TRAINING SEMINAR ON BHEL,

RANIPUR, HARIDWAR
DEPARTMENT OF MECHANICAL ENGG
MBSCET
TRAINEES
S.NO NAME ROLL NO
1) SABATANTER VERMA 04/10
2) RAGHAV BAKSHI 244/10
3) MOHIT SHARMA 273/10
4) ANKUSH THAPPA 343/10
5) JATIN PAL SINGH 176/10
6) AMARDEEP SINGH 180/10
7) SIDHANT KAPAHI 232/10

TRAINEES
S.NO NAME ROLL NO
8) BHUPESH RANA 37/10
9) PARAS GUPTA 279/10
10) PARDEEP 248/10
11) SAGAR PRASHER 59/10
12) HIMANSHU TANDON 32/10
13) DHEERAJ KHAJURIA 42/10
14) TANVEER SINGH 78/10
15) SIDDHARTH SHARMA 342/10
Entrance to BHEL Ranipur,
Haridwar plant
HISTORY
BHELs first plant was set up in BHOPAL in
1964 under INDO-SOVIET agreement.
First heavy engineering industry in India.
Supplies equipment capable for generating
6000MW/year.
It progressed rapidly and three more factories
went into production in 1965.
BHEL IN PRESENT SENARIO
A widespread network comprising of 14
manufacturing companies.
It is the 7
th
largest power equipment
manufacture in the world.
With an export presence in more than 60
countries.
INR 5824 crores profit during financial year
2012-13
It is one of the only seven mega PSUs of India
clubbed under the esteemed status of
MAHARATNA in Feb. 2013
CONTD
150 Project sites.
9 Service Centers.
4 Power Sector Regional Centers.
Quality management systems (ISO9001:2008).
Environmental management systems
(ISO14001:2004).
Occupational health and safety management
system (OHSAS18001:2007)
BHEL filed 351 patents and copyrights.
Empowered by over 48,399 (march 2013)
employees.
Industry Electrical Equipments
Founded 1964
Headquarters New Delhi, India
Area served Worldwide
Revenue US $9.07 billion (2012)
Net Income US $1.33 billion (2012)
Total Assets US $2.37 billion (2012)
Employees 48,399 (2013)
board of directors
Chairman & Managing Director
[Mr. B.P. Rao ]
Director [ Mr. Ambuj Sharma]
Director [Mr. Trimbakdas S. Zanwar]
Director [Mr. S. Ravi]
Director- Indutrial Systems&Product [Mr.
W.V.K.Krishna Shankar]
Director-Finance [Mr. P.K. Bajpai]
Director-HR [Mr. R. Krishnan ]
Director-Power [Mr. Atul Saraya]
Director(Part time) [Ms. Kusumjit Sidhu]
HARIDWAR
BHOPAL
BANGALORE
GOINDWAL
JAGDISHPUR
JHANSI
HYDERABAD
TIRUCHY
RANIPET
RUDRAPUR

UNITS
UNIT PERIOD TYPE
1. BHOPAL Established 1956
Production started 1960
Heavy Electrical Plant
2. Haridwar
HEEP
CFFP
Established 1963
Production started 1967
Established 1974
Production started 1976
Heavy Electrical Equipment Plant,
Central Foundry Forge Plant
3.Tiruchi
HPBP
SSTP
Established 1963
Production started 1965
Production started 1979
High Pressure Boiling Plant
4.Banglore
EDN
EPD
Established 1963
Established 1972
Established 1977
Control equipment division
Electro Porcelain division
UNITS
UNIT PERIOD TYPE
5.Ranipet
BAP
Established 1976 Boiler Auxiliaries Plant
6.Goindwal Established 1983 Industrial Valves Plant
7.Jagdishpur Production started 1984 High tension ceramic Insulation
Plates
8.Rudrapur Production started 1984 Component Fabrication Plant (bus
duct)
9.Gurgoan Solar Photovoltaic Cells
sectors served
POWER
INDUSTRY
TRANSPORTATION
TRANSMISSION
TELECOMMUNICATION
DEFENCES ETC.
CONTRIBUTION OF B.H.E.L IN
MAKING EQUIPMENTS FOR
POWER GENERATION
53
15
32
0
20
40
60
80
100
Haridwar Others BHEL other than
Hardwar
%age
Others: Siemens,
Adani Ports,
Jaypee Infra,
Lanco Infratech, etc.
ABOUT B.H.E.L. HARIDWAR
UNIT
B.H.E.L. Haridwar has campus of about 7000
acres (28 sq. km).
Mr. B. P. RAO is the chairman and M.D. of
B.H.E.L.
Units of B.H.E.L. :-
HEEP (Heavy Electrical Equipment Plant).
Eight blocks 1-8.
CFFP (Central Foundry And Forge Plant).
Steel Melting Shop
Steel Foundry Shop
Light Foundry Shop
Forge shop
CONTD

BHEL Haridwar plant has manufactured and
supplied around 250 steam turbines sets of
different ratings of 100/ 195/ 200/ 210/ 250 &
500 MW to different power stations in the
country, which forms the backbone of Indias
power infrastructure.


