend for2015-16* and 2016-17, includes Interim Dividend for the Current Year and Final Dividend for the Previous Year as per Ind AS 1. B.H.E.L. 1.1. OVERVIEW BHEL is one of the few companies in the world having the capability to manufacture the entire range of power plant equipment and has proven turnkey capabilities for executing power projects from concept-to commissioning. The power sector of the company comprises thermal, gas, hydro and nuclear power plants. BHEL: ▪ Has the capability to supply steam turbines, generators, boilers and their auxiliaries up to 800 MW with capability to supply up to 1000 MW. Currently executing projects on EPC (Engineering, procurement and construction) basis including supercritical sets of 660/700/800 MW ratings. ▪ Has the capability to supply hydro turbines and generators up to 400 MW. ▪ Has the capability to supply nuclear turbine generator sets including 220/235/540/550/ 700MWe. ▪ Has proven expertise in plant performance improvement through renovation, modernization and uprating of a variety of power plant equipment. ▪ Has special knowhow of residual life assessment, health diagnostics and life extension of plants. ▪ Has supplied thermal sets that have consistently exceeded national average availability and efficiency parameters.
  • 10.
    10 1.2. BHEL UNITS: UNITTYPE PRODUCT 1. Bhopal Heavy Electrical Part Steam Turbines, Turbo Generators, Hydro Sets, Switch Gear Controllers 2. Haridwar Hydro Turbines, Steam Turbines, Gas Turbines, Turbo Generators, Heavy Castings HEEP Heavy Electrical Equipment and Forging, Control Panels, Light Aircrafts, Plant Electrical Machines. CFFP Central Foundry Forge Plant 3. Hyderabad Industrial Turbo-Sets, Compressor Pumps and Heaters, Bow Mills, Heat Exchangers HPEP Heavy Power Equipment Plant Oil Rings, Gas Turbines, Switch Gears, Power Generating Sets. 4. Trichy Seamless Steel Tubes, Spiral Fin Welded HPBP High Pressure Boiling Plant Tubes. 5. Jhansi Transformers, Diesel Shunt Less AC locos TP Transformer Plant and EC EMU. 6. Bangalore Energy Meters, Watt Meters, Control Equipment, Capacitors, Photo Voltaic Panels, EDN Electronics Division Simulator, Telecommunication System, Other Advanced Microprocessor based Control EPD Electro Porcelains Division System, Insulator and Bushing, Ceramic Liners
  • 11.
    11 7. Ranipet Electrostatic Precipitator, AirPre-Heater, Fans, Wind Electric Generators, Desalination BAP Boiler Auxiliary Plant Plants. 8. Goindwal Industrial Valves Plant Industrial Valves & Fabrication 9. Jagdishpur High tension ceramic, Insulation Plates and IP Insulator Plant Bushings 10. Rudrapur Component Fabrication Plant Windmill, Solar Water Heating system 11. Gurgaon Amorphous Silicon Solar Cell Solar Photovoltaic Cells, Solar Lanterns, Plant. Chargers, Solar clock Table-1 1.3. BHEL HARIDWAR 1.3.1. LOCATION It is situated in the foot hills of Shivalik range in Haridwar. The main administrative building is at about 8 km from Haridwar. 1.3.2. ADDRESS Bharat Heavy Electrical Limited (BHEL) Ranipur, Haridwar PIN- 249403 1.3.3. AREA BHEL Haridwar consists of two manufacturing units, namely Heavy Electrical Equipment Plant
  • 12.
    12 (HEEP) and CentralFoundry Forge Plant (CFFP), having area HEEP area: - 8.45 sq. km CFFP area: - 1.0 sq. km The Heavy Electricals Equipment Plant (HEEP) located in Haridwar, is one of the major manufacturing plants of BHEL. The core business of HEEP includes design and manufacture of large steam and gas turbines, turbo generators, hydro turbines and generators, large AC/DC motors and so on. Central Foundry Forge Plant (CFFP) is engaged in manufacture of Steel Castings: Up to 50 Tons per Piece Wt. & Steel Forgings: Up to 55 Tons per Piece Wt. 1.3.4. UNITS There are two units in BHEL Haridwar as followed: 1) Heavy Electrical Equipment Plant (HEEP) 2) Central Foundry Forge Plant (CFFP) There are 8 Blocks in HEEP: Blocks Work Performed in Block I) Electrical Machine Turbo Generator, Generator Exciter, Motor (AC and DC)
  • 13.
