B.H.E.L. HARIDWAR

BHEL HARIDWAR – KALPESH SUTHAR Page 1
AN INDUSTRIAL TRAINING REPORT
ON
TURBINE MANUFACTURING at B.H.E.L.,HARIDWAR
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR
THE AWARD OF THE DEGREE OF
BACHELOR OF TECHNOLOGY IN
MECHANICAL ENGINEERING
By
KALPESH SUTHAR
(16ESKME079)
Submitted to
Mr. DINESH KUMAR
Mr. PRAVEEN SARASWAT
Department of Mechanical Engineering
Swami Keshvanand Institute of Technology, Management & Gramothan
Jaipur

ACKNOWLEDGEMENT
We take this opportunity to thank the Industrial Training Co-Ordinator of Mechanical Engineering
Department for allowing us to work on such an interesting & informative topic. We are highly indebted to
our project guide Asst. Professor MR. DINESH KUMAR & PRAVEEN SARASWAT Sir for there
guidance & words of wisdom. They always showed us the right direction during the course of this project
work. We are duly thankful to them to referring us to sites like science direct, openpdf & providing many
research papers which had some research work.
Success in such comprehensive report can’t be achieved single handed. It is the team effort that sail the
ship to the coast. So I would like to express my sincere thanks to my mentor MR. SUYESH KUMAR
Sir.
I am also grateful to the management of Bharat Heavy Electricals Limited (B.H.E.L.), Haridwar for
permitting me to have training during 6th
June to 6st
July, 2013.
We worked as a team and saw ups and downs which are part of any project work. But in the end it was
their Guidance and my team work which made this project possible. Last but not the least we would also
like to thank all our teachers & friends for their constructive criticism given in right spirit.
Kalpesh Suthar
(16ESKME079)
7TH
Sem B.tech
Department of Mechanical Engineering
SKIT , JAIPUR

ABSTRACT
In the era of Mechanical Engineering, Turbine, A Prime Mover ( Which uses the Raw Energy of
a substance and converts it to Mechanical Energy) is a well known Machine most useful in the
the field of Power Generation. This Mechanical energy is used in running an Electric Generator
which is directly coupled to the shaft of turbine. From this Electric Generator, we get electric
Power which can be transmitted over long distances by means of transmission lines and
transmission towers.
In my Industrial Training in B.H.E.L., Haridwar I go through all sections in Turbine
Manufacturing. First management team told me about the history of industry, Area, Capacity,
Machines installed & Facilities in the Industry.
After that they told about the Steam Turbine its types , parts like Blades, Casing, Rotor etc. Then
they told full explanation of constructional features and procedure along with equipement used.
Before telling about the machines used in Manufacturing of Blade, they told about the safety
precautions, Step by Step arrangement of machines in the block with a well defined proper
format. They also told the material of blade for a particular desire, types of Blades, Operations
performed on Blades, their New Blade Shop less with Advance Technology like CNC Shaping
Machine.
I would like to express my deep sense of Gratitude and thanks to Mr. Alok Shukla(AGM) our
in charge of training in Turbine Block in B.H.E.L., Haridwar. Without the wise counsel and able
guidance, it would have been impossible to complete the report in this manner. Finally, I am
indebted to all who so ever have contributed in this report and friendly stay at Bharat Heavy
Electricals Limited (BHEL).

Contents
TURBINE MANUFACTURING at B.H.E.L.,HARIDWAR...................................................................................1
BACHELOR OF TECHNOLOGY IN ..............................................................................................................1
INDEX............................................................................................................ Error! Bookmark not defined.
FIGURE INDEX..........................................................................................................................................1
1 B.H.E.L.....................................................................................................................................................3
1.1 OVERVIEW..........................................................................................................................................3
1.2 WORKINGAREA…………………………………………………………………………………………….5
1.4 HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT...............................................................8
1.4.1 ENVIRONMENTAL POLICY..........................................................................................................8
1.4.2 OCCUPATIONAL HEALTH AND SAFETY POLICY.....................................................................8
1.5 BHEL UNITS...................................................................................................................................... 10
1.6.3 AREA............................................................................................................................................... 11
1.6.4 UNITS.............................................................................................................................................. 11
2. STEAM TURBINE.................................................................................................................................... 15
2.1 INTRODUCTION................................................................................................................................ 15
2.2 ADVANTAGES:- ................................................................................................................................ 17
2.3 DISADVANTAGES:- .......................................................................................................................... 17
2.4 STEAM TURBINES THE MAINSTAY OF BHEL:-.............................................................................. 17
3. TYPES OF STEAM TURBINE................................................................................................................... 18
4. TURBINE PARTS...................................................................................................................................... 19
4.1 TURBINE BLADES............................................................................................................................. 19
4.2 TURBINE CASING............................................................................................................................. 20
4.3 TURBINE ROTORS............................................................................................................................ 20
5. CONSTRUCTIONAL FEATURES OF A BLADE........................................................................................ 21
5.1 H.P. BLADEPROFILES...................................................................................................................... 21
5.2 CLASSIFICATION OF PROFILES...................................................................................................... 22
5.3 H.P. BLADE ROOTS........................................................................................................................... 23
5.4 LP BLADEROOTS ............................................................................................................................. 24
5.5 DYNAMICS IN BLADE...................................................................................................................... 24
5.6 BLADING MATERIALS..................................................................................................................... 26
6. MANUFACTURINGPROCESS............................................................................................................. 26
6.1 INTRODUCTION................................................................................................................................ 26
6.2 CLASSIFICATION OF MANUFACTURING PROCESSES.................................................................. 26
6.2.1 PRIMARY SHAPINGPROCESSES .................................................................................................. 27
6.2.2 SECONDARY OR MACHINING PROCESSES................................................................................. 27

