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Introduction to B.H.E.L

1.1 GENERAL
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 caters to core sectors of the Indian Economy viz., Power Generation's & Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense, etc. The wide network of BHEL's 14 manufacturing division, four power Sector regional centers, over 150 project sites, eight service centers and 18 regional offices, enables the Company to promptly serve its customers and provide them with suitable products, systems and services efficiently and at competitive prices. BHEL has already attained ISO 9000 certification for quality management, and ISO 14001 certification for environment management. VISION World-class, innovative, competitive and profitable engineering enterprise providing total business solutions. MISSION The leading Indian engineering enterprise providing quality products systems and services in the fields of energy, transportation, infrastructure and other potential areas. VALUES Meeting commitments made to external and internal customers. Foster learning creativity and speed of response.

Respect for dignity and potential of individuals. Loyalty and pride in the company. Team playing. Zeal to excel. Integrity and fairness in all matters.

1.2 POWER GENERATION

Power generation sector comprises thermal, gas, hydro and nuclear power plant business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the total installed capacity of 99,146 MW in the country, as against nil till 1969-70. BHEL has proven turnkey capabilities for executing power projects from concept to commissioning; it possesses the technology and capability to produce thermal sets with super critical parameters up to 1000 MW unit rating and gas turbine generator sets of up to 240 MW units rating. Co-generation and combined-cycle plants have been introduced to achieve higher plant efficiencies. to make efficient use of the high-ash-content coal available in India, BHEL supplies circulating fluidized bed combustion boilers to both thermal and combined cycle power plants. The company manufactures 235 MW nuclear turbine generator sets and has commenced production of 500 MW nuclear turbine generator sets. Custom made hydro sets of Francis; Pelton and Kaplan types for different head discharge combination are also engineering and manufactured by BHEL. In all, orders for more than 700 utility sets of thermal, hydro, gas and nuclear have been placed on the Company as on date. The power plant equipment manufactured by BHEL is based on contemporary technology comparable to the best in the world and is also internationally competitive. The Company has proven expertise in Plant Performance Improvement through renovation modernization and updating of a variety of power plant equipment besides specialized know how of residual life assessment, health diagnostics and life extension of plants.

1.3 POWER TRANSMISSION & DISTRIBUTION (T & D)

BHEL offer wide ranging products and systems for T & D applications. Products manufactured include power transformers, instrument transformers, dry type transformers, series and stunt reactor, capacitor tanks, vacuum and SF circuit breakers gas insulated switch gears and insulators. A strong engineering base enables the Company to undertake turnkey delivery of electric substances up to 400 kV level series compensation systems (for increasing power transfer capacity of transmission lines and improving system stability and voltage regulation), shunt compensation systems (for power factor and voltage improvement) and HVDC systems (for economic transfer of bulk power). BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV Facts (Flexible AC Transmission System) project under execution.

1.4 INDUSTRIES
BHEL is a major contributor of equipment and systems to industries. Cement, sugar, fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and other process industries lines and improving system stability and voltage regulation, shunt compensation systems (for power factor and voltage improvement) and HVDC systems (for economic transfer of bulk power) BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV FACTS (Flexible AC Transmission System) projects is under execution. The range of system & equipment supplied includes: captive power plants, cogeneration plants DG power plants, industrial steam turbines, industrial boilers and auxiliaries. Water heat recovery boilers, gas turbines, heat exchangers and pressure vessels, centrifugal compressors, electrical machines, pumps, valves, seamless steel tubes, electrostatic precipitators, fabric filters, reactors, fluidized bed combustion boilers, chemical recovery boilers and process controls.

The Company is a major producer of large-size thruster devices. It also supplies digital distributed control systems for process industries, and control & instrumentation systems for 3

power plant and industrial applications. BHEL is the only company in India with the capability to make simulators for power plants, defense and other applications. The Company has commenced manufacture of large desalination plants to help augment the supply of drinking water to people.

1.5 TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production, installation, and maintenance and after-sales service of Rolling Stock and traction propulsion systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000 HP, dieselelectric locomotives from 350 HP to 3100 HP, both for mainline and shunting duly applications. BHEL is also producing rolling stock for special applications viz., overhead equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use, BHEL manufactures traction propulsion systems for other rolling stock producers of electric locomotives, diesel-electric locomotives, electrical multiple units and metro cars. The electric and diesel traction equipment on India Railways are largely powered by electrical propulsion systems produced by BHEL. The company also undertakes retooling and overhauling of rolling stock in the area of urban transportation systems. BHEL is geared up to turnkey execution of electric trolley bus systems, light rail systems etc. BHEL is also diversifying in the area of port handing equipment and pipelines transportation system.

1.6 TELECOMMUNICATION
BHEL also caters to Telecommunication sector by way of small, medium and large switching systems.

1.7 RENEWABLE ENERGY

Technologies that can be offered by BHEL for exploiting non-conventional and renewable sources of energy include: wind electric generators, solar photovoltaic systems, solar lanterns and battery-powered road vehicles. The Company has taken up R&D efforts for development of multi-junction amorphous silicon solar cells and fuel based systems.

1.8 INTERNATIONAL OPERATIONS

BHEL has, over the years, established its references in around 60 countries of the world, ranging for the United States in the West to New Zealand in the Far East. These references encompass almost the entire product range of BHEL, covering turnkey power projects of thermal, hydro and gas-based types, substation projects, rehabilitation projects, besides a wide variety of products, like transformers, insulators, switchgears, heat exchangers, castings and forgings, valves, well-head equipment, centrifugal compressors, photo-voltaic equipment etc. Apart from over 1110MW of boiler capacity contributed in Malaysia, and execution of four prestigious power projects in Oman, Some of the other major successes achieved by the Company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan, Sri Lanka, Iraq etc. The Company has been successful in meeting demanding customer's requirements in terms of complexity of the works as well as technological, quality and other requirements viz extended warrantees, associated O&M, financing packages etc. BHEL has proved its capability to undertake projects on fast-track basis. The company has been successful in meeting varying needs of the industry, be it captive power plants, utility power generation or for the oil sector requirements. Executing of Overseas projects has also provided BHEL the experience of working with world renowned Consulting Organizations and inspection Agencies. In addition to demonstrated capability to undertake turnkey projects on its own, BHEL possesses the requisite flexibility to interface and complement with International companies for large projects by supplying complementary equipment and meeting their production needs for intermediate as well as finished products. The success in the area of rehabilitation and life extension of power projects has established BHEL as a comparable alternative to the original equipment manufactures (OEMs) for such plants.

1.9 TECHNOLOGY UPGRADATION AND RESEARCH & DEVELOPMENT

To remain competitive and meet customers' expectations, BHEL lays great emphasis on the continuous up gradation of products and related technologies, and development of new products. The Company has upgraded its products to contemporary levels through continuous

in house efforts as well as through acquisition of new technologies from leading engineering organizations of the world. The Corporate R&D Division at Hyderabad, spread over a 140 acre complex, leads BHEL's research efforts in a number of areas of importance to BHEL's product range. Research and product development centers at each of the manufacturing divisions play a complementary role. BHEL's Investment in R&D is amongst the largest in the corporate sector in India. Products developed in-house during the last five years contributed about 8.6% to the revenues in 2000-2001. BHEL has introduced, in the recent past, several state-of-the-art products developed inhouse: low-NQX oil / gas burners, circulating fluidized bed combustion boilers, highefficiency Pelton hydro turbines, petroleum depot automation systems, 36 kV gas-insulated sub-stations, etc. The Company has also transferred a few technologies developed in-house to other Indian companies for commercialization. Some of the on-going development & demonstration projects include: Smant wall blowing system for cleaning boiler soot deposits, and micro-controller based governor for diesel-electric locomotives. The company is also engaged in research in futuristic areas, such as application of super conducting materials in power generations and industry, and fuel cells for distributed, environment-friendly power generation.

1.10 HUMAN RESOURCE DEVELOPMENT INSTITUTE

The most prized asset of BHEL is its employees. The Human Resource Development Institute and other HRD centers of the Company help in not only keeping their skills updated and finely honed but also in adding new skills, whenever required. Continuous training and retraining, positive, a positive work culture and participative style of management have engendered development of a committed and motivated work force leading to enhanced productivity and higher levels of quality.

1.11 HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT

BHEL, as an integral part of business performance and in its endeavor of becoming a world-

class organization and sharing the growing global concern on issues related to Environment. Occupational Health and Safety, is committed to protecting Environment in and around its own establishment, and to providing safe and healthy working environment to all its employees. For fulfilling these obligations, Corporate Policies have been formulated as: 1.11.1 ENVIRONMENTAL POLICY Compliance with applicable Environmental Legislation/Regulation; Continual Improvement in Environment Management Systems to protect our natural environment and Control Pollution; Promotion of activities for conservation of resources by Environmental Management; Enhancement of Environmental awareness amongst employees, customers and suppliers. BHEL will also assist and co-operate with the concerned Government Agencies and Regulatory Bodies engaged in environmental activities, offering the Company's capabilities is this field. 1.11.2 OCCUPATIONAL HEALTH AND SAFETY POLICY Compliance with applicable Legislation and Regulations; Setting objectives and targets to eliminate/control/minimize risks due to Occupational and Safety Hazards; Appropriate structured training of employees on Occupational Health and Safety (OH&S) aspects; Formulation and maintenance of OH&S Management programmes for continual improvement; Periodic review of OH&S Management System to ensure its continuing suitability, adequacy and effectiveness; Communication of OH&S Policy to all employees and interested parties.

The major units of BHEL have already acquired ISO 14001 Environmental Management

System Certification, and other units are in advanced stages of acquiring the same. Action plan has been prepared to acquire OHSAS 18001 Occupational Health and Safety Management System certification for all BHEL units. In pursuit of these Policy requirements, BHEL will continuously strive to improve work particles in the light of advances made in technology and new understandings in Occupational Health, Safety and Environmental Science.

1.12 PARTICIPATION IN THE "GLOBAL COMPACT" OF THE UNITED NATIONS

The "Global Compact" is a partnership between the United Nations, the business community, international labor and NGOs. It provides a forum for them to work together and improve corporate practices through co-operation rather than confrontation. BHEL has joined the "Global Compact" of United Nations and has committed to support it and the set of core values enshrined in its nine principles:

1.13 PRINCIPLES OF THE "GLOBAL COMPACT"

1.13.1 HUMAN RIGHTS 1. Business should support and respect the protection of internationally proclaimed human rights; and 2. Make sure they are not complicit in human rights abuses. 1.13.2 Labor Standards 3. Business should uphold the freedom of association and the effective recognition of the right to collective bargaining; 4. The elimination of all form of forces and compulsory labour. 5. The effective abolition of child labour, and 6. Eliminate discrimination. 1.13.3 Environment

7. Businesses should support a precautionary approach to environmental challenges; 8. Undertake initiatives to promote greater environmental responsibility and 9. Encourage the development and diffusion of environmentally friendly technologies. By joining the "Global Compact", BHEL would get a unique opportunity of networking with corporate and sharing experience relating to social responsibility on global basis.

1.14 ACTIVITY PROFILE

PRODUCTS Power Generation & Transmission - Steam Turbine-Generator Sets & Auxiliaries - Boiler and Boiler Auxiliaries - Once-through Boilers - Nuclear Power Generation Equipment - Hydro Turbine-Generator Sets & Auxiliaries - Mini/Micro Hydro Generator Sets - Gas Turbine-Generator Sets - Waste Heat Recovery Boilers - Heat Exchangers - Condensers - Bowi Mills and Tube Mills - Gravimetric Feeders - Regenerative Air Pre-Heaters - Electrostatic Precipitators - Bag Filters - Valves - Pumps - Electrical Machines - Piping Systems - Power, Distribution & Instrument Transformers - Reactors - Synchronous Condensers - Switchgear 9 - Industrial Fans - Seamless steel Tubes - Fabric Filters - AC DC Motors, Variable speed - AC Drive - Electronic Control Gear & Automation Equipment DDC for Process Industry Thruster Equipment Power Devices Energy Meters Transformer Switch gear Insulator Capacitors Broad Gauge AC, AC/DC Loco

Motives - Diesel-Electric Shunting Locomotives - Traction Motors & Control Equipment - Electric Trolley Buses - AC/DC Electric Multiple Units - Drives and Controls for Metro Systems - Battery-Operated Passengers Vans - X-Mas Trees and Well Heads - Cathodic Protection Equipment - Digital Switching Systems

- Control gear - Distributed Digital Control for Power Stations - Bus Ducts - Rectifiers - Porcelain Insulators - Ceralin INDUSTRIES/TRANSPORTATION/OIL GAS/ TELECOMMUNICATION/RENEWABLE ENERGY - Steam Turbine-Generator Sets - Gas Turbine-Generator Sets - Diesel Engine-Based Generators - Industrial Steam Generators - Heat Recovery Steam Generators - Fluidized Bed Combustion Boilers Drive Turbine Manne Turbines Industrial Heat Exchangers Centrifugal Compressor

- Rural Automatic Exchange - Simulators & Wind Electric Generators Solar Powered Water Pumps Solar Water Heating Systems Photo Voltaic Systems Defense Equipment Reverse Osmoses Desalination

Plants SYSTEMS & SERVICES - Turkey Utility Power Stations/ EPC Contracts Captive Power Plants Co-generation Systems Combined Cycle Power Plants Modernization & Renovation of

Power Stations and FLA Studies - Switch yards and Substations - HVDC Transmission Systems - Shorts sines condensation Systems - Power system analysis - Electron commission and Operation - Consultancy services - Consultancy Services

- Industrial Valves - Reactors - Columns - Pressure Vessels - Pumps

1.15 SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS CORE SECTORS

Power Generation THERMAL RATING (MW)

NO. OF SET S

TOTAL CAPACITY (MW)

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500 250 210/200 120/125/130 195 110 100 70/67.5 60 30 TOTAL (THERMAL) GAS FRAME SIZE/ SCOPE

30 9 138 20 1 38 6 6 14 5 267

15000 2250 28570 2420 195 4180 600 410 840 150 54615

NO. OF SET S

TOTAL CAPACITY (MW)

NUCLEAR

9 6 5 3 V 94.2 6FA STG GEN TOTAL (GAS) RATING (MW)

5 17 13 6 2 3 24 4 74

NO. OF SET S

730 580 309 48 286 207 1190 87 3437 TOTAL CAPACITY (MW)

500 220 TOTAL (NUCLEAR) TOTAL (THERMAL+GAS+NUCLEAR) HYDRO GRAND TOTAL

2 10 12

1000 2200 3200

353 402 755

61252 18735 79987

1.16 POWER TRANSMISSION & DISTRIBUTION

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In the T&D sector, BHEL is both a leading equipment-manufacturer and a system-integrator. BHEL-manufactured T&D products have a proven track record in India and abroad. In the area of T&D systems, BHEL provides turnkey solutions to utilities. Substations and shunt compensation installations set up by BHEL are in operation all over the country. EHV level series compensation schemes have been installed in KSEB, MSEB, SMPSEB and POWERGRID networks. Complete HVDC systems can be delivered by BHEL. The technology for state-of-the-art Flexible AC Transmission Systems (FACTS) is being developed.

1.16 MANUFACTURING DIVISIONS

Heavy Electrical Plant, Piplani, Bhopal Electricals Machines Repair Plant (EMRP), Mumbai Transformer Plant P.O. BHEL, Jhansi. Bharat Heavy Electricals Limited : Heavy Electricals Equipment Plant, Central Foundary Forge Plant., Ranipur, Hardwar Heavy Equipment Repair Plant, Varanasi. Insulator Plant, Jagdishpur, Distt. Sultanpur. Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad High Pressure Boiler Plant & Seamless Steel Tube Plant, Tiruchirappalli. Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex, Ranipet. Industrial Valves Plant, Goindwal.

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Electronics Division : Electronics Systems Division. Amorphous Silicon Solar Cell Plant (ASSCP). Electroporcelains Division. Industrial Systems Group, Bangalore .

Component Fabrication Plant, Rudrapur. Piping Centre, Chennai. Regional Operations Division, New Delhi

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Turbine Block-3

3.1 GENERAL
Block-III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and Turbines Blades. Special Tooling for all products are also manufactured in the Tool Room located in the same block. Equipment layout plan is as per Drawing appended in Section III. Details of facilities are given in Section II. The Block consists of four Bays, namely, Bay-I and II of size 36x378 meters and 36x400 meters respectively and Bay-III and IV of size 24x402 meters and 24x381 meters respectively. The Block is equipped with the facilities of EOT Cranes, compressed air, Steam; over speed Balancing Tunnel, indicating stands for steam turbine, rotors, one Test stand for testing 210 MW steam turbines Russian Design, one Test Stand for Hydro Turbine Guide Apparatus and two separate Test Stands for the testing of Governing Assemblies of Steam and Hydro Turbines. All the parts are conserved, painted and packed before dispatch. The Block-3 is divided into two sections namely 13

1. Turbine Blade Manufacturing (TBM) 2. Turbine Unit Manufacturing (TUM)

3.2 TURBINE BLADE MANUFACTURING

Blade definition: The Blade is a streamlined body having a thick, rounded leading edge and a thin (sometime sharp) trailing edge. It maximum thickness occurs somewhere nears the

midpoint of the chord. The backbone line lying midway between the upper and lower surfaces is known as the camber line. The blades have Aerofoil shaped. Parts of Blade: The blades have mainly three parts. Theyre following as. 1. Shroud Profile 2. Profile 3. Roots The upper part of the blades is known as Shroud. The center portion of the blade which give the desire direction of the flow is known as Profile The power part of the blade is known as Root. 14

Basic principle of blades: The basic principle and the works of blades on the NEWTEONS 2nd LAW. According to which the rate of change of momentum is equal to force acting on the blade. d/dt (momentum)=force In the Stream Turbine many aerofoil shaped blades are used which are fitted in the rotor of the Stream Turbine.

As we see in a single blade of the stream turbine when the stream passes through the blade, a region of low pressure will be created on the upper part of the blade whereas a region of high pressure will be created on the lower parts of the guide blade. Hence a trust F will be acted on the blade in upward direction, which keeps or put the blades in the motion and as a result of which the rotor also remained in the motion. Types of Blades: There are three types of blades on the basis of turbine in TBM section in BLOCK III. 1. High pressure blades (HP blade) 2. Intermediate pressure blade (IP blade) 3. Low pressure blade (LP blade) HP & IP Blade: S.no . 1. HP Blades If we will take a moving blade than expansion angle at root end in HP blades is almost straight because the rotor of HP turbine does not have as much variation in its diameter. While in guide blade of HP blade the shroud end is almost straight. IP Blades In moving blade at root side expansion angle in the IP blade is more than the HP blade.

3.

In guide blade at shroud side expansion angle in the IP blade is more than the HP blade.

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2.

HP blade is small in size.

IP blades are larger in size than HP blades.

There are two types of blades on the basis of their position. 1. Moving Blade: It is the blade which is situated on the rotor and move with the rotor. 2. Guide Blade: It is the blade which is situated in the casing also known as stator and these are stationary blades and does not rotate. Route card for HP, IP & LP Blades: Route card or Job card is the card by which we can know all the information about that blade. By Route Card we can determine the power of turbine ,type of blade and the position of the blade .For all HP , IP & LP Blades route card are different .In Route card there is one docket no and project name and description of part and material code. By these things we can get all the information in as follows manner : Docket No : It is the no. of 6 digits in which each and every digit has its own meaning. Ex. 5 14 5 06 First digit stands for its power means this blade is of 500 MW turbine. Combined no. of second and third digits stands for the set of the blade.It means it is blade of the 14 set . Third digit stands for the type of the blade means about moving and guide and about HP, IP & LP blades. The list is as follows : 1 - High pressure Moving blade 2 - Intermediate pressure Moving blade 3 - Low pressure Moving blade 5 - High pressure Guide blade 6 - Intermediate pressure Guide blade 7 - Low pressure Guide blade Combined no. of fifth and sixth digits stands for the position of blade in left or right direction .If this no. starts from zero digit than the digit after zero will be its position in RIGHT direction and if the no starts with digit 5 than the digit after the no. 5 will be its position in LEFT direction. So in giving example it is the blade of 6th position in Right direction.

Description of the part: By this column we know the type of profile of blade and thickness of milling and angle of rhomboid and the blade position and direction. The information of this column of the example blade of above docket no is like this : Ex. T4 - 36 57 ST 6 R In this ex. we get following information : It is the blade of T-4 type of profile.

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 36 is the thickness of milling. By the use of 57 we determine the angle of rhomboid in following way : (i) If blades profile is of type T-4 than firstly we will add 12 in the no. of third place and after than we will subtract it from 90 than final solution will give us the angle of rhomboid. (ii) If blades profile is of type T-2 than firstly we will add 13 in the no. of third place and after than we will subtract it from 90 than final solution will give us the angle of rhomboid. Now in giving example blades profile is of T-4 type than angle of rhomboid will be : Angle of rhomboid = 90 ( 57 + 12 ) = 21 degree ST means it is the blade of Steam Turbine. 6 R means it is the blade of 6th position of right direction, which is same as given by Docket no. Note: In TBM section of Block III, We make only T-4 and T-2 type of blades while other advanced form of blades like 3DS, TX-Profile, BANANA Type, F-Type blades are made in NEW BLADE SHOP which is fully CNC.

HP & IP BLADES: Difference between Moving and Guide Blade of HP & IP: Both Moving and Guide blades are same in profile but the main difference is that the root side of the moving blade is thinner than blade profile while in guide blade the root side is thicker than blade profile.

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Description about some main machines for HP & IP Blades: 1. Band saw : This machine is used for blank size.In this raw material which is in the form of rectangular bars is cut into specified length .It has Hydraulically operated bed. 2. Vertical milling machine : This machine is used for milling thickness and width.It has carbide tips tools and it is manually operated . It has feed motor , automatic gear change motor , hydraulic clamp and cutting oil is servo cut oil with water. 3. Surface grinder : This machine is used for grinding the surface .It has electric magnet for clamping the job and one motor is for motion to grinder and second motor is for feed .Bed is hydraulically operated. Coolant is servo cut oil. 4. Plano milling machine / Duplex milling machine : This machine is used for rhomboid cutting. It has angle bed of fixture on which Bar will be mounted .In this machine cutter is on both side left and right.Coolant is servo cut oil. Bed is gear operated by electric machine but fixture is hydraulic operated .In this machine 0.8 mm of extra material is left in job . 5. CH BACH grinder for Rhomboid grinding : 0.8 mm of extra material is removed in this machine .It is NC operated machine. It has hydraulic operated bed. Coolant is servo cut oil. In this machine clamping fixture varies accordingly blade size and angle. :

The list is as follows:

Blade size 20 25 28 32 36 40 46 56 64

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Tolerance limit is of +0.00 and -0.03 mm for blade size. Angle (degrees) 17 19 21 23 25 27 Tolerance limit for the angle is +0.03 to -0.03 degree. 6. T-Root machine / Special purpose machine : This machine is called T Root machine because the final root is same as in shape of alphabet T . It is 6 station machine. It is CNC and hydraulically operated machine. VEEDOL Cutting oil is used in this machine. The functions of 6 stations are as follows : 1- Loading / Unloading of the job 2- Taper milling operation 3- Root roughing : At this station there are 4 cutters and two cutters are on both sides . Here root made is of rough quality . 4- Step milling : Here are two cutters for cutting. 5- Finishing of rough root : Here the rough root is finished and for checking this Plug Guage is there. 6- Root end radius : 3 cutters are here. One is for upper portion and remaining two are for chamfer portion. First three stations are hydraulic stations and last three are CNC stations. LP SECTION: There are two types of blades in LP Section. 1. FIR-TREE ROOT BLADE 2. T ROOT BLADE T-Root blade is used for 1 stage of LP Turbine while for further stages Fir-tree root blades are used. . IMPROVEMENT IN THE STEAM TURBINE BLADE DESIGN: Turbine blading being the most crucial component of the flow path has been the focal point for improving the efficiency. A great deal of research and development efforts has been put into the redesign of the turbine blading aimed at reducing the aerodynamic losses. The flow through the steam turbines is of extreme complexity and three-dimensional owing to effects of viscosity, compressibility and unsteadiness. Three-dimensional computational tools like CFD techniques developed in past ten years have helped a lot in dealing with these complexities.

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(i)High Pressure and Intermediate pressure blading: In reaction steam turbines, the high pressure and intermediate pressure blades so far have been of cylindrical design, i.e. with a blade. constant profile over the entire length .The profiles used have been optimized with respect to profile losses and section modulus. Figure 1 shows the relative flow losses at various points of HP and IP turbines.

FIG.. 1 RELATIVE FLOW LOSSES IN HP AND IP TURBINES WITH CYLINDRICAL BLADES The initial stages of HP and IP turbine exhibit relatively high secondary losses due to low volume flow rates and low aspect ratio (blade height to chord). For usages in these stages, 3DS blades have been developed to enhance efficiency by reducing secondary losses. The design is characterized by the inclination of the blade in root and shroud regions. This angling of the blade imparts an additional radial force to the steam. This results in lower aerodynamic forces on the profile sections on the blade tips. Blade of such type of construction is shown in the figure 2.

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FIG. 2 3DS BLADE Development of new improved TX profile now affords a higher overall stage efficiency compared to T4 profile used so far. TX profile yields advantages for part-load operation over a pre-defined load range. TX blades show a significant efficiency improvement of over T4 blades. In rear stages of HP & IP turbines and in few middle stages of the low-pressure turbine, profile losses due to improper incidence flow on the relatively long cylindrical blade are very high. This requires implementation of blades with a pronounced twist and narrower outer sectional profiles. The use of various profiles of decreasing cross-section along the height significantly reduces profile losses. The incident and exhaust flow angles are better optimized and the blade can be made longer. The blades described here are equipped with T-roots and integral shrouds. Integral shrouds enable better sealing with the inner casing thus reducing tip clearance losses in such stages. Blade of such type of construction is shown in the figure 3.

FIG. 3 TWISTED BLADE WITH INTEGRAL SHROUD ii) LP BLADING: Optimizing the flow distribution in large blade grid was the first step in developing advanced LP blading. An efficient long blade design requires uniform distribution of steam flow along the length of the blade. Maximum mass flow should be established in working profile section with the best thermodynamic performance. Boundary layer losses at the hub and tip sections should be minimized by reducing the mass flow in these sections. The final stage in the exhaust region is, however, quite different. To positively influence the flow in this area, a tapered and forward-leaning stationary blade profile was developed. The inclination is designed such that the downstream face of the profile faces the rotor. With earlier design of tapered guide blade flow separation at hub region of moving blade was taking place due to low degree of reaction. Tapered and forward leaning guide blade (shown in figure 4) directs the steam flow towards the inner diameter providing sufficient flow at the hub section and thereby minimizing the chances of flow separation in the root area. 22

FIG. 4 Tapered & forward leaning guide blade (BANANA BLADE)

3.3 TURBINE UNIT MANUFACTURING

In TUM Section of Block III, all casings of HP, IP & LP Turbines are manufactured. In this section all required operations are done for the casings like milling, boring, grinding and all required operations are performed here and all desired operations for rotor are also performed here and after the making of rotor and casing, the blades which come from TBM Section, are fitted in the casing and rotor. Final assembly of turbine is done in this section. There is one Governing Assembly also there in TUM Section.

3.4 MANUFACTURING FACILITIES

3.4.1 HYDRO TURBINES For manufacturing of Hydro Turbines, Bay-I has the following sections: (a) Circular Components Machining Section This section is equipped with a number of large/ heavy size Horizontal and Vertical Boring Machines, Drilling Machines, Centre Lathes, Marking Table and Assembly Bed. The major components machined in this section are Spiral Casing with Stay Ring, Spherical and Disc Valve bodies and

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Rotors. (b) Runner and Servo Motor Housing Machining Section This section is equipped with NC/CNC and conventional machines comprising Heavy and Medium size vertical and Horizontal Boring Machines, Centre Lathes, Grinding machines and Drilling Machines, Marking Table, Assembly Bed, Assembly Stands for Steam Turbine and Gas Turbine assemblies and Wooden Platform for overturning heavy components. Hydro Turbine Runners, Servomotors, cylinders, Labyrinth Ring, Regulating Ring, Stay Ring, Turbine Cover, Lower Ring, Kaplan Turbine Runner Body and Blades are machined here. (c) Guide Vanes and Shaft Machining Section This section is equipped with Heavy duty Lathe machines upto 16 meters bed, CNC turning machines, Horizontal Boring Machine, Heavy planer, Deep Drilling Machine, Boring Machines, marking Table, Marking Machines and Assembly Beds. Turbine shafts, Guide Vanes, Journals and Rotors of Spherical and Disc Valves are machined here. Rotors of Steam Turbines are also machined in this section. (d) Assembly Section In this section, assembly and testing of Guide Apparatus, Disc Valve, Spherical Valves, Servo motor shaft and combined Boring of coupling holes are done. (e) Preservation and Packing Section Final preservation and packing of all the Hydro Turbine components / assemblies is done here. (f) Small components Machining Section This is equipped with Planetary Grinding Machine, Cylindrical Grinding Machines, small size Lathes, Planers, Vertical and Horizontal Boring Machines. Small components like Bushes, Levers, Flanges etc. and Governing assemblies and machines here.

(g)

Governing Elements Assembly and Test Stand Section This section is equipped with facilities like oil Pumping Unit, Pressure Receiver, Servomotors etc. for assembly and Testing of Governing Elements.

3.4.2 STEAM TURBINES 24

The facilities and parts manufactured in the various sections of Steam Turbine manufacture are as follows: (a) Turbine casing Machining Section It is equipped with large size Planer, Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines etc. Fabrication work like casings, Pedestals etc. are received from Fabrication Block-II. (b) Rotor Machining Section It is equipped with large size machining tools like Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree Groove Milling Machine etc. Some rotor forgings are imported from Russia and Germany and some are indigenously manufactured at CFFP, BHEL Haridwar. (c) Rotor Assembly Section This is equipped with Indicating Stand, Small size Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and Discs. Machined Rotor, Discs and Blades are assembled here. Balancing and over speeding of Rotor is done on the dynamic balancing machine. (d) Turbine casing Assembly Section Machined casings are assembled and hydraulically tested by Reciprocating Pumps at two times the operating pressure. (e) Test Station - Test station for testing of 210 MW USSR Steam Turbine at no load is equipped with condensers, Ejector, Oil Pumps, Oil containers Steam Connections etc, required for testing. Overspeed testing is done for emergency Governor. Assembly Test Stands for different modules of Siemens design are equipped with accessory devices. (f) Painting Preservation and Packing Section All the parts are painted, preserved and packed here for final dispatch. (g) Bearings and Miscellaneous Parts Machining Section This section is equipped with small and medium size basic machine tools, e.g., lathes, Milling M/c, Horizontal Borer, Vertical Borer, drilling M/c etc. for manufacture of bearings and other miscellaneous parts of turbine. (h) Sealing and Diaphragm Machining Section It is equipped with medium size Vertical Boring, Horizontal Boring, Planning, Drilling Machines etc. wherein castings of sealing Housings, Liner housings, Forgings of Rotor Discs, castings and fabricated Diaphragms and components are machined. It is also equipped with CNC machining 25

center. Precision Horizontal Boring, Plano-Milling machines etc, are for manufacture of Governing Casting, Servo Casings and other medium parts of governing and Main Turbine assemblies. (i) Governing Machining Section This section is equipped with medium size and small size lathes, medium CNC lathe, Milling, Grinding, Drilling, Slotting and Honing Machines. Governing assembly parts are machined here. (j) Diaphragm and Governing Assembly Section It is equipped with deflection testing equipment for Diaphragms, Dynamic Balancing Machine for balancing Impeller of Centrifugal Oil Pumps and small fittings and assembly equipment. Governing test stand is equipped with the facilities like Oil Pumping Unit, Pressure Receiver, Servomotor, overspeed testing of Emergency Governor etc. (k) Light machine shop In addition to normal conventional machine tools it is equipped with CNC Lathes, CNC Milling, CNC Vertical Boring, Precision Milling, planetary grinding machines etc. for manufacture of small and medium precision components of governing and other turbine parts. 3.4.3 GAS TURBINE All the components of Gas Turbine are machined and assembled using the facilities available for manufacturing of steam and hydro turbines except the following facilities which are procured exclusively for the manufacturing of Gas Turbine and are installed in the areas specified for gas turbine manufacturing. a) Hydraulic Lifting Platform This facility is used for assembly and disassembly of G.T. Rotor. This is a hydraulically operated platform which travels upto 10 M height to facilitate access to different stages of Rotor. This is installed in Bay-I assembly area. b) CNC Creep Feed Grinding M/c. This is installed in Gas Turbine machining area Bay-II Extn. This M/c grinds the hearth serration on rotor disc faces. Hirth serrations are radial grooves teeth on both the faces 26

of rotor discs. Torque is transmitted trough these serrations, which are very accurately ground. c) External Broaching Machine This machine is installed in GT machining area and is used to make groove on the outer dia. of rotor discs for the fitting of moving blades on the discs. d) CNC Facing Lathe This machine is installed in GT machining area and is used basically for facing rotor disc but can turn other components also. e) CNC Turning Lathe This machine is installed in Bay-I Heavy Machine Shop and is used to turn Tie Rods of Gas Turbine, which have very high length / diameter ratio. Tie-Rod is a very long bolt (length approx. 10 meter & dia 350 mm) which is used to assembly and hold the gas turbine rotor discs to form a composite turbine rotor. f) Wax Melting Equipment This is low temp. electric furnace installed in Gas Turbine blading area in Bay-II. It is used to mix and melt Wax and Colaphonium, which is required to arrest the blade movement during the blade tip machining of stator blade rings. g) Gas Turbine Test Bed This test bed is installed near the Gas Turbine Machining area in Bay-II. This facility is used to finally assemble the gas turbine. Combustion chambers are not assembled here, which are assembled with main assembly at the site.

h)

Combustion Chamber Assembly Platform This facility is a 3 Tier Platform installed in Bay-I assembly area and is used for assembly of Combustion Chambers of Gas Turbine.

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4
Manufacturing Process of Turbines

This is the topic assigned to me for training. I have worked over this topic and this is the brief manufacturing of three types of turbines viz; Hydro Turbines, Steam Turbine & Gas Turbine. At the training period the work on steam and hydro turbine, therefore I am unable to see gas turbine. As a whole its very hard to understand the every part and every detail of all turbines, but I tried a lot to understand as far as possible for me. Below is the manufacturing process of the above mentioned turbines.

4.1 GENERAL INTRODUCTION

Of all Heart 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 and /or heart are needed for processes. These include: pulp mills, refineries, petrochemical plants, food processing plants, destination plants and district heating plants. Advantages includes 1. Ability to utilize high pressure and high temperature steam 2. High efficiency 3. High rotational speed 4. High capacity/weight ratio. 5. Smooth, nearly vibration free operation. 6. No internal lubrication 7. Oil free exhausts stream. Disadvantages are For slow speed application reduction gears are required .The steam Turbine cannot be made reversible. The efficiency of small simple turbines is poor. STEAM TRUBINES: THE MAIN STAY OF BHEL BHEL has the capability to design; manufacture and commission steam turbines of up to 1000 MW ration for steam parameters ranging from 30 bars to 300 bars pressure and initial & rehear temperature up to 600 C.Turbines are built on the building block system. Consisting of module suitable for a range of output and steam parameters. For a desired output and steam parameters appropriate turbines blocks can be selected

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APPLICATION RANGE OF STEAM TURBINES SERIES TYPE OF SPEED STEAM RPM GENERATOR POWER OUTPUT MW MAIN STEAM CONDITION O BAR C 130250 40-70 500540 250300 REHEAT STEAM CONDITION O BAR C 30-70 500600 200250 500540 BACK PRESSURE MBAR

Turbines for Fossil Fuel Power Plants Turbine for Nuclear Power Plant Turbines for Combined Cycle Application

Fossil Fuel 3000 Steam Generator Pressurized 3000 Light Water Reactor Heat Recovery 3000 Steam Generator

1001000

20-300

Upto 1000

8-15

20-300

Upto 300

30-140 500540

30-50

20-300

Another various types of steam Turbines can be classified in the following manner. 1. On the base of flow direction a) Axial b) Radial c) Tangential 2. On the basis of expansion process a) Impulse b) Reaction c) Combined Impulse and reaction 3. On the basis of number of Stages a) Single Stage b) Multi Stage 4. On the basis of Steam entry configuration a) Fully admission b) Partial admission 5. On the basis of Application a) Electric Power Generation b) Industrial c) Marine ]

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Steam Turbines
The purpose of a steam turbine is to convert heat energy contained in high pressure and high temperature steam into mechanical energy. The source of the high pressure / temperature steam is a boiler, usually in a power station. Fossil fuel (i.e. coal or oil), or nuclear energy is consumed to provide the heat energy in the boiler. Construction Details of Steam Turbines Show in the left diagram is a single row of typical turbine blades. You may notice that the cross-section of each blade is that of an aerofoil! Well, do you understand what the purpose of an aerofoil is? An aerofoil is a machine that produces lift. The air stream on the top of the aerofoil must travel further than the straighter air stream on the bottom. But the same amount of air must travel from the front tip (or leading edge ) to the rear tip (or trailing edge ) ..... so the upper air stream's velocity must increase. Remembering Bernoullis Theorem, this means that the pressure in the upper air stream must reduce. Now, think what has happened. We now have a low pressure region above the aerofoil and a normal higher pressure region at the lower surface of the aerofoil. The difference in pressure implies that the aerofoil will want to move upward; and hence an upward force of the aerofoil results!! Many small steam turbines have only a single row of blades, as in the upper left figure, but for large power station steam turbines this is not the case. Multiple rows of turbine blades and

guide vanes compose the steam turbine. Guide vanes are required to 'straighten' the steam path, so that it impinges on the proceeding turbine blade correctly. The steam path through one row of turbine blades ( grey in the figure ) and one row of guide vanes ( purple in colour ) is shown in the figure below

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Power station steam turbines are divided into individual and separate high pressure ( HP ) and low pressure ( LP ) turbines, connected only by their rotating shafts. This is done to enhance

the efficiency of the steam turbine ... The HP turbine if the first compartment of the steam turbine to receive the superheated steam, the superheated steam is at boiler pressure and high temperature. The steam leaving .

the HP steam turbine is at a lower pressure and temperature, as steam energy has been transferred to the turbine blades in the form of mechanical energy. In some sophisticated power stations, the steam leaving the HP turbine is re-heated in the boiler before entering the LP turbine. In this way more energy can be put into the steam cycle without requiring further latent heat, thus improving the plant efficiency - but is more complex! As the steam entering the LP turbine is at a lower pressure a larger surface area is required to extract the steam energy, and hence the diameter of the LP turbine is larger than the HP turbine. The LP steam turbine may itself be divided into a number of smaller low pressure steam turbines, each having larger blade diameters. The steam finally exits the LP steam turbine and enters the condenser. The overall construction of a typical steam turbine is well shown in the figure below. The HP section of the steam turbine is the extreme bottom, while the LP sections extend from the HP section upwards. Notice the scale of steam turbine - compare to one of the working engineers!

OPERATION PRINCIPLES
IMPULSE TURBINE The principle of the impulse steam turbine consists of a casing containing stationary steam nozzles and a rotor with moving or rotating buckets .

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The steam passes through the stationary nozzles and is directed at high velocity against rotor buckets causing the rotor to rotate at high speed The following events take place in the nozzles : 1. The steam pressure decreases . 2. The enthalpy of the steam decreases . 3. The steam velocity increases. 4. The volume of the steam increases. 5. There is a conversion of heat energy to kinetic energy as the heat energy from the decrease in steam enthalpy is converted in to kinetic energy by the increased steam velocity. The nozzles may be conversion nozzles or they may be convergent divergent nozzles. Converted nozzles are used for smaller pressure drops where the minimum exit pressure is 0.577 X the Intel pressure (the critical pressure for nozzles) If the exit pressure is less than 0.577 X Intel pressure, eddy-currents are developed and the exit velocity will be less than calculated. The convergent divergent nozzles prevent eddy-currents and the calculated velocity will be obtained over at large pressure drops.

The Impulse principle

If steam at high pressure is allowed to expand through stationary nozzles. the result will be a drop in the steam pressure and an increase in steam velocity . In fact , the steam will issue from the nozzle,the result will be a drop in the steam pressure and an nicrease in steam velocity.In fact, the steam will issue from the nozzle in the form of a igh speed jet.If this high steam is applied to a properly shaped turbine blade, it will change in Direction due to the shape of the blade. The effect of this change in direction of the steam flow will e to produce an impulse force, on the blade causing it to move ,If the blade is attached to the rotor of a turbine, then the rotor will revolve/Force applied to the blade is developed by causing the steam to change direction of flow (Newtons Law change of momentum). The change of momentum produces the impulse force. The fact that the pressure does not drop across the moving blades is the distinguishing feature of the impulse turbine. The pressure at the inlet to the moving blades is the same as the pressure at the outlet from the moving blades.

Reaction principle
A reaction turbine has rows of fixed blades alternating with rows of moving blades .The steam expands first in the stationary or fixed blades where it gains some velocity as It drops in pressure. It then enters the moving blades where its direction of flow is changed thus producing and impulse force on the moving blades .In addition , however, the steam upon

33

passing through the moving blades again expands and further drops in pressure giving a creation force to the blades .This sequence is repeated as the steam passes through additional rows of fixed and moving blades. Special Aspects of Reaction Turbines There is difference in pressure across the moving blades .The steam will therefore tend to leak around the periphery of the blades instead of passing through them. Blades clearances therefore must be kept to minimum. Also, due to be developed upon rotor and some arrangement must be made to balance this. Impulse Turbine Staging In order for the steam to vive up all its kinetic energy to the moving blades in an impulse turbine, it should leave the blades at zero absolute velocity. This condition will exist if the blade velocity is equal to one half of the steam velocity. Therefore, for good efficiency the blade velocity should be about one half of steam velocity. In order to reduce steam velocity and blade velocity, the following methods may be used: 1. Pressure compounding. TURBINE CASING Casings or cylinders are of the horizontal split type. This is not ideal ,as the heavy flanges of the joints are slow to follow the temperature changes of the cylinder walls. However, for assembling and inspection purposes there is not other solution. The casing is heavy in order to withstand the high pressures and temperature. 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 dowels pins are often added to secure exact alignment of the flange joint Double casing 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. TURBINE ROTORS The design of a turbine rotor depends on the operating principle of the turbine. The impulse turbine with pressure drop across the stationary blades must have seals between stationary blades and rotors. The smaller the sealing area, the smaller the leakage; therefore the stationary blades are mounted in diaphragms with labyrinth seals around the shaft. This construction requires a disc rotor. Basically there are two types of rotor; Disc Rotors All larger disc rotors are now machined out of a solid forging of nickel steel; this should give the strongest rotor and a folly balanced rotor, It is rather expensive ,as the weight of the final

34

rotor is approximately 50% of the initial forging. Older or smaller disc rotors have shaft and discs made in separate pieces with the discs rotors have shaft and discs made in separate pieces with the discs shrink in the shaft. The bore of the discs is made 0.1% smaller in diameter than the shaft. The discs are then heated until they easily are slid along the shaft and located in thee correct position on the shaft and shaft key. A small clearance between the discs prevents thermal stress in the shaft. Drum Rotor The first reaction turbines had solid forged dim rotors .They were strong, generally well balanced as they were machined over the total surface. With the increasing size of turbines the solid rotors got too heavy pieces .For good balancing the drum must be machined both outside and inside and the drum must be open at one end. The second part of the rotor is the drum end cover with shaft. The end cover is made with shrink fit and weld of 600-700 *10^6 Pascal. TURBINE BEARING Journal Bearing The bearings for small turbines are often self-aligning spherical ball or roller-bearings for that may be ring lubricated sleeve bearing with bronze or Babbitt lining. Thrust Bearings The main purpose of the thrust bearings are 1. To keep the rotor in an exact position in the casing 2. To absorb any axial thrust on the rotor.

TURBINES SEALS
Blade Seals The efficiency of reaction turbines depends to a large extent on the blade seals ; radial as well as axial seals are often part of the shroud with the seal clearance kept as small as possible. As protection for the axial seals some manufacture apply an adjustable thrust bearing. The whole thrust block is pushed able to the axial adjusted. During startup the thrust block is pushed against a stop in the direction of exhaust of exhaust for maximum seal clearances. When turbine is heated up and has been on load for a short time the thrust block is pulled forward against a forward stop for minimum seal clearance and maximum blade efficiency.

Shaft Seals
Shaft seals must be provided in order to prevent or at least reduce steam leakage where the shafts extend through the casings. Also when low pressure turbines are under vacuum the seals must prevent air from leaking into the casing.

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Ordinary soft packing may be used for shaft sealing in small turbines. Carbon rings are also very common for small turbines. The carbon ring is made up to of three segments butting together tightly under the pressure of a garter spring. The ring has few hundreds of millimeter clearance around the shaft and is prevented from turning by a locking pin. The ring has a slight side clearance in the housing allowing it to move freely in radial directions. Carbon rings are self-lubrication but have a tendency to corrode the shaft when the turbine is shut down. Water Seal The water seal cannot operate properly at low speed and gland steam must be applied for sealing during start-up until the turbine speed is approximately 2000rev/mm. Water seals are supplied with clean cool condensate from the extraction pump. It may be supplied directly or via a head tank with automatic level-control TURBINE COUPLINGS

The purpose of couplings is to transmit power from the prime mover to the driven piece of machinery. For heavy loads the solid flange coupling is used. The flanges are generally integral parts of the shaft; by they may be separate parts for smaller turbines. In this case each coupling part has a tapered bore and keyway to fit the tapered end of the shaft. Following the taper the shaft has a large thread allowing the coupling to be secured tightly with a large nut. The friction between the coupling halves and the shear force of the bolts transmits the power. For maximum shear stress the bolts must be fitted. The coupling bolts should be undercut, that is machined off to a diameter slightly less than the bottom diameter of the thread to avoid any strain on the thread. In some cases the couplings must compensate for axial expansion and contraction of the rotors and in this case a flexible coupling is applied. The outer half has internal gears, while the inner part has matching external gears. The coupling works like the spline on a driveshaft for a car. The couplings for very large shafts will need a large diameter if the bolts are used to transmit the power .The bolts can be much smaller if they are a not allowed to transmit power .In the coupling shear pins carry the load. The area exposed to shear is the shear pins to e located at a large radius from the shaft center. The coupling bolts are not fitted as they are exposed to tensile stress only. STEAM TRUBINES FOR FOSSIL FUEL 1. Three cylinder turbines (HMN Series), comprising of High pressure (HP) turbine Intermediate pressure (IP) turbine Low pressure (LP) turbines 2. Two cylinder turbines comprising of combined (HP & IP) and LP turbine (KN series) 36

3. Two cylinder turbines comprising of HP and combined (IP and LP) turbines (HE series) SALIENT FEATURES 1. Turbines for both nozzle control as well as throttle control mode. 2. Turbines can operate with any boiler and are suitable for i Constatnt pressure as well as sliding pressure operation ii Base load as well as two-shift opearion iii Sub critical as well as super critical parameters 3. All the rotors are monoblock 4. HP & IP casings have double shell construction and LP has three shell construction 5. IP turbines with single flow or with double flow. 6. Hollow guide blades with suction slits for moisture removal in last LP stage. 7. Baring pedestals isolated from turbine casings. 8. Combined stop & control valves with individuals servomotor. 9. Sophisticated control and monitoring equipment such as Electro-hydraulic governing, automatic turbine run up system ,turbine stress controller ,automatic turbine tester etc. 10. High operational flexibility 1. Fast start up and shut down. 2. Sharp load changes. 3. Operation under wide frequency range (47.5 to 51.5 Hz) STEAM TURBINE FOR COMBINED CYCLE 1. Combined cycles offer substantial improvement in thermal cycle efficiency by lowering the heat rejection temperature. 2. Exhaust from gas turbine is used effectively for generating steam in fired or unfired heat recovery steam generator for running a suitable steam turbine. 3. Open cycle gas turbines can be profitably converted to a combined cycle plant even at a later stage depending upon the convenience of the utility. 4. BHEL Haridwar manufactures steam turbines for combined cycle power stations with gas turbines of 66 MW and 255 MW ISO ratings. 5. Steam cycle may be single, dual or triple pressure cycle. 6. With triple pressure cycle and suitable block combination of gas turbines, HRSG and steam turbines, cycle efficiency of about 58% can be achieved. TURBINES WITH ADVANCED STEAM PARAMETERS Application of higher parameters is the most direct way of increasing heat input to the cycle 1. Steam parameters of 300 bar pressure and 600 C temperature 2. Six percent improvement in thermal cycle efficiency 3. New materials for high temperature applications 4. Impulse diagonal blading for the first stage HP and IP turbines 37

5. Heat shield at intel of IP turbine 6. Increased wall sections for increased pressures The plant is fully equipped with the most modern and sophisticated manufacturing and testing facilities to produce sets up to 1000 MW rating . These include: Blade shop for manufacture of both moving and stationary blades Special purpose CNC machine tools. Over speed & Vacuum Balancing Tunnel a unique facility for balancing and over speeding of rotors for turbines.

MANUFACTURING FACILITIES ENGINEERING CAPABILITIES BHEL carries out life extension programs on steam turbines of various ratings ,which forewarn the impending failure and help in reducing costly plant breakdowns by recommending replacement and up gradation of defective components. Over the past two decades , BHEL has gained a vast experience in design , manufacture , erection and commissioning of various capacities of turbine Generator sets ranging from 100 MW to 500 MW. Many specific features to suit the customer requirements, layout & operation are taken care of To name a few : BHEL Haridwar has a strong engineering base with qualified and experienced engineers supported by technicians , spanning the functions of proposal , performance and product engineering , project management , field engineering ,research and development , computerization etc. RENOVATION & MODERNISATION (R&M) Depending on the actual operating condition, material properties of the components degrade as function of service life due to one or more time dependent material damage mechanisms such as creep, fatigue, corrosion, erosion, wear embattlement etc. Life extension programme (LEP) is a special package comprising systems and methodologies, which evaluates the residual life of components through sophisticated NDT, FEM stress analysis and metallurgical technique. Many improvements in material and design of critical components with state-of-art design is a part of the life extension process. Thus the performance availability and efficiency of the plant may be improved by R&M programs. MICROSTRUCTURE EXAMINATION OF ROTOR

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HP/LP bypass turbine stress evaluator, hand barring Gear and Automatic Turbine R run up system for MW Russian Turbine. Base load /cycle /Twoshift operations Throttle /Nozzle governing. Constant /sliding pressure operation.

4.2 DESCRIPTION OF STEAM TURBINE PARTS

SPIRAL CASING The spiral casing is of logarithmic form and designed to maintain optimum flow conditions .It is manufactured in parts, depending on transport limitations. For larger sizes, spiral-casing segments are welded at site, The welded at site. The welding seams are tested by radiography, Ut and the complete casing is tested under hydraulic pressure. STAY RING & GUIDE APPARATUS Stay rings up to 12.5 m in diameter can be machined on BHEL s vertical boring machines .The rings are welded in the works .For high head machines, the stay rings are made of low alloy cast steel. The guide apparatus assembly of low and medium head turbines is carried out on dummy stay ring or its own stay ring Maximum possible check-assembly of the various matching component of the turbine is carried out in works .Pit-type and tandem type servomotors have been installed. Rubber lips and hydrodynamic seals have been used as shaft sealing . Self-lubricated self-aligned and water lubricated guide bearings have been used depending upon speed requirement RUNNER : The type and size of runner has been so designed that it can meet the requirement of developing a rated output of 7740 KW at rated head of 13.5 m and 8900 KW at max. head of 15.3 m a speed of 166.7 rpm. The adjustable blades of runner with four cast stainless steel blades and a low alloy cast steel hub is fitted with high duty bronze for the blades journal & sliding blocks Reliable and durable sealing are provided between blade journals and runner body to prevent water entering into hub and the oil leaking out of it. The sealing is kept in their working position by a set of spring. The sealing rings can be replaced without dismantling the runner blades from the runner. The blades have integral trunnions, which are machined true and are complete with rigid operating levers, which are held in position with the help of nut & located by means of pins. A streamlined runner cone is secured to runner hub by bolts. Suitable arrangement for emptying and filling oil in the hub, in stationery condition, has been 39

provided. The runner hub is connected to the lower flange of the shaft by a set of bolts and cylindrical pins, placed radically to take the axial load and torque respectively .The shaft flange also serves as covers of the runner servomotor. SPHERICAL AND BUTTERFLY VALVES Main Inlet valves and penstock valves of butterfly type (for low head applications) and spherical valves (for high head applications) are designed and supplied a by BHEL Valves of sizes ranging from 500 mm to 530 mm diameter and for heads up to 1020 m have been supplied. BHEL has also designed and developed double seal type and lattice door type B.F valves. BLADES OPERARION MACHANISM : It consists of a pressure oil servomotor, built into runner hub in which a piston moves up & down. Special nut has been provided to holds blades onto lever. The blades for pinned to levers, which are connected to piston of runner servomotor thought links and sliding blocks. Thus reciprocation motion of the piston causes the angular motion of blades for opening and closing to suit the operating requirement. Oil enters the servomotor form the oil header placed on top of the generator and passes through the oil pipes located in the central bore of main shafts. OIL HEADER The oil header serves for the supply of oil under pressure from oil pressure unit to the runner servomotor through a set of concentric pipelines placed inside the bores of turbine and generator shafts. Supply of oil for opening or closing of runner blades is actuated by the main slide valve of the governor. TURBINE SHAFT Turbine shaft is of forged steel with solid forged flanges at both ends for coupling to the generator shaft and runner hub. The lower flange also serves as cover of the runner servomotors. The shaft is bored for its full length to ascertain its soundless and accommodate oil pipes. The bearing skirt is polished to a fine finish. GUIDE BEARING Turbine guide bearing of self lubrication segment type is situated above the shaft sealing as close to the runner as possible .Guide bearing consists of 8 babbit lined segments arranged along the skirt of the shaft .The segment rest on a ring fixed to the horizontal flange of the bearing body and are kept immersed in an oil bath up to centerline of guide bearing in stationary condition. Radial holes have been provided in the skirt of act as centrifugal pumps, during the shaft rotation, thus forcing the oil under pressure to pass through the gap

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between the segment & shaft and take a wedge form and oil film is formed ensuring lubrication of guide bearing. TURBINE SEALING To prevent leakage of water through the gap between the shaft and turbine top cover, a turbine sealing is provided below the guide bearing. Two rubber rings acting as the sealing element are used against the stainless steel cylinder bolted onto the turbine shaft. Clean water is supplied at a pressure of 2-3 kg/sq. cm between the two rings to check the entry of dirty water from below. This also helps in cooling and lubricating of rubber seals. Clean water is also supplied to the upper chamber of sealing for the same purpose. GUIDE APPARATUS The guide apparatus regulates the flow of water through the turbine with change in load and serves as a closing device .It consists of : a) TOP COVER: Turbine top cover is fabricated in tow parts due to transport limitation and joined together with the help of bolts. Top cover is bolted to the staying and is suitable for accommodation guide vane bearing housing for upper journals It serves as a support for runner & shaft assembly when turbine shaft is disconnected from generator shaft. b) LOWER RING: The lower ring is fabricated from steel plates in two parts joined together with nuts and bolts. Its throat is shaped to guide the water onto the runner chamber. The lower ring is reinforced by ribs and bolted to the runner chamber. It is fitted with bronze bushes for the support of guide vane lower journals and rubber seal is fitted to prevent water leakage into bushes . c) SET OF GUIDE VANES: The guide vanes, 24 in number, are made of cast steel and have a smooth Hydraulic profile, with integral journals protected by collars and drilled through for grease lubrication of the lower journals bearings by automatic centralized grease lubrication system. Journals of each guide vane are supported in three bronze bushes. The tow upper journal busing is pressed into cat iron bearing bodies housed in top cover. The busing for lower journal is pressed into the lower ring. The journals are sealed against water by shaped collars and rubber cup sealing. The guide vanes are connected to the regulating ring by lever, links, shear pins for their smooth operation

d) REGULATING RING: The regulating ring made of welded construction from steel plates .It is supported and guide on the top cover. It is provided with bronze

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pads on the surface, rubbing against the supported and these pads are immersed in an oil bath to minimize friction. Oil is poured in the bath through a special funnel provided for the purpose .The regulating ring is provided with two anchors with pins and bonze bushes for connecting it with servomotors. e) GUIDE VANE REGULATING MECHANISM : The turning of guide vanes is carried out by two double acting tandem type servomotors, mounted on the top cover through the regulating ring, links, straps and levers. The levers are fixed to the guide vanes with the help of cylindrical wedge type keys. The lever and straps are connected to each other thought safety shear pins which get sheared off, in the event of a foreign body getting wedged between the vanes thus protecting the guide vanes and turning mechanism against any damage .Contacts have been provided for signaling in case of shear pins failure. Stoppers are provided to prevent movement of guide vanes beyond the fully opened and closed positing in the case of failure of shear pin. A cover has been provided on the lever .The suspended type design for guide vane is suspended from this cover. The suspended type design for guide vane allows for accurate adjustment of guide vane top and bottom face clearances. f) SERVOMOTOR FOR GUIDE APPARATUS : Two nos, tandem type servomotor of diameter 220 mm each are provided for turning the regulating of load on turbine and closing /opening of guide apparatus. One of the servomotors is provided with a stopper lock for retaining the turbine in closed position during its shut down for longer periods. The stopper is provided with contracts, which indicates its closed or open position on the control panel.

4.3 GOVERNING SYSTEM

OIL PUMPING UNIT Each unit is provided with its own oil pressure system. The pumping unit is equipped with two screw pumps driven by electric motors through flexible coupling and of sufficient capacity ,to meet all the oil requirements of turbine. The pumps with motors are mounted on the top of sump rank. Pumping of oil is mainly carried out by the main pump, under the control of relief cum safety valve to maintain the pressure in the pressure accumulator. The oil pump driven by motor draws oil from the oil sump and delivers it under pressure through non return valve into the pressure accumulator. The sump is divided into two compartments by a perforated sheet, which filters all the oil returned to the sump, before it is drawn by the pumps, Fitting & accessories are provided for intermittent running of pumps. PRESSURE ACCUMULATOR It is a fabricated pressure vessel. It is an air oil pressure accumulator filled with oil and compressed air & server as the source of energy for driving the power organs of the system by means of oil under pressure. It is fitted with pressure gauge, pressure switches, and low level alarm switch of float type, sight level gauge. A manhole is also provided for inspection and cleaning of the accumulator.

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 OIL LEAKAGE UNIT The oil leakage unit is indicates for the collection of oil leakage from the guide apparatus servomotors and other valve systems etc. and periodic pumping from tank of oil pressure unit. The O.L.U. consists of a tank and mounted on it is pump motor set. In the tank a level relay is installed for controlling the pump and for alarm.

4.4 MANUFACTURING PROCESS OF TURBINES

4.4.1 HYDRO TURBINES The major processes involved in various Hydro Turbine Sections are as follows: Marking and checking of blanks manual as well as with special marking M/c. Machining on Horizontal Boring, Vertical Boring, Lathes etc. as the case may be on CNC /Conventional Machines. Intermediate assembly operation is carried out on the respective assembly beds provided. Then the assembly is machined as per requirement. The sub-assemblies are further assembled for hydraulic/functional testing. Hydraulic testing is done using a power driven triple piston horizontal hydraulic pump which can generate a pressure of 200 Kg/Cm 2. It can also be carried out using a power pack. On Governing elements / assembly and test stand, the components / subassemblies / assemblies are tested up to a hydraulic pressure of 200 Kg / c m 2 using the piston pump. Oil testing upto 40 Kg / c m 2 is carried out with oil pumping unit, which is permanently installed on this bed.

4.4.2 STEAM TURBINE

Balancing of Rotor of Steam Turbine 43

Processes carried out in various sections of steam turbine manufacture are based on the following main phases. (a) Machine section Castings, Forgings, welded structures and other blanks are delivered to this section. The manufacturing process is based on the use of high efficiency carbide tipped tools, high speed and high feed machining techniques with maximum utilization of machine tool capacity and quick acting jigs and fixtures. (b) Assembly Section Casings and Governing assemblies are hydraulically tested for leakage on special test Bed. Assembled unit of governing and steam distribution systems are tested on Governing Test Bed. General Assembly and testing of Steam Turbine is carried out on the main Test Bed in Bay-II. (c) Painting, Preservation and Packing After testing the turbine, it is disassembled and inspected. Then the parts are painted, conserved and packed for final dispatch.

4.4.3 GAS TURBINE

The major processes involved in manufacturing Gas Turbine in various sections of BkIII are as follows: a) Machining Castings, Forgings, welded structures and other blanks are received from concerned agencies in the respective sections. These are machined keeping in view optimum utilization of machine tools and toolings. Special jigs and fixtures are made available to facilitate accurate and faster machining. Proper regime and tool grades have been established to machine the materials like inconel, which have poor machinablity. b) Main Assembly Final assembly is done on test bed. Parts are assembled to make sub-assemblies. These sub-assemblies are again machined as per technological and design requirements and are made ready for final assembly. After assembly and insulation assembled Gas Turbine is sent to site.

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c)

Rotor Assembly The rotor is assembled on Hydraulic Lifting Platform and sent to main assembly, where after checking clearances, it is sent for machining. After balancing, turbine side of rotor is disassembled, inner casing is fitted and rotor reassembled. This work is also carried out on Hydraulic Lifting Platform. Finally rotor is sent for assembly on test bed.

d)

Combustion Chamber Assembly This assembly is carried out on 3 tier platform installed for this purpose in Bay-I assembly. After machining of all components, ceramic tiles are fitted in flame tube. Burner and piping etc. is fitted in dome and combustion chamber is finally assembled. It is directly sent to site after insulation.

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Conclusion

Here, in the end, where I would like to conclude my whole report with some short sign. I must say that, to rise in the field of Mechanical Engineering, one must have the good knowledge of all the manufacturing processes. The most important thing is to study the drawings and make the route sheet, planning, shop floor management of the consequent operations. And in that way I prefer myself to get training at B.H.E.L, Haridwar. Because B.H.E.L is growing in the field of Manufacturing and is a very big manufacturing unit so its very good to learn at this place the mechanical and the strategies of management too. Electric power has always been an important part of the world's power supply, providing reliable, cost effective electricity, and will continue to do so in the future. The future of turbines will depend upon future demand for electricity and the future is very bright as we have no source to produce without turbines, be it Hydro Turbine, Steam Turbine or Gas Turbine. In this report, you will find some very refined data, which is referenced from a number of books and manuals and websites. This is just an effort to make my report more efficient.

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References

1. Fluid Mechanics by D.S Kumar. 2. Fluid Mechanics by R.K Bansal. 3. Fluid Mechanics by R.K Rajput. 4. Thermal Engineering by R.K Rajput. 5. Thermal Engineering by B.L Ballaney. 6. Reference data Available in Block-3.

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