BHEL HARIDWAR (HEEP)
Block-1:- In block 1 turbo generator, generator,
exciter motors (A.C & D.C) are manufactured &
assembled.
Block-2:- In block 2 large size fabricated
assemblies/component for power equipment are
manufactured & assembled.
Block-3:- In block 3 steam turbine and turbines
blade are manufactured & assembled.
Block-4:- In block 4 winding for turbo generator,
hydro generator, insulation of A.C & D.C motors
insulating component for turbo generator, hydro
generator motors are manufactured & assembled.
CONTD
Block-5:- In block 5 fabricated parts of steam
turbine, water box, hydro turbine parts are
manufactured & assembled.
Block-6:- In block 6 fabricated oil tanks, hollow
guide blades, rings, stator frames rotor spiders
are manufactured & assembled.
Block-7:- In block 7 all types of dies including
stamping dies, stamping for generators &
motors are manufactured & assembled.
Block-8:- In block 8 LP heaters, ejectors, steam
coolers, oil coolers, oil tanks are manufactured
& assembled.
TURBINE SHOP 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
36x380 meters and 36x400 meters respectively and
Bay-III and IV of size 24x400 meters and 24x380
metres respectively
Facilities of Cranes, compressed air, Steam,
Overspeed Balancing Tunnel, stands for turbine
rotors, one Test stand for testing 210 MW steam
turbines .

BLOCK-3 LAYOUT
DETAILS OF BAY 1 :
Size- 36x380 meters.
BAY-1 is further divided in three parts

1. HMS:- In this heavy machine work is done with help of different
NC and CNC machines such as center lathes, vertical and
horizontal boring and milling machines.
2. ASSEMBLY SECTION:- In this section assembly of steam turbines
are done. Blades of turbine are first assemble on rotor and after
this rotor is transported to balancing tunnel where the balancing
is done.
3. OSBT(Over speed balancing tunnel):- In this section rotors of all
types of turbines like LP, HP and IP rotors of stream turbine, rotors
of gas and hydro turbines are balanced. In a large tunnel, vacuum
of two torr is created with help of pumps and after that rotor is
placed on pedestals with speed of 2500-4500 rpm.
DETAILS OF BAY 2 :
Size:- 36x400 Meters.
BAY-2 is further divided in three parts

1) HMS:-In this shop several components of steam turbine like HP, LP
and IP rotors, internal and external casing are manufactured with
help of different operations carried out through different NC and
CNC.
2) ASSEMBLY SECTION:- In this section assembly of steam turbines
upto 1000MW is assembled.
DETAILS OF BAY 3 :
Size:-24x400 meters.
BAY-3 is further divided in three parts

1) BEARING SECTION:-In this section manufacturing of journal
bearing are carried out to overcome vibration and rolling friction
by proper lubrication.
2) TURNING SECTION:-In this section small lathe machines, milling
and boring machines, grinding machines are installed.
3) GOVERNING SECTION:-In this sections governors are
manufactured, these governors are used in turbines for controlling
the speed of rotor within certain limits.

DETAILS OF BAY 4 :
Size:- 24x380 metres.
BAY-4 is further divided in three parts

1) TBM(TURBINE BLADE MANUFACTURING) SHOP:-In this shop solid
blade of both steam and gas turbines are manufactured with the
help of NC and CNC.
2) TURNING SECTION:-In this section, there are several machines like
lathes, milling, boring, grinding machines.
3) HEAT TREATMENT SHOP:-In this section there are several tests are
performed for checking the hardness of different components.

STEAM TURBINE
Steam conditions
TURBINE INLET
TEMP.
(deg C)
INLET
PRESSURE
(bar A)
INLET
STEAM
WETNESS
OUTLET
TEMP.
(deg C)
OUTLET
PRESSURE
(bar A)

OUTLET
STEAM
WETNESS

HP
564 151.67 / 363 42.05 /
IP
564 37.57 / 230 3.10 /
LP
229 3.03 / 30 0.04 8%
STEAM TURBINE rotor
IP TURBINE inner CASING
IP TURBINE OUTER CASING
MANUFACTURING PROCESSES
The facilities and parts in 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: Equipped
with large size machining tools like Turning Lathe,
CNC Lathes, Horizontal Boring Machines, special
purpose Groove Milling Machine etc.
CONTD
ROTOR ASSEMBLY SECTION: Equipped with Indicating
Stand, Small size Grinding, Milling, Drilling, machines, Press
and other devices for fitting Rotors and Discs.
TURBINE CASING ASSEMBLY SECTION: Machined
casings are assembled and hydraulically tested by
Reciprocating Pumps at two times the operating pressure.
TEST STATION: Equipped with condensers, Ejector, Oil
Pumps, Oil containers, Steam Connections etc., required for
testing.
OVER SPEED VACUUM BALANCING
TUNNEL(OSBT): frequency of vibration of rotor shaft is
tested at very high speed of 3700rpm.
OSBT
For balancing and over-speed testing of rotors upto 320T, 18m and 6900mm under
vacuum condition of 1 Torr
15 metric ton capacity.
Two cranes in each BAY.
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
Blade shop is divided into four distinct areas:-
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.




MANUFACTURING PROCESS
The manufacturing
process of turbine
blades primarily
depends on the type of
blade e.g. Bar type,
Brazed type, Gas
Turbine blade.
BAR TYPES BLADES
PROCESS/ OPERATION MACHINE TOOL/ EQUIPMENT USED
Blanking of area material Circular/ band saw
Sizing to rectangular shape Horizontal Milling Machine
Thickness grinding Surface grinder
Rhomboid milling Duplex milling machine
Taper grinding Surface grinder
Grinding and polishing of profile Abrasive belt polishing machine
BRAZED TYPE BLADES
PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED
Cutting of drawn profile & spacer
blank
Horizontal Milling machine
Thickness grinding Surface grinder
Cutting-off spacer Abrasive cutting
Milling of width Duplex milling machine
Grinding and polishing Abrasive belt polishing machine
GAS TURBINE BLADES
PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED
Cerrobend casting Cerrobend casting equipment
Root machining Horizontal Machining center
Length cutting Circular saw/ horizontal Milling machine
Tenon Horizontal Milling machine
Grinding and polishing of
fillet
Abrasive belt polishing machine
THANK
YOU