7. BLOCK 3 LAY-OUT................................................................................................................................ 28
BAY 3 IS DIVIDED INTO 3 PARTS: ......................................................................................................... 30
BAY-4 IS DIVIDED INTO 3 PARTS:........................................................................................................ 30
9 BLADE SECTION………………………………………………………………………………………………32
9.1 TYPES OF BLADES.......................................................................................................................... 31
9.2 OPERATIONS PERFORMED ON BLADES........................................................................................ 33
9.3 MACHINING OF BLADES.................................................................................................................. 33
10 CONCLUSION…………………………………………………………………………………………………..35
FIGURE INDEX
Sr. No. Topic Page no.
1. SECTIONAL VIEW OF STEAM TURBINE 14
2. FLOW DIAGRAM OF A STEAM TURBINE 15
3. HIGH PRESSURE BLADE PROFILE 20
4. OVERSPEED AND VACCUM BALANCING WHEEL 29
5. STEAM TURBINE CASING AND ROTORS IN ASSEMBLING
AREA
31
6. CNC ROTOR TURNING LATHE 31
7. TYPES OF BLADES 32
8. SCHMETIC DIAGRAM OF A CNC MACHINE 33
9. CNC SHAPING MACHINE 34

INTRODUCTION
BHEL is the largest engineering and manufacturing enterprise in India in the energy related
infrastructure sector today. BHEL was established more than 40 years ago when its first plant was
setup in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India a dream
which has been more than realized with a well recognized track record of performance it has been
earning profits continuously since1971-72.
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
14001certification for environment management.
The company’s inherent potential coupled with its strong performance make this one of the
“NAVRATNAS”, which is supported by the government in their endeavor to become future global
players.

B.H.E.L.
1.1 OVERVIEW
 Bharat Heavy Electricals Limited (B.H.E.L.) is the largest engineering and manufacturing
enterprise in India. BHEL caters to core sectors of the Indian Economy viz., Power
Generation's & Transmission, Industry, Transportation, Telecommunication, Renewable
Energy, Defense and many more.
 Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the area of
Scientific, Technical and Industrial Cooperation.
 BHEL has its setup spread all over India namely New Delhi, Gurgaon, Haridwar,
Rudrapur, Jhansi, Bhopal, Hyderabad, Jagdishpur , Tiruchirapalli, Bangalore and many
more.
 Over 65% of power generated in India comes from BHEL-supplied equipment.Overall it
has installed power equipment for over 90,000 MW.
 BHEL's Investment in R&D is amongst the largest in the corporate sector in India. Net
Profit of the company in the year 2011-2012 was recorded as 6868crore having a high of
21.2% in comparison to last year.
 BHEL has already attained ISO 9000 certification for quality management, and ISO
14001 certification for environment management.
 It is one of India's nine largest Public Sector Undertakings or PSUs, known as the
NAVRATNAS or 'The Nine Jewels’.
 The power plant equipment manufactured by BHEL is based on contemporary
technology comparable to the best in the world.
 The wide network of BHEL's 14 manufacturing divisions, 4 Power Sector regional
centre, over 100 project sites, 8 Service Centre and 18 regional offices, enables the
Company to promptly serve its customers and provide them with suitable products,
systems and services efficiently.

1.2 WORKING AREAS
1.2.1POWER 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
unit 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 upgrading of a variety of power plant equipment besides specialized know
how of residual life assessment, health diagnostics and life extension of plants.
1.2.2 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.

1.2.3 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, co-generation 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
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.
1.2.4 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 5000HP, diesel-electric
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.

1.2.5 TELECOMMUNICATION
BHEL also caters to Telecommunication sector by way of small, medium and large switching
system
1.2.6 RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional and renewable
sources of energy include: wind electric generators, solar photo voltaic 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.
1.2.7 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, switch gears, 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 manufacturers (OEM’S) for such
plants.

1.3 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 in-house:
low-NOx oil / gas burners, circulating fluidized bed combustion boilers, high-efficiency Pelton
hydro turbines, petroleum depot automation systems, 36kV 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: Smart 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.
1.3.1 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 workforce leading to enhanced productivity and
higher levels of quality.

1.4 HEALTH, SAFETY AND ENVIRONMENTMANAGEMENT
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.
1.4.1 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.
1.4.2 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 programs 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 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.
1.4.3 PRINCIPLES OF THE "GLOBAL COMPACT"
 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.
 LABOUR STANDARDS
1. Business should uphold the freedom of association and the effective recognition of the
right to collective bargaining.
3. Eliminate discrimination.
4. The elimination of all form of forces and compulsory labour.
5. The effective abolition of child labour.
6. Eliminate discrimination.
 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.

