A VOCATIONAL TRAINNING REPORT

ON
GENERAL AWARENESS OF STEAM TURBINE
AT

HARIDWAR

IIMT COLLEGE OF ENGINEERING

GR.NOIDA
Department Of Mechanical Engineering

SUBMITED TO
MR. A.K.SHRIVASTAV
MECHANICAL DEPARMENT
IIMT COLLEGE OF ENGG.

SUBMITED BY
SHUBHAM AGRAWAL
B.TECH (M.E-A)
th.
4 YEAR
ROLL-1121640100

Declaration

I Shubham Agrawal student of B-Tech 3 rd year of IIMT College of Engineering

hereby declare that the training report entitled Turbine blade shopis an
original work and the same has not been submitted to any other institute.

SHUBHAM AGRAWAL
B.Tech (M.E-4th.Yr.)
Roll No. -1121640100

PREFACE
Industrial training plays the most vital role in the career of an aspiring engineer. It
introduces the industrial world to the engineering student and links the theoretical
knowledge gained in the college classrooms to their practical application on the field.
It gives an idea to the student of what to expect after completing his engineering
3

course and prepares him better for his career up ahead. I consider myself highly
fortunate to be one of the few who get the opportunity to undergo their industrial
training at the BHART HEAVY ELECTRICALS LTD. Haridwar. The knowledge and
experience gained during the training period has been of incomparable value. The
training has helped me get an idea about the overwhelming scale of production at
the industrial level. It has also given me knowledge of the extraordinary level of
coordination and skill required to run an industry of such epic proportions. And in the
case of my field of study, mechanical engineering, it has given me the opportunity to
gain physical knowledge of the machinery used in the plant, which is invaluable for a
mechanical engineer. My days spent here have truly made me a better engineer by
further enhancing my knowledge by many folds and I am sure that this knowledge
will play a very important role in my career.

SHUBHAM AGRAWAL
B.Tech (M.E-4th.Yr.)
Roll No. -1121640100

Acknowledgement
The soul of any training program are its instructors. And in this case they are the highly
skilled and hardworking engineers, employees and workers of BHEL HWR who have played
an invaluable part in my industrial training. They have spent their most valuable time with
me to give as much of their knowledge to me as was possible during the timeframe provided.
To them goes my sincerest gratitude.
The list of those who helped me during my training period is very long but there are a few
individuals whose names need to mentioned because of whom this training program was
possible in the first place and to whom we owe most of the knowledge we gained in BHEL
HWR.
My thanks goes to Mr. RAJ SINGH, incharge HRDC haridwar because of whom this training
program has been possible. I thank to Mr. ALOK SHUKLA, Asst. G.M.OF Block 3 for his
cooperation and guidance which made our training period as comfortable as it could be
without compromising the opportunity to gain all the knowledge we could gain during the
training period.
My heartiest thanks goes to Mr. Sandeep kumar who has guided us through each and every
day that we have spent in BHEL HWR. If it wasnt for him, our training wouldnt have been
half as productive as it has actually been. He has also been the guiding force behind the
development of this report.
I also thank Mr. VIRENDRA KUMAR GUPTA, Mr. NANDKISHORE, for sharing their
highly valuable knowledge with us about the functioning of the respective units.
And in the end I would like thank the Almighty for sending this opportunity my way and
keeping me in good health during the training, my parents for their never ending support and
love and my group mates whose friendship made this experience more enjoyable and lively
than it could ever get.

SHUBHAM AGRAWAL

B.Tech (M.E-4th.Yr.)
Roll No. -1121640100
CONTENTS
S.NO

TOPIC

1.

Introduction

PAGE NO.

6-8
2.

Company Profile

9-11

3.

Major Products

12-13

4.

Turbine & Auxiliary Block

14-21

5.

Steam Turbine

22-33

6.

Another block

34

7.

Heavy fabrication Block

34-38

8.

C.F.F.P PLANT

39-42

9.

CONCLUSION

43

10.

REFERENCE

44

(1.)INTRODUCTION
Bharat Heavy Electricals Ltd. (BHEL) is the largest engineering and
manufacturing enterprise of its kind in India and is one of the leading
international companies in the field of power equipment manufacture.In 1956
first step was taken by Indian government by establishing the first unit of Heavy
Electricals Engineering Manufacturing Limited at Bhopal . It progressed rapidly
and three more factories went into production in 1965.Heavy Electricals (India)
Limited formally merged with Bharat Heavy Electricals Limited (BHEL) in
1974. In 1969 BHEL supplied its first unit to Basin Bridge Thermal Power
Station in Tamil Nadu. Within a decade BHEL had commissioned the 100 th unit
at Santaldih,WB.The present scenario of BHEL consists of 11 manufacturing
divisions, 9 service centers, 4 power sector regional center, about 350 large
consumers(in India ) and many countries also. The companies inherent potential
coupled with its strong performance make this one of the MAHARATNAS,
which are supported by the government in their endeavor to become future
global players.
The Heavy Electrical Equipment Plant in Haridwar designs and manufactures
turbo generators, AC and DC motors, gas turbines and huge steams. The Central
Foundry Forge Plant in Haridwar deals with steel castings

The BHEL plants in Haridwar have earned the ISO - 9001 and 9002 certificates
for its high quality and maintenance. These two units have also earned the ISO 14001 certificates. Situate in Ranipur near Haridwar, the Bharat Heavy
Engineering Limited employs over 8,000 people and manufacturing of steel
forgings.
BHEL has a share of around 59% in India's total installed generating capacity
contributing 69% (approx.) to the total power generated from utility sets
(excluding non-conventional capacity) as of March 31, 2012. We have been
exporting our power and industry segment products and services for
approximately 40 years. We have exported our products and services to more
than 70 countries. We had cumulatively installed capacity of over 8,500 MW
outside of India in 21 countries, including Malaysia, Iraq, the UAE, Egypt and
New Zealand. Our physical exports range from turnkey projects to after sales
services.
BHEL work with a vision of becoming a world-class engineering enterprise,
committed to enhancing stakeholder value.
Our greatest strength is our highly skilled and committed workforce of over
49,000 employees. Every employee is given an equal opportunity to develop
himself and grow in his career. Continuous training and retraining, career
planning, a positive work culture and participative style of management - all
these have engendered development of a committed and motivated workforce
setting new benchmarks in terms of productivity, quality and responsiveness.

