AN INDUSTRIAL TRAINING REPORT 

ON 

General Awareness on Steam Turbine Manufacturing 

B.H.E.L., Haridwar 

SUBMITTED 

By 
 RISHABH NISHAD 

DEPARTMENT OF MECHANICAL ENGINEERING 

KIET GROUP OF INSTITUTIONS, GHAZIABAD 

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ACKNOWLEDGEMENT 

I  take  this  opportunity  to  thank  the  Industrial  Training  Co-Ordinator  of 
Mechanical  Engineering  Department  for  allowing  us  to  avail  this  great 
opportunity. 

I  am  also  grateful  to  the  management  of  Bharat  Heavy  Electricals  Limited 
(B.H.E.L.),  Haridwar  for  permitting  me  to  have  training  during  9th  June  to  9th 
July 2018. 

Last  but  not  the  least  I  would  also  like  to  thank  all  our  teachers  &  friends  for 
their constructive criticism given in right spirit. 

Rishabh Nishad 

7th Semester, B.Tech. 

Mechanical Engineering 

KIET GROUP OF INSTITUTIONS 

2
  
ABSTRACT 

In  my  Industrial  Training  in  B.H.E.L.,  Haridwar  I  have  gone  through  all  sections 
in  Turbine  Manufacturing.  Also,  I  got  to  know  about  the  history  of  industry, 
Area, Capacity, Machines installed & Facilities in the Industry. 

In  power  generation  mostly  steam  turbine  is  used  because  of  its  greater 
thermal  efficiency  and  higher  power-to-weight  ratio.  Of  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  is  needed for process. Because 
the  turbine  generates  rotary  motion,  it  is  particularly  suited  to  be  used  to  drive 
an  electrical  generator  –  about  80%  of  all  electricity  generation  in  the  world  is 
by  use  of  steam  turbines.  Rotor  is  the  heart  of  the  steam  turbine  and  it  affects 
the  efficiency  of  the  steam  turbine.  In  this  report  we  have  mainly  discussed 
about  the working process of a steam turbine. The thermal efficiency of a steam 
turbine is much higher than that of a steam engine. 

I  learned  about  the  Steam  Turbine  its types, parts like Blades, Casing, Rotor etc. 

Constructional  features  and  procedure  along  with  equipment  used,  material  of 
blade,  types  of  Blades,  Operations  performed  on  Blades,  their  New Blade Shop 
with Advance Technology like CNC Shaping Machine. 

I  would  like  to  express  my  deep  sense  of  Gratitude  and  thanks  to  Mr.  VIMAL 
KUMAR  (DY.  MANAGER)  our  in  charge  of  training,  Turbine  Block-3,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). 

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INDEX: 
Sr. No. Topic  Page No. 
ACKNOWLEDGEMENT  2 
ABSTRACT  3 

INTRODUCTION  6 

1. BHEL  9 
1.1  OVERVIEW 
1.2  BHEL UNITS 
1.3 BHEL HARIDWAR 
1.3.1 LOCATION 
1.3.2 ADDRESS 
1.3.3 AREA 
1.3.4 UNITS 
1.3.5 HEEP PRODUCT PROFILE 

2. MANUFACTURING OF STEAM TURBINE  16 

2.1 INTRODUCTION 
2.2  PRINCIPLE 
2.3 ADVANTAGES 
2.4 DISADVANTAGES 
2.5 STEPS INVOLVED IN THE DESIGN OF STEAM TURBINES 

3. TYPES OF STEAM TURBINE  19 

3.1 COMPARISION BETWEEN IMPULSE AND REACTION TURBINE 

4. TURBINE PARTS  21 

4.1 NOZZLE 
4.2  DIFFUSER 
4.3  TURBINE BLADES 
4.4  GUIDE BLADES 
4.4  TURBINE CASING 
4.5  SHAFT, ROTOR, SPINDLE 
4.6 TURBINE GOVERNING SYSTEM 