1.5 BHEL UNITS
UNIT TYPE PRODUCT
1. Bhopal Heavy Electrical Part Steam Turbines, Turbo Generators, Hydro
Sets,
Switch Gear Controllers
2. Haridwar
HEEP
CFFP
Heavy Electrical Equipement
Plant
Central Foundry Forge Plant
Hydro Turbines, Steam Turbines, Gas
Turbines, Turbo Generators, Heavy Castings
and Forging, Control Panels, Light Aircrafts,
Electrical Machines.
3. Hyderabad
HPEP Heavy Power Equipement Plant
Industrial Turbo-Sets, Compressor Pumps
and Heaters, Bow Mills, Heat Exchangers
Oil Rings, Gas Turbines, Switch Gears,
Power Generating Sets.
4. Trichy
HPBP High Pressure Boiling Plant
Seamless Steel Tubes, Spiral Fin Welded
Tubes.
5. Jhansi
TP Transformer Plant
Transformers, Diesel Shunt Less AC locos
and EC EMU.
6. Banglore
EDN
EPD
Electronics Division
Electro Porcelains Devision
Energy Meters, Watt Meters, Control
Equipement, Capacitors, Photo Voltic Panels,
Simulator, Telecommunication System, Other
Advanced Microprocessor based Control
System, Insulator and Bushing, Ceramic
Liners
7. Ranipet
BAP Boiler Auxilary Plant
Electrostatic Precipitator, Air Pre-Heater,
Fans, Wind Electric Generators, Desalination
Plants.
8. Goindwal Industrial Valves Plant Industrial Valves & Fabrication
9. Jagdishpur
IP Insulator Plant
High tension ceramic, Insulation Plates and
Bushings
10. Rudrapur Component Fabrication Plant Windmill, Solar Water Heating system
11. Gurgaon Amorphous Silicon Solar Cell
Plant.
Solar Photovoltaic Cells, Solar Lanterns,
Chargers ,Solar clock
Table-1

1.6BHEL HARIDWAR
1.6.1 LOCATION
It is situated in the foot hills of Shivalik range in Haridwar. The main administrative building is
at a distance of about 8 km from Haridwar.
1.6.2 ADDRESS
Bharat Heavy Electrical Limited (BHEL)
Ranipur, Haridwar PIN- 249403
1.6.3 AREA
BHEL Haridwar consists of two manufacturing units, namely Heavy Electrical Equipment Plant
(HEEP) and Central Foundry Forge Plant (CFFP), having area
HEEP area:- 8.45 sq km
CFFP area:- 1.0 sq km
The Heavy Electricals Equipment Plant (HEEP) located in Haridwar, is one of the major
manufacturing plants of BHEL. The core business of HEEP includes design and manufacture of
large steam and gas turbines, turbo generators, hydro turbines and generators, large AC/DC
motors and so on.
Central Foundry Forge Plant (CFFP) is engaged in manufacture of Steel Castings:Up to 50 Tons
per Piece Wt & Steel Forgings: Up to 55 Tons per Piece Wt.
1.6.4 UNITS
There are two units in BHEL Haridwar as followed:
1) Heavy Electrical Equipment Plant (HEEP)
2) Central Foundry Forge Plant (CFFP)

There are 8 Blocks in HEEP:
Blocks Work Performed In Block
I) Electrical Machine Turbo Generator, Generator Exciter , Motor (AC and DC)
II) Fabrication Large Size Fabricated Assemblies or Components
III)Turbines &
Auxilary
Steam , Hydro Turbines, Gas turbines, Turbine Blade, Special Tooling.
IV) Feeder Winding of Turbo ,Hydro Generators, Insulation for AC & DC Motors
V) Fabrication Fabricated Parts of Steam Turbine, Water Boxes, Storage Tank, Hydro
Turbine Parts
VI)Fabrication
Stamping&Die
Manufacturing
Fabricated Oil Tanks, Hollow Guide Blades, Rings, Stator Frames and
Rotor Spindle, All Dies, Stamping for Generators and Motor
VII) Wood Working Wooden Packing, Spacers
VIII)Heaters &
Coolers
LP heaters, Ejectors, Glands, Steam and Oil Coolers, Oil Tank, Bearing
Covers
There are 3 Sections in CFFP:
Table-2
Blocks Work Performed In Block
1. Foundry Casting of Turbine Rotor, Casing and Francis Runner
2. Forging Forging of Small Rotor Parts
3. Machine Shop Turning, Boring, Parting off, Drilling etc.
Table -3

1.6.5 HEEP PRODUCT PROFILE
1. THERMAL SETS:
 Steam turbines and generators up to 500 MW capacity for utility and combined cycle applications
 Capability to manufacture up to 1000 MW unit cycle.
2. GAS TURBINES:
 Gas turbines for industry and utility application range 3 to 200 MW (ISO).
 Gas turbines based co-generation and combined cycle system.
3. HYDRO SETS:
 Custom– built conventional hydro turbine of Kaplan, Francis and Pelton with matching
generators up to 250 MW unit size.
 Pump turbines with matching motor-generators.
 Mini / micro hydro sets.
 Spherical butterfly and rotary valves and auxiliaries for hydro station.
4. EQUIPMENT FOR NUCLEAR POWER PLANTS:
 Turbines and generators up to 500MW unit size.
 Steam generator up to 500MW unit size.
 Re-heaters / Separators.
 Heat exchangers and pressure vessels.
5. ELECTRICAL MACHINES:
 DC general purpose and rolling mill machines from 100 to 19000KW suitable for operation on
voltage up to 1200V. These are provided with STDP, totally enclosed and duct ventilated
enclosures.
 DC auxiliary mill motors
6. CONTROL PANEL:
 Control panel for voltage up to 400KW and control desks for generating stations and EMV sub–stations.

7. CASTING AND FORGINGS:
 Sophisticated heavy casting and forging of creep resistant alloy steels, stainless steeland other grades of
alloy meeting stringent international specifications.
8.DEFENCE:
 Naval guns with collaboration of Italy.