BHEL UNITS
UNIT

PERIOD

TYPE

1. Bhopal

Established 1956

Heavy Electrical Plant

Production started1960
2. Haridwar

Established 1963

HEEP

Production started1967

CFFP

Established 1974

Heavy
Electrical
Equipment
Plant,
Central Foundry Forge
Plant

Production started1976
3.Hyderabad
HPEP
4.Tiruchi

Established 1963
Production started1965
Established 1963

HPBP

Production started1965

SSTP

Production started1979

5.Jhansi TP

Production started1976

Heavy
Power
Equipment Plant
High Pressure Boiling
Plant

Transformer Plant

6.Banglore
EDN

Established 1963

EPD

Established 1972

ISG

Established 1977

8.Goindwal

Established 1983

9.Jagdishpur IP

Production started1984

10.Rudrapur

Production started1984

11.Gurgoan

Control
division

equipment

Electro
division

Porcelain

High tension ceramic

Insulation Plates

Solar Photovoltaic Cells

(2.)COMPANY PROFILE
BHEL HARDWAR
LOCATION
BHEL or the Bharat Heavy Engineering Limited is one of the largest
engineering and manufacturing organizations in the country and the BHEL,
Haridwar is their gift to Uttaranchal.
ADDRESS
Bharat Heavy Electrical LIMITED
Ranipur, Hardwar
PIN 249403
AREA
BHEL Hardwar consists of two manufacturing units, namely Heavy Electrical
Equipment Plant (HEEP) and Central Foundry Forge Plant (CFFP), having area
(a) HEEP: 845 sq km
(b) CFFP: 1.0 sq km
MANUFACTURING PLANTS
10

BHEL Haridwar has two manufacturing plants:- Heavy Electrical Equipment

Plant (HEEP) and Central Foundry Forge Plant (CFFP).
HEEP includes design and manufacture of large steam and gas turbines, turbo
generators, hydro turbines and generators, hydro turbines and generators, large
AC/DC motors and so on.
CFFP is engaged in manufacture of Steel Castings: Upto 50 Tons Per Piece
Wt& Steel Forgings: Upto 55 Tons Per Piece Wt.
BHEL is an integrated power plant equipment manufacturer and one of the
largest engineering and manufacturing companies in India in terms of turnover.
BHEL was established in 1964, ushering in the indigenous Heavy Electrical
Equipment industry in India - a dream that has been more than realized with a
well-recognized track record of performance. The company has been earning
profits continuously since 1971-72 and paying dividends since 1976-77 .BHEL
is engaged in the design, engineering, manufacture, construction, testing,
commissioning and servicing of a wide range of products and services for the
core sectors of the economy, viz. Power, Transmission, Industry, Transportation,
Renewable Energy, Oil & Gas and Defence.BHEL has 15 manufacturing
divisions, two repair units, four regional offices, eight service centres, eight
overseas offices and 15 regional centres and currently operate at more than 150
project sites across India and abroad. BHEL places strong emphasis on
innovation and creative development of new technologies. Our research and
development (R&D) efforts are aimed not only at improving the performance
and efficiency of our existing products, but also at using state-of-the-art
technologies and processes to develop new products. This enables us to have a
strong customer orientation, to be sensitive to their needs and respond quickly
to the changes in the market.
The high level of quality & reliability of our products is due to adherence to
international standards by acquiring and adapting some of the best technologies
from leading companies in the world including General Electric Company,
Alstom SA, Siemens AG and Mitsubishi Heavy Industries Ltd., together with
technologies developed in our own R&D centres. Most of our manufacturing
units and other entities have been accredited to Quality Management Systems
(ISO 9001:2008), Environmental Management Systems (ISO 14001:2004) and
Occupational Health & Safety Management Systems (OHSAS 18001:2007).

11

In HEEP thera are 8 blocks

BLOCKS

PRODUCTS

I. Electrical Machine

Turbo generator, generator exciter , motor (ac,dc)

II. Fabrication

Large size fabricated assemblies/components

III. Turbine & Auxiliary

Steam ,hydro ,gas turbines, turbine blade , special tooling

IV. Feeder

Winding of Turbo ,hydro gen. ,insulation for ac & dc motors

V. Fabrication

Fabricated parts of steam turbine , water boxes ,storage tank ,hydro

turbine parts.

12

VI.FabricationStamping
and die manufacturing

Fabricated oil tanks, hollow guide blades, rings, stator frames, and
rotor spindle. All dies. Stamping for gen. and motors

VII. Wood working

Wooden packing, spacers

VIII. Heaters & coolers

LP heaters, ejectors, glands, steam and oil coolers, oil tank, bearing
covers.

