INTRODUCTION TO BHEL

AN OVERVIEW
In 1956 India took a major step towards the establishment of its heavy engineering industry when Bharat Heavy Electricals Ltd., (BH !" setup at Bhopal# It progressed rapidly and three more fa$tories went into produ$tion in 1965# %he main aim of establishing BH ! was to meet the growing power re&uirement of the $ountry# BH ! appeared on the power map of India in 1969 when the first unit supplied by it was $ommissioned at the Basin Bridge %hermal 'ower (tation in %amilnadu# )ithin a de$ade* BH ! had $ommissioned the 1++th unit at (antaldih* )est Bengal# BH ! has taken India from a near total dependen$e on imports to $omplete self,relian$e in this vital area of power plant e&uipment# BH ! has supplied 9-. of the power generating e&uipment that was $ommissioned in India during 19-9,/+# BH ! has already supplied generating e&uipment to various utilities produ$e annually0 e&uipment $apable of generating 6+++1)# %his will grow further to enable BH ! to meet all of India2s proje$ted power e&uipment re&uirements* as well as si3eable portion of e4port targets# 'robably the most signifi$ant aspe$t of BH !2s growth has been its diversifi$ation# %he $onstant reorientation of the organi3ation to meet the varied needs in time with time a philosophy that has led to the development of a total $apability 5 from $on$ept to $ommissioning not only in the field of energy but also in industry and transportation# In the world power s$ene* BH ! ranks among the top ten manufa$turers of power plant e&uipment and in terms of the spe$trum of produ$ts and servi$es offered* it is right on top# BH !2s te$hnologi$al e4$ellen$e and turnkey $apabilities have won it world wide re$ognition# 6ver 7+ $ountries in the world over have pla$ed orders with BH ! $overing individual e&uipment to $omplete power stations on a turnkey basis# In 19-/, -9 e4port earnings rea$hed 8s#199 $rores* the highest for any year# BH ! has its head&uarters at :ew ;elhi# Its operations are spread over 11 manufa$turing plants and number of engineering and servi$e divisions lo$ated a$ross the $ountry# %he servi$e divisions in$lude a network of regional bran$h offi$es throughout India#

The vario s !actories a"d #ai" $rod cts are

%ACTORIE&
BHO'AL BAN)LORE HARDWAR )OINDWAL ,A)DI&H'UR ,HAN&I H-DERABAD TIRUCHIRA'ALLI RANI'ET Heavy Electrical E( i$#e"t 'la"t Co"trol E( i$#e"t Divisio", Electro*'orcelai" Divisio" Heavy Electrical E( i$#e"t 'la"t, Ce"tral %o "dry %or+e 'la"t I"d strial Valves 'la"t Hi+h Te"sio" Cera#ic I"s latio" 'la"t Tra"s!or#er 'la"t Heavy 'o.er E( i$#e"t 'la"t Hi+h 'ress re Boiler 'la"t Boiler A /iliaries 'ro0ect

%he 9++<19+ set of BH ! forms the ba$kbone of the thermal generating $apa$ity in the $ountry# It has started manufa$turing 5++ 1) sets# =onsidering the fa$t that the first 9++ 1) set was taken up for manufa$ture only in 19-9* the progress a$hieved by BH ! is spe$ta$ular# %he just set was tested in 19-> and $ommissioned in 19--# %ill the end of 1ar$h 19/>* BH ! manufa$tured power e&uipment totaling about 99+++1)#

The vario s colla1orators are

Co#1 stio" E"+i"eeri"+ I"c. U.&.A. Air 'reheats Co. I"c. U.&.A. & l0e. Brothers &.it2erla"d I"ter"atio" )e"eral Electrical Co. I"c. U.&.A. Cre set Loire %ra"ce

 N oveo 'i+"ore &.'.A. Italy &ve"s3a %la3ta1rites &.ede" &ie#e"s A+. W. )er#a"y E"+lish Electric Co. U.4. 'ro" # Ashe"$ort U.&.&.R. Hitachi ,a$a" Weir ' #$s Ltd. U.4. BH ! is aware that both its national and international $ommitments will in$rease greatly in the years to $ome# ?nd it fa$es the $hallenges and the tasks ahead with the $onfiden$e a$&uired through the wealth of e4perien$e in the world market it serves# ?gainst the pi$tures&ue (hivalik foot hill of the Himalayas and on the banks of the holy @anges in 8anipur near Hardwar are lo$ated the two manufa$turing plants of BH !A Heavy Electrical E( i$#e"t 'la"t 5HEE'6 a"d Ce"tral %o "dry %or+e 'la"t 5C%%'6 e#$loyi"+ a1 t 789:: $eo$le. Heavy le$tri$al &uipment 'lant is e&uipped to produ$e steam and Hydro %urbines with mat$hing @enerators* Industrial manufa$turing %hermal sets up to 1+++1) $apa$ity# !o$ated immediately south of H ' is the =entral Boundry Borge 'lant setup#

Bor produ$tion of alloy and spe$ial steel $asting* forging and blooms essentially re&uired to $omplete the produ$tion profile of BH !# The 'oll tio" Co"trol Research I"stit te 5'CRI6 has also 1ee" set $ at BHEL, Hard.ar .ith the hel$ o! U"ited Natio"s Develo$#e"t 'ro+ra# 5UND'6. %he institute is lo$ated just below the (hivalik hills towards the northern side of H '# %he Heavy le$tri$al &uipment 'lant was set up in te$hni$al $ollaboration with ;<s 'ro##ash*e/$ort o! U&&R. %he $onstru$tion of the plant $ommen$ed in 1969 and the produ$tion of e&uipment was initiated in early 196-# In 19-6* BH ! entered into a $ollaboration agreement with 1<s Craftwerk Dnion ?#@# of )est @ermany for design* manufa$ture* ere$tion and $ommissioning of large si3e steam turbines and turbo generators of unit rating up to 1+++1)# %he present produ$t profile of H ' isA ,

'RODUCT 'RO%ILE O% HEE'= &.No.