    13 II) Fabrication LargeSize Fabricated Assemblies or Components III) Turbines & Auxiliary Steam, Hydro Turbines, Gas turbines, Turbine Blade, Special Tooling. IV) Feeder Winding of Turbo, Hydro Generators, Insulation for AC & DC Motors V) Fabrication Fabricated Parts of Steam Turbine, Water Boxes, Storage Tank, Hydro Turbine Parts VI) Fabrication Fabricated Oil Tanks, Hollow Guide Blades, Rings, Stator Frames and Stamping & Die Manufacturing Rotor Spindle, All Dies, Stamping for Generators and Motor VII) Wood Working Wooden Packing, Spacers VIII) Heaters & LP heaters, Ejectors, Glands, Steam and Oil Coolers, Oil Tank, Bearing Coolers Covers Table-2 There are 3 Sections in CFFP: Blocks Work Performed in Block 1. Foundry Casting of Turbine Rotor, Casing and Francis Runner 2. Forging Forging of Small Rotor Parts 3. Machine Shop Turning, Boring, parting off, Drilling etc. Table -3
  • 14.
    14 1.3.5. HEEP PRODUCTPROFILE 1. THERMAL SETS: • Steam turbines and generators up to 1000 MW capacity for utility and combined cycle applications. • Capability to manufacture up to 1000 MW unit cycle. 2. GAS TURBINES: • Gas turbines for industry and utility application range 3 to 200 MW (ISO). • Gas turbines based co-generation and combined cycle system. 3. HYDRO SETS: • Custom– built conventional hydro turbine of Kaplan, Francis and Pelton with matching generators up to 250 MW unit size. • Pump turbines with matching motor-generators. Mini / micro hydro sets. • Spherical butterfly and rotary valves and auxiliaries for hydro station. 4. EQUIPMENT FOR NUCLEAR POWER PLANTS: • Turbines and generators up to 500MW unit size. • Steam generator up to 500MW unit size. • Re-heaters / Separators. • Heat exchangers and pressure vessels.
  • 15.
    15 5. ELECTRICAL MACHINES: •DC general purpose and rolling mill machines from 100 to 19000KW suitable for operation on voltage up to 1200V. These are provided with STDP, totally enclosed and duct ventilated enclosures. • DC auxiliary mill motors. 6. CONTROL PANEL: Control panel for voltage up to 400KW and control desks for generating stations and EMV sub–stations. 7. CASTING AND FORGINGS: • Sophisticated heavy casting and forging of creep resistant alloy steels, stainless steel and other grades of alloy meeting stringent international specifications. 8. DEFENCE: • Naval guns with collaboration of Italy.
  • 16.
    16 2. MANUFACTURING OFSTEAM TURBINE 2.1. INTRODUCTION: A steam turbine is a mechanical device that converts thermal energy in pressurized steam into useful mechanical work. The steam turbine derives much of its better thermodynamic efficiency because of the use of multiple stages in the expansion of the steam. A turbine is a rotary engine that extracts energy from a fluid flow and converts it into useful work. The simplest turbines have one moving part, a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades, or the blades react to the flow, so that they move and impart rotational energy to the rotor. Fig.1 Sectional View of a Steam Turbine
  • 17.
    17 2.2. PRINCIPLE: The steamenergy is converted mechanical work by expansion through the turbine. The expansion takes place through a series of fixed blades (nozzles) and moving blades each row of fixed blades and moving blades is called a stage. The moving blades rotate on the central turbine rotor and the fixed blades are concentrically arranged within the circular turbine casing which is substantially designed to withstand the steam pressure. Since the fluid is at a lower pressure at the exit of the turbine than at the inlet, it is common to say the fluid has been “expanded” across the turbine. Because of the expanding flow, higher volumetric flow occurs at the turbine exit (at least for compressible fluids) leading to the need for larger turbine exit areas than at the inlet. Fig.2 Flow Diagram of a Steam Turbine Also note that turbines in high inlet-pressure applications are sometimes called expanders. The terms “turbine” and “expander” can be used interchangeably for most applications, but expander is not used when referring to kinetic energy applications, as the fluid does not go through significant expansion.
  • 18.
    18 2.3. ADVANTAGES: • Abilityto utilize high pressure and high temperature steam. • High efficiency. • High rotational speed. • High capacity/weight ratio. • Smooth, nearly vibration-free operation. • No internal lubrication. • Oil free exhausts steam. 2.4. 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. 2.5. STEPS INVOLVED IN THE DESIGN OF STEAM TURBINES: - 1. Perform thermodynamic and axial thrust calculations to decide diameters and axial length of blading. 2. Perform rotor dynamic calculation and suggest any change of lengths and diameters to repeat step one. 3. Select suitable turbine extensions and diameters to meet above blading geometry. 4. Select suitable materials to meet steam parameters. 5. Select suitable governing system and protection system. 6. Prepare ordering / manufacturing documents incorporating above selections.
  • 19.