(3.)MAJOR PRODUCTS MANUFACTURED BY B.H.E.L :

Power
Air Preheaters
Boilers
Control Relay Panels
Electrostatic
Precipitators
Fabric Filters
Fans
Gas Turbines
Hydro Power Plant
Piping Systems
Pulverizers
Pumps
Seamless Steel Tubes
Soot blowers
Steam Generators
Steam Turbines
Turbogenerators
13

 Valves

Industry
Capacitors
Ceralin
Compressors
Desalination Plants
Diesel Generating Sets
Industrial Motors &
Alternators
Gas Turbines
Oil Field Equipment
Solar Photovoltaics
Power Semiconductor
Devices
Seamless Steel Tubes
Sootblowers
Steel Castings &
Forgings
Steam Generators
Steam Turbines
Turbogen

Transmission
Power
Transformers/Reactors
Instrument Transformers
Switchgears
Control & Protection
Equipments
Thyristorequipments
Insulators
Bushing
Capacitors

Transportation
Electric Rolling Stock
14

Electrics for Rolling

Stock
Electrics for Urban
Transportation System

Non ConventionalEnergySource
Mini/Micro Hydro Sets
Solar Lanterns
Solar Photovoltaics
Solar Water Heating
Systems
Wind Electric Generators

R&D Products
Fuel Cells
Surface Coatings
Automated storage &Retrivals
Load Sensors
Transparent Conducting
Oxide

(4.)TURBINE SHOP BLOCK 3

GENERAL DETAILS OF BLOCK- 3:
GENERAL DETAILS OF BLOCK- 3 Steam Turbines, Gas Turbines and
Turbines Blades Special Tooling for all products in the Tool Room located in
the same 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 metres respectively Facilities of EOT Cranes, compressed
air, Steam, Overspeed Balancing Tunnel, indicating stands for steam turbine,
rotors, one Test stand for testing 210 MW steam turbines .
DETAILS OF BAY- 1:
DETAILS OF BAY- 1 Size- 36x378 meters. Consists of following machines:Hydraulic lifting platform, CNC turning lathe, assembly platform for casing
,Vertical boring Machines
15

DETAILS OF BAY - 2:
DETAILS OF BAY - 2 Size:- 36x400 meters Rotor assembly section ,CNC
creep feed grinding machine, External broaching machine, CNC facing lathe,
Steam turbine test bed, Vertical boring machine,
DETAILS OF BAY 3 :
DETAILS OF BAY 3 Size :-24x402 meters CNC stub borer CNC milling
machine Universal milling machine CNC bed type milling machine CNC
surface broaching machine, steam turbine governing section
DETAILS OF BAY - 4:
DETAILS OF BAY - 4 Size:- 24x381 metres Turbine blade machining shop,
milling machines, jig and fixtures department, blade cutting section, Heat
treatment zone
MANUFACTURING FACILITIES:
(a) Hydraulic Lifting Platform: used for assembly and disassembly of G.T.
Rotor.
b) CNC Creep Feed Grinding M/c: grinds the hearth serration on rotor disc
faces.
c) External Broaching Machine: used to make groove on the outer dia of rotor
discs for the fitting of moving blades on the discs.
d) CNC Facing Lathe : used for facing rotor disc.
e) CNC Turning Lathe: used to turn Tie Rods of steam Turbine.
f) Wax Melting Equipment: used to mix and melt Wax to arrest the blade
movement during the blade tip machining of stator blade rings.
g) ROTOR ASSEMBLY SECTION : Equipped with Indicating Stand, Small
size Grinding, Milling, Drilling, machines, Press and other devices for fitting
Rotors and Discs.
h)TURBINE CASING ASSEMBLY SECTION : Machined casings are
assembled and hydraulically tested by Reciprocating Pumps at two times the
operating pressure.
I)TEST STATION : Equipped with condensers, Ejector, Oil Pumps, Oil
containers Steam Connections etc, required for testing.
j)OVER SPEED VACUUM BALANCING TUNNEL: Vibration and frequency
of rotor shaft is tested at very high speed of 4500rpm.
SPECIFICATIONS OF MACHINES AVAILABLE IN BLOCK-III:
16

Vertical Boring Machine :

Max diameter of work piece accommodated
12500mm

:10000mm

Max height of work piece

:5000mm

Diameter of table

:8750mm

Max travel of vertical tool head RAM slides

:3200mm

Max travel of vertical tool heads from centre of :5250mm

Table
Max weight of work piece

:200 T

Diameter of boring spindle of combined head

:160mm

Travel of boring spindle

:1250mm

Taper hole of boring spindle

:100metric

Centre Lathe :(Biggest of all BHEL)

Max diameter over bed

:3200mm

Max diameter over saddle

:250mm

Length between centers

:16m

Max weight of work piece

:100 T

Spindle bore

:96mm

CNC Lathe :
Manufacturer: Safop, Italy
17

to

 Swing over carriage

:3500mm

Centre distance

:9000mm

Weight capacity

:120 T

Spindle power

:196KW

External chucking range

:250-2000mm

Hydrostat steady range

:200-1250mm

Max spindle rpm

:200

CNC system

:SINUMERIK 840D

CNC Indicating stand :

Manufacturer : Heinrich Georg, Germany
Turning diameter

:5.3m

Turning length

:15m

Weight capacity

:160 T

CNC Vertical Borer :

Manufacturer : M/S PietroCarnaghi, Italy
Machine model

:AP 80TM-6500

Table diameter

:6500mm

Max turning diameter

:8000mm

Min boring diameter

:660mm

18

 Max height for turning and milling

:7000mm

Table Speed

:0.2-50 rpm

Table load capacity

:200 T

Milling spindle speed

:3.4-3000rpmat40KW

Spindle taper

:BT 50

CNC system

:SINUMERIK 840D

CNC Facing Lathe : KH-200-CNC

Step

Swing over bed

Swing over carriage
Max distance between faced plate and carriage
Max weight of job held in chuck
Face plate diameter
Spindle speed
Main spindle drive

:2300mm
:1800mm
:2000mm
:6000kg
:1800mm
:1.4-400rpm
:95.5KW

boring Machine :
Max boring diameter
Min boring diameter
Table
Max weight of job
Headstock travel

:2500mm
:625mm
:4000mmx4000mm
:100 T
:4000mm

Double Column Vertical Borer :

Table diameter
Max travese of cross rail
Max weight of work piece
Max weight of job
CNC Skoda Horizontal Borer :
Spindle diameter
Taper spindle
RAM size :450x450mm
RAM length