7. 8.

'RODUCT
%hermal sets Hydro sets

RAN)E
(team %urbines E %urbo @enerators of unit si3e upto 1+++ 1)# =ustom,built $onventional Hydro %urbine of Caplan* Bran$is E 'elton with mat$hing generators upto 95+ 1) unit si3e#

>.

@as %urbines =ombined 6+*15+ E 9++ 1)#I(6 8atings# =y$le 'ower 'lant# )ith (team %urbines upto >++ 1)# le$tri$al 1a$hines# 1edium E !arge si3ed ?=<;= le$tri$al 1a$hines various $apa$ities upto 9+1) 7,6 1eF !ina$ ?$$elerator 1a$hine for treatment of $an$er#

?.

9. @.

1edi$al e&uipment# &uipment for 'ower 'lant#

:u$lear %urbines E generators up to 5++1) (team generator up to 5++1) unit si3e* 8eheaters<(eparators* Heat e4$hangers E pressure vessels# =ontrol panel for voltage upto 7++ k) E $ontrol desks for generating stations E 1F sub,stations# !ight air$raft namely G()?%I# :aval guns with $ollaboration of Italy#

A.

=ontrol 'anel#

B. C.

?viation# ;efense e&uipment#

'RODUCT 'RO%ILE O% C%%' (#:o#

7.

'RODUCT
(teel $astings#

RAN)E
Dp to 5+ %<p$#wt# =ast weld upto /+%<p$#wt#

8.

(teel forging shafts# Dp to 55%<p$#wt# 1a4# ;ia 9+++ mm# !ength 5 17m# 8ings# ;is$s# 1a4# ;ia >+++mm# %hi$kness, >/++mm# 1a4# ;ia# >5++mm# %hi$kness,variable#

>. ?.

?t present nearly >-. of the $ountry2s ele$tri$al energy is generated from the sets manufa$tured by BH !* Hardwar# Boundry Borging 'lant (=BB'" is lo$ated# 1u$h before the manufa$turing of the first ele$tri$al ma$hine at H ' BH ! Hardwar* the H8; =entre was established in the year 196># known as %e$hni$al training ($hool in the yesteryears* the foundation stone of H8; was laid on 1- th Huly 196> by the then =hief 1inister of Dttar 'radesh* !ate (hri =#B#@upta# %he %e$hni$al %raining ($hool of 196> be$ame popular as %raining ($hool in the later years# In fa$t the $ampus and building of H8; was the first to be built in BH ! %ownship# %he earlier years saw training of first bat$h of artisans and engineers in the erstwhile I%e$hni$al %raining ($hool2# %he =entre was utili3ed for large s$ales fabri$ation a$tivity* whi$h helped the ere$tion of Heavy le$tri$al &uipment 'lant# 6ver a period of >6 long years spanning more than three de$ades* the $enter has grown both in its field of a$tivities and magnitude of efforts made to develop human resour$e# Initially the obje$tive was solely training of artisans who were to man the plant of H '# (kill training in the various trades relevant to the plant was indeed the primary goal# %he s$ope and fun$tion of the =entre later e4panded to in$lude training of supervisors* engineers and managers# %he growth of =enter kept pa$e with the demands of $hanging te$hnology and $omple4ities of management due to ever $hanging environment $onditions#

A CHART &HOWIN) THE DI%%ERENT BLOC4& O% B.H.E.L, HARDWAR

BHARAT HEAVY ELECTRICALS LTD.

HARDWAR HARDWAR

HEEP (HEAVYEL ECTRICAL EQUIPMENT PLANT)

CFFP (CENTRAL FOUNDARY FORGED PLANT)

BLOCK-': ELECTRICAL MACHINE SHOP

BLOCK-2: HEAVY FABRICATION SHOP

BLOCK-3: TURBINE MANUFACTURING BLOCK

BLOCK-4: CIM (COILS INSULATION MANUFACTURING) BLOCK

BLOCK-!: CONDENCER FABRICATION FORGR BLOCK BLOCK-": FABRICATION SHOP# DIE SHOP# STAMPING SHOP)

BLOCK-$: CARPANTARY SHOP

BLOCK-%: HEAT E&CHANGER SHOP

DE&CRI'TION O% B BLOC4& O% HEE'

BLOC4*7D %his is the main blo$k of H ' named as Electrical ;achi"e &ho$. %he main produ$ts of this blo$k 51 are turbo generators* hydro generators E ?= and ;= motors# In this blo$k there are > bays whi$h are known as H1( (Heavy 1a$hine (hop"#In this shop all $omponents of generators E motors are manufa$tured on different ma$hines su$h as !athes* verti$al E hori3ontal boring ma$hines and verti$al E hori3ontal milling ma$hines# %here is also one important dept#6BI (6ver speed Balan$ing Installation" in whi$h balan$ing of 8otors of generators E motors is $arried out# )inding of generators E motors is also done# BLOC4*8D %his is a Heavy %a1ricatio" &ho$ in whi$h fabri$ation of all type of parts of turbines as well as generators are done# In whi$h internal and e4ternal $asing of turbines and generators fabri$ated# In this blo$k Hollow and (olid Blades of (team %urbines are welded on a disk whi$h is fitted on the rotor# In this blo$k work is divided into four steps namely Bay,1* Bay,9* Bay,>* and Bay,7#In Bay,1 'reparatory work is been done i#e# $utting* shaping* grinding* pressing et$# In Bay 59 E Bay,> assembly work is done# Bay,7 is $alled H1( (Heavy 1a$hine (hop" in whi$h all types of $omponents of turbine* generators and motors are manufa$tured# In Bay,7 small Heat 4$hanger are also manufa$tured whi$h is used in turbines for $ooling purpose# ? (mall (heet 1etal (hop is also a part of this Blo$k# ? gentry shop is also a part of this blo$k where raw material is been kept and transported to different bays#

