Bhel Mechanical (4th Year) Internship - Block-3 (Turbine Shop)

06/09/2017 BHEL MECHANICAL ( 4TH YEAR ) INTERNSHIP -BLOCK-3(TURBINE SHOP)
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Our greatest strength is our highly skilled and committed workforce of over 49,000 employees. Every employee is given an ...
80% of all electricity generation in the world is by use of steam turbines. The steam turbine is a form of heat engine th...
ate turbine blocks can be selected. Types These arrangements include single casing, tandem compound and cross compound...
Principle of Operation and Design An ideal steam turbine is considered to be an isentropic process, or constant entropy ...
rotor, with no net change in steam velocity across the stage but with a decrease in both pressure and temperature. DIFFE...
BHEL HARIDWAR 1. LOCATION It is situated in the foot hills of Shivalik range in Haridwar. The main administrative buildi...
TURBINE PARTS 1 TURBINE BLADES Cylindrical reaction blades for HP, IP and LP Turbines 3-DS blades, in initial stages of...
DRUM ROTORS The first reaction turbines had solid forged drum rotors. They were strong, generally well balanced as they ...
and an identical point on the next blade. HIGH PRESSURE BLADE AIRFOIL PROFILE
1.2 CLASSIFICATION OF PROFILES There are two basic types of profiles - Impulse and Reaction. In the impulse type of profi...
of a problem. It has to be machined by broaching, and the broaching machine available could not handle the sizes of the r...
sections and shorter heights. They also have integral shrouds. These shrouds of adjacent blades butt against each other f...
material and aerodynamic damping exists. In a periodically varying excitation force, it may frequently happen that the fo...
has come to this extent that every different aspect of this technology has become a full- fledged fundamental and advance...
components are subjected to one or more number of machining operations in machine shops, to obtain the desired shape and ...
5. CLASSIFICATION OF BLOCK 3 BAY-1 IS FURTHER DIVIDED INTO THREE PARTS 1. HMS In this shop heavy machine work is done w...
1. HMS In this shop several components of steam turbine like LP, HP & IP rotors, Internal & external casing are manufact...
Fig 5. Steam Turbine Casing & Rotors in Assembly Area 2. Turning Section Same as the turning section in Bay-3, there are...
Basically the design of blades is classified according to the stages of turbine. The size of LP TURBINE BLADES is general...
5.3 MACHINING OF BLADES Machining of blades is done with the help of Lathe & CNC machines. Some of the machines are:- C...
shown on heavy to medium machines. Duty lathes were planted in the same line where the specified work was undertaken. Th...
BHEL MECHANICAL ( 4TH YEAR ) INTERNSHIP -BLOCK-3(TURBINE SHOP)
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1. 1. INDUSTRIAL TRAINING REPORT (JUNE JULY 2014) Submitted in partial fulfilment of the requirements Of the degree of Bachelor of
Technology In Mechanical Engineering By (ABHISHEK CHAUDHARY) (1101201085) (School of Civil and Mechanical Engineering) GALGOTIAS
UNIVERSITY GREATER NOIDA 2011-2015
2. 2. ACKNOWLEDGEMENT An engineer with only theoretical knowledge is not a complete Engineer. Practical knowledge is very important to
develop and apply engineering skills. It gives me a great pleasure to have an opportunity to acknowledge and to express gratitude to those who were
associated with me during my training at BHEL. I am very grateful to Mr. JAIKESH SINGH for providing me with an opportunity to undergo training
under his able guidance. Furthermore, special thanks to Mr. Raj Singh for his help and support in Haridwar. Last, but not the least, I would also like to
acknowledge the support of my college friends, who pursued their training with me. We shared some unforgettable moments together. I express my
sincere thanks and gratitude to BHEL authorities for allowing me to undergo the training in this prestigious organization. I will always remain indebted
to them for their constant interest and excellent guidance in my training work, moreover for providing me with an opportunity to work and gain
experience. THANK YOU
3. 3. ABSTRACT In the era of Mechanical Engineering, Turbine, A Prime Mover ( Which uses the Raw Energy of a substance and converts it to
Mechanical Energy) is a well known Machine most useful in the the field of Power Generation. This Mechanical energy is used in running an Electric
Generator which is directly coupled to the shaft of turbine. From this Electric Generator, we get electric Power which can be transmitted over long
distances by means of transmission lines and transmission towers. In my Industrial Training in B.H.E.L., Haridwar I go through all sections in Turbine
Manufacturing. First management team told me about the history of industry, Area, Capacity, Machines installed & Facilities in the Industry. After that
they told about the Steam Turbine its types , parts like Blades, Casing, Rotor etc. Then they told full explanation of constructional features and
procedure along with equipement used. Before telling about the machines used in Manufacturing of Blade, they told about the safety precautions, Step
by Step arrangement of machines in the block with a well defined proper format. They also told the material of blade for a particular desire, types of
Blades, Operations performed on Blades, their New Blade Shop less with Advance Technology like CNC Shaping Machine. I would like to express my
deep sense of Gratitude and thanks to MR. JAIKESH SINGH in charge of training in Turbine Block in B.H.E.L., Haridwar. Without the wise counsel
and able guidance, it would have been impossible to complete the report in this manner. Finally, I am indebted to all who so ever have contributed in
this report and friendly stay at Bharat Heavy Electricals Limited (BHEL).
4. 4. INDEX ACKNOWLEDGEMENT ABSTRACT SR NO TOPIC PAGE NO. 1. INTERODUCTION 2. BHEL-AN OVERVEIW 3. STEAM
TURBINE 4. TYPES OF STEAM TURBINE 5. BHEL UNITS 6. BHEL HARIDWAR 7. TURBINE PARTS 8. MANUFACTURING PROCESS 9.
BLADE SHOP
5. 5. 10. CONCLUSION INTRODUCTION BHEL is the largest engineering and manufacturing enterprise in India in the energy related infrastructure
sector today. BHEL was established more than 40 years ago when its first plant was setup in Bhopal ushering in the indigenous Heavy Electrical
Equipment Industry in India a dream which has been more than realized with a well recognized track record of performance it has been earning profits
continuously since1971-72. BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission, Industry, Transportation,
Telecommunication, Renewable Energy, Defense, etc. The wide network of BHEL's 14 manufacturing division, four power Sector regional centers,
over 150 project sites, eight service centers and 18 regional offices, enables the Company to promptly serve its customers and provide them with
suitable products, systems and services efficiently and at competitive prices. BHEL has already attained ISO 9000 certification for quality
management, and ISO 14001certification for environment management. The companys
6. 6. inherent potential coupled with its strong performance make this one of the NAVRATNAS, which is supported by the government in their endeavor
to become future global players
7. 7. B.H.E.L- An Overview BHEL or the Bharat Heavy Engineering Limited is one of the largest engineering and manufacturing organizations in the
country and theBHEL, Haridwar is their gift to Uttaranchal. With two large manufacturing plants, BHEL in Haridwar is among the leading industrial
organizations in the state. 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, gas turbines and huge steams. The
Central Foundry Forge Plant in Haridwar deals withsteel 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. Situate in Ranipur
near Haridwar, the Bharat Heavy Engineering Limited employs over 8,000 people. BHEL is an integrated power plant equipment manufacturer and
oneof the largest engineering and manufacturing companies in India in terms of turnover. BHEL was established in 1964, ushering in the indigenous
Heavy Electrical Equipment industry in India - a dream that has been more than realized with a well-recognized track record of performance. The
company has been earning profits continuously since 1971-72 and paying dividends since 1976-77 .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, Renewable Energy, Oil & Gas and Defence. BHEL has 15 manufacturing divisions, two repair units,
four regional offices, eight service centres, eight overseas offices and
8. 8. 15 regional centres and currently operate at more than 150 project sites across India and abroad. BHEL places strong emphasis on innovation and
creative development of new technologies. Our research and development (R&D) efforts are aimed not only at improving the performance and
efficiency of our existing products, but also at using state-of-the-art technologies and processes to develop new products. This enables us to have a
strong customer orientation, to be sensitive to their needs and respond quickly to the changes in the market. The high level of quality & reliability of our
products is due to adherence to international standards by acquiring and adapting some of the best technologies from leading companies in the world
including General Electric Company, Alstom SA, Siemens AG and Mitsubishi Heavy Industries Ltd., together with technologies developed in our own
R&D centres. Most of our manufacturing units and other entities have been accredited to Quality Management Systems (ISO 9001:2008),
Environmental Management Systems (ISO 14001:2004) and Occupational Health & Safety Management Systems (OHSAS 18001:2007). BHEL has a
share of around 59% in India's total installed generating capacity contributing 69% (approx.) to the total power generated fromutility sets (excluding
non-conventional capacity) as of March 31, 2012. We have been exporting our power and industry segment products and services for approximately 40
years. We have exported our products and services to more than 70 countries. We had cumulatively installed capacity of over 8,500 MW outside of
India in 21 countries, including Malaysia, Iraq, the UAE, Egypt and New Zealand. Our physical exports range from turnkey projects to after sales
services. BHEL work with a vision of becoming a world-class engineering enterprise, committed to enhancing stakeholder value.
9. 9. Our greatest strength is our highly skilled and committed workforce of over 49,000 employees. Every employee is given an equal opportunity to
develop himself and grow in his career. Continuous training and retraining, career planning, a positive work culture and participative style of
management - all these have engendered development of a committed and motivated workforce setting new benchmarks in terms of productivity,
quality and responsiveness. STEAM TURBINE A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and
converts it into rotary motion.Its modern manifestation was invented by Sir Charles Parsons in 1884. It has almost completely replaced the
reciprocating piston steam engine primarily because of its greater thermal efficiency and higher power-to-weight ratio. Because the turbine generates
rotary motion, it is particularly suited to be used to drive an electrical generator about
10. 10. 80% of all electricity generation in the world is by use of steam turbines. The steam turbine is a form of heat engine that derives much of its
improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the
ideal reversible process. ADVANTAGES:- ed. -free operation. DISADVANTAGES:- For slow speed application reduction gears are required. The
steam turbine cannot be made reversible. The efficiency of small simple steam turbines is poor. STEAM TURBINES THE MAINSTAY OF BHEL:-
commission steam turbines of up to 1000 MW rating for steam parameters ranging from 30 bars to 300 bars pressure and initial & reheat temperatures
up to 600C. ting of modules suitable for a range of output and steam parameters.
11. 11. ate turbine blocks can be selected. Types These arrangements include single casing, tandem compound and cross compound turbines. Single casing
units are the most basic style where a single casing and shaft are coupled to a generator. Tandem compound are used where two or more casings are
directly coupled together to drive a single generator. A cross compound Steam turbines are made in a variety of sizes ranging from small 1 hp (0.75
kW) units (rare) used as mechanical drives for pumps, compressors and other shaft driven equipment, to 2,000,000 hp (1,500,000 kW) turbines used to
generate electricity. There are several classifications for modern steam turbines. Steam Supply and Exhaust Conditions These types include condensing,
non-condensing, reheat, extraction and induction. Non-condensing or backpressure turbines are most widely used for process steam applications. The
exhaust pressure is controlled by a regulating valve to suit the needs of the process steam pressure. These are commonly found at refineries, district
heating units, pulp and paper plants, and desalination facilities where large amounts of low pressure process steam are available. Condensing turbines
are most commonly found in electrical power plants. These turbines exhaust steam in a partially condensed state, typically of a quality near 90%, at a
pressure well below atmospheric to a condenser. Reheat turbines are also used almost exclusively in electrical power plants. In a reheat turbine, steam
flow exits from a high pressure section of the turbine and is returned to the boiler where additional superheat is added. The steam then goes back into an
intermediate pressure section of the turbine and continues its expansion. Casing or Shaft Arrangements Turbine arrangement features two or more shafts
not in line driving two or more generators that often operate at different speeds. A cross compound turbine is typically used for many large applications.
12. 12. Principle of Operation and Design An ideal steam turbine is considered to be an isentropic process, or constant entropy process, in which the
entropy of the steam entering the turbine is equal to the entropy of the steam leaving the turbine. No steam turbine is truly isentropic, however, with
typical isentropic efficiencies ranging from 20%- 90% based on the application of the turbine. The interior of a turbine comprises several sets of blades,
or buckets as they are more commonly referred to. One set of stationary blades is connected to the casing and one set of rotating blades is connected
to the shaft. The sets intermesh with certain minimum clearances, with the size and configuration of sets varying to efficiently exploit the expansion of
steam at each stage. Turbine Efficiency To maximize turbine efficiency, the steam is expanded, generating work, in a number of stages. These stages are
characterized by how the energy is extracted from them and are known as impulse or reaction turbines. Most modern steam turbines are a combination
of the reaction and impulse design. Typically, higher pressure sections are impulse type and lower pressure stages are reaction type. Impulse Turbines
An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets contain significant kinetic energy, which the rotor
blades, shaped like buckets, convert into shaft rotation as the steam jet changes direction. A pressure drop occurs across only the stationary blades, with
a net increase in steam velocity across the stage. Reaction Turbines In the reaction turbine, the rotor blades themselves are arranged to form convergent
nozzles. This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor. Steam is
directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet that fills the entire circumference of the rotor. The steam then changes
direction and increases its speed relative to the speed of the blades. A pressure drop occurs across both the stator and the rotor, with steam accelerating
through the stator and decelerating through the
13. 13. rotor, with no net change in steam velocity across the stage but with a decrease in both pressure and temperature. DIFFERENCES BETWEEN
IMPULSE AND REACTION TURBINE
14. 14. BHEL HARIDWAR 1. LOCATION It is situated in the foot hills of Shivalik range in Haridwar. The main administrative building is at a distance of
about 8 km from Haridwar. 2. ADDRESS Bharat Heavy Electrical Limited (BHEL) Ranipur, Haridwar PIN- 249403 3. AREA BHEL Haridwar consists
of two manufacturing units, namely Heavy Electrical Equipment Plant ( HEEP) and Central Foundry Forge Plant (CFFP), having area HEEP area:- 8.45
sq km CFFP area:- 1.0 sq km The Heavy Electricals Equipment Plant (HEEP) located in Haridwar, is one of the major manufacturing plants of BHEL.
The core business of HEEP includes design and manufacture of large steam and gas turbines, turbo generators, hydro turbines and generators, large
AC/DC motors and so on. Central Foundry Forge Plant (CFFP) is engaged in manufacture of Steel Castings:Up to 50 Tons per Piece Wt & Steel
