STEAM TURBINES

OUR MAINSTAY

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 upto 600 oC. Turbines are built on the building block system, consisting of modules suitable for a range of output and steam parameters. For a desired output and steam parameters appropriate turbine blocks can be selected. Turbines are classified based on method of steam generation.

APPLICATION RANGE OF STEAM TURBINE

SERIES TYPE OF STEAM GENERATOR SPEED RPM POWER OUTPUT MW 100-1000 Upto 1000 Upto 300 MAIN STEAM CONDITION O BAR C 130-250 40-70 30-140 500-540 250-300 500-540 REHEAT STEAM CONDITION O BAR C 30-70 8-15 30-50 500-600 200-250 500-540 BACK PRESSURE MBAR 20-300 20-300 20-300

Turbines for Fossil Fuel Fossil Fuel Power Plants Steam Generator Turbines for Nuclear Pressurised Light Power Plants Water Reactor Turbines for Combined Heat recovery Cycle Applications Steam Generator

3000 3000 3000

STEAM TURBINES FOR FOSSIL FUEL POWER PLANTS

Three cylinder turbines (HMN Series), comprising of:

High pressure (HP) turbine Intermediate pressure (IP) turbine Low pressure (LP) turbines i. ii. iii.
Sliding pressure operation Base load as well as two-shift operation Sub critical as well as super critical parameters

All the rotors are monoblock HP & IP casings have double shell construction and LP has three-shell construction. IP turbines with single flow or with double flow. LP turbines are designed for normal as well as high back pressure conditions. Hollow guide blades with suction slits for moisture removal in last LP stage. Bearing pedestals isolated from turbine casings. Combined stop & control valves with individual servomotor. Sophisticated control and monitoring equipment such as Electro-hydraulic governing, automatic turbine run up system, turbine stress controller, automatic turbine tester etc. High operational flexibility

i. ii.

Fast start up and shut down Sharp load changes

Operation under wide frequency range (47.5 to 51.5 Hz) Two cylinder turbines comprising of combined (HP&IP) and LP turbine (KN series) Two cylinder turbines comprising of HP and combined (IP&LP) turbines (HE series)

STEAM TURBINES FOR COMBINED CYCLES

Combined cycles offer substantial improvement in thermal cycle efficiency by lowering the heat rejection temperature. Exhaust from gas turbine is used effectively for generating steam in fired or unfired heat recovery steam generator for running a suitable steam turbine. Open cycle gas turbines can be profitably converted to a combined cycle plant even at a later stage depending upon the convenience of the utility. BHEL Hardwar manufactures steam turbines for combined cycle power stations with gas turbines of 66 MW, 159 MW and 255 MW ISO ratings. Steam cycle may be single, dual or triple pressure cycle. With triple pressure cycle and suitable block combination of gas turbines, HRSG and steam turbines, cycle efficiency of about 58% can be achieved.

TURBINES WITH ADVANCED STEAM PARAMETERS

Application of higher parameters is the most direct way of increasing heat input to the cycle Steam parameters of 300 bar pressure and 600 oC temperature Six percent improvement in thermal cycle efficiency New materials for high temperature applications Impulse diagonal blading for the first stage HP and IP turbines Heat shield at inlet of IP turbine Increased wall sections for increased pressures

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 blade Tapered and forward leaning for optimised mass flow distribution

ENGINEERING CAPABILITIES
Over the past two decades, BHEL has gained a vast experience in design, manufacture, erection and commissioning of various capacities of Turbine Generator sets ranging from 100 MW to 500 MW. Many specific features to suit the customer requirements, layout & operation are taken care of. To name a few:

HP/LP bypass Turbine Stress Evaluator, hand Barring Gear and Automatic Turbine Run-up System for 210 MW Russian Turbine. Base load/cycle /Two-shift operations Throttle /Nozzle governing Constant/Sliding pressure operation High back pressure for desert application. BHEL Hardwar has a strong engineering base with qualified and experienced engineers supported by technicians, spanning the functions of proposal, performance and product engineering, project management, field engineering, research and development, computerisation etc.