BLOC4*>D %his blo$k is $alled T r1i"e ;a" !act ri"+ Bloc3. %his blo$k $ontributes ma4imum in terms of turnover# )here steam* @as E Hydro all three types of turbines are manufa$tured# %his Blo$k also divided into 7 Bays# ?nd these bays are further divided into several se$tions and shops#

A CHART GIVEN ON THE NE&T PAGE SHOWS THE CLASSIFICTION OF THE BLOCK-3 (TURBINE MANUFACTURING BLOCK)(

A CHART &HOW& THE CLA&&I%ICATION O% BLOC4*> BLOCK-3

BAY-'

BAY-2

BAY-3

BAY-4

HMS (H)*+, M*-./0) 1.23)

ASSEMBY SECTION

HMS

BEARING SECTION
TURNING SECTION

BLADE SHOP

ASSEMBLY SECTION

TURNING SECTION HEAT TREATMEN -T SECTION

OSBT

ASSEMBLY SECTION

GOVERNING SECTION

Bay,1 is further divided into three parts

1 H;& ,In this shop heavy ma$hine work is done with the help of different := E =:= ma$hines su$h as $enter lathes* verti$al and hori3ontal boring E milling ma$hines# ?sia2s largest verti$al boring ma$hine is installed here and =:= hori3ontal boring milling ma$hines from (koda of =3e$hoslovakia# Asse#1ly &ectio" 5o! hydro t r1i"es6 * In this se$tion assembly of hydro turbines are done# Blades of turbine are Ist assemble on the rotor E after it this rotor is transported to balan$ing tunnel where the balan$ing is done# ?fter balan$ing the rotor* rotor E $asings both internal E e4ternal are transported to the $ustomer# %otal assembly of turbine is done in the $ompany whish pur$hased it by B#H# #!# O&BT 5over s$eed 1ala"ci"+ t ""el6* In this se$tion* rotors of all type of turbines like !'(low pressure" * H'(high pressure"E I'(Intermediate pressure" rotors of (team turbine * rotors of @as E Hydro turbine are balan$ed #In a large tunnel * Fa$uum of 9 tor# is $reated with the help of pumps E after that rotor is pla$ed on pedestal and rotted with speed of 8

>

95++,75++ rpm #?fter it in a $omputer $ontrol room the a4is of rotation of rotor is seen with help of $omputer E then balan$e the rotor by inserting the small balan$ing weight in the grooves $ut on rotor# Bay 59 is divided in to 9 partsA 1 H;& 5 In this shop several $omponents of steam turbine like !'* H' E I' rotors* Internal E e4ternal $asing are manufa$tured with the help of different operations $arried out through different := E =:= ma$hines like grinding* drilling* verti$al E hori3ontal milling and boring ma$hines* $enter lathes* planer* Copp milling ma$hine# Asse#1ly sectio" 5 In this se$tion assembly of steam turbines up to 1+++ 1) are assembled# Ist moving blades are inserted in the grooves $ut on $ir$umferen$es of rotor* then rotor is balan$ed in balan$ing tunnel in bay,1# ?fter it final assembly operation is done in whish guide blades are assembled inside the internal $asing E then rotor is fitted inside this $asing# ?fter it this internal $asing with rotor is inserted into the e4ternal#

Bay > is divided into > partsA 1 9 > Beari"+ sectio" 5 In this se$tion Hournal bearings are manufa$tured whish are used in turbines to over $ome the vibration E rolling fri$tion by providing the proper lubri$ation# T r"i"+ sectio" 5 In this se$tion small lathe ma$hines* milling E boring ma$hines* grinding ma$hines E drilling ma$hines are installed# In this se$tion small jobs are manufa$tured like rings* studs* disks et$# )over"i"+ sectio" 5 In this se$tion governors are manufa$tured# %hese governors are used in turbines for $ontrolling the speed of rotor within the $ertain limits# Ist all $omponents of governor are made by different operations then these all parts are treated in heat treatment shop for providing the hardness# %hen these all $omponents are assembled into $asing# %here are more than 1+++ $omponents of @overnor#

Bay,7 is divided into > partsA 1 TB; 5t r1i"e 1lade #a" !act ri"+6 sho$, In this shop solid blade of both steam E gas turbine are manufa$tured# (everal =:= E := ma$hines are installed here su$h as =opying ma$hine* @rinding ma$hine* 8homboid milling ma$hine* ;uple4 milling ma$hine* %, root ma$hine $enter* Hori3ontal tooling $enter* Ferti$al E Hori3ontal boring ma$hine et$#

9 >

T r"i"+ sectio", (ame as the turning se$tion in Bay,>* there are several small ma$hines like lathes ma$hines* milling* boring* grinding ma$hines et$# Heat treat#e"t sho$, In this se$tion there are several tests performed for $he$king the hardness of different $omponents# %ests performed are (terelliting * :itriding *;' test