:4000mm
:4250mm
:4200mm
:50 T
:200mm
:BT 50
:1600mm
19

Spindle length:2000mme
Headstock
Table :4000x35
CNC systemSIMENS
Job

:5000mm
: 850mm
: I.P. Outer

Horizontal Borer : LSTG 8006

Spindle diameter
Height of machining bed
Max boring depth with spindle
Max extension of RAM
Width of bed guide ways
Actual length of headstock with vertical lift
Actual length of coloum of horizontal feed
Lowest position of spindle axis upon bed
Guideways
Machine weight with electrical equipments
Height of machine
CNC Lathe : 1-120
Manufacturer :Ravensburg
Main spindle bore
Distance between centers
Turning diameter over bed cover
Turning diameter over carriage
Workpiece weight unsupported
Workpiece weight between centers
Centre Lathe : 1-23
Manufacturer :K3TC, USSR
Max diameter over bed
Max diameter over saddle
Length between centers
Max weight of work piece
Spindle bore
Machine wattage
Horizontal Boring Machine : 1-28
Diameter of spindle
Working surface of table

:250mm
:600mm
:2000mm
:1600mm
:2500mm
:2150mm
:15000mm
:1475mm
:140 T
:10.3m

:150mm
:12m
:1400mm
:1100mm
:4000kg
:20 T
:1250mm
:900mm
:6300mm
:25 T
:80mm
:55KW
:150mm
:2250x1250mm

20

 Max travel of table

:1200mm
Max vertical travel of headstock
:2000mm
Horizontal Boring Machine :
Boring spindle taper
:BT50
Boring spindle diameter
:160mm
Headstock vertical travel
:3000mm
Longitudinal RAM travel
:700mm
Longitudinal spindle travel
:1000mm
Column cross travel
:10m
Rotary table travel
:3000mm
Table load
:40 T
Horizontal Boring Machine : 1-11
Boring spindle internal taper material
:200
Boring spindle diameter
:320mm
Max spindle travel
:2500mm
Vertical head travel
:6000mm
Transverse column travel
:6000mm
Max longitudinal column travel
:800mm
Machine wattage
:90KW
Double Column Rotary Table Vertical Borer :
Max diameter of work piece accommodated
:10m/12.5m
Max height of work piece accommodated
:5m
Diameter of table
:8.75m
Max travel of vertical tool head RAM slides
:3.2m
Max travel of vertical tool head from centre of table
:5.25m
Max weight of work piece :200T for N<=8rpm;100T for any speed
Diameter of boring spindle of combined head
:160mm
Travel of boring spindle
:1250mm
Taper hole of boring spindle
:100mm
Horizontal borer : 1-2
Spindle diameter
Working surface
Max vertical travel
Max transverse travel of column
Max longitudinal travel of column
Max longitudinal travel of spindle
CNC Lathe : 2-360
21

:220mm
:8100 x 5000mm
:3mm
:6m
:6m
:1.8m

Manufacturer :Hoesch
Max load
Max length between centers
Swing over bed
Horizontal Borer : 2-198
Spindle diameter
Max vertical travel
Max transverse travel of column
Max longitudinal travel of column
Max longitudinal travel of spindle
Working surface
Creep Feed Grinding Machine :
Diameter of job
Job height
Table rpm
Table diameter
Swing diameter
CNC control
Broaching Machine : SIEMENS-3GG
Broaching capacity
Broaching stroke
Broaching slide width
Broaching specific cutting stroke
Broaching specific return stroke
Max diameter of disc
Max move of table
Helix angle/skew angle setting
Cone angle
CNC Lathe :
Manufacturer :InnseBerardi, Italy
Swing over carriage
Swing over bed
Capacity
Cost
CNC system
Over Speed Balancing of Turbines :
Main features :
22

:320 T
:18m
:3.2m
:220mm
:3m
:6m
:6m
:1.8m
:1800x500mm
:2m
:2.4m
:10rpm(max)
:2050mm
:2500mm

:32 T
:10.3m
:1500mm
:1.25m/min
:60m/min
:2300mm
:600mm
:+45/-45
:0-20

:1500mm
:2000mm
:30 T
:16 crore
:SINUMERIK 840D

Type of pedestials
Rotor weight
Rotor diameter
Rotor journal diameter
Bearing centre distance
Balancing speed
Min vibration limit
Max vacuum

:DH 90/DH 12
:Min 4 MT, Max 320 MT
:Max 6900mm
:Min 250mm,Max 950mm
:Min3000mm,Max 15700mm
:180-3600rpm
:1 micron
:1 torr

Tunnel Features :
Tunnel length
Tunnel diameter
Max thickness of tunnel
Steel plate thickness
Cost of balancing equipment(FE)
Total cost of balancing tunnel
Main Features of Drive :
Drive motors (2 no.)
Total drive pow:7 MW(2x3.5)

MG set of Drive :
Synchronous motors
DC Generator (2 no.)

:19000mm
:6900mm
:2500mm
:32mm
:444 lakhs
:770 lakhs
:950V DC, 500rpm,3.5 MW each

:11 KV,9MW,50Hz,500rpm
:950V,500rpm,3.8MW each

23

(5.)STEAM TURBINE:

24

Steam turbine technology is one of the leading technologies used in electricity

production since more than one hundred years.
Turbine modules of different sizes providea broad range of power ratings. To
meetspecific project requirements, BHEL offers the appropriate modules and
customizes the individual blade paths.Proven pre-engineered modules reduce
site assembly and commissioning timeas well as technical risks.
Thanks to their power generation capabilities, BHEL steam turbines
haveconsistently occupied the top positions Inindian ranking lists for many
years.
A steam turbine is a mechanical device that extracts thermal energy from
pressurized steam, and converts it into rotary motion. Its modern manifestation
was invented by Sir Charles Parsons in 1884. It has almost completely replaced
the reciprocating piston steam engine (invented by Thomas Newcomen and
greatly improved by James Watt) primarily because of its greater thermal
efficiency and higher power-to-weight ratio. Because the turbine generates
rotary motion, it is particularly suited to be used to drive an electrical generator
about 80% of all electricity generation in the world is by use of steam
turbines. The steam turbine is a form of heat engine that derives much of its
improvement in thermodynamic efficiency through the use of multiple stages in
the expansion of the steam, which results in a closer approach to the ideal
reversible process.
Types
These arrangements include single casing, tandem compound
and cross compound turbines. Single casing units are the most
25

basic style where a single casing and shaft are coupled to a

generator. Tandem compound are used where two or more
casings are directly coupled together to drive a single
generator. A cross compound Steam turbines are made in a
variety of sizes ranging from small 1 hp (0.75 kW) units (rare)
used as mechanical drives for pumps, compressors and other
shaft driven equipment, to 2,000,000 hp (1,500,000 kW)
turbines used to generate electricity. There are several
classifications for modern steam turbines.
Steam Supply and Exhaust Conditions
These types include condensing, non-condensing, reheat, extraction and
induction. Non-condensing or backpressure turbines are most widely used for
process steam applications. The exhaust pressure is controlled by a regulating
valve to suit the needs of the process steam pressure. These are commonly
found at refineries, district heating units, pulp and paper plants, and desalination
facilities where large amounts of low pressure process steam are available.
Condensing turbines are most commonly found in electrical power plants.
These turbines exhaust steam in a partially condensed state, typically of a
quality near 90%, at a pressure well below atmospheric to a condenser. Reheat
turbines are also used almost exclusively in electrical power plants. In a reheat
turbine, steam flow exits from a high pressure section of the turbine and is
returned to the boiler where additional superheat is added. The steam then goes
back into an intermediate pressure section of the turbine and continues its
expansion.
Casing or Shaft Arrangements
Turbine arrangement features two or more shafts not in line driving two or more
generators that often operate at different speeds. A cross compound turbine is
typically used for many large applications.
Principle of Operation and Design
An ideal steam turbine is considered to be an isentropic process, or constant
entropy process, in which the entropy of the steam entering the turbine is equal
to the entropy of the steam leaving the turbine. No steam turbine is truly
isentropic, however, with typical isentropic efficiencies ranging from 20%90% based on the application of the turbine. The interior of a turbine comprises
26

several sets of blades, or buckets as they are more commonly referred to. One
set of stationary blades is connected to the casing and one set of rotating blades
is connected to the shaft. The sets intermesh with certain minimum clearances,
with the size and configuration of sets varying to efficiently exploit the
expansion of steam at each stage.

Turbine Efficiency
To maximize turbine efficiency, the steam is expanded, generating work, in a
number of stages. These stages are characterized by how the energy is extracted
from them and are known as impulse or reaction turbines. Most modern steam
turbines are a combination of the reaction and impulse design. Typically, higher
pressure sections are impulse type and lower pressure stages are reaction type.

Impulse Turbines
An impulse turbine has fixed nozzles that orient the steam flow into high speed
jets. These jets contain significant kinetic energy, which the rotor blades, shaped
like buckets, convert into shaft rotation as the steam jet changes direction. A
pressure drop occurs across only the stationary blades, with a net increase in
steam velocity across the stage.
Reaction Turbines
In the reaction turbine, the rotor blades themselves are arranged to form
convergent nozzles. This type of turbine makes use of the reaction force
produced as the steam accelerates through the nozzles formed by the rotor.
Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the
stator as a jet that fills the entire circumference of the rotor. The steam then
changes direction and increases its speed relative to the speed of the blades. A
pressure drop occurs across both the stator and the rotor, with steam
accelerating through the stator and decelerating through the rotor, with no net
change in steam velocity across the stage but with a decrease in both pressure
and temperature, reflecting the work performed in the driving of the rotor.
MANUFACTURING PROCESSES :
27

The facilities and parts manufacturing of Steam Turbine are as follows:

TURBINE CASING MACHINING SECTION: equipped with large size Planer,
Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical
Boring machines .
ROTOR MACHINING SECTION : E quipped with large size machining tools
like Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose
Fir tree Groove Milling Machine etc
STEAM TURBINE MANUFACTURED BY BHEL ACCORDING TO
POWER GENERATION CAPACITY
1.
2.
3.
4.

250 MW
500 MW
600 MW
660 MW BASED ON NEW GERMAN TECHNOLOGY

CONSTRUCTION OF STEAM TURBINE

Steam turbine are usually manufactured in three parts
1. High pressure turbine (H.P. Turbine) It is a single flow turbine. Steam is
enter from inlet and exit from outlet
2. Intrermidiate pressure turbine(I.P. Turbine) It is a double flow turbine.
Steam is enter from middle of it and exhaust from its both ends
3. Low pressure turbine(L.P. Turbine) - It is also a double flow turbine.
Steam is enter from middle of it and exhaust from its both ends.
The difference between L.P. and I.P. is that
1. The size of L.P. is large as compare to I.P.
2. The last stage of blading in L.P. turbine is openly stage . It is not locked
by lockin assembly.
3. In the last stage of L.P. turbine blading fertitry blades are usede which is
also known as free standing blade
BLADE SHOP:
Turbine Blade Machining Shop is located in Bay-IV of Block-III. A batch
production shop comprising of various kinds of CNC Machines and Machining
Centers .
MANUFACTURING FACILITIES:
MANUFACTURING FACILITIES blade shop is divided into four distinct
areas:28

PLAIN MILLING SECTION: it prepares accurate reference surfaces on the

blade blanks by milling and grinding operation.
COPY MILLING SECTION: the semi blanks prepared from plain milling
section are further machined by copy milling machines for concave and convex
aero-dynamic profile forms.
LP SECTION: this area deals with all types of free standing and forged blades
for steam turbine compressor.
POLISHING SECTION: blade contours are ground and polished to achieve the
desired surface finish and other aerofoil requirements.