MANUFACTURING FACILITIES

The plant is fully equipped with the most modern and sophisticated manufacturing and testing facilities to produce sets upto 1000 MW rating. These include: Blade Shop for manufacture of both moving and stationary blades Special purpose CNC machine tools Overspeed & Vacuum Balancing Tunnel-a unique facility for balancing and overspeeding of rotors for turbines

QUALITY A MATTER OF COMMITMENT

An ISO 9001 Company Quality, a watchword in incoming materials, in-process, machining, assembly and testing. Quality Assurance, Quality Plan, Field Quality being an integral part of the total process. Fully equipped Centre Plant Laboratory to support, sophisticated testing and measuring instruments viz. CNC 3 D Co-ordinate Measuring Machine. NDT facilities: X-ray, Gama ray, Ultrasonic Magnetic particle testing. Recognised by MIS TUV, Germany as a reputed manufacturer of pressure vessels ASME U stamp ASME R Stamp

Technology / Collaborations
The technological base of BHEL in the area of Steam turbines and Turbo Generators has been created by acquiring technological information from the collaborators. Initially BHEL had collaboration with M/s LMW USSR for 100 and 210 MW sets. In 1976, BHEL entered into technical collaboration agrrement with M/s Siemens-KWU, Germany to acquire the knowhow and know-why for turbine generator sets upto 1000 MW. This collaboration still continues. This helps BHEL to keep pace with the worldwide technological progress and offer state of the art equipment to it's customer. Under this collaboration agreement, BHEL has established strong design, manufacturing and servicing base for unit upto 500 MW ratings.

BHELS LARGE SIZE GAS TURBINES

FUEL FLEXIBILITY Gas Turbine burners are designed to burn a wide variety of fuels ranging from clean fuels like Natural Gas, Distillate Oil, Naphtha, LPG to heavy fuels like LSHS. Gas Turbines can be operated in mix-mode also.

HIGH RELIABILITY High reliability and long operating life are the prime basis of the design philosophy adopted for these Gas Turbines. The reliability of M/s SIEMENS/ BHEL designed Gas Turbine is unsurpassed with more than 2 million hours of successful operation for module V94.2 itself. This measure of high reliability has been achieved through a combination of sound design engineering, established manufacturing processes with well defined quality management systems.

HIGH EFFICIENCY These Gas Turbines have high efficiency in Open Cycle and in Combined Cycle Operation. The provision of inlet guide vanes improves the combined cycle efficiency at part loads.

LOW EMISSION While on natural gas very low NOx and negligible CO emissions are achieved without steam/water spray in specially designed Hybrid Burners. Steam/water spray assists in reduction of NOx emissions when firing liquid fuels like Naphtha, Distillate No.2 etc.

HIGHLY EFFICIENT NEWLY DEVELOPED 'A' SERIES GAS TURBINES

NEW DESIGN BASED ON PROVEN FEATURES Advanced series of gas turbine designed to meet higher efficiencies have been developed by Siemens and designated as Vxx.3A series of machines. The 3A series machines are state-of-art machines with basic features adapted from previous gas turbine series. Important design features of the 3A gas turbine are: 1. 2. 3. 4. 5. New compressor blading Fewer hot gas path components Film cooled turbine blades Hybrid burner ring (HBR) combustor with 24 burners Lower cooling air requirement and thus more air available for clean combustion

Advances made in the development of this series of gas turbines are particularly evident in the combustion chamber. The ring type combustion chamber is connected to the turbine outer casing. The hybrid burners form a continuos ring flame thus eliminating the localized hot and cold spots. The objective here is to reduce the pollutant emissions.

THE MAJOR BENEFITS FOR ADVANCE GAS TURBINE 1. Large saving in operating costs due to lowest fuel consumption 2. Low maintenance costs as a result of readily maintainable machine construction and long intervals between inspections 3. Excellent operating availability and reliability 4. Lower life-cycle cost

MANUFACTURING FACILITIES
The plant is fully equipped with the modern and sophisticated machine-tools and testing equipment to produce steam turbine sets upto 1000MW ratings and Gas Turbine sets upto 300MW ratings.