BLOC4,7J Blo$k,7 is $alled as CI; 5COIL& E IN&ULATION6 BLOC4 # In this blo$k $oils of @enerators E motors are made E assembled# ?lso insulation of all ;= E ?= motors and @enerators are done# %he material of $oils is $opper (=u"* there are small $ranes* trolleys* $onveyors* E tru$ks are used for transportation# =oiling E insulation of all motors E @enerators of ca$acity $to 9:: ;W.made in Blo$k,1 are done here with the help of several ma$hines E manpower# Electric co"trol $a"el E co$$er 1ars o! t r1o +e"erators are also #a" !act red here. =oiling of motor E generators are done with help of taping operation# BLOC4*9D Blo$k,5 is $alled as CONDEN&ER %ABRICATION E %OR)E BLOC4 ?ll type of $ondenser used for refrigeration purpose in turbines are fabri$ated here# %his blo$k is small as $ompare to Blo$k,9# In these blo$k different types of ma$hines like (ubmerged ar$ )elding ma$hine* 'laner ma$hine* =:= milling ma$hines* grinding ma$hine et$ are used for fabri$ated the $ondensers# BLOC4*@D Blo$k 56 is divided into > parts %a1ricatio" sho$, Die sho$, &ta#$i"+ sho$# %here are some details about (tamping shopA 1, 'roje$t san$tioned by government of India# (?",(tamping (hop 5 9+,1+,196/# (B",;ie (hop,+6,+-,19-6# 9, =ost of proje$t 5 595 la$ks# (?",(tamping shop,779 la$ks# (B",;ie (hop,15> la$ks# >, Installed =apa$ity,>9++ %ons< year# (?",(tamping (hopA Farnished , 9>++ %ons<year# Dnvarnished , 9>++ %ons<year# (B",;ie (hop,15-+++ :<H8(# 7, =overed area 5---6 s&# m (tamping (hop,76+/ s&# m ;ie (hop,>16/ s&# m 5, 1ain 'ower as 6n,+1,+7,9++1# 10

Bloc3*AD %his Bo$k is $alled as CAR'ENTR- &HO'. In this Blo$k all $arpentry work is done su$h as making of wood pattern for $asting purpose* making of fi4tures# !arge wood $ontainer used for pa$king of several jobs like different $omponents of %urbines* @enerators* motors et$#
Bloc3*BD %his is the last blo$k of Heavy le$tri$al &uipment 'lant (H '" named as HEAT EFCHAN)ER &HO'. In this Blo$k all type of Heat 4$hanger of (team turbines are manufa$tured# %his blo$k also manufa$tures pressure vessels# In this blo$k work is done with help of several ma$hines like submerged ar$ welding* Ferti$al E Hori3ontal Boring ma$hine et$# (everal $omponents of Heat 4$hanger are as given belowA (1",!#' (low pressure" Heater of 91+ 1) E 5++ 1)# In 91+ 1) Brass tube E in 5++ 1) (tainless steels tube are used# (9",@lind steam =ondenser (@( =ondenser" (>",@lind steam $ooler (7",Inje$tor (5",6il seal (6",;ifferent types of =oolers su$h asA 'rimary water $ooler =ontrol float $ooler %urbine oil $ooler (tator water $ooler ;rain $ooler ?#=#@ water $ooler

DE'ART;ENT& O% BHEL 5HARDWAR6

ngineering E $ommer$ial# 'ersonnel E ?dministration# )orks engineering E servi$es# Binan$e# le$tri$al 1a$hine manufa$turing# %urbine manufa$turing# Babri$ation E )elding# Kuality 1anagement# %e$hnology E %ool room# Insulation system E @#8#I# 11

1aterial 1anagement# ;efense proje$ts Business ;evelopment# 'rodu$tivity E %K1# 8esour$e planning E %e$hnologi$al development# Kuality surveillan$e# 1aterial 1anagement E Inventory $ontrol# @as %urbine proje$ts# C)D(Craft )ork Dnit" $ollaboration Figilan$e# 'ollution $ontrol resear$h Institute .

Beside these there are four sub,departments whi$h are $ontrolled by personnel E administration# %hey are as followsA, 'ersonnel# %ownship administration E ;evelopment# 1edi$al# Human 8esour$e ;evelopment =enter or training $enter#

The $erso""el de$t. has 1ee" ! rther s 1*divided i"to the !ollo.i"+
1# 'ersonnel (6 E 'oli$y" 9# 'ersonnel ( E = < I8" ># 6peration $ell 7# )elfare 5# =anteen 6# @eneral ?dministration $ell < legal -# !aw /# 8e$ruitment $ell 9# !iaison $ell 1+# 1anpower 'lanning

CLA&&I%ICATION O% E;'LO-EE& O% BHEL 5HARDWAR6

EFECUTIVE& 1# ; 9# @1 ># ?@1 7# (r# ;@1 5# ;@1 6# (r# 1anager -# 1anager /# ;ee# 1anager 12

9# (r# ngineer<(r# 'ersonnel 6ffi$er<(r# ?dm# 6ffi$er# 1+# (tores 6ffi$er<(r# ?$$ounts 6ffi$er 11# ngineer<'ersonnel 6ffi$er<?dm# 6ffi$er< 19# (tore offi$er<?$$ounts 6ffi$er &U'ERVI&OR& 1# (r# 4e$utive Boreman 9# 4e$utive Boreman ># @eneral Boreman<=hief (upervisor 7# Boreman<(tore holder @rade I<(r# ?$$ountant @rade I< (r# 6ffi$er (uperintendent 5# ?sst# Boreman<(tore holder @rade II<?$$ountant @rade II < 6ffi$er superintendent 6# =harge man<(tore holder @rade III<?$$ountant @rade III< ?sst# 6ffi$er superintendent TECHNICIAN 1# 9# ># 7# 5# =hief %e$hni$ian @eneral %e$hni$ian 1aster %e$hni$ian (r# %e$hni$ian %e$hni$ian

ARTI&AN& 1# le$tri$al 9# ;raftsman ># Bitters 7# 1a$hinist 5# %urner 6# )elder -# )inder /# 8igger 9# =rane 6perator 1+# !ab# ?ssistant 11# Bla$k smith 19# 'atternmaker @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF @rade I*II*III*IF

CLERICAL &TA%% 5NON*&U'ERVI&OR6 1# 9# ># 7# 5# 6# !ibrarian =ompounder 'harma$ists :urses ;resser %ele4<%elephone operator 13

-# ;river UN&4ILLED<&E;I*&4ILLED WOR4ER&A 1# 9# ># 7# 'eons 1ails (weepers )orkers on daily wages et$#

'ER&ONNEL DE'ART;ENT IN B.H.E.L 5HARDWAR6

%he $orporate personnel obje$tives enshrined in the $ompany2s $orporate plan first issued in 19-7 areA G To evolve a $artici$ate style o! #a"a+e#e"t .hich .ill e"s re .or3i"+ co"ditio"s E 0o1 satis!actio" to all e#$loyees, .a+e co##e"s rate .ith their $er!or#a"ce, career adva"ce#e"t E +ood.ill a#o"+st all e#$loyees, E res$ect !or the h #a" i"divid al.G OB,ECTIVE& %o plan the manpower re&uirement E budget the human resour$es with ne$essary &ualifi$ation* skills* aptitude* merit E suitability in a$$ordan$e with the organi3ational re&uirements# %o ensure that the $ompany attra$ts E retains the best of personnel in ea$h of the areas of fun$tioning# %o fo$us on pla$ement of employees in the job to whi$h they are best fitted# %o adapt to E fulfill the so$ioe$onomi$ $ommitment of the govt# to the unfortunate<minority se$tions# %o systemati$ally build up a model system for the guidan$e of E emulation by other enterprises both in the publi$ E private se$tors# Farious se$tions E sub, se$tion at work in personnel division of H '* Hardwar is $alled CELL&# ? brief overview of the fun$tioning E basi$ pro$edure $arried out at different $ells of personnel division is as followsA

HUALIT- 'OLIC- O% B.H.E.L

IIn its &uest to be world $lass* BHEL, pursues $ontinual# Improvement in the &uality of its produ$ts* servi$es and performan$es leading to total $ustomer satisfa$tion and Business @rowth* trough dedi$ation* $ommitment and team work of all employee#L

TOTAL HUALIT- ;ANA)E;ENT 5TH;6

%#K#1 is defined as IE!!ective ;a"a+e#e"t o! 1 si"ess e"ter$rise thro +h !oc s o" its $eo$le a"d $rocesses 1y co#$a"y .ide c sto#ers drive" leadershi$ 14

&TEA; TURBINE&

HARDWAR

15

&TEA; TURBINE&
INTRODUCTION
6f all heat engines and prime movers the steam turbine is nearest to the ideal and it is widely used in power plants and in all industries where power and<or heat are needed for pro$esses# %hese in$ludeA pulp mills* refineries* petro$hemi$al plants* food pro$essing plants* desalination plants and distri$t heating plants#

Adva"ta+es i"cl de
1# 9# ># 7# 5# 6# -# ?bility to utili3e high pressure and high temperature steam# High effi$ien$y# High rotational speed# High $apa$ity<weight ratio# (mooth* nearly vibration,free operation# :o internal lubri$ation# 6il free e4hausts steam#

Disadva"ta+es are
Bor slow speed appli$ation redu$tion gears are re&uired# %he steam turbine $annot be made reversible# %he effi$ien$y of small simple steam turbines is poor#

&TEA; TURBINE& THE ;AIN&TA- O% BHEL

BH ! has the $apability to design* manufa$ture and $ommission steam turbines of up to 1+++ 1) rating for steam parameters ranging from >+ bars to >++ bars pressure and initial E reheat temperatures upto 6++ o=# %urbines are built on the building blo$k system* $onsisting of modules suitable for a range of output and steam parameters# Bor a desired output and steam parameters appropriate turbine blo$ks $an be sele$ted# %urbines are $lassified based on method of steam generation

16

A''LICATION RAN)E O% &TEA; TURBINE

&ERIE& T-'E O% &'EED 'OWER ;AIN &TEA; REHEAT &TEA; OUT'UT CONDITION &TEA; )ENERATOR R'; CONDITION ;W O O BAR C BAR C %ossil % el >::: 7::*7::: 7>:* 9::*9?: >:* 9::*@:: &tea# 89: A: )e"erator 'ress ri2ed >::: U$to ?:*A: 89:*>:: B*79 8::*89: Li+ht Water 7::: Reactor Heat recovery >::: U$to >:: >:* 9::*9?: >:* 9::*9?: &tea# 7?: 9: )e"erator BAC4 'RE&&URE ;BAR 8:*>::

T r1i"es !or %ossil % el 'o.er 'la"ts T r1i"es !or N clear 'o.er 'la"ts T r1i"es !or Co#1i"ed Cycle A$$licatio"s

8:*>::

8:*>::

17

T-'E& O% TURBINE&
CONDEN&IN) TURBINE&
)ith the $ondensing turbine* the steam e4hausts to the $ondenser and the latent heats of the steam is transferred to the $ooling water# %he $ondensed steam is returned to the boiler as feed water#

CONDEN&IN) BLEEDER TURBINE&

%he $ondensing bleeder turbine redu$es the $ondenser losses as steam is bled off at several points of the turbine# %he bleed,steam is used for feed water heating up to 9+. of the total steam flow may be bled off#

BAC4*'RE&&URE TURBINE&
Ba$k,pressure turbines are often used in industrial plants0 they a$t as a redu$ing station between boiler and pro$ess steam header# %he pro$ess steam pressure is kept $onstant and the generator output depends on the demand for pro$ess steam# %he ba$kpressure turbine may also have bleed points and is then $alled a ba$k,pressure,bleeder,turbine#