Forgings: Up to 55 Tons per Piece Wt. 4. UNITS There are two units in BHEL Haridwar as followed: 1) Heavy Electrical Equipment Plant (HEEP) 2)
Central Foundry Forge Plant (CFFP)
15. 15. TURBINE PARTS 1 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 o Free standing LP moving blades Tip sections with supersonic design. o Fir-tree root o Flame hardening of the leading edge o
Banana type hollow guide blade o Tapered and forward leaning for optimized mass flow distribution o Suction slits for moisture removal 2 TURBINE
CASING Casings or cylinders are of the horizontal split type. This is not ideal, as the heavy flanges of the joints are slow to follow the temperature
changes of the cylinder walls. However, for assembling and inspection purposes there is no other solution. The casing is heavy in order to withstand the
high pressures and temperatures. It is general practice to let the thickness of walls and flanges decrease from inlet- to exhaust-end. The casing joints are
made steam tight, without the use of gaskets, by matching the flange faces very exactly and very smoothly. The bolt holes in the flanges are drilled for
smoothly fitting bolts, but dowel pins are often added to secure exact alignment of the flange joint. Double casings are used for very high steam
pressures. The high pressure is applied to the inner casing, which is open at the exhaust end, letting the turbine exhaust to the outer casings. 3
TURBINE ROTORS The design of a turbine rotor depends on the operating principle of the turbine. The impulse turbine with pressure drop across the
stationary blades must have seals between stationary blades and the rotor. The smaller the sealing area, the smaller the leakage; therefore the stationary
blades are mounted in diaphragms with labyrinth seals around thes haft. This construction requires a disc rotor. Basically there are two types of rotor:
DISC ROTORS All larger disc rotors are now machined out of a solid forging of nickel steel; this should give the strongest rotor and a fully balanced
rotor. It is rather expensive, as the weight of the final rotor is approximately 50% of the initial forging. Older or smaller disc rotors have shaft and discs
made in separate pieces with the discs shrunk on the shaft. The bore of the discs is made 0.1% smaller in diameter than the shaft. The discs are then
heated until they easily are slid along the shaft and located in the correct position on the shaft and shaft key. A small clearance between the discs
prevents thermal stress in the shaft.
16. 16. DRUM ROTORS The first reaction turbines had solid forged drum rotors. They were strong, generally well balanced as they were machined over
the total surface. With the increasing size of turbines the solid rotors got too heavy pieces. For good balance the drum must be machined both outside
and inside and the drum must be open at one end. The second part of the rotor is the drum end cover with shaft. 1. CONSTRUCTIONAL FEATURES
OF A BLADE The blade can be divided into 3 parts: The profile, which converts the thermal energy of steam into kinetic energy, with a certain
efficiency depending upon the profile shape. The root, which fixes the blade to the turbine rotor, giving a proper anchor to the blade, and transmitting
the kinetic energy of the blade to the rotor. The damping element, which reduces the vibrations which necessarily occur in the blades due to the steam
flowing through the blades. These damping elements may be integral with blades, or they may be separate elements mounted between the blades. Each
of these elements will be separately dealt with in the following sections. 1.1 H.P. BLADE PROFILES In order to understand the further explanation, a
familiarity of the terminology used is required. The following terminology is used in the subsequent sections. If circles are drawn tangential to the
suction side and pressure side profiles of a blade, and their centers are joined by a curve, this curve is called the camber line. This camber line intersects
the profile at two points A and B. The line joining these points is called chord, and the length of this line is called the chord length. A line which is
tangential to the inlet and outlet edges is called the bitangent line. The angle which this line makes with the circumferential direction is called the setting
angle. Pitch of a blade is the circumferential distance between any point on the profile
17. 17. and an identical point on the next blade. HIGH PRESSURE BLADE AIRFOIL PROFILE
18. 18. 1.2 CLASSIFICATION OF PROFILES There are two basic types of profiles - Impulse and Reaction. In the impulse type of profiles, the entire heat
drop of the stage occurs only in the stationary blades. In the reaction type of blades, the heat drop of the stage is distributed almost equally between the
guide and moving blades. Though the theoretical impulse blades have zero pressure drop in the moving blades, practically, for the flow to take place
across the moving blades, there must be a small pressure drop across the moving blades also. Therefore, the impulse stages in practice have a small
degree of reaction. These stages are therefore more accurately, though less widely, described as low-reaction stages. The presently used reaction profiles
are more efficient than the impulse profiles at part loads. This is because of the more rounded inlet edge for reaction profiles. Due to this, even if the
inlet angle of the steam is not tangential to the pressure-side profile of the blade, the losses are low. However, the impulse profiles have one advantage.
The impulse profiles can take a large heat drop across a single stage, and the same heat drop would require a greater number of stages if reaction
profiles are used, thereby increasing the turbine length. The Steam turbines use the impulse profiles for the control stage (1st stage), and the reaction
profiles for subsequent stages. There are four reasons for using impulse profile for the first stage: a) Most of the turbines are partial arc admission
turbines. If the first stage is are action stage, the lower half of the moving blades do not have any inlet steam, and would ventilate. Therefore, most of
the stage heat drop should occur in the guide blades. b) The heat drop across the first stage should be high, so that the wheel chamber of the outer casing
is not exposed to the high inlet parameters. In case of -4turbines, the inner casing parting plane strength becomes the limitation, and therefore requires a
large heat drop across the 1st stage. c) Nozzle control gives better efficiency at part loads than throttle control. d) The number of stages in the turbine
should not be too high, as this will increase the length of the turbine. There are exceptions to the rule. Turbines used for CCPs, and BFP drive turbines
do not have a control stage. They are throttle-governed machines. Such designs are used when the inlet pressure slides. Such machines only have
reaction stages. However, the inlet passages of such turbines must be so designed that the inlet steam to the first reaction stage is properly mixed, and
occupies the entire 360 degrees. There are also cases of controlled extraction turbines where the L.P. control stage is an impulse stage. This is either to
reduce the number of stages to make the turbine short, or to increase the part load efficiency by using nozzle control, which minimizes throttle losses.
1.3 H.P. BLADE ROOTS The root is a part of the blade that fixes the blade to the rotor or stator. Its design depends upon the centrifugal and steam
bending forces of the blade. It should be designed such that the material in the blade root as well as the rotor / stator claw and any fixing element are in
the safe limits to avoid failure. The roots are T-root and Fork-root. The fork root has a higher loadcarrying capacity than the T-root. It was found that
machining this T-root with side grip is more
19. 19. of a problem. It has to be machined by broaching, and the broaching machine available could not handle the sizes of the root. The typical roots used
for the HP moving blades for various steam turbine applications are 1) T-ROOT 2) T-ROOT WITH SIDE GRIP 2 L.P. BLADE PROFILES The LP
blade profiles of moving blades are twisted and tapered. These blades are used when blade height-to-mean stage diameter ratio (h/Dm) exceeds 0.2. 2.1
LP BLADE ROOTS The roots of LP blades are as follows: 1) 2 Blading : a. The roots of both the LP stages in 2 type of LP Blading are T-roots. 2) 3
Blading: a. The last stage LP blade of HK, SK and LK blades have a fork-root. SK blades have4-fork roots for all sizes. HK blades have 4-fork roots up
to 56 size, where modified profiles are used. Beyond this size, HK blades have 3 fork roots. LK blades have 3-forkroots for all sizes. The roots of the
LP blades of preceding stages are of T-roots. 2.2 DYNAMICS IN BLADE The excitation of any blade comes from different sources. They are Nozzle-
passing excitation: As the blades pass the nozzles of the stage, they encounter flow disturbances due to the pressure variations across the guide blade
passage. They also encounter disturbances due to the wakes and eddies in the flow path. These are sufficient to cause excitation in the moving blades.
The excitation gets repeated at every pitch of the blade. This is called nozzle-passing frequency excitation. The order of this frequency =no. of guide
blades x speed of the machine. Multiples of this frequency are considered for checking for resonance. Excitation due to non-uniformities in guide-
blades around the periphery. These can occur due to manufacturing inaccuracies, like pitch errors, setting angle variations, inlet and outlet edge
variations, etc. For HP blades, due to the thick and cylindrical cross-sections and short blade heights, the natural frequencies are very high. Nozzle-
passing frequencies are therefore necessarily considered, since resonance with the lower natural frequencies occurs only with these orders of excitation.
In LP blades, since the blades are thin and long, the natural frequencies are low. The excitation frequencies to be considered are therefore the first few
multiples of speed, since the nozzlepassing frequencies only give resonance with very high modes, where the vibration stresses are low. The HP moving
blades experience relatively low vibration amplitudes due to their thicker
20. 20. sections and shorter heights. They also have integral shrouds. These shrouds of adjacent blades butt against each other forming a continuous ring.
This ring serves two purposes it acts as a steam seal, and it acts as a damper for the vibrations. When vibrations occur, the vibration energy is
dissipated as friction between shrouds of adjacent blades. For HP guide blades of Wesel design, the shroud is not integral, but a shroud band is riveted
to a number of guide blades together. The function of this shroud band is mainly to seat the steam. In some designs HP guide blades may have integral
shrouds like moving blades. The primary function remains steam sealing. In industrial turbines, in LP blades, the resonant vibrations have high
amplitudes due to the thin sections of the blades, and the large lengths. It may also not always be possible to avoid resonance at all operating conditions.
This is because of two reasons. Firstly, the LP blades are standardized for certain ranges of speeds, and turbines may be selected to operate anywhere in
the speed range. The entire design range of operating speed of the LP blades cannot be outside the resonance range. It is, of course, possible to design a
new LP blade for each application, but this involves a lot of design efforts and manufacturing cycle time. However, with the present-day computer
packages and manufacturing methods, it has become feasible to do so. Secondly, the driven machine may be a variable speed machine like a compressor
or a boiler-feed-pump. In this case also, it is not possible to avoid resonance. In such cases, where it is not possible to avoid resonance, a damping
element is to be used in the LP blades to reduce the dynamic stresses, so that the blades can operate continuously under resonance also. There may be
blades which are not adequately damped due to manufacturing inaccuracies. The need fora damping element is therefore eliminated. In case the
frequencies of the blades tend towards resonance due to manufacturing inaccuracies, tuning is to be done on the blades to correct the frequency. This
tuning is done by grinding off material at the tip (which reduces the inertia more than the stiffness) to increase the frequency, and by grinding off
material at the base of the profile (which reduces the stiffness more than the inertia) to reduce the natural frequency. The damping in any blade can be of
any of the following types: a) Material damping: This type of damping is because of the inherent damping properties of the material which makes up
the component. b) Aerodynamic damping: This is due to the damping of the fluid which surrounds the component in operation. c) Friction damping:
This is due to the rubbing friction between the component under consideration with any other object. Out of these damping mechanisms, the material
and aerodynamic types of damping are very small in magnitude. Friction damping is enormous as compared to the other two types of damping. Because
of this reason, the damping elements in blades generally incorporate a feature by which the vibrational energy is dissipated as frictional heat. The
frictional damping has a particular characteristic. When the frictional force between the rubbing surfaces is very small as compared to the excitation
force, the surfaces slip, resulting in friction damping. However, when the excitation force is small when compared to the frictional force, the surfaces do
not slip, resulting in locking of the surfaces. This condition gives zero friction damping, and only the
21. 21. material and aerodynamic damping exists. In a periodically varying excitation force, it may frequently happen that the force is less than the friction
force. During this phase, the damping is very less. At the same time, due to the locking of the rubbing surfaces, the overall stiffness increases and the
natural frequency shifts drastically away from the individual value. The response therefore also changes in the locked condition. The resonant response
of a system therefore depends upon the amount of damping in the system (which is determined by the relative duration of slip and stick in the system,
i.e., the relative magnitude of excitation and friction forces) and the natural frequency of the system (which alters between the individual values and the
locked condition value, depending upon the slip or stick condition). 2.3 BLADING MATERIALS Among the different materials typically used for
blading are 403 stainless steel, 422 stainless steel, A-286, and Haynes Satellites Alloy Number 31 and titanium alloy. The403 stainless steel is
essentially the industrys standard blade material and, on impulse steam turbines, it is probably found on over 90 percent of all the stages. It is used
because of its high yield strength, endurance limit, ductility, toughness, erosion and corrosion resistance, and damping. It is used within a Brinell
hardness range of 207 to 248 to maximize its damping and corrosion resistance. The 422 stainless steel material is applied only on high temperature
stages (between 700 and 900F or 371 and 482C), where its higher yield, endurance, creep and rupture strengths are needed. The A-286 material is a
nickel-based super alloy that is generally used in hot gas expanders with stage temperatures between 900 and 1150F (482 and 621C). The Haynes
Satellites Alloy Number 31 is a cobalt-based super alloy and is used on jet expanders when precision cast blades are needed. The Haynes Satellite
Number 31 is used at stage temperatures between 900 and 1200F (482 and 649C). Another blade material is titanium. Its high strength, low density,
and good erosion resistance make it a good candidate for high speed or long-last stage blading. 3. MANUFACTURING PROCESS 3.1
INTRODUCTION Manufacturing process is that part of the production process which is directly concerned with the change of form or dimensions of
the part being produced. It does not include the transportation, handling or storage of parts, as they are not directly concerned with the changes into the
form or dimensions of the part produced. Manufacturing is the backbone of any industrialized nation. Manufacturing and technical staff in industry
must know the various manufacturing processes, materials being processed, tools and equipments for manufacturing different components or products
with optimal process plan using proper precautions and specified safety rules to avoid accidents. Beside above, all kinds of the future engineers must
know the basic requirements of workshop activities in term of man, machine, material, methods, money and other infrastructure facilities needed to be
positioned properly for optimal shop layouts or plant layout and other support services effectively adjusted or located in the industry or plant within a
well planned manufacturing organization. Todays competitive manufacturing era of high industrial development and research, is being called the age of