5. FEATURES OF BLADE  24 

5.1 BLADE MATERIALS 

5.2 H.P. BLADE PROFILES 

5.3 CLASSIFICATION OF PROFILES 
5.4 H.P. BLADE ROOTS 
   

4
 
6. CLASSIFICATION OF BLOCK-3  27 
6.1 BAY-1 
6.2 BAY-2 
6.3 BAY-3 
6.4 BAY-4 

7. BLADE SHOP  32 

9.1 TYPES OF BLADES 
9.2 OPERATIONS PERFORMED ON BLADES 
9.3 MACHINING OF BLADES 
9.4 NEW BLADE SHOP 

9. END NOTE  36 

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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 since 1971-72. 

BHEL  has  a  mammoth  20,000  MW  per  annum capability for manufacturing of 

power  generation  equipment.  A  widespread  network  of  17  manufacturing 
units,  2  repair  units,  4  regional  offices,  8  service  centers,  1  subsidiary,  4 
overseas  offices,  6  joint  ventures,  15  regional  marketing  centers  and  current 
project  execution  at  more  than  150  project  sites  across  India  and  abroad 
corroborates  the  humongous  scale  and  size  of  its  operations.  With  key  focus 
on  project  execution,  the  worldwide  installed  base  of  power  generating 
equipment  supplied  by  BHEL  has  exceeded  178  GW.  BHEL’s  54%  share  in 
India’s  total  installed  capacity  and  58%  share  in  the  country’s  total  generation 
from  thermal  utility  sets  (coal  based)  as  of March 31, 2017 stand a testimony to 
its valuable contribution towards nation building. 

6
 
World of BHEL: 
1. Did you know - 
▪ BHEL  is  the  single  largest  contributor  to  the  country’s  total  installed 
electric utilities.

▪ All  Indian  satellites  launched  by  ISRO  are  equipped  with  BHEL  supplied 
solar panels since 2002 & batteries since 2005.

▪ World's  largest  ±800  kV,  6000  MW  multiterminal  HVDC 

NE-Agra transmission project under execution by BHEL.

▪ All  the  three  ships  of  the  Kolkata-class  stealth  guided  missile  destroyers 
equipped with BHEL’s 76/ 62 mm Super Rapid Gun Mount (SRGM) and

Auxiliary Control System. 

▪ 95% of hydroelectric generating capacity in Bhutan installed by BHEL.

▪ BHEL’s  first  power  generating  set  was  the  30 MW thermal power station 

installed at Basin bridge in Tamil Nadu, way back in 1969.

▪ All  the  states  &  six  union  territories  of  the  country  have  power  generating 
equipment installed by BHEL.

2. Innovation- 

▪ Innovation  R&D  Expenditure  >2.5%  of  Turnover-highest  in  Indian 

engineering field.

▪ Five research institutes.

14 Centres of Excellence. 

▪ In-house R&D Centres of 12 Manufacturing units/Divisions recognized by

DSIR 

3. Unparalleled industrial experience- 

▪ 570,000+ MVA transmission equipment supplied.

▪ 31,000+ AC machines- supplied, largest Indian manufacturer.

▪ >50%  of  Indian  Railways  rolling  stock  equipped  with  BHEL's  traction 
equipment.

▪ 360 electric locos supplied to Indian Railways & other industries.

▪ 385+ compressors & 90 oil drilling rigs- supplied.

7
 
4. Energizing India- 

▪ Major integrated power plant equipment manufacturer in the world with 

20,000 MW p.a. manufacturing capacity.

▪ 178+ GW power generating equipment installed till date.

▪ 55% of India’s nuclear power generating capacity (conventional island) 

installed by BHEL.

▪ Commissioned country’s first 660 MW indigenously manufactured 

supercritical set at NTPC Barh-5, in 2013.

▪ 16,500+ MW Captive Power Plant installed.

▪ 350+ MW- cumulative shipments of PV cells, modules, and systems.