2. STEAM TURBINE
2.1 INTRODUCTION
A turbine is a device that converts chemical energy into mechanical energy, specifically when a rotor of
multiple blades or vanes is driven by the movement of a fluid or gas. In the case of a steam turbine, the
pressure and flow of newly condensed steam rapidly turns the rotor. This movement is possible because
the water to steam conversion results in a rapidly expanding gas. As the turbine’s rotor turns, the rotating
shaft can work to accomplish numerous applications, often electricity generation.
Fig.1 Sectional View Of A Steam Turbine
In a steam turbine, the steam’s energy is extracted through the turbine and the steam leaves the turbine at
a lower energy state. High pressure and temperature fluid at the inlet of the turbine exit as lower pressure
and temperature fluid. The difference is energy converted by the turbine to mechanical rotational energy,
less any aerodynamic and mechanical inefficiencies incurred in the process. Since the fluid is at a lower
pressure at the exit of the turbine than at the inlet, it is common to say the fluid has been “expanded”
across the turbine. Because of the expanding flow, higher volumetric flow occurs at the turbine exit (at
least for compressible fluids) leading to the need for larger turbine exit areas than at the inlet.

The generic symbol for a turbine used in a flow diagram is shown in Figure below. The symbol diverges
with a larger area at the exit than at the inlet. This is how one can tell a turbine symbol from a compressor
symbol. In Figure, the graphic is colored to indicate the general trend of temperature drop through a
turbine. In a turbine with a high inlet pressure, the turbine blades convert this pressure energy into
velocity or kinetic energy, which causes the blades to rotate. Many green cycles use a turbine in this
fashion, although the inlet conditions may not be the same as for a conventional high pressure and
temperature steam turbine. Bottoming cycles, for instance, extract fluid energy that is at a lower pressure
and temperature than a turbine in a conventional power plant. A bottoming cycle might be used to extract
energy from the exhaust gases of a large diesel engine, but the fluid in a bottoming cycle still has
sufficient energy to be extracted across a turbine, with the energy converted into rotationalenergy.
Fig.2 Flow Diagram Of A Steam Turbine
Turbines also extract energy in fluid flow where the pressure is not high but where the fluid has sufficient
fluid kinetic energy. The classic example is a wind turbine, which converts the wind’s kinetic energy to
rotational energy. This type of kinetic energy conversion is common in green energy cycles for
applications ranging from larger wind turbines to smaller hydrokinetic turbines currently being designed
for and demonstrated in river and tidal applications. Turbines can be designed to work well in a variety of
fluids, including gases and liquids, where they are used not only to drive generators, but also to drive
compressors or pumps.
One common (and somewhat misleading) use of the word “turbine” is “gas turbine,” as in a gas turbine
engine. A gas turbine engine is more than just a turbine and typically includes a compressor, combustor
and turbine combined to be a self-contained unit used to provide shaft or thrust power. The turbine
component inside the gas turbine still provides power, but a compressor and combustor are required to
make a self-contained system that needs only the fuel to burn in the combustor.
An additional use for turbines in industrial applications that may also be applicable in some green energy
systems is to cool a fluid. As previously mentioned, when a turbine extracts energy from a fluid, the fluid
temperature is reduced. Some industries, such as the gas processing industry, use turbines as sources of
refrigeration, dropping the temperature of the gas going

through the turbine. In other words, the primary purpose of the turbine is to reduce the temperature of the
working fluid as opposed to providing power. Generally speaking, the higher the pressure ratio across a
turbine, the greater the expansion and the greater the temperature drop. Even where turbines are used to
cool fluids, the turbines still produce power and must be connected to a power absorbing device that is
part of an overall system.
Also note that turbines in high inlet-pressure applications are sometimes called expanders. The terms
“turbine” and “expander” can be used interchangeably for most applications, but expander is not used
when referring to kinetic energy applications, as the fluid does not go through significant expansion.
2.2 ADVANTAGES:-
 Ability to utilize high pressure and high temperature steam.
 High efficiency.
 High rotational speed.
 High capacity/weight ratio.
 Smooth, nearly vibration-free operation.
 No internal lubrication.
 Oil free exhausts steam.
2.3 DISADVANTAGES:-
 For slow speed application reduction gears are required. The steam turbine cannot be made reversible.
The efficiency of small simple steam turbines is poor.
2.4 STEAM TURBINES THE MAINSTAY OF BHEL:-
 BHEL has the capability to design, manufacture and commission steam turbines of up to 1000
MW rating for steam parameters ranging from 30 bars to 300 bars pressure and initial & reheat
temperatures up to 600ºC.
 Turbines are built on the building block system, consisting of modules suitable for a range of
output and steamparameters.
 For a desired output and steam parameters appropriate turbine blocks can be selected.

3. TYPES OF STEAM TURBINE
There are complicated methods to properly harness steam power that give rise to the two primary turbine
designs: impulse and reaction turbines. These different designs engage the steam in a different method so
as to turn the rotor.
3.1 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. 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 into kinetic energy by the increased steam velocity.
3.2 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 in the form
of a high-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 be 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 (Newton’s 2nd
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.

3.3 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 an impulse force on the moving
blades. In addition, however, the steam upon passing through the moving blades again expands and
further drops in pressure giving a reaction force to the blades. This sequence is repeated as the steam
passes through additional rows of fixed and moving blades.
3.4 IMPULSE TURBINE STAGING
In order for the steam to give 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 velocit y 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. 2.Velocity
compounding. 3.Pressure-velocity
compounding. 4.Pressure
Compounding.
4. TURBINE PARTS
4.1 TURBINE BLADES
 Cylindrical reaction blades for HP,IP and LP Turbines
 3-DS blades, in initial stages of HP and IP Turbine, to reduce secondary losses.
 Twisted blade with integral shroud, in last stages of HP,IP and initial stages of LP turbines, to
reduce profile and Tip leakage losses
 Free standing LP moving blades Tip sections with supersonic design
 Fir-tree root
 Flame hardening of the leading edge
 Banana type hollow guide blad

