BHEL steam turbine manufacturing

An internship presentation on BHEL Haridwar steam turbine manufacturing plant.

1. An Industrial Training Presentation on General Awareness in steam Turbine Manufacturing Presented by: Sakshyam Rai 1403040093 Presented to: Mr. N ilesh Sonawane Faculty in charge

2. Contents: Introduction to BHEL, overview and product range BHEL Haridwar Steam turbines- components and types Manufacturing of components- operations Few Heavy Duty Machines Conclusion

3. BHARAT HEAVY ELECTRICALS LIMITED

4. Overview of BHEL BHEL was established in 1964. BHEL is one of the only 7 PSUs of India clubbed under the esteemed ' Maharatna ' status. (1st February 2013). 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), Oil & Gas and defence . BHEL has 15 manufacturing divisions, two repair units, four regional offices, eight service centers and 15 regional centers

5. Main Manufacturing Units BHEL 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(Karnataka Jagdishpur (Uttar Pradesh) Rudrapur ( Uttrakhand ) Industrial ValvesPlant , Goindwal (Punjab) BHEL Ranipur , Haridwar ( Uttarakhand ) Bharat Heavy Plates and Vessels Limited( Vizag )

6. Product Range Boiler(stream generator) Gas Generator Hydro Generator Steam turbine Gas turbine Hydro turbine Transportation Equipments Traction Machines Transformer Switchgear Oil field equipments OFE Boiler drum Water wall panel Wind mill Valve

7. BHEL HARIDWAR Unit BHEL 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.

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

9. Block-3: Turbine Manufacturing Shop

10. Steam Turbine Turbine is an engine that converts energy of fluid into mechanical energy . Steam turbine depends completely upon the dynamic action of the steam. Steam turbine is steam driven rotary engine.

11. Working Principle: A  steam turbine  is a device that extracts  thermal energy  from pressurized steam  and uses it to do mechanical work  on a rotating output shaft . An ideal steam turbine is considered to be an isentropic process, in which the entropy of the steam entering the turbine is equal to the entropy of the steam leaving the turbine. E= KE+P+T Total ∆E= ∆KE+ ∆H Degree of Reaction= ∆ H/( ∆KE+ ∆ H) DOR = 0 : Impulse Turbine = 1 : Reaction Turbine

12. Components of Steam Turbine Rotor Blades Casings Control valves Coupling Bearing steam ejector Gland

13. Types of steam turbine Impulse turbine Reaction turbine And depending upon pressure: High pressure turbine (H.P. Turbine) Intermediate pressure turbine (I.P. Turbine) Low pressure turbine (L.P. Turbine)

14. Impulse Turbine:- Steam is expanded only in nozzles. Blade passage of constant cross-section area . Only velocity changes across the blades. Reaction Turbine:- Pressure drop in fixed & moving blade. Blade passage of varying cross-section area. Reaction and Impulse turbine Degree of Reaction= ∆H/(∆KE+ ∆H)

15. High pressure turbine Specification of HP Turbine(500 MW ): Main Steam Temp- 537˚C Main steam pressure- 170 kg/cm 2 Reheat steam temp- 537˚C Length of Rotor - 4.61m Height -2.15m Weight -86400kg High pressure and temperature fluid at the inlet of the turbine, exit as lower pressure and temperature fluid.

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

17. INTERMEDIATE PRESSURE TURBINE Intermediate pressure turbine having more pressure then L.P turbine and less than the high pressure turbine(H.P) . Its blade is larger than high pressure turbine

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

19. Low Pressure Turbine Main Steam Temp- 320˚C Main steam pressure- 8 kg/cm 2 Reheat steam temp- 320˚C Length of Rotor - 8.71m Height -10.7m Weight-345000kg LP 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)

20. Low Pressure Turbine blade LP blade is larger than HP & IP.

21. BLADE SHOP As we understood that the efficiency and reliability of a steam turbine depends on the proper design of blades, e.g. in impulse turbine, the entire heats drop occurs in stationary blades . Operations Performed On Blades: Inspection Cutting Milling Grinding on both the surface Machining Of Blades: Horizontal milling machine Central lathe machine CNC machine Vertical boring machine

22. Manufacturing of blade process Processes followed: R aw material ( Stainless Steel / Titanium Alloy ) procurement and inspection. Length cutting Blanking-by blank saw m/c Thickness MILLING and GRINDING Rhomboid MILLING and GRINDING- Rhomboid shape is provided by Duplex milling machine Facing and size milling Root Milling (horizontal CNC) Root radius milling (vertical milling) Width milling Convex and concave milling Taper milling and grinding Fitting and polishing

23. FEW HEAVY DUTY MACHINES

24. SINUMERIK CNC lathe Swing over carriage:3500mm Centre distance :9000mm Weight capacity:120 T Spindle power:196KW External chucking range:250-2000mm Max spindle rpm:200 CNC system 840D:SINUMERIK

25. INNSE Horizontal CNC machine 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

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

27. Conclusions: Summer Training gives the idea of ‘general awareness in steam turbine manufacturing ’ & its processes. It provides practical idea of manufacturing several components of turbine. Also: BHEL is the largest engineering and manufacturing enterprise in India . The company manufactures 235 MW nuclear turbine generator sets and in future it will 500 MW. BHEL is a major contributor of equipment and systems to industries.

28. Thank You !