• Financial Report BHEL (2016-17): ​-

Figures are restated as per Ind AS 
# Dividend for 2015-16* and 2016-17, includes Interim Dividend for the Current Year 
and Final Dividend for the Previous Year as per Ind AS 

8
  
1. B.H.E.L. 

1.1. OVERVIEW 

BHEL  is  one  of  the  few  companies  in  the  world  having  the  capability  to 
manufacture  the  entire  range  of  power  plant  equipment  and  has  proven 
turnkey  capabilities  for  executing  power  projects  from  concept-to 
commissioning.  The  power  sector  of  the  company  comprises  thermal,  gas, 
hydro and nuclear power plants. BHEL: 

▪ Has  the  capability  to supply steam turbines, generators, boilers and their 

auxiliaries  up  to  800  MW  with  capability  to  supply  up  to  1000  MW. 
Currently  executing  projects  on  EPC  (Engineering,  procurement  and 
construction)  basis  including  supercritical  sets  of  660/700/800  MW 
ratings.

▪ Has  the  capability  to  supply  hydro  turbines  and  generators  up  to  400 
MW.

▪ Has  the  capability  to  supply  nuclear  turbine  generator  sets  including 
220/235/540/550/ 700MWe.

▪ Has  proven  expertise  in  plant  performance  improvement  through 

renovation,  modernization  and  uprating  of  a  variety  of  power  plant 
equipment.

▪ Has  special  knowhow  of  residual life assessment, health diagnostics and 

life extension of plants.

▪ Has  supplied  thermal  sets  that  have  consistently  exceeded  national 

average availability and efficiency parameters.

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1.2. ​BHEL UNITS: 
Sno  Location  Unit  PRODUCT 

Steam Turbines, Turbo Generators, Hydro 

1  Bhopal  Heavy Electrical Part (HEP) 
Sets, Switch Gear Controllers 

Heavy Electrical Equipment 

Hydro Turbines, Steam Turbines, Gas 
Plant (HEEP) 
Turbines, Turbo Generators, Heavy Castings 
2  Haridwar   
& Forgings, Control Panels, Light Aircrafts, 
Central Foundry Forge Plant 
Electrical Machines 
(CFFP) 
Industrial Turbo-Sets, Compressor Pumps 
Heavy Power Equipment  and Heaters, Bow Mills, Oil Rings, Gas 
3  Hyderabad 
Plant (HPEP)  Turbines, Switch Gears, Power Generating 
Sets. 

High Pressure Boiling Plant  Seamless Steel Tubes, Spiral Fin Welded 
4  Trichy 
(HPBP)  Tubes. 

Transformers, Diesel Shunt Less AC locos 

5  Jhansi  Transformer Plant (TP) 
and EC EMU. 

Energy Meters, Watt Meters, Control 

Electronics Division (EDN)  Equipment, Capacitors, Photo Voltaic 
  Panels, Simulator, other Telecommunication 
6  Bangalore 
Electro Porcelains Division  System, Advanced Microprocessor based 
(EPD)  control system, Insulator & Bushing 
Ceramic Liners 
Electrostatic Precipitator, Air Pre-Heater, 
7  Ranipet  Boiler Auxiliary Plant (BAP)  Fans, Electric Generators, Desalination 
Plants 

8  Goindwal  Industrial Valves Plant (IVP)  Industrial Valves & Fabrication 

High tension ceramic, Insulation Plates And 

9  Jagdishpur  Insulator Plant (IP) 
Bushings 

Component Fabrication 
10  Rudrapur  Windmill, Solar Water Heating system 
Plant (CFP) 

Amorphous Silicon Solar  Solar Photovoltaic Cells, Solar Lanterns, 

11  Gurgaon 
Cell Plant (ASSCP)  Chargers, Solar clock 
Table-1 

1.3. BHEL HARIDWAR 

1.3.1. LOCATION 
It  is  situated  in  the  foot  hills  of  Shivalik  range  in  Haridwar.  The  main 
administrative building is at about 8 km from Haridwar. 

1.3.2. ADDRESS 

Bharat Heavy Electrical Limited (BHEL) 

Ranipur, Haridwar PIN- 249403 

1.3.3. 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. 
 