 Tapered and forward leaning for optimized mass flow distribution
 Suction slits for moisture removal
4.2 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 no other solution. The casing is heavy in order to withstand the high pressures and
temperatures. It is general practice to let the thickness of walls and flanges decrease from inlet- to
exhaust-end. The casing joints are made steam tight, without the use of gaskets, by matching the flange
faces very exactly and very smoothly. The bolt holes in the flanges are drilled for smoothly fitting bolts,
but dowel pins are often added to secure exact alignment of the flange joint. Double casings are used for
very high steam pressures. The high pressure is applied to the inner casing, which is open at the exhaust
end, letting the turbine exhaust to the outer casings.
4.3 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 the rotor. The
smaller the sealing area, the smaller the leakage; therefore the stationary blades are mounted in
diaphragms with labyrinth seals around thes haft. This construction requires a disc rotor. Basically there
are two types of rotor:
4.3.1 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 fully balanced rotor. It is rather expensive, as the weight of the final rotor is
approximately 50% of the initial forging. Older or smaller disc rotors have shaft and discs made in
separate pieces with the discs shrunk on 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 the correct
position on the shaft and shaft key. A small clearance between the discs prevents thermal stress in the
shaft.
4.3.2 DRUM ROTORS
The first reaction turbines had solid forged drum 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 balance 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.

5. CONSTRUCTIONALFEATURES OF A BLADE
The blade can be divided into 3 parts:
 The profile, which converts the thermal energy of steam into kinetic energy, with a certain
efficiency depending upon the profile shape.
 The root, which fixes the blade to the turbine rotor, giving a proper anchor to the blade, and
transmitting the kinetic energy of the blade to the rotor.
 The damping element, which reduces the vibrations which necessarily occur in the blades due to
the steam flowing through the blades. These damping elements may be integral with blades, or
they may be separate elements mounted between the blades. Each of these elements will be
separately dealt with in the following sections.
5.1 H.P. BLADE PROFILES
In order to understand the further explanation, a familiarity of the terminology used is required.
The following terminology is used in the subsequent sections.

If circles are drawn tangential to the suction side and pressure side profiles of a blade, and their centers
are joined by a curve, this curve is called the camber line. This camber line intersects the profile at two
points A and B. The line joining these points is called chord, and the length of this line is called the chord
length. A line which is tangential to the inlet and outlet edges is called the bitangent line. The angle which
this line makes with the circumferential direction is called the setting angle. Pitch of a blade is the
circumferential distance between any point on the profile and an identical point on the next blade.
5.2 CLASSIFICATION OF PROFILES
There are two basic types of profiles - Impulse and Reaction. In the impulse type of profiles, the entire
heat drop of the stage occurs only in the stationary blades. In the reaction type of blades, the heat drop of
the stage is distributed almost equally between the guide and moving blades. Though the theoretical
impulse blades have zero pressure drop in the moving blades, practically, for the flow to take place across
the moving blades, there must be a small pressure drop across the moving blades also. Therefore, the
impulse stages in practice have a small degree of reaction. These stages are therefore more accurately,
though less widely, described as low-reaction stages. The presently used reaction profiles are more
efficient than the impulse profiles at part loads. This is because of the more rounded inlet edge for
reaction profiles. Due to this, even if the inlet angle of the steam is not tangential to the pressure-side
profile of the blade, the losses are low. However, the impulse profiles have one advantage. The impulse
profiles can take a large heat drop across a single stage, and the same heat drop would require a greater
number of stages if reaction profiles are used, thereby increasing the turbine length. The Steam turbines
use the impulse profiles for the control stage (1st stage), and the reaction profiles for subsequent stages.
There are four reasons for using impulse profile for the first stage:
a) Most of the turbines are partial arc admission turbines. If the first stage is are action stage, the lower
half of the moving blades do not have any inlet steam, and would ventilate. Therefore, most of the stage
heat drop should occur in the guide blades.
b) The heat drop across the first stage should be high, so that the wheel chamber of the outer casing is not
exposed to the high inlet parameters. In case of -4turbines, the inner casing parting plane strength
becomes the limitation, and therefore requires a large heat drop across the 1st
stage.
c) Nozzle control gives better efficiency at part loads than throttle control.
d) The number of stages in the turbine should not be too high, as this will increase the length of the
turbine.
There are exceptions to the rule. Turbines used for CCPs, and BFP drive turbines do not have a control
stage. They are throttle-governed machines. Such designs are used when the inlet pressure slides. Such
machines only have reaction stages. However,the inlet passages of such turbines must be so designed that
the inlet steam to the first reaction stage is properly mixed, and occupies the entire 360 degrees. There are
also cases of controlled extraction turbines where the
L.P. control stage is an impulse stage. This is either to reduce the number of stages to make the turbine
short, or to increase the part load efficiency by using nozzle control, which minimizes throttle losses.

5.3 H.P. BLADE ROOTS
The root is a part of the blade that fixes the blade to the rotor or stator. Its design depends upon the
centrifugal and steam bending forces of the blade. It should be designed such that the material in the blade
root as well as the rotor / stator claw and any fixing element are in the safe limits to avoid failure. The
roots are T-root and Fork-root. The fork root has a higher load- carrying capacity than the T-root. It was
found that machining this T-root with side grip is more of a problem. It has to be machined by broaching,
and the broaching machine available could not handle the sizes of the root. The typical roots used for the
HP moving blades for various steam turbine applications are shown in the following figure:
T-ROOT
T-ROOT WITH SIDE GRIP
Table 4 Blade Roots
FORK ROOT