    19 3. TYPES OFSTEAM TURBINE Steam turbines may be classified into different categories depending on their construction, the process by which heat drop is achieved, the initial and final conditions of steam used and their industrial usage. Most of the industrial steam turbines are high speed turbines for the power output range of 1- 30MW with speed reduction by turbo gears which in turn means smaller sizes and higher efficiency for the turbine for the output of 30MW and above the turbine speed is 3000rpm. • Impulse turbines. • Axial Reaction turbines. • Radial reaction turbines without any stationary guide blades. • Radial reaction turbines having stationary guide blades. • Single – stage turbines with one or more velocity stages usually of small power capacities, mostly used for driving centrifugal compressors, blowers and other similar machinery. • Multistage impulse and Reaction turbines, made in a wide range of power capacities varying from small to large. There are complicated methods to properly harness steam power that give rise to the two primary turbine designs: impulse and reaction turbines. 3.1 Comparison Between Impulse and Reaction Turbine: • In impulse turbine the pressure of steam remains constant during its flow through the moving blades. But in reaction turbine, the pressure of steam reduces during its flow through the moving blades. • In impulse turbine the steam flows through the nozzle and strikes on the moving blades. In reaction turbine steam first flows through the guide mechanism and then flows through the moving blades.
  • 20.
    20 • In impulsesturbine, steam strikes on the moving blades with kinetic energy only. But in the reaction turbine, the steam which glides over the moving blades possesses both pressure and kinetic energy.
  • 21.
    21 4. TURBINE PARTS 4.1NOZZLE: The nozzle expands steam of comparatively low velocity and high static pressure within considerable increase in velocity. The nozzle is so positioned as to direct the flow of steam into the rotor passage. 4.2 DIFFUSER: It is a mechanical device that is designed to control the characteristics of steam at the entrance to a thermodynamic open system. Diffusers are used to slow the steam's velocity and to enhance its mixing into the surrounding steam. 4.3 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. o Free standing LP moving blades Tip sections with supersonic design. o Fir-tree root o Flame hardening of the leading edge. 4.4 GUIDE BLADES: Often a turbine is arranged with a series of rotor flow passages. Intervening between the blades comprising the rotor passages are rows of stationary guide blades. The purpose of this guide is to reverse the direction of steam leaving the preceding moving blade row so that general direction of steam leaving the preceding moving blade rows is similar. If guide blades were not
  • 22.
    22 provided, opposing forcewould be exerted on the rotor which would largely negate each other. 4.5. TURBINE CASING: The turbine enclosure is generally called the casing although the other two names are in common use. The nozzle and guide are fixed on casing, which in addition to confining the steam serves as support for the bearings. 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 to withstand the high pressures and temperatures. It is general practice to let the thickness of walls and flanges decrease from inlet- to exhaust-end. The casing joints are made steam tight, without the use of gaskets, by matching the flange faces very exactly and very smoothly. The bolt holes in the flanges are drilled for smoothly fitting bolts, but dowel pins are often added to secure exact alignment of the flange joint. Double casings are used for very high steam pressures. The high pressure is applied to the inner casing, which is open at the exhaust end, letting the turbine exhaust to the outer casings. 4.6. SHAFT, ROTOR, SPINDLE: These terms are applied to the rotating assembly which carries the blades.
  • 23.
    23 4.7 TURBINE GOVERNINGSYSTEM: Mechanical governor: The purpose of a mechanical governor is to maintain the speed of the turbine at a desired value when the generator is disconnected from the power supply. Main parts of mechanical governor: Flyweights Bracket Spring etc. Mechanism: When the turbine shaft rotates, the governor flyweights respond to the centrifugal forces created by the rotations. As turbine speed increases, the centrifugal force increases, causing the flyweights to move outward, overcoming the tension of the spring.
  • 24.
    24 5. FEATURES OFA BLADE Blades are the heart of a turbine, as they are the principal elements that convert the energy of working fluid into kinetic energy. Efficiency of the turbine depends on the following parameters. • Inlet and outlet angle of the blade • Surface finishing of the blade • Profile of the blade The blade can be divided into 3 parts: • The profile, which converts the thermal energy of steam into kinetic energy, with a certain efficiency depending upon the profile shape. • The root, which fixes the blade to the turbine rotor, giving a proper anchor to the blade, and transmitting the kinetic energy of the blade to the rotor. • The damping element, which reduces the vibrations which necessarily occur in the blades due to the steam flowing through the blades. These damping elements may be integral with blades, or they may be separate elements mounted between the blades. 5.1. Blade Material: - Among the different materials typically used for blading are 403 stainless steel, 422 stainless steel, A286, and and titanium alloy. The 403 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.
  • 25.