1.3.4. UNITS 

There are two units in BHEL Haridwar as followed: 

1) Heavy Electrical Equipment Plant (HEEP)

2) Central Foundry Forge Plant (CFFP)

Blocks in HEEP: 
Blocks  Work Performed in Block 

I) Electrical Machine  Turbo Generator, Generator Exciter, Motor (AC and DC) 

II) Fabrication  Large Size Fabricated Assemblies or Components 

Steam, Hydro Turbines, Gas turbines, Turbine Blade, Special 

III) Turbines & Auxiliary 
Tooling. 
Winding of Turbo, Hydro Generators, Insulation for AC & DC 
IV) Feeder 
Motors 
Fabricated Parts of Steam Turbine, Water Boxes, Storage 
V) Fabrication 
Tank, Hydro Turbine Parts 
Fabricated Oil Tanks, Hollow Guide Blades, Rings, Stator 
VI) Fabrication Stamping 
Frames and Rotor Spindle, All Dies, Stamping for Generators 
& Die Manufacturing 
and Motor 

VII) Wood Working  Wooden Packing, Spacers 

LP heaters, Ejectors, Glands, Steam and Oil Coolers, Oil Tank, 

VIII) Heaters & Coolers 
Bearing Covers 

 
Table-2 

Sections in CFFP: 

Blocks  Work Performed in Block 

1.  Foundry  Casting of Turbine Rotor, Casing and Francis Runner 

2.  Forging  Forging of Small Rotor Parts 

3.  Machine Shop  Turning, Boring, parting off, Drilling etc. 

Table -3 

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1.3.5. HEEP PRODUCT PROFILE 

1. THERMAL SETS:

• Steam  turbines  and  generators  up  to  1000  MW  capacity  for  utility 
and combined cycle applications.

• Capability to manufacture up to 1000 MW unit cycle.

2. GAS TURBINES:

• Gas  turbines for industry and utility application range 3 to 200 MW 
(ISO).

• Gas turbines based co-generation and combined cycle system.

3. HYDRO SETS:

• Custom–  built  conventional  hydro  turbine  of  Kaplan,  Francis  and 

Pelton with matching generators up to 250 MW unit size.

• Pump  turbines  with  matching  motor-generators.  Mini  /  micro 

hydro sets.

• Spherical  butterfly  and  rotary  valves  and  auxiliaries  for  hydro 

station.

4. EQUIPMENT FOR NUCLEAR POWER PLANTS:

• Turbines and generators up to 500MW unit size.

• Steam generator up to 500MW unit size.

• Re-heaters / Separators.

• Heat exchangers and pressure vessels.

14
5.  ELECTRICAL MACHINES:

• DC  general  purpose  and  rolling  mill  machines  from  100  to 
19000KW  suitable  for  operation  on  voltage  up  to  1200V.  These 
are  provided  with  STDP,  totally  enclosed  and  duct  ventilated 
enclosures.

• DC auxiliary mill motors.

6. CONTROL PANEL:

Control  panel  for  voltage  up  to  400KW  and  control  desks  for  generating 
stations and EMV sub–stations. 

7. CASTING AND FORGINGS:

• Sophisticated  heavy  casting  and  forging  of  creep  resistant  alloy 

steels,  stainless  steel  and  other  grades  of  alloy  meeting  stringent 
international specifications.

8. DEFENCE:

• Naval guns with collaboration of Italy.

15
 
2. MANUFACTURING OF STEAM TURBINE

2.1. INTRODUCTION: 

A  steam  turbine  is  a  mechanical  device  that  converts  thermal  energy  in 
pressurized  steam  into useful mechanical work. The steam turbine derives much 
of  its  better  thermodynamic  efficiency  because  of  the  use  of  multiple  stages  in 
the  expansion  of  the  steam.  A  turbine  is  a  rotary  engine  that  extracts  energy 
from  a  fluid  flow  and  converts  it  into  useful  work.  The  simplest  turbines  have 
one  moving  part,  a  rotor  assembly,  which  is  a  shaft  or  drum  with  blades 
attached.  Moving  fluid  acts  on the blades, or the blades react to the flow, so that 
they move and impart rotational energy to the rotor. 