5.4 L.P. BLADE PROFILES
The LP blade profiles of moving blades are twisted and tapered. These blades are used when blade height-
to-mean stage diameter ratio (h/Dm) exceeds 0.2.
5.5 LP BLADE ROOTS
The roots of LP blades are as follows:
1) 2 Blading :
a. The roots of both the LP stages in –2 type of LP Blading are T-roots.
2) 3 Blading:
a. The last stage LP blade of HK, SK and LK blades have a fork-root. SK blades have4-fork
roots for all sizes. HK blades have 4-fork roots up to 56 size, where modified profiles are
used. Beyond this size, HK blades have 3 fork roots. LK blades have 3-forkroots for all
sizes. The roots of the LP blades of preceding stages are of T-roots.
5.6 DYNAMICS IN BLADE
The excitation of any blade comes from different sources. They are
 Nozzle-passing excitation: As the blades pass the nozzles of the stage, they encounter flow
disturbances due to the pressure variations across the guide blade passage. They also
encounter disturbances due to the wakes and eddies in the flow path. These are sufficient to
cause excitation in the moving blades. The excitation gets repeated at every pitch of the
blade. This is called nozzle-passing frequency excitation. Theorder of this frequency =no. of
guide blades x speed of the machine. Multiples of this frequency are considered for checking
for resonance.
 Excitation due to non-uniformities in guide-blades around the periphery. These can occur
due to manufacturing inaccuracies, like pitch errors, setting angle variations, inlet and
outlet edge variations, etc.
For HP blades, due to the thick and cylindrical cross-sections and short blade heights, the natural
frequencies are very high. Nozzle-passing frequencies are therefore necessarily considered, since
resonance with the lower natural frequencies occurs only with these orders of excitation.
In LP blades, since the blades are thin and long, the natural frequencies are low. The excitation
frequencies to be considered are therefore the first few multiples of speed, since the nozzle- passing
frequencies only give resonance with very high modes, where the vibration stresses are low.
The HP moving blades experience relatively low vibration amplitudes due to their thicker
sections and shorter heights. They also have integral shrouds. These shrouds of adjacent blades
butt against each other forming a continuous ring. This ring serves two purposes – it acts as a
steam seal, and it acts as a damper for the vibrations. When vibrations occur, the vibration energy
is dissipated as friction between shrouds of adjacent blades.
For HP guide blades of Wesel design, the shroud is not integral, but a shroud band is riveted to a
number of guide blades together. The function of this shroud band is mainly to seat the steam. In
some designs HP guide blades may have integral shrouds like moving blades. The primary
function remains steam sealing.

In industrial turbines, in LP blades, the resonant vibrations have high amplitudes due to the thin
sections of the blades, and the large lengths. It may also not always be possible to avoid resonance
at all operating conditions. This is because of two reasons. Firstly, the LP blades are standardized
for certain ranges of speeds, and turbines may be selected to operate anywhere in the speed range.
The entire design range of operating speed of the LP blades cannot be outside the resonance range.
It is, of course, possible to design a new LP blade for each application, but this involves a lot of
design efforts and manufacturing cycle time. However, with the present-day computer packages
and manufacturing methods, it has become feasible to do so. Secondly, the driven machine may be a
variable speed machine like a compressor or a boiler-feed-pump. In this case also, it is not possible
to avoid resonance. In such cases, where it is not possible to avoid resonance, a damping element
is to be used in the LP blades to reduce the dynamic stresses, so that the blades can operate
continuously under resonance also. There may be blades which are not adequately damped due to
manufacturing inaccuracies. The need fora damping element is therefore eliminated. In case the
frequencies of the blades tend towards resonance due to manufacturing inaccuracies, tuning is to be
done on the blades to correct the frequency. This tuning is done by grinding off material at the tip
(which reduces the inertia more than the stiffness) to increase the frequency, and by grinding off
material at the base of the profile (which reduces the stiffness more than the inertia) to reduce the
natural frequency.
The damping in any blade can be of any of the following types:
a) Material damping: This type of damping is because of the inherent damping properties of the
material which makes up the component.
b) Aerodynamic damping: This is due to the damping of the fluid which surrounds the
component in operation.
c) Friction damping: This is due to the rubbing friction between the component under
consideration with any other object.
Out of these damping mechanisms, the material and aerodynamic types of damping are very small in
magnitude. Friction damping is enormous as compared to the other two types of damping. Because of this
reason, the damping elements in blades generally incorporate a feature by which the vibrational energy is
dissipated as frictional heat. The frictional damping has a particular characteristic. When the frictional force
between the rubbing surfaces is very small as compared to the excitation force, the surfaces slip, resulting in
friction damping. However, when the excitation force is small when compared to the frictional force, the
surfaces do not slip, resulting in locking of the surfaces. This condition gives zero friction damping, and
only the material and aerodynamic damping exists. In a periodically varying excitation force, it may
frequently happen that the force is less than the friction force.
During this phase, the damping is very less. At the same time, due to the locking of the rubbing surfaces, the
overall stiffness increases and the natural frequency shifts drastically away from the individual value. The
response therefore also changes in the locked condition. The resonant response of a system therefore
depends upon the amount of damping in the system (which is determined by the relative duration of slip and
stick in the system, i.e., the relative magnitude of excitation and friction forces) and the natural frequency of
the system (which alters between the individual values and the locked condition value, depending upon the
slip or stick condition).