Materials used for Blade manufacturing:

The commonly used

material for blade manufacturing is H22

Aluminium alloy 5251 is a medium strength alloy possessing good ductility and
therefore good formability. Alloy 5251 is known for work hardening rapidly and
is readily weldable. It also possesses high corrosion resistance particularly in
marine environments.
Characteristics for grade H22
Grade
Standard
Classification

H22
USA ASTM`
Alloy tool steel

Chemical composition
Element
Magnesium (Mg)
Manganese (Mn)
Iron (Fe)
Silicon (Si)
Titanium (Ti)
Others (Total)
Chromium (Cr)
Copper (Cu)
Zinc (Zn)
Other (Each)
Aluminium (Al)

%percentage
1.70 - 2.40
0.10 - 0.50
0.0 - 0.50
0.0 - 0.40
0.0 - 0.15
0.0 - 0.15
0.0 - 0.15
0.0 - 0.15
0.0 - 0.15
0.0 - 0.05
Balance

Generic physical property

Density
Melting Point
Thermal Expansion
Thermal Conductivity
Modulus of Elasticity

2.69 g/cm
625 C
25 x10-6 /K
134 W/m.K
70 GPa
29

Electrical Resistivity

0.044 x10-6 .m

Mechanical properties
Proof Stress
Tensile Strength
Hardness Brinell

120 Min MPa

190 - 230 MPa
56 HB

WELDABILITY
Aluminium alloy H22 is a readily weldable alloy.
Weldability Gas: Very Good
Weldability Arc: Very Good
Weldability Resistance: Very Good
Brazability: Poor
FABRICATION
Workability Cold: Very Good
Machinability: Average
INSPECTION DEVICES:
INSPECTION DEVICES 3 D Coordinate Measuring Machines for taper and
rhomboid checking. Moment weighing Equipment.Real time Frequency
analyzer for checking frequency of free standing blades. Contour plotter for
plotting of blade profile with various magnification. Magna spray crack
detection equipment.
3d coordinate measuring machine in new blade shop:
Model refrence:
22129 LIETZ Germany
Plan no
3-068
Measuring range:
X axis
2200mm
Y axis
1200mm
Z axis
900 mm
Volumetric error: (max)
1.5 micron
Resolution:
0.05 micron
Max weight of job:
2250 kg
Accuracy:
1.5+L/350 micron
Application: dimensional and profile management of turbine
moving and guide blades

30

1 2 3

45 6

31

32

Major Components of Steam Turbine:

LP Rotor
LP Inner Casing Upper Half
LP Inner Casing Lower Half
LP Outer Casing Upper Half
LP Outer Casing Lower Half
IP Rotor
IP Inner Casing Upper Half
IP Inner Casing Lower Half
IP Outer Casing Upper Half
IP Outer Casing Lower Half
HP Rotor
HP Inner Casing Upper Half
HP Inner Casing Lower Half
33

HP Outer Casing Upper Half

HP Outer Casing Lower Half
Diffuser
GBC (Guide Blade Carrier)
IVCV (Intercept Valve Control Valve)
ESVCV (Emergency Stop Valve Control Valve)

Auxiliary Parts of Steam Turbine:

1)
2)
3)
4)
5)
6)
7)
8)
9)

Valve Seal
U-Ring
Piston Rod
Base Plate
Sealing Ring
Liner
Guide Ring
Valve Cover
Guide Blades :
Fixed Blades
Moving Blades
10)
Support
11)
Bearing
12)
Bearing Shell
13)
Angle Ring
14)
Sleeve
15)
Pin Taper (25x140)
16)
Journal Bearing Shell
17)
Casing
18)
Guide bush
19)
Piston (500MW)
20)
Valve Cone
21)
Yoke
22)
Mandrel
23)
Support Ring
24)
Thrust Ring
25)
Adjusting Ring
26)
Shaft Sealing Cover
Nomenclature of Blade:
1. Root
2. Ferate
3. Core Width
34

4. Shroud
5. Neck
6. Tang Hight
Types of blades:
1. Acoording to the profile
A. TX Blade
B. F Blade
C. 3DS Blade
D. Special Profile Blade
2. According to the Root
A. T Root
B. Double Root
C. Hook Root
D. Special Root

Operation performed during Blade manufacturing:

Total operation time
for 1Blade
Operations:some main operations are disscused below
1. Center
2. Skin rough
3. Rough Plane
4. Rough Hub
5. Rough Shroud
6. Blade Roof
7. Open cut peel
8. Open Prefinish blade
9. Rough Intersection
10.Rough Slot
11.Prefin Rough Shoulder
12.Prefin Rough Hub
13.Fin Surf Shroud
14.Fin slot
15.Open fin blade
16.Radiush shroud
35

120 min

17.Fin intersection
18.Face Finishing
19.Final inspection
20. Blade out

(6.)ANOTHER BLOCK
(7.)BLOCK 2(heavy fabrication block)
The various processes and machinery are as follows:
A)HydraulicPress:Ahydraulic press is a hydraulic mechanism for applying
a large lifting or compressive force. It is the hydraulic equivalent of a
mechanical lever, and is also known as a Bramah press after the inventor,
Joseph Bramah. Hydraulic presses are the most commonly-used and efficient
form of modern press.The hydraulic press depends on Pascal's principle: the
pressure throughout closed system is constant. At one end of the system is a
piston with a small cross-sectional area driven by a lever to increase the
force. Small-diameter tubing leads to the other end of the system. A fluid,
such as oil, is displaced when either piston is pushed inward. The small
piston, for a given distance of movement, displaces a smaller amount of
volume than the large piston, which is proportional to the ratio of areas of
the heads of the pistons. Therefore, the small piston must be moved a large
distance to get the large piston to move significantly. The distance the large
piston will move is the distance that the small piston is moved divided by the
ratio of the areas of the heads of the pistons.
B)Oxy-Fuel Welding And Cutting: Oxy-fuel welding (commonly called
oxyacetylene welding or oxy welding or in the U.S. gas welding) and Oxy36