TO''IN) TURBINE&
%opping turbines have been used when old boilers are repla$ed with new high pressure boilers# %he turbine is a ba$kpressure turbine e4hausting to the old boiler header still supplying steam to the old lower pressure turbines#

;IFED 'RE&&URE TURBINE&

1i4ed pressure turbines are used where e4$ess steam from pro$ess is available for the low pressure part of the turbine* while steam at boiler pressure may be added to the high pressure part of the turbine when more loads is applied to the turbine#

18

O'ERATION 'RINCI'LE&
I;'UL&E TURBINE
%he prin$iple of the impulse steam turbine $onsists of a $asing $ontaining stationary steam no33les and a rotor with moving or rotating bu$kets# %he steam passes through the stationary no33les and is dire$ted at high velo$ity against rotor bu$kets $ausing the rotor to rotate at high speed# %he following events take pla$e in the no33lesA 1# %he steam pressure de$reases# 9# %he enthalpy of the steam de$reases# ># %he steam velo$ity in$reases# 7# %he volume of the steam in$reases# 5# %here is a $onversion of heat energy to kineti$ energy as the heat energy from the de$rease in steam enthalpy is $onverted into kineti$ energy by the in$reased steam velo$ity# %he no33les may be $onvergent no33les or they may be $onvergent,divergent no33les# =onvergent no33les are used for smaller pressure drops where the minimum e4it pressure is +#5-- 4 the inlet pressure (the $riti$al pressure for no33les"# If the e4it pressure is less than +#5-- 4 inlet pressures* eddy,$urrents are developed and the e4it velo$ity will be less than $al$ulated# %he $onvergent,divergent no33les prevent eddy,$urrents and the $al$ulated velo$ity will be obtained even at large pressure drops#

The I#$ lse 'ri"ci$le

If steam at high pressure is allowed to e4pand through stationary no33les* the result will be a drop in the steam pressure and an in$rease in steam velo$ity# In fa$t* the steam will issue from the no33le in the form of a high,speed jet# If this high steam is applied to a properly shaped turbine blade* it will $hange in dire$tion due to the shape of the blade# %he effe$t of this $hange in dire$tion of the steam flow will be to produ$e an impulse for$e* on the blade $ausing it to move# If the blade is atta$hed to the rotor of a turbine* then the rotor will revolve# Bor$e applied to the blade is developed by $ausing the steam to $hange dire$tion of flow (:ewton2s 9 nd !aw 5 $hange of momentum"# %he $hange of momentum produ$es the impulse for$e# %he fa$t that the pressure does not drop a$ross the moving blades is the distinguishing feature of the impulse turbine# %he pressure at the inlet to the moving blades is the same as the pressure at the outlet from the moving blades#

19

Reactio" $ri"ci$le
? rea$tion turbine has rows of fi4ed blades alternating with rows of moving blades# %he steam e4pands first in the stationary or fi4ed blades where it gains some velo$ity as it drops in pressure# It then enters the moving blades where its dire$tion of flow is $hanged thus produ$ing an impulse for$e on the moving blades# In addition* however* the steam upon passing through the moving blades again e4pands and further drops in pressure giving a rea$tion for$e to the blades# %his se&uen$e is repeated as the steam passes through additional rows of fi4ed and moving blades#

&$ecial As$ects o! Reactio" T r1i"es

%here is a differen$e in pressure a$ross the moving blades# %he steam will therefore tend to leak around the periphery of the blades instead of passing through them# Blade $learan$es therefore must be kept to a minimum# ?lso* due to be developed upon rotor and some arrangement must be made to balan$e this#

I#$ lse T r1i"e &ta+i"+

In order for the steam to give up all its kineti$ energy to the moving blades in an impulse turbine* it should leave the blades at 3ero absolute velo$ity# %his $ondition will e4ist if the blade velo$ity is e&ual to one half of the steam velo$ity# %herefore* for good effi$ien$y the blade velo$ity should be about one half of steam velo$ity# In order to redu$e steam velo$ity and blade velo$ity* the following methods may be usedA 1# 'ressure $ompounding# 9# Felo$ity $ompounding# ># 'ressure,velo$ity $ompounding# 7# 'ressure =ompounding

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TURBINE 'ART&
TURBINE BLADE&

=ylindri$al rea$tion blades for H'* I' and !' %urbines >,;( blades* in initial stages of H' and I' %urbine* to redu$e se$ondary losses %wisted blade with integral shroud* in last stages of H'* I' and initial stages of !' losses Bree standing !' moving blades
o o o

%ip se$tions with supersoni$ design Bir,tree root Blame hardening of the leading edge

Banana type hollow guide blade

o o

%apered and forward leaning for optimi3ed mass flow distribution (u$tion slits for moisture removal

21

COMPUTATIONAL MESH FOR 3D ANALY

TURBINE CA&IN)
=asings or $ylinders are of the hori3ontal split type# %his is not ideal* as the heavy flanges of the joints are slow to follow the temperature $hanges of the $ylinder walls# However* for assembling and inspe$tion purposes there is no other solution# %he $asing is heavy in order to withstand the high pressures and temperatures# It is general pra$ti$e to let the thi$kness of walls and flanges de$rease from inlet, to e4haust,end# %he $asing joints are made steam tight* without the use of gaskets* by mat$hing the flange fa$es very e4a$tly and very smoothly# %he bolt holes in the flanges are 22

drilled for smoothly fitting bolts* but dowel pins are often added to se$ure e4a$t alignment of the flange joint# ;ouble $asings are used for very high steam pressures# %he high pressure is applied to the inner $asing* whi$h is open at the e4haust end* letting the turbine e4haust to the outer $asings#

TURBINE ROTOR&
%he design of a turbine rotor depends on the operating prin$iple of the turbine# %he impulse turbine with pressure drop a$ross the stationary blades must have seals between stationary blades and the rotor# %he smaller the sealing area* the smaller the leakage0 therefore the stationary blades are mounted in diaphragms with labyrinth seals around the shaft# %his $onstru$tion re&uires a dis$ rotor# Basi$ally there are two types of rotorA Disc Rotors ?ll larger dis$ rotors are now ma$hined out of a solid forging of ni$kel steel0 this should give the strongest rotor and a fully balan$ed rotor# It is rather e4pensive* as the weight of the final rotor is appro4imately 5+. of the initial forging# 6lder or smaller dis$ rotors have shaft and dis$s made in separate pie$es with the dis$s shrunk on the shaft# %he bore of the dis$s is made +#1. smaller in diameter than the shaft# %he dis$s are then heated until they easily are slid along the shaft and lo$ated in the $orre$t position on the shaft and shaft key# ? small $learan$e between the dis$s prevents thermal stress in the shaft# Dr # Rotors %he first rea$tion turbines had solid forged drum rotors# %hey were strong* generally well balan$ed as they were ma$hined over the total surfa$e# )ith the in$reasing si3e of turbines the solid rotors got too heavy pie$es# Bor good balan$e the drum must be ma$hined both outside and inside and the drum must be open at one end# %he se$ond part of the rotor is the drum end $over with shaft# %he end $over is made with a shrink fit and welded of 6++,-++ M1+N6 'as$al#

TURBINE BEARIN)
,o r"al Beari"+s %he bearings for small turbines are often self,aligning spheri$al ball or roller, bearings or they may be ring lubri$ated sleeve bearings with bron3e or Babbitt lining# Thr st Beari"+s %he main purposes of the thrust bearings areA 23

1# %o keep the rotor in an e4a$t position in the $asing# 9# %o absorb any a4ial thrust on the room#

TUEBINE &EAL&
Blade seals %he effi$ien$y of rea$tion turbines depends to a large e4tent on the blade seals0 radial as well as a4ial seals are often part of the shroud with the seal $learan$es kept as small as possible# ?s prote$tion for the a4ial seals some manufa$turers apply an adjustable thrust bearing# %he whole thrust blo$k is able to be a4ially adjusted# ;uring startup the thrust blo$k is pushed against a stop in the dire$tion of e4haust of e4haust for ma4imum seal $learan$es# )hen turbine is heated up and has been on load for a short time the thrust blo$k is pulled forward against a forward stop for minimum seal $learan$e and ma4imum blade effi$ien$y# &ha!t &eals (haft seals must be provided in order to prevent or at least redu$e steam leakage where the shafts e4tend through the $asings# ?lso when low pressure turbines are under va$uum the seals must prevent air from leaking into the $asing# 6rdinary soft pa$king may be used for shaft sealing in small turbines# =arbon rings are also very $ommon for small turbines# %he $arbon ring is made up of three segments butting together tightly under the pressure of a garter spring# %he ring has a few hundreds of millimeter $learan$e around the shaft and is prevented from turning by a lo$king pin# %he ring has a slight side $learan$e in the housing allowing it to move freely in radial dire$tions# =arbon rings are self, lubri$ating but have a tenden$y to $orrode the shaft when the turbine is shut down#

Water &eal %he water seal $annot operate properly at low speed and gland steam must be applied for sealing during start,up until the turbine speed is appro4imately 9+++rev<mm# )ater seals are supplied with $lean $ool $ondensate from the e4tra$tion pump# It may be supplied dire$tly or via a head tank with automati$ level,$ontrol#

TURBINE COU'LIN)&

24

%he purpose of $ouplings is to transmit power from the prime mover to the driven pie$e of ma$hinery# Bor heavy loads the solid flange $oupling is used# %he flanges are generally integral parts of the shafts* but they may be separate parts for smaller turbines# In this $ase ea$h $oupling part has a tapered bore and keyway to fit the tapered end o f the shaft# Bollowing the taper the shaft has a large thread allowing the $oupling to be se$ured tightly with a large nut# %he fri$tion between the $oupling halves and the shear for$e of the bolts transmits the power# Bor ma4imum shear stress the bolts must be fitted# %he $oupling bolts should be under$ut* that is ma$hined off to a diameter slightly less than the bottom diameter of the thread to avoid any strain on the thread# In some $ases the $ouplings must $ompensate for a4ial e4pansion and $ontra$tion of the rotors and in this $ase a fle4ible $oupling is applied# %he outer half has internal gears* while the inner part has mat$hing e4ternal gears# %he $oupling works like the spline on a driveshaft for a $ar# %he $ouplings for very large shafts will need a large diameter if the bolts are used to transmit the power# %he bolts $an be mu$h smaller if they are not allowed to transmit power# In the $oupling shear pins $arry the load# %he area e4posed to shear is the shear pins to be lo$ated at a large radius from the shaft $entre# %he $oupling bolts are not fitted as they are e4posed to tensile stress only#

&TEA; TURBINE& %OR %O&&IL %UEL

25

&ALIENT %EATURE&

1. Three cyli"der t r1i"es 5H;N &eries6, co#$risi"+ o!

High for pressure (H'" turbine %urbines both no33le $ontrol as well as throttle $ontrol mode# Intermediate pressure (I'" boiler turbine %urbines $an operate with any and are suitable for i#