mechanization, automation and computer integrated manufacturing. Due to new researches in the manufacturing field, the advancement
22. 22. has come to this extent that every different aspect of this technology has become a full- fledged fundamental and advanced study in itself. This has
led to introduction of optimized design and manufacturing of new products. New developments in manufacturing areas are deciding to transfer more
skill to the machines for considerably reduction of manual labor. 3.2 CLASSIFICATION OF MANUFACTURING PROCESSES For producing of
products materials are needed. It is therefore important to know the characteristics of the available engineering materials. Raw materials used
manufacturing of products, tools, machines and equipments in factories or industries are for providing commercial castings, called ingots. Such ingots
are then processed in rolling mills to obtain market form of material supply in form of bloom, billets, slabs and rods. These forms of material supply are
further subjected to various manufacturing processes for getting usable metal products of different shapes and sizes in various manufacturing shops. All
these processes used in manufacturing concern for changing the ingots into usable products may be classified into six major groups as Primary shaping
processes Secondary machining processes Metal forming processes Joining processes Surface finishing processes and Processes effecting change in
properties 3.2.1 PRIMARY SHAPING PROCESSES Primary shaping processes are manufacturing of a product from an amorphous material. Some
processes produces finish products or articles into its usual form whereas others do not, and require further working to finish component to the desired
shape and size. The parts produced through these processes may or may not require to undergo further operations. Some of the important primary
shaping processes are: Casting Powder metallurgy Plastic technology Gas cutting Bending and Forging 3.2.2 SECONDARY OR MACHINING
PROCESSES As large number of components require further processing after the primary processes. These
23. 23. components are subjected to one or more number of machining operations in machine shops, to obtain the desired shape and dimensional accuracy
on flat and cylindrical jobs. Thus, the jobs undergoing these operations are the roughly finished products received through primary shaping processes.
The process of removing the undesired or unwanted material from the work-piece or job or component to produce a required shape using a cutting tool
is known as machining. This can be done by a manual process or by using a machine called machine tool (traditional machines namely lathe, milling
machine, drilling, shaper, planner, slotter). In many cases these operations are performed on rods, bars and flat surfaces in machine shops. These
secondary processes are mainly required for achieving dimensional accuracy and a very high degree of surface finish. The secondary processes require
the use of one or more machine tools, various single or multi-point cutting tools (cutters), jobholding devices, marking and measuring instruments,
testing devices and gauges etc. forgetting desired dimensional control and required degree of surface finish on the work-pieces. The example of parts
produced by machining processes includes hand tools machine tools instruments, automobile parts, nuts, bolts and gears etc. Lot of material is wasted
as scrap in the secondary or machining process. Some of the common secondary or machining processes are: Turning Threading Knurling Milling
Drilling Boring Planning Shaping Slotting Sawing Broaching Hobbing Grinding Gear Cutting Thread cutting and Unconventional machining processes
namely machining with Numerical control (NC) machines tools or Computer Numerical Control (CNC) machine tool using ECM, LBM, AJM, USM
setups. 4. BLOCK 3 LAY-OUT Table 5: Lay-out of Block 3
24. 24. 5. CLASSIFICATION OF BLOCK 3 BAY-1 IS FURTHER DIVIDED INTO THREE PARTS 1. HMS In this shop heavy machine work is done
with the help of different NC &CNC machines such as center lathes, vertical and horizontal boring & milling machines. Asias largest vertical boring
machine is installed here and CNC horizontal boring milling machines from Skoda of Czechoslovakia. 2. Assembly Section (of hydro turbines) In this
section assembly of hydro turbines are done. Blades of turbine are1st assemble on the rotor & after it this rotor is transported to balancing tunnel where
the balancing is done. After balancing the rotor, rotor &casings both internal & external are transported to the customer. Total assembly of turbine is
done in the company which purchased it by B.H.E.L. 3. OSBT (Over Speed Balancing Tunnel) In this section, rotors of all type of turbines like LP(low
pressure), HP(high pressure) & IP(Intermediate pressure) rotors of Steam turbine ,rotors of Gas & Hydro turbine are balanced .In a large tunnel,
Vacuum of 2 torr is created with the help of pumps & after that rotor is placed on pedestal and rotted with speed of 2500-4500 rpm. After it in a
computer control room the axis of rotation of rotor is seen with help of computer & then balance the rotor by inserting the small balancing weight in the
grooves cut on rotor. Fig 4: Over speed & Vacuum Balancing Tunnel For balancing and over speed testing of rotors up to 320 tons in weight, 1800 mm
in length and 6900 mm diameter under vacuum conditions of 1 Torr. BAY 2 IS DIVIDED IN TO 2 PARTS:
25. 25. 1. HMS In this shop several components of steam turbine like LP, HP & IP rotors, Internal & external casing are manufactured with the help of
different operations carried out through different NC & CNC machines like grinding, drilling, vertical & horizontal milling and boring machines, center
lathes, planer, Kopp milling machine. 2. Assembly Section In this section assembly of steam turbines up to 1000 MWIs assembled. 1st moving blades
are inserted in the grooves cut on circumferences of rotor, then rotor is balanced in balancing tunnel in bay-1.After is done in which guide blades are
assembled inside the internal casing & then rotor is fitted inside this casing. After it this internal casing with rotor is inserted into the external. BAY 3 IS
DIVIDED INTO 3 PARTS: 1. Bearing Section In this section Journal bearings are manufactured which are used in turbines to overcome the vibration &
rolling friction by providing the proper lubrication. 2. Turning Section In this section small lathe machines, milling & boring machines, grinding
machines & drilling machines are installed. In this section small jobs are manufactured like rings, studs, disks etc. 3. Governing Section In this section
governors are manufactured. These governors are used in turbines for controlling the speed of rotor within the certain limits. 1st all components of
governor are made by different operations then these all parts are treated in heat treatment shop for providing the hardness. Then these all components
are assembled into casing. There are more than 1000 components of Governor. BAY-4 IS DIVIDED INTO 3 PARTS: 1. TBM (Turbine Blade
Manufacturing) Shop In this shop solid blade of both steam & gas turbine are manufactured. Several CNC & NC machines are installed here such as
Copying machine, Grinding machine, Rhomboid milling machine, Duplex milling machine, T- root machine center, Horizontal tooling center, Vertical
& horizontal boring machine etc.
26. 26. Fig 5. Steam Turbine Casing & Rotors in Assembly Area 2. Turning Section Same as the turning section in Bay-3, there are several small Machine
like lathes machines, milling, boring, grinding machines etc. Fig 6. CNC Rotor Turning Lathe 3. Heat Treatment Shop In this shop there are several
tests performed for checking the Hardness of different components. Tests performed are Sereliting, Nitriding, DP Test. 5. BLADE SHOP Blade shop is
an important shop of Block 3. Blades of all the stages of turbine are made in this shop only. They have a variety of centre lathe and CNC machines to
perform the complete operation of blades. The designs of the blades are sent to the shop and the Respective job is distributed to the operators. Operators
perform their job in a fixed interval of time. 5.1 TYPES OF BLADES
27. 27. Basically the design of blades is classified according to the stages of turbine. The size of LP TURBINE BLADES is generally greater than that of
HP TURBINE BLADES. At the first T1, T2, T3 & T4 kinds of blades were used, these were 2nd generation blades. Then it was replaced by TX, BDS
(for HP TURBINE) & F shaped blades. The most modern blades are F & Z shaped blades. Cylindrical Profile TX Blade HP/IP Intermediate stages &
LP Initial 3 Dimesional 3DS Blade HP/IP Initial Stages Twisted Profile F Blade HP/IP Rear Stages Fig. 7 Types Of Blades 5.2 OPERATIONS
PERFORMED ON BLADES Some of the important operations performed on blade manufacturing are:- Milling Blank Cutting Grinding of both the
surfaces Cutting Root milling
28. 28. 5.3 MACHINING OF BLADES Machining of blades is done with the help of Lathe & CNC machines. Some of the machines are:- Centre lathe
machine Vertical Boring machine Vertical Milling machine CNC lathe machine Fig 8. Schmetic Diagram of a CNC Machine 5.4 NEW BLADE SHOP
A new blade shop is being in operation, mostly 500mw turbine blades are manufactured in this shop. This is a highly hi tech shop where complete
manufacturing of blades is done using single advanced CNC machines. Complete blades are finished using modernized CNC machines. Some of the
machines are:- Pama CNC ram boring machine. Wotum horizontal machine with 6 axis CNC control. CNC shaping machine. Fig 9. CNC Shaping
Machine 6. CONCLUSION Gone through 1 month training under the guidance of capable engineers and workers of BHEL Haridwar in Block-3
TURBINE MANUFACTURING headed by Senior Engineer of department Mr. jaikesh singh situated in Ranipur, Haridwar,(Uttarakhand). The
training was specified under the Turbine Manufacturing Department. Working under the department I came to know about the basic grinding, scaling
and machining processes which was
29. 29. shown on heavy to medium machines. Duty lathes were planted in the same line where the specified work was undertaken. The training brought to
my knowledge the various machining and fabrication processes went not only in the manufacturing of blades but other parts of the turbine.
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Bhel Mechanical (4th Year) Internship - Block-3 (Turbine Shop)

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BHEL MECHANICAL ( 4TH YEAR ) INTERNSHIP -BLOCK-3(TURBINE SHOP)

BHEL MECHANICAL ( 4TH YEAR ) INTERNSHIP -BLOCK-

Abhishek Chaudhary, Student at Galgotias University

Published on Nov 18, 2014

BHEL MECHANICAL ( 4TH YEAR ) INTERNSHIP -BLOCK-3(TURBINE SHOP)

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Ritesh sharma , Student at SUNDERDEEP ENGINEERING COLLEGE, DASNA, GHAZIABAD. at Self-employed

Muzamil hussain , Greater Noida Institute of Technology

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BHEL MECHANICAL ( 4TH YEAR ) INTERNSHIP -BLOCK-3(TURBINE SHOP)

Bhel steam turbine manufacturing

Turbine manufacturing process

Project report on BHEL

Construction and manufacturing of steam turbine

B.H.E.L., Haridwar Summer Training Report

LinkedIn Corporation 2017

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