fuel cuttingare processes that use fuel gases and oxygen to either weld or cut
metals.
There are a few differences between the two. In Oxy-fuel welding, a welding
torch is used to weld metals. In Oxy-fuel cutting, a cutting torch is used to heat
up ferrous metal to kindling temperature (about 980C). A stream of pure
oxygen is trained on the hot metal which chemically combines with the iron
which then flows out of the cut, or kerf, as an iron-oxide slag
Torches that do not mix pure oxygen with the fuel inside the torch, but burn it
with atmospheric air, are not oxy-fuel torches and can be identified by their
single tank. (Oxy-fuel welding/cutting needs two tanks, fuel and oxygen.) Most
metals cannot be melted with such single-tank torches, so they can only be used
for soldering and brazing, not welding.
Apparatus used in Oxy-Fuel welding and cutting:
The apparatus used in gas welding consists basically of an oxygen source and a
fuel gas source (usually cylinders), two pressure regulators and two flexible
hoses (one of each for each cylinder), and a torch. This sort of torch can also be
used for soldering and brazing. The cylinders are often carried in a special
wheeled trolley.
There have been examples of oxyhydrogen cutting sets with small (scuba-sized)
gas cylinders worn on the user's back in a backpack harness, for rescue work
and similar.
There are also examples of pressurized liquid fuel cutting torches, usually using
gasoline. These are used for their increased portability.
C)Planers: A planer is a type of metalworking machine tool that is analogous to
a shaper, but larger, and with the entire workpiece moving beneath the cutter,
instead of the cutter moving above a stationary workpiece. The work table is
moved back and forth on the bed beneath the cutting head either by mechanical
means, such as a rack and pinion gear, or by a hydraulic cylinder.
Planers and shapers were used generally for two types of work: generating
accurate flat surfaces and cutting slots (such as keyways). Planers and shapers

37

are now obsolescent, because milling machines have eclipsed them as the
machine tools of choice for doing such work.
D)Plasma Cutting:Plasma cutting is a process that is used to cut steel and
other metals (or sometimes other materials) using a plasma torch. In this
process, an inert gas (in some units, compressed air) is blown at high speed out
of a nozzle; at the same time an electrical arc is formed through that gas from
the nozzle to the surface being cut, turning some of that gas to plasma. The
plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast
to blow molten metal away from the cut.
Cutting Methods: Plasma cutters have also been used in CNC machinery.
Manufacturers build CNC cutting tables, some with the cutter built in to the
table. The idea behind CNC tables is to allow a computer to control the torch
head making clean sharp cuts. Modern CNC plasma equipment is capable of
multi-axis cutting of thick material, allowing opportunities for complex welding
seams on CNC welding equipment that is not possible otherwise.
E)Three roll bending machine: Roll benders use three rolls (typically) to bend
solids, extrusions and tube and pipe to various diameters by adjusting one or
two rolls. The pyramid style roll benders have one moving roll, usually the top
roll. Double pinch type roll benders have two adjustable rolls, usually the
bottom rolls, and a fixed top roll. Large arcs, circles and spirals are typical
applications for roll benders.
The roll bending machine in BHEL has following specifications:
Maximum working length:8000 mm.
Minimum diameter of forming:1300 mm.
Plate thickness:32 mm,
Upper rolled dia.:7550 mm.
Lower roll dia.:680 mm.
Speed of forming :5 m per minute.
Speed of lowering upper roll :60 mm per minute.
38

Speed of raising upper roll :120 mm per minute

F) Boot Press Furnace: This press was having following furnace :
Power:750KW.
Furnace size : length-4000 mm
Width :2400 mm.
Height :1600 mm.
Zones: 5
G)Centre lathe with three and four jaws: A metal lathe is generic description
for a rigid machine tool designed to remove material from a workpiece, through
the action of a cutting tool. They were originally designed to machine metals;
however, with the advent of plastics and other materials, and with their inherent
versatility, they are used in a wide range of applications, and a broad range of
materials.
A center lathe is a dual head machine where the work remains fixed and the
heads move towards the workpiece and machine a center drill hole into each
end. The resulting workpiece may then be used "between centers" in another
operation. The usage of the term metal lathe may also be considered somewhat
outdated these days, plastics and other composite materials are in wide use and
with appropriate modifications, the same principles and techniques may be
applied to their machining as that used for metal.
A center lathe or engine lathe may be considered the basis for the metal lathe
and is the type most often used by the general machinist or hobbyist.The center
lathe may be considered a useful starting point. The engine lathe is the name
applied to a traditional 20th century lathe. It is assumed that the 'engine' was
added to the description to separate them from the 'foot lathes' (lathes turned by
pedals) or other hand rotated pieces of machinery. Early engine lathes were
generally 'cone heads', in that the spindle usually had attached to it a multi-step
pulley designed to accept a flat belt. Different spindle speeds could be obtained
by moving the flat belt to different steps on the cone pully. It was assumed that
a cone head lathe would be powered by a Line shaft which was the industrial
standard of the time
39

H)Manipulator:Parts that cannot be welded easily by ordinary welding,

specially internal curved parts are welded by manipultaors .
I)Non Destructive Testing: Nondestructive testing (NDT) has been defined as
comprising those test methods used to examine an object, material or system
without impairing its future usefulness. The term is generally applied to non
medical investigations of material integrity.
The main NDT processes at the fabrication block are as follows:
1)Visual inspection : It is the simplest ,cheapest and most widely used method
amongst all the NDTs.A simple visual test reveal gross surface defects easily
and quickly . However for detection of final defects, device/equipments having
high degree of precision and illumination are required.
2)Radiography: In this test the X-rays and gamma rays are used to detect deep
seated internal defects. The short wavelengths of X-ray permitted to penetrate
through the opaque material. Gamma rays are the electro-magnetic radiations
that are emitted from an unstable nucleus
3)Penetrant Testing- Penetrant solution is applied to the surface of a
precleaned component. The liquid is pulled into surface-breaking defects by
capillary action. A developer is applied to pull the trapped penetrant back to the
surface where it is spread out and forms an indication. The indication is much
easier to see than the actual defect
J) Vertical boring machine C-208: The specification of this machine is as
follows:
Chuck diameter

= 4m

Maximum chuck speed = 30 rpm

Minimum chuck speed =.2 rpm
Use to make Guide blade carrier
Feed can be given at any time .
Pendant is used for the performance on the job.
40

Operations performed are turning, facing, boring, taper machining.

K)CNC Flame Cutting
Setup in BHEL in 1982 and imported from Germany.
Maximum depth of cutting: 250mm -300mm.
Gas used oxyacetylene
Program are saved and made by the programmer.
Different nozzle are used for different jobs.
L)CNC Plasma Cutting Machine
Arc is maintained between a non consumable electrode and work piece.
High temperature is reached upto 35000c
Cu nozzle is used through which tungsten electrode is fed.
Maximum cutting thickness is 80 mm.
Much faster.
Narrow heat affected zone.
Used for cutting non ferrous metal

(8.)C.F.F.P PLANT(The Central Foundry Forge Plant)

CASTING

41

Casting is a manufacturing process by which a liquid material is usually poured

into a mold, which contains a hollow cavity of the desired shape, and then
allowed to solidify. The solidified part is also known as a casting, which is
ejected or broken out of the mold to complete the process. Casting materials are
usually metals or various cold setting materials that cure after mixing two or
more components together; examples are epoxy, concrete, plaster and clay.
Casting is most often used for making complex shapes that would be otherwise
difficult or uneconomical to make by other methods.
Casting is a 6000 year old process. The oldest surviving casting is a copper frog
from 3200 BC.
TYPES OF CASTING
There are many types of castings but one of the most important is sand casting.
(SAND CASTING)
Sand casting, also known as sand molded casting, is a metal casting process
characterized by using sand as the mold material. The term "sand casting" can
also refer to an object produced via the sand casting process. Sand castings are
produced in specialized factories called foundries. Over 70% of all metal
castings are produced via a sand casting process.
Sand casting is relatively cheap and sufficiently refractory even for steel
foundry use. In addition to the sand, a suitable bonding agent (usually clay) is
mixed or occurs with the sand. The mixture is moistened, typically with water,
but sometimes with other substances, to develop strength and plasticity of the
clay and to make the aggregate suitable for molding. The sand is typically
contained in a system of frames or mold boxes known as a flask. The mold
cavities and gate system are created by compacting the sand around models, or
patterns, or carved directly into the sand.
BASIC PROCESSES
There are six steps in this process:
1. Place a pattern in sand to create a mold.
2. Incorporate the pattern and sand in a gating system.
3. Remove the pattern.
4. Fill the mold cavity with molten metal.
5. Allow the metal to cool.
6. Break away the sand mold and remove the casting.

42

43

FORGING
Forging is a manufacturing process involving the shaping of metal using
localized compressive forces.
Forging is often classified according to the temperature at which it is performed:
1. Cold Forging
2. Hot Forging
All of the forging processes can be performed at various temperatures, however
they are generally classified by whether the metal temperature is above or
below the recrystallization temperature.
If the temperature is above the material's recrystallization temperature it is
deemed hot forging.
if the temperature is below the material's recrystallization temperature but above
30% of the recrystallization temperature (on an absolute scale) it is deemed
warm forging;
if below 30% of the recrystallization temperature (usually room temperature)
then it is deemed cold forging.
The main advantage of hot forging is that as the metal is deformed work
hardening effects are negated by the recrystallization process. Cold forging
typically results in work hardening of the piece.
Forged parts can range in weight from less than a kilogram to 580 metric tons.
Advantages and disadvantages
Forging can produce a piece that is stronger than an equivalent cast or machined
part. As the metal is shaped during the forging process, its internal grain
deforms to follow the general shape of the part. As a result, the grain is
continuous throughout the part, giving rise to a piece with improved strength
characteristics.
Some metals may be forged cold, but iron and steel are almost always hot
forged. Hot forging prevents the work hardening that would result from cold
forging, which would increase the difficulty of performing secondary machining
operations on the piece. Also, while work hardening may be desirable in some
circumstances, other methods of hardening the piece, such as heat treating, are
generally more economical and more controllable. Alloys that are amenable to
precipitation hardening, such as most aluminium alloys and titanium, can be hot
forged, followed by hardening.
Production forging involves significant capital expenditure for machinery,
tooling, facilities and personnel. In the case of hot forging, a high-temperature
furnace (sometimes referred to as the forge) is required to heat ingots or billets.
Owing to the massiveness of large forging hammers and presses and the parts
they can produce, as well as the dangers inherent in working with hot metal, a
special building is frequently required to house the operation. In the case of
drop forging operations, provisions must be made to absorb the shock and
44

vibration generated by the hammer. Most forging operations use metal-forming

dies, which must be precisely machined and carefully heat-treated to correctly
shape the workpiece, as well as to withstand the tremendous forces involved.
PRESS FORGING
Press forging works by slowly applying a continuous pressure or force, which
differs from the near-instantaneous impact of drop-hammer forging. The amount
of time the dies are in contact with the workpiece is measured in seconds (as
compared to the milliseconds of drop-hammer forges). The press forging
operation can be done either cold or hot.

THANK YOU
45