5.7 BLADING MATERIALS
Among the different materials typically used for blading are 403 stainless steel, 422 stainless steel, A-286,
and Haynes Satellites Alloy Number 31 and titanium alloy. The403 stainless steel is essentially the
industry’s standard blade material and, on impulse steam turbines, it is probably found on over 90 percent
of all the stages. It is used because of its high yield strength, endurance limit, ductility, toughness, erosion
and corrosion resistance, and damping. It is used within a Brinell hardness range of 207 to 248 to
maximize its damping and corrosion resistance. The 422 stainless steel material is applied only on high
temperature stages (between 700 and 900°F or 371 and 482°C), where its higher yield, endurance, creep
and rupture strengths are needed.
The A-286 material is a nickel-based super alloy that is generally used in hot gas expanders with stage
temperatures between 900 and 1150°F (482 and 621°C). The Haynes Satellites Alloy Number 31 is a
cobalt-based super alloy and is used on jet expanders when precision cast blades are needed. The Haynes
Satellite Number 31 is used at stage temperatures between 900 and 1200°F (482 and 649°C). Another
blade material is titanium. Its high strength, low density, and good erosion resistance make it a good
candidate for high speed or long-last stage blading.
6. MANUFACTURING PROCESS
6.1 INTRODUCTION
Manufacturing process is that part of the production process which is directly concerned with the change
of form or dimensions of the part being produced. It does not include the transportation, handling or
storage of parts, as they are not directly concerned with the changes into the form or dimensions of the
part produced. Manufacturing is the backbone of any industrialized nation. Manufacturing and technical
staff in industry must know the various manufacturing processes, materials being processed, tools and
equipments for manufacturing different components or products with optimal process plan using proper
precautions and specified safety rules to avoid accidents. Beside above, all kinds of the future engineers
must know the basic requirements of workshop activities in term of man, machine, material, methods,
money and other infrastructure facilities needed to be positioned properly for optimal shop layouts or
plant layout and other support services effectively adjusted or located in the industry or plant within a well
planned manufacturing organization. Today’s competitive manufacturing era of high industrial
development and research, is being called the age of mechanization, automation and computer integrated
manufacturing. Due to new researches in the manufacturing field, the advancement has come to this
extent that every different aspect of this technology has become a full-fledged fundamental and advanced
study in itself. This has led to introduction of optimized design and manufacturing of new products. New
developments in manufacturing areas are deciding to transfer more skill to the machines for considerably
reduction of manual labor.
6.2 CLASSIFICATION OF MANUFACTURING PROCESSES
For producing of products materials are needed. It is therefore important to know the characteristics of the
available engineering materials. Raw materials used manufacturing of products, tools, machines and
equipments in factories or industries are for providing commercial castings, called ingots. Such ingots are
then processed in rolling mills to obtain market form of material supply in form of bloom, billets, slabs
and rods. These forms of material supply are further subjected to various manufacturing processes for
getting usable metal products of different shapes and sizes in various manufacturing shops. All these
processes used in manufacturing concern for changing the ingots into usable products may be classified
into six major groups as

 Primary shaping processes
 Secondary machining processes
 Metal forming processes
 Joining processes
 Surface finishing processes and
 Processes effecting change in properties
6.2.1 PRIMARY SHAPING PROCESSES
Primary shaping processes are manufacturing of a product from an amorphous material. Some processes
produces finish products or articles into its usual form whereas others do not, and require further working to
finish component to the desired shape and size. The parts produced through these processes may or may not
require to undergo further operations. Some of the important primary shaping processes are:
 Casting
 Powdermetallurgy
 Plastic technology
 Gas cutting
 Bending and
 Forging
6.2.2 SECONDARY OR MACHINING PROCESSES
As large number of components require further processing after the primary processes. These components
are subjected to one or more number of machining operations in machine shops, to obtain the desired shape
and dimensional accuracy on flat and cylindrical jobs. Thus, the jobs undergoing these operations are the
roughly finished products received through primary shaping processes. The process of removing the
undesired or unwanted material from the work-piece or job or component to produce a required shape using
a cutting tool is known as machining. This can be done by a manual process or by using a machine called
machine tool (traditional machines namely lathe, milling machine, drilling, shaper, planner, slotter).
In many cases these operations are performed on rods, bars and flat surfaces in machine shops. These
secondary processes are mainly required for achieving dimensional accuracy and a very high degree of
surface finish. The secondary processes require the use of one or more machine tools, various single or
multi-point cutting tools (cutters), jobholding devices, marking and measuring instruments, testing devices
and gauges etc. forgetting desired dimensional control and required degree of surface finish on the work-
pieces. The example of parts produced by machining processes includes hand tools machine tools
instruments, automobile parts, nuts, bolts and gears etc. Lot of material is wasted as scrap in the secondary
or machining process. Some of the common secondary or machining processes are:
 Turning
 Threading
 Knurling
 Milling

 Boring
 Planning
 Slotting
 Sawing
 Shaping
 Broaching
 Hobbing
 Grinding
 Gear Cutting
 Thread cutting and
 Unconventional machining processes namely machining with Numerical control (NC)
machines tools or Computer Numerical Control (CNC) machine tool using ECM, LBM,
AJM, USM setups.
4. BLOCK 3 LAY-OUT

Table 5: Lay-out of Block 3
5. CLASSIFICATIOCNOF BLOCK3
BAY-1 IS FURTHER DIVIDEDINTO THREE PARTS
1. HMS
In this shop heavy machine work is done with the help of different NC &CNC machines such as
center lathes, vertical and horizontal boring & milling machines. Asia’s largest vertical boring machine is
installed here and CNC horizontal boring milling machines from Skoda of Czechoslovakia.
2. Assembly Section (ofhydro turbines)
In this section assembly of hydro turbines are done. Blades of turbine are1st assemble on the rotor &
after it this rotor is transported to balancing tunnel where the balancing is done. After balancing the rotor,
rotor &casings both internal & external are transported to the customer. Total assembly of turbine is done
in the company which purchased it by B.H.E.L.
3. OSBT (Over Speed Balancing Tunnel)
In this section, rotors of all type of turbines like LP(low pressure), HP(high pressure) &
IP(Intermediate pressure) rotors of Steam turbine ,rotors of Gas & Hydro turbine are balanced .In a large
tunnel, Vacuum of 2 torr is created with the help of pumps & after that rotor is placed on pedestal and
rotted with speed of 2500-4500 rpm. After it in a computer control room the axis of rotation of rotor is
seen with help of computer & then balance the rotor by inserting the small balancing weight in the
grooves cut on rotor.
Fig 4: Over speed & Vacuum Balancing Tunnel
For balancing and over speed testing of rotors up to 320 tons in weight, 1800 mm in length and 6900 mm
diameter under vacuum conditions of 1 Torr.

BAY–2 IS DIVIDED IN TO 2 PARTS:
1 HMS
In this shop several components of steam turbine like LP, HP & IP rotors, Internal & external casing are
manufactured with the help of different operations carried out through different NC & CNC machines like
grinding, drilling, vertical & horizontal milling and boring machines, center lathes, planer, Kopp milling
machine.
2 Assembly Section
In this section assembly of steam turbines up to 1000 MWIs assembled. 1st moving blades are inserted in
the grooves cut on circumferences of rotor, then rotor is balanced in balancing tunnel in bay-1.After is
done in which guide blades are assembled inside the internal casing & then rotor is fitted inside this
casing. After it this internal casing with rotor is inserted into the external.
BAY3 IS DIVIDED INTO 3 PARTS:
1. Bearing Section
In this section Journal bearings are manufactured which are used in turbines to overcome the
vibration & rolling friction by providing the proper lubrication.
2. Turning Section
In this section small lathe machines, milling & boring machines, grinding machines & drilling
machines are installed. In this section small jobs are manufactured like rings, studs, disks etc.
3. Governing Section
In this section governors are manufactured. These governors are used in turbines for controlling
the speed of rotor within the certain limits. 1st all components of governor are made by different
operations then these all parts are treated in heat treatment shop for providing the hardness. Then these all
components are assembled into casing. There are more than 1000 components of Governor.
BAY-4 IS DIVIDED INTO 3 PARTS:
1. TBM (Turbine Blade Manufacturing) Shop
In this shop solid blade of both steam & gas turbine are manufactured. Several CNC & NC machines are
installed here such as Copying machine, Grinding machine, Rhomboid milling machine, Duplex milling
machine, T- root machine center, Horizontal tooling center, Vertical & horizontal boring machine etc.
Fig 5. Steam Turbine Casing & Rotors in Assembly Area

2. Turning Section
Same as the turning section in Bay-3, there are severalsmall Machine like lathes machines, milling,
boring, grinding machines etc.
Fig 6. CNC Rotor Turning Lathe
3. Heat TreatmentShop
In this shop there are severaltests performed for checking the Hardness of different components.
Tests performed are Sereliting, Nitriding, DP Test.
9.BLADE SHOPE
Blade shop is an important shop of Block 3. Blades of all the stages of turbine are made in this shop only.
They have a variety of centre lathe and CNC machines to perform the complete operation of blades. The
designs of the blades are sent to the shop and the Respective job is distributed to the operators. Operators
perform their job in a fixed interval of time.
9.1 TYPES OF BLADES
Basically the design of blades is classified according to the stages of turbine. The size of LP TURBINE BLADES is
generally greater than that of HP TURBINE BLADES. At the first T1, T2, T3 & T4 kinds of blades were used, these
were 2nd generation blades. Then it was replaced by TX, BDS (for HP TURBINE) & F shaped blades. The most
modern blades are F & Z shaped blades.

3 Dimesional
3DS Blade
HP/IP Initial Stages
Cylindrical Profile TX
Blade
HP/IP Intermediate stages
& LP Initial
Twisted Profile
F Blade
HP/IP Rear Stages

9.2 OPERATIONS PERFORMED ON BLADES
Some of the important operations performed on blade manufacturing are:-
 Milling
 Blank Cutting
 Grinding of both the surfaces
 Cutting
 Root milling
9.3 MACHINING OF BLADES
Machining of blades is done with the help of Lathe & CNC machines. Some of the machines are:-
 Centre lathe machine
 VerticalBoring machine
 VerticalMilling machine
 CNC lathe machine
Fig 8. Schmetic Diagram ofa CNC Machine
9.4 NEW BLADE SHOP
A new blade shop is being in operation, mostly 500mw turbine blades are manufactured in this shop. This is
a highly hi tech shop where complete manufacturing of blades is done using single advanced CNC
machines. Complete blades are finished using modernized CNC machines. Some of the machines are:-
 Pama CNC ram boring machine.
 Wotum horizontal machine with 6 axis CNC control.
 CNC shaping machine.

Fig 9. CNC Shaping Machine

10. CONCLUSION
Gone through rigorous 6 Weeks training under the guidance of capable engineers and workers of BHEL
Haridwar in Block-3 “TURBINE MANUFACTURING” headed by Senior Engineer of department Mr.
SUYESH KUMAR situated in Ranipur, Haridwar,(Uttarakhand).
The training was specified under the Turbine Manufacturing Department. Working under the department I
came to know about the basic grinding, scaling and machining processes which was shown on heavy to
medium machines. Duty lathes were planted in the same line where the specified work was undertaken.
The training brought to my knowledge the various machining and fabrication processes went not only in
the manufacturing of blades but other parts of the turbine.

B.H.E.L. HARIDWAR

Recommandé

Recommandé

Contenu connexe

Similaire à B.H.E.L. HARIDWAR

Similaire à B.H.E.L. HARIDWAR (20)

Dernier

Dernier (20)

B.H.E.L. HARIDWAR