!ow pressure (!'" turbines =onstant pressure as well as sliding pressure operation Base load as well as two,shift operation (ub $riti$al as well as super $riti$al parameters

ii# iii#

?ll the rotors are monoblo$k H' E I' $asings have double shell $onstru$tion and !' has three,shell $onstru$tion# I' turbines with single flow or with double flow# !' turbines are designed for normal as well as high ba$k pressure $onditions# Hollow guide blades with su$tion slits for moisture removal in last !' stage# Bearing pedestals isolated from turbine $asings# =ombined stop E $ontrol valves with individual servomotor# (ophisti$ated $ontrol and monitoring e&uipment su$h as le$tro,hydrauli$ governing* automati$ turbine run up system* turbine stress $ontroller* automati$ turbine tester et$# High operational fle4ibility i# ii# iii# Bast start up and shut down (harp load $hanges 6peration under wide fre&uen$y range (7-#5 to 51#5 H3"

2. T.o cyli"der t r1i"es co#$risi"+ o! co#1i"ed 5H'EI'6 a"d L' t r1i"e 54N series6

3. T.o cyli"der t r1i"es co#$risi"+ o! H' a"d co#1i"ed 5I'EL'6 t r1i"es 5HE series6

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&TEA; TURBINE %OR CO;BINED C-CLE

=ombined $y$les offer substantial improvement in thermal $y$le effi$ien$y by lowering the heat reje$tion temperature# 4haust from gas turbine is used effe$tively for generating steam in fired or unfired re$overy steam generator for running a suitable steam turbine# 6pen $y$le gas turbines $an be profitably $onverted to a $ombined $y$le plant even later stage depending upon the $onvenien$e of the utility# BH ! Haridwar manufa$tures steam turbines for $ombined $y$le power stations with turbines of 66 1)* 159 1) and 955 1) I(6 ratings# (team $y$le may be single* dual or triple pressure $y$le# )ith triple pressure $y$le and suitable blo$k $ombination of gas turbines* H8(@ and turbines* $y$le effi$ien$y of about 5/. $an be a$hieved#

TURBINE& WITH ADVANCED &TEA; 'ARA;ETER&

A$$licatio" o! hi+her $ara#eters is the #ost direct .ay o! i"creasi"+ heat i"$ t to the cycle

(team parameters of >++ bar pressure and 6++ o= temperature (i4 per$ent improvement in thermal $y$le effi$ien$y :ew materials for high temperature appli$ations Impulse diagonal blading for the first stage H' and I' turbines Heat shield at inlet of I' turbine In$reased wall se$tions for in$reased pressures

;ANU%ACTURIN) %ACILITIE& 27

%he plant is fully e&uipped with the most modern and sophisti$ated manufa$turing and testing fa$ilities to produ$e sets upto 1+++ 1) rating# %hese in$ludeA

Blade (hop for manufa$ture of both moving and stationary blades (pe$ial purpose =:= ma$hine tools 6verspeed E Fa$uum Balan$ing %unnel,a uni&ue fa$ility for balan$ing and overspeeding of rotors for turbines

EN)INEERIN) CA'ABILITI&=
BH ! $arries out life e4tension programs on steam turbines of various ratings* whi$h forewarn the impending failure and help in redu$ing $ostly plant breakdowns by re$ommending repla$ement and up gradation of defe$tive $omponents# 6ver the past two de$ades* BH ! has gained a vast e4perien$e in design* manufa$ture* ere$tion and $ommissioning of various $apa$ities of %urbine @enerator sets ranging from 1++ 1) to 5++ 1)# 1any spe$ifi$ features to suit the $ustomer re&uirements* layout E operation are taken $are of# %o name a fewA

H'<!' bypass %urbine (tress valuator* hand Barring @ear and ?utomati$ %urbine 8un,up (ystem for 91+ 1) 8ussian %urbine# Base load<$y$le <%wo,shift operations %hrottle <:o33le governing =onstant<(liding pressure operation

28

BH ! Haridwar has a strong engineering base with &ualified and e4perien$ed engineers supported by te$hni$ians* spanning the fun$tions of proposal* performan$e and produ$t engineering* proje$t management* field engineering* resear$h and development* $omputeri3ation et$#

RENOVATION E ;ODERNI&ATION 5RE;6

;epending on the a$tual operating $onditions* material properties of the $omponents degrade as fun$tion of servi$e life due to one or more time dependent material damage me$hanisms su$h as $reep* fatigue* $orrosion* erosion* wear embattlement et$# !ife e4tension programme (! '" is a spe$ial pa$kage $omprising systems and methodologies* whi$h evaluates the residual life of $omponents through sophisti$ated :;%* B 1 stress analysis and metallurgi$al te$hni&ue# 1any improvements in material and design of $riti$al $omponents with state,of,art design is a part of the life e4tension pro$ess# %hus the performan$e* availability and effi$ien$y of the plant may be improved by 8E1 'rograms#

MICROSTRUCTURE EXAMINATION OF ROTOR

29

Tech"olo+y < Colla1oratio"s

%he te$hnologi$al base of BH ! in the area of (team turbines and %urbo @enerators has been $reated by a$&uiring te$hnologi$al information from the $ollaborators# Initially BH ! had $ollaboration with 1<s !1) D((8 for 1++ and 91+ 1) sets# In 19-6* BH ! entered into te$hni$al $ollaboration agreement with 1<s (iemens,C)D* @ermany to a$&uire the know,how and know,why for turbine generator sets upto 1+++ 1)# %his $ollaboration still $ontinues# %his helps BH ! to keep pa$e with the worldwide te$hnologi$al progress and offer state of the art e&uipment to its $ustomer# Dnder this $ollaboration agreement* BH ! has established strong design* manufa$turing and servi$ing base for unit upto 5++ 1) ratings#

30