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BHARAT HEAVY ELECTRICALS LIMITED, haridwarPresentation By:-ANIL KUMAR GUPTA1202940031

Industrial Training on NEW TURBINE SHOP

Overview of BHELBHEL was established in 1964.BHEL is one of the only 7 Public Sector Undertakings (PSUs) of India clubbed under the esteemed 'Maharatna'status . On 1st February 2013, theGovernment of IndiagrantedMaharatnastatus toBHEL.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 (Railway), Renewable Energy, Oil & Gas and defence.BHEL has 15 manufacturing divisions, two repair units, four regional offices, eight service centers and 15 regional centers.

Main Manufacturing UnitsBHEL Bhopal (Madhya Pradesh )BHEL Ramachandrapuram, Hyderabad (Andhra Pradesh)Transformer Plant, BHEL Jhansi(Uttar Pradesh)High Pressure Boiler Plant and Seamless Steel Tube Plant, Tiruchirapalli(Tamil Nadu) Boiler Auxiliaries Plant, Ranipet (Tamil Nadu)ElectronicsDivision and Electro Porcelain Division, Bangalore(KarnatakaJagdishpur (Uttar Pradesh)Rudrapur (Uttrakhand)Industrial ValvesPlant, Goindwal (Punjab)BHEL Ranipur, Haridwar (Uttarakhand) Bharat Heavy Plates and Vessels Limited(Vizag)

Product RangeBoiler(stream generator) Gas GeneratorHydro GeneratorSteam turbineGas turbineHydro turbineTransportation EquipmentsTraction MachinesTransformerSwitchgearOil field equipments OFEBoiler drumWater wall panelWind millValve Electro-static PrecipitatorsR & D products

BHEL HARIDWAR UnitBHEL 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 UTTARAKHAND With two large manufacturing plants. It has established a Heavy Electrical Equipment Plant or HEEP and a Central Foundry Forge Plant or CFFP in Haridwar.The Heavy Electrical Equipment Plant in Haridwar designs and manufactures turbo generators, AC and DC motors, STEAM turbines, heat exchangers. The Central Foundry Forge Plant in Haridwar deals with steel castings and manufacturing of steel forgings.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. Situated in Ranipur near Haridwar, the Bharat Heavy Engineering Limited employs over 8,000 people.

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Heavy Electrical Equipment Plant(HEEP)BLOCK-1: Electrical Machine ShopBLOCK-2: Heavy Fabrication ShopBLOCK-3: Turbine Manufacturing ShopBLOCK-4: CIM (Coils & Insulation Manuf.)BLOCK-5: Condenser Fabrication & Forge ShopBLOCK-6: Fabrication Shop & Die ShopBLOCK-7: Carpentry & Heat Treatment ShopBLOCK-8: Heat Exchanger Shop

BLOCK 3 TURBINE SHOP BAY 1 BAY 2 BAY 3HEAVY MACHINE SHOP(HMS)BEARING SECTIONBLADE SHOPASSEMBLY SECTIONTURNING SECTIONTURNING SECTIONASSEMBLY SECTIONHEAT TREATMENT SHOP GOVERNING SECTION

Block-3: Turbine Manufacturing Shop

STEAM TURBINEA steam turbine works on the principle ofconversionofHighpressure& temperature steam into high Kinetic energy , thereby giving torque to a moving rotor.

Types of steam turbine

1.High pressure turbine (H.P. Turbine)2.Intermediate pressure turbine (I.P. Turbine) 3.Low pressure turbine (L.P. Turbine)

High pressure turbine (H.P. Turbine) High pressure and temperature fluid at the inlet of the turbine exit as lower pressure and temperature fluid. Specification of HP Turbine(500 MW) Main Steam Temp- 537C main steam pressure- 170 kg/cm2 Reheat steam temp- 537C Length of Rotor - 4.61m Height -2.15m Weight -86400kg

HIGH PRESSURE TURBINE

H.P turbine blades

. The blades are responsible for extracting energy from the high temperature, high pressure steam produced by the boiler.

INTERMEDIATE PRESSURE TURBINEIntermediate pressure turbine having more pressure then L.P turbine and lass than the high pressure turbine(H.P) . Its blade is larger than high pressure turbine.

IP TURBINE

Blade of intermediate pressure turbineThe size of blades of I.P steam turbine is larger than H.P steam turbine , but smaller than L.P steam turbine.

Low Pressure TurbineLP turbine is designed to be a dual flow turbine. Steam enters the centre of the turbine from the crossover pipe and flows across the reaction blading in two opposite directions. This configuration reduces axial thrust on the turbine and allows for a smaller turbine installation. Specification of LP Turbine(500 MW) Main Steam Temp- 320C Main steam pressure- 8 kg/cm2 Reheat steam temp- 320C Length of Rotor - 8.71m Height -10.7mWeight-345000kg.

LP TURBINE

Low Pressure Turbine

Low Pressure Turbine blade Titanium alloys offer high strength to intermediate temperatures at a density almost half that of steel and nickel-based super alloys. As a result, they have been adopted widely in the fan and compressor stages of the gas turbine for both disc and blade applications..LP blade is larger than HP & IP.

HEAVY DUTY MACHINES

SINUMERIK CNC lathe

Swing over carriage:3500mmCentre distance :9000mmWeight capacity:120 TSpindle power:196KWExternal chucking range:250-2000mmMax spindle rpm:200CNC system 840D:SINUMERIK

INNSE Horizontal CNC machine :

Boring spindle diameter:160mmHeadstock vertical travel:3000mmLongitudinal RAM travel:700mmLongitudinal spindle travel:1000mmColumn cross travel:10mRotary table travel:3000mmTable load:40 T

Tacchi heavy duty CNC lathe:

Skoda Vertical CNC latheFinishing machining casings including guide blade grooves are carried out in vertical position on this lathe. The machine is provided with 840-C CNC system.

CASING SHELL OR CYLINDER

ASTM A 356 Grade 1 for cast carbon steelNodular Cast Iron G40The reason is that cast carbon steel is weld repairable(LP turbine inner casing rings,)1-2 Cr Mo steels low temperature steamCast 9 Cr 1 Mo- V Nb alloys9-12-cr Martensite /ferrite steel

Casing Materials

Casing

Lower halfUpper half

BLADE SHOPVarious operations consist in manufacturing of blades of steam turbine.Check the raw material(Stainless Steel / Titanium Alloy)Blanking-by blank saw m/cMILLING- width and thickness are maintainedMill Rhomboid Rhomboid shape is provided by Duplex milling machineBlanking of Rhomboid shape

Rhomboid grinding-by CH-BACH M/c

Right angle-by Horizontal milling m/c

External profiling-by Hydraulic coping m/c or CNC Coping m/cInternal profiling

Hydraulic coping m/c or CNC Coping m/c

Template (checking for external profile)

T-ROOT PROFILE OF BLADE

T ROOT profiling is done by NC M/c at various stationSTATION 1- Clamping the w/p on NC m/c .

STATION 2- Rough Tapering

STATION 3- T-ROOT Cutting, Chamfering

STATION 4- Stepping

STATION 5- Smoothing o/p(final milling).

RUSSIAN DESIGN BLADE

GERMAN DESIGN BLADE

CONCLUSION Summer Training gives the idea of general awareness in steam turbine manufacturing, & its process. Its provides practical idea to manufacturing several components of turbine.