Fig.1 Sectional View of a Steam Turbine 

16
 
2.2. PRINCIPLE: 

The  steam  energy  is  converted  mechanical  work  by  expansion  through  the 
turbine.  The  expansion  takes  place  through  a  series  of  fixed  blades  (nozzles) 
and  moving  blades  each  row  of  fixed  blades  and  moving  blades  is  called  a 
stage.  The  moving  blades  rotate  on  the  central  turbine  rotor  and  the  fixed 
blades  are  concentrically  arranged  within  the  circular  turbine  casing  which is 
substantially designed to withstand the steam pressure. 

Since  the  fluid  is  at a lower pressure at the exit of the turbine than at the inlet, 

it  is  common  to  say  the  fluid  has  been  “expanded”  across  the  turbine. 
Because  of  the  expanding  flow,  higher  volumetric  flow  occurs  at  the  turbine 
exit  (at least for compressible fluids) leading to the need for larger turbine exit 
areas than at the inlet. 

Fig.2 Flow Diagram of a Steam Turbine 

Also  note  that  turbines  in  high  inlet-pressure  applications  are  sometimes 
called  expanders.  The  terms  “turbine”  and  “expander”  can  be  used 
interchangeably  for  most  applications,  but  expander  is  not  used  when 
referring  to  kinetic  energy  applications,  as  the  fluid  does  not  go  through 
significant expansion​. 
17
 
2.3. ADVANTAGES: 

• Ability to utilize high pressure and high temperature steam.

• High efficiency.

• High rotational speed.

• High capacity/weight ratio.

• Smooth, nearly vibration-free operation.

• No internal lubrication.

• Oil free exhausts steam.

2.4. 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: - 

BHEL  has  the  capability  to  design,  manufacture  and  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 600ºC. 

2.5. STEPS INVOLVED IN THE DESIGN OF STEAM TURBINES: - 

1. Perform thermodynamic and axial thrust calculations to decide 

diameters and axial length of blading. 
 
2. Perform rotor dynamic calculation and suggest any change of lengths 
and diameters to repeat step one. 
 
3. Select suitable turbine extensions and diameters to meet above blading 
geometry. 
 
4. Select suitable materials to meet steam parameters. 
 
5. Select suitable governing system and protection system. 
 
6. Prepare ordering / manufacturing documents incorporating above 
selections. 

18
 

3. TYPES OF STEAM TURBINE

Steam  turbines  may  be  classified  into  different  categories  depending  on their 
construction,  the  process  by  which  heat  drop  is  achieved,  the  initial  and final 
conditions  of  steam  used  and  their  industrial  usage.  Most  of  the  industrial 
steam  turbines  are  high  speed  turbines  for  the  power  output  range  of 
1-30MW  with  speed  reduction  by  turbo  gears  which  in  turn  means  smaller 
sizes  and  higher  efficiency  for  the  turbine  for  the output of 30MW and above 
the turbine speed is 3000rpm. 

• Impulse turbines.

• Axial Reaction turbines.

• Radial reaction turbines without any stationary guide blades.

• Radial reaction turbines having stationary guide blades.

• Single – stage turbines with one or more velocity stages usually of small 
power capacities, mostly used for driving centrifugal compressors, 
blowers and other similar machinery.

• Multistage impulse and Reaction turbines, made in a wide range of power

capacities varying from small to large. 

There are complicated methods to properly harness steam power that give 
rise to the two primary turbine designs: impulse and reaction turbines. 

3.1 Comparison Between Impulse and Reaction Turbine: 

• In impulse turbine the pressure of steam remains constant during its flow 
through the moving blades. But in reaction turbine, the pressure of steam 
reduces during its flow through the moving blades.

• In impulse turbine the steam flows through the nozzle and strikes on 
the moving blