The document discusses a study on the manufacturing of steam turbines. It provides an outline that includes an abstract, introduction, literature review, classifications of steam turbines, results and conclusions, and references. The introduction describes steam turbines and how they work, as well as heat exchangers, pumps, and ferrous foundries which are involved in steam turbine manufacturing. It also classifies steam turbines as either impulse or reaction turbines and describes the key components of each type. The results and conclusions sections summarize the learning from an internship in steam turbine manufacturing.

1. Department of
Mechanical Engineering
M.SIDDARTHA NAIK
H.T.No.: 20071A0329
Y.DATTA SAI REDDY
H.T.No: 20071A0358
Under the guidance of,
Dr.M.V.R DURGA PRASAD
Professor
Mechanical Engineering
Study of Manufacturing of Steam Turbine

2. Department of
Mechanical Engineering
Abstract
Introduction
Literature Review
Classifications of Steam Turbines.
Results And Conclusions
References
OUTLINE OF PRESENTATION

3. Department of
Mechanical Engineering
Abstract
In the era of mechanical engineering , Steam turbine is an excellent prime mover to
convert heat energy of steam to mechanical energy. 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. In power generation mostly
steam turbine is used 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. Rotor is the heart of the steam turbine and it affects
the efficiency of the steam turbine. In this project 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.
In our Industrial Training in B.H.E.L,Hyderabad.we go through all sections in steam
turbine manufacturing first management team told us about history of industry,area
,capacity and facilities in industry . After that they tpld about the steam turbine and its
parts like Blades,Casing,Rotor etc..During our training we were guided to manufacturing
processes of different parts of steam turbines,heat exchanger,pumps,and ferrous
foundry.

4. Department of
Mechanical Engineering
Introduction
STEAM TURBINE:
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. This results in a 32closer approach to the ideal reversible process. Steam turbines
are made in a variety of sizes ranging from small 0.75 kW units used as mechanical drives
for pumps, compressors and other shaft driven equipment, to 150 MW turbines used to
generate electricity. Steam turbines are widely used for marine applications for vessel
propulsion systems. In recent times gas turbines, as developed for aerospace applications,
are being used more and more in the field of power generation once dominated by steam
turbines.
The steam turbine is a form of heat engine that derives much of its improvement
in thermodynamic efficiency from the use of multiple stages in the expansion of the
steam, which results in a closer approach to the ideal reversible expansion process.

5. Department of
Mechanical Engineering
Introduction
HEAT EXCHANGER:
A heat exchanger is a system used to transfer heat between a source and a working fluid.
Heat exchangers are used in both cooling and heating processes. The fluids may be
separated by a solid wall to prevent mixing or they may be in direct contact. They are
widely used in space heating, refrigeration, air conditioning, power stations, chemical
plants, petrochemical plants, petroleum refineries, natural-gas processing, and sewage
treatment. The classic example of a heat exchanger is found in an internal combustion
engine in which a circulating fluid known as engine coolant flows through radiator coils
and air flows past the coils, which cools the coolant and heats the incoming air. Another
example is the heat sink, which is a passive heat exchanger that transfers the heat
generated by an electronic or a mechanical device to a fluid medium, often air or a liquid
coolant.

6. Department of
Mechanical Engineering
Introduction
PUMPS:
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by
mechanical action, typically converted from electrical energy into hydraulic energy.
Mechanical pumps serve in a wide range of applications such as pumping water from
wells, aquarium filtering, pond filtering and aeration, in the car industry for water-cooling
and fuel injection, in the energy industry for pumping oil and natural gas or for
operating cooling towers and other components of heating, ventilation and air
conditioning systems. In the medical industry, pumps are used for biochemical processes
in developing and manufacturing medicine, and as artificial replacements for body parts,
in particular the artificial heart and penile prosthesis.

7. Department of
Mechanical Engineering
Introduction
FERROUS FOUNDRY:
Ferrous foundry means any source used for melting or refining ferrous metals such as iron
consisting of, but not limited to, furnace proper, checkers, flues, stacks, tuyeres, fans or
blowers, tapping spout, charging equipment, gas cleaning devices, and other auxiliaries.
The foundry furnaces may be cupola, rotary, reverberatory, electric, air, open hearth,
crucible, or others.
Ferrous foundry means a place where malleable iron, grey iron, nodular iron, or steel or a
combination of these metals are melted and poured into molds in the making of castings.
Foundries are one of the largest contributors to the manufacturing recycling movement,
melting and recasting millions of tons of scrap metal every year to create new durable
goods. Moreover, many foundries use sand in their molding process. These foundries
often use, recondition, and reuse sand, which is another form of recycling.