    25 The 422 stainlesssteel material is applied only on high temperature stages (between 370 and 480°C), where its higher yield, endurance, creep and rupture strengths are needed. Another blade material is titanium. Its high strength, low density, and good erosion resistance make it a good candidate for high speed or long-last stage blading. Blades are made of alloy steel which mainly contains carbon, chromium, nickel, molybdenum. 5.2. H.P. BLADE PROFILES 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 setting angle. Pitch of a blade is the circumferential distance between any point on the profile and an identical point on the next blade.
  • 26.
    26 5.3. CLASSIFICATION OFPROFILES 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. The Steam turbines use the impulse profiles for the control stage (1st stage), and the reaction profiles for subsequent stages. 5.4. 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. The roots are T-root and Fork-root. The fork root has a higher load-carrying capacity than the T-root the typical roots used for the HP moving blades for various steam turbine applications are shown in the following figure: T-ROOT T-ROOT WITH SIDE GRIP
  • 27.
    27 BLOCK 3 LAY-OUT 6.CLASSIFICATION OF BLOCK 3 6.1. 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.
  • 28.
    28 2. Assembly Section(of hydro turbines) In this section assembly of hydro turbines are done. Blades of turbine are1st assemble on the rotor & after it this rotor is transported to balancing tunnel where the balancing is done. After balancing the rotor, rotor &casings both internal & external are transported to the customer. Total assembly of turbine is done in the company which purchased it by B.H.E.L. 3. OSBT (Over Speed Balancing Tunnel) In this section, rotors of all type of turbines like LP (low pressure), HP (high pressure) & IP (Intermediate pressure) rotors of Steam turbine, rotors of Gas & Hydro turbine are balanced. In a large tunnel, Vacuum of 2 torr is created with the help of pumps & after that rotor is placed on pedestal and rotted with speed of 2500-4500 rpm. After it in a computer control room the axis of rotation of rotor is seen with help of computer & then balance the rotor by inserting the small balancing weight in the grooves cut on rotor. Fig 4: Over speed & Vacuum Balancing Tunnel For balancing and over speed testing of rotors up to 320 tons in weight, 1800 mm in length and 6900 mm diameter under vacuum conditions of 1 Torr.
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    29 6.2. BAY –2IS 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. 6.3. 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.
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    30 3. Governing Section Inthis 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. 6.4. 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 5. Steam Turbine Casing & Rotors in Assembly Area
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    31 2. Turning Section Sameas the turning section in Bay-3, there are several small Machine- like lathes machines, milling, boring, grinding machines etc. Fig 6. CNC Rotor Turning Lathe 3. Heat Treatment Shop In this shop there are several tests performed for checking the Hardness of different components. Tests performed are Sereliting, Nitriding, DP Test.
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    32 7. BLADE SHOP Bladeshop 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 center 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. 7.1. TYPES OF BLADES • HP BLADES (high pressure blades) • IP BLADES (intermediate pressure blades) • LP BLADES (low pressure blades) Constructional Features of Blades: High pressure blades are mainly divided into three parts: a) Profile: The profile which converts thermal energy of steam into kinetic energy and with certain efficiency depending on the shape of profile. b) Root: The root which fixes into the turbine rotor which gives the proper anchor to the blade and transmitting the kinetic energy of blade to the rotor. Different kinds of roots of blades used are • T-root • Double T-root • Fork root • Firtree root • Dove tail root c) Shroud: The dampening element which reduces the vibration the vibration occurs in the blade which forms due to the flowing of high pressure steam
  • 33.
    33 through the blades.This dampening element may be integral with the blade or that may be separate element mounted between the blades. 3 Dimensional Cylindrical Profile Twisted Profile 3DS Blade TX Blade F Blade HP/IP Initial Stages HP/IP Intermediate stages HP/IP Rear Stages & LP Initial Fig. 7 Types of Blades 7.2. OPERATIONS PERFORMED ON BLADES Some of the important operations performed on blade manufacturing are: - • Blank Cutting. (length cutting o/p) • Width Milling o/p. • Surface Grinding o/p. • Angular/Orbital/Rhomboid Milling o/p. (angular shape) • Angular/Orbital/Rhomboid Grinding. • Profile Cutting. • Root making.
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    34 7.3. MACHINING OFBLADES 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. 7.4. 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 horizontal boring machine with 6 axis CNC control. • CNC shaping machine.
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    35 8. BHEL inyear 2016-17 at a glance.
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    36 9. END NOTE. Gonethrough rigorous 4 Weeks training under the guidance of capable engineers and workers of BHEL Haridwar in Block-3 “TURBINE MANUFACTURING” 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 and machining processes which was shown on heavy to medium machines. 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.
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    37 10. REFRENCES: - ▪BHEL Annual Report. (2016-17, 2015-16) ▪ BHEL Official Website. ▪ International Refereed Journal of Engineering and Science (IRJES)
  • 38.