This document provides an overview of steam turbine manufacturing at Bharat Heavy Electricals Limited (BHEL) Hyderabad. It discusses BHEL's main turbine types, the thermal power plant system, Rankine cycles, steam turbine components, compounding methods, and the manufacturing process for steam turbine blades at BHEL Hyderabad. The 201 Shop focuses on turbine manufacturing using various machine bays and production processes to fabricate turbine components from raw materials.

1. A STUDY OF MANUFACTURING OF STEAM TURBINES
Submitted by:
I. Viswanath Raju
Reg.no: 11707458
B. Tech(2nd year)
Mechanical Engineering.
Bharat Heavy Electricals Limited

2. Table of content
 Overview of BHEL
 Introduction to BHEL Hyderabad
 BHEL Hyderabad shops and its products
 201 Shop TURBINES Manufacturing
 BHEL’s main types of turbines they manufacture
 Thermal Power Plant System
 Rankine cycle
 Reheat Rankine cycle
 Regenerative Rankine cycle
 Steam turbine, parts of steam turbines
 Compounding of steam turbines
 Manufacturing process of steam turbine blades

3. Overview of BHEL
 BHEL was established in 1964.
 BHEL is the power plant equipment manufacturer and one of the largest
engineering and manufacturing companies in India in terms of turnover.
 BHEL have a share of 59% in India's total installed generating capacity contributing
69% (approx.) to the total power generated from utility sets (excluding non-
conventional capacity) as of March 31, 2012.
 BHEL 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. They have 15 manufacturing
divisions, two repair units, four regional offices, eight service centres and 15
regional centres and currently operate at more than 150 project sites across India
and abroad.

4. Introduction to BHEL Hyderabad
 The Hyderabad unit was set up in 1963 and started its operations with manufacture
of Turbo-generator sets and auxiliaries for 60 and 110 MW thermal utility sets.
 BHEL-Hyderabad unit has collaborations with world renowned MNCs like M/S
General Electric, USA, M/S Siemens, Germany, M/S Nuovo Pignone, etc.
 Over the years it has increased its capacity range and diversified its operations to
many other areas. To day, a wide range of products are manufactured in this unit,
catering to the needs of variety of industries like Fertilisers & Chemicals,
Petrochemicals & Refineries , Paper, sugar, steel , etc.

5. BHEL hyderabad shops and its products:
SHOP PRODUCT/ PROCESS AREAS
01 Steam Turbines, Gas Turbines & Centrifugal Compressors
02 Turbo Generators and Exciters etc
03 Switch Gears
04 Ferrous Foundry
05 Non-Ferrous Foundry
06 Heat Exchangers
07 Tool Room
08 Heat Treatment
09 Pattern Shop
10 Spares Manufacturing
11 Oil Field Equipment’s (Oil Rigs)
12 Coal Pulverizers
13 Centrifugal Pumps

6. 201 Shop TURBINES Manufacturing
 Bay-1: Super Heavy Machine Shop
 Bay-2: Heavy machine shop
 Bay-3: Blade Shop
 Bay-4: Rotor Shop
 Bay-5: Welding / GT Wheel Shop
 Bay-6: Medium Machine Shop
 Bay-7: GT Machine shop

8. BHEL’S MAIN TYPES OF TURBINES
They manufacture:
 Utility Turbines - Max. capacity is 150MW and for power
production
 Industrial Turbines - Capacity varies from 5MW to 70MW
 Drive Turbines - For driving mechanical components like pumps,
compressors etc.

9. AS PER BHEL
Power generation
 Upto 50 MW
 For 50 - 100 MW
 For 100 - 200 MW
 For 200 - 300 MW
 >300 MW
Max inlet steam pressure
 60 - 70 Bar
 70 - 130 Bar
 130 - 170 Bar
 170 - 230 Bar
 Upto 270 Bar

10. Thermal Power Plant System
 Working principle of thermal power plant:
A thermal power station works on the principle that heat is released by
burning fuel which produces steam from water. The steam so produced runs the
turbine coupled to generator which produces electrical energy.

11. Rankine cycle
 The Rankine cycle is a thermodynamic cycle which converts heat into work.
T-S PLOT
 1-2: Isentropic compression in a pump
 2-3: Constant pressure heat addition in a
boiler
 3-4: Isentropic expansion in a turbine
 4-1: Constant pressure heat rejection in a
condenser
The four processes in the Rankine cycle

12. REHEAT RANKINE CYCLE

13. REGENERATIVE RANKINE CYCLE

14. STEAM TURBINE
 A steam turbine is a device that extracts thermal energy from
pressurized steam and uses it to do mechanical work on a rotating output shaft.

15. PARTS OF STEAM TURBINE:
 Turbine Casings
 Turbine rotors
 Turbine Blades
 Turbine Bearings
 Governors
 Thrust Bearings

16. Types of turbines
Impulse Turbine Reaction Turbine

17. COMPOUNDING OF STEAM TURBINES
 Velocity compounding
 Pressure compounding
 Pressure-Velocity Compounding

19. MANUFACTURING PROCESS OF STEAM
TURBINE BLADES IN BHEL HYDERABAD
 RAW MATERIAL CUTTING
 SIZE MILLING
 SIZE GRINDING
 RHOMBOID MILLING
 RHOMBOID GRINDING
 SIZE LENGTH CUTTING, ROOT & RADIUS, FACE CHAMFERING
 BACK PROFILE MILLING
 BACK WIDENING
 CHANNEL MILLING
 CHANNEL WIDENING
 TAPPER MILLING
 POLISHING
 CRACK TEST ANALYSIS
 QUALITY CONTROL