8. Department of
Mechanical Engineering
Literature Review
Historically , First steam turbine was produced by Hero ,a Greek Philosopher, in 120 B.C.
In 1629,an Italian named Bean Actually antipated the boiler stream turbine combination
that is a major source of power today. Charles Parson introduced first practical stream
turbine in 1844, which was also a reaction type. Just after five years, In 1889,Gustav.
DE-Laval produced the first pratical impulse turbine
* The first turbine was made by Hero of Alexandria in the second
* In the end of XVIII century the industrial Revolution began
* The first steam turbines were constructed in 1883 by Dr gustaf de laval in 1884 by sir
Charles parsons
* in 1896 Charles Curtis received a patient on impulse turbine .
* In 1910 was created radial turbine (Ljungstrom).

9. Department of
Mechanical Engineering
Classifications of Steam Turbines
Turbines are classified as 1.Impulse turbine
2.Reaction Turbines
Impulse Turbines:
An impulse turbine has fixed nozzles that orient the steam flow into high speed jets.
These jets contain significant kinetic energy, which is converted into shaft rotation by the
bucket-like shaped rotor blades, 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. As the steam flows through the nozzle its pressure falls from inlet pressure to the
exit pressure (atmospheric pressure or, more usually, the condenser vacuum). Due to this
high ratio of expansion of steam, the steam leaves the nozzle with a very high velocity.
The steam leaving the moving blades has a large portion of the maximum velocity of the
steam when leaving the nozzle. The loss of energy due to this higher exit velocity is
commonly called the carry over velocity or leaving loss.

10. Department of
Mechanical Engineering
Classifications of Steam Turbines
a) 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.
b) 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. In contrast, a nozzle is
often intended to increase the discharge velocity and to direct the flow in one particular
direction. Flow through nozzles and diffusers may or may not be assumed to be
adiabatic.
c) Blades Or Buckets:
The blades or buckets form the rotor flow passage and serves to change the
direction and hence the momentum of the steam received in the stationary nozzles.

11. Department of
Mechanical Engineering
Classifications of Steam Turbines
d) Guide Or 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 provided, opposing force would be exerted on
the rotor which would largely negate each other.
e) Casing Shell Or Cylinder:
The turbine enclosure is generally called the casing although the other two names
are in common use. The nozzle and guide are fixedon casing, which in addition to
confining the steam serves as support for the bearings. Sometimes the word cylinder is
restricted as a cylindrical form attached to inside of the casing to which the guides are
fixed.
f) Shaft, Rotor, Spindle: These terms are applied to the rotating assembly which carries
the blades.

12. Department of
Mechanical Engineering
Classifications of Steam Turbines
Working:
In these turbines, the static pressure inside the runner is constant, and the turbine
runner is at atmospheric pressure. The runner spins in the air, and the fluid is sprayed to
the blades through the nozzle to exchange energy with the turbine. A jet nozzle or a
series of nozzles directs the high-speed flow to the blades, which are usually in the shape
of buckets or cups. Therefore, only pressure changes occur in the nozzles.

13. Department of
Mechanical Engineering
Classifications of Steam Turbines
Reaction turbine:
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.

14. Department of
Mechanical Engineering
Working:
Heat exchangers work because heat naturally flows from higher temperature to lower
temperatures. Therefore if a hot fluid and a cold fluid are separated by a heat conducting
surface heat can be transferred from the hot fluid to the cold fluid.
Heat exchanger

15. Department of
Mechanical Engineering
Working:
The basic principle of operation of centrifugal pumps is – force vortex flow. This means,
when a body of liquid is acted upon by an external torque, it increases the pressure head
of the rotating liquid. This increase in pressure is directly proportional to the velocity of
the liquid.
Pump

16. Department of
Mechanical Engineering
Working:
foundry is a factory where castings are produced by melting metal, pouring liquid metal
into a mold, then allowing it to solidify. Even if you have never been to a foundry, or even
know what one looks like, you are surrounded by the metal castings they produce. There
is a good chance that you are reading this less than 10 feet away from one.
Ferrous Foundry

17. Department of
Mechanical Engineering
Results
Finally after completion of our Internship training on Steam Turbines , We learned about
types of steam turbines and working principles of turbines.
And we learned about constructional features of Turbines and productions rate of
Turbines.
Conclusions
 Steam Turbines operates at silent and quiet conditions.
 They develop high powers and enables high speeds for large vessels.
 Steam Turbine is prime mover in which potential energy is transformed into kinetic
energy then transferred into mechanical energy by turbine shaft.
 Steam Turbines are very useful for power and electricity generation.
 Steam Turbines are very useful for mechanical work.
Results and Conclusions

18. Department of
Mechanical Engineering
References
 ACETO industries-2004,Update of hydraulic governing system in SKOODA 110 MW
steam turbine,Egypt.
 Rk.Rajput,thermal engineering, 8th edition 2010,chapter 19,steam turbine , India.
 Woodbank communication Ltd, south crescent road, chester, CH47AU(Unite
kingdom), Viewed 2005, United kingdom.
 Bayar, Tildy (31 July 2014). "Global gas and steam turbine market to reach $43.5bn by
2020". Power Engineering International.

19. Department of
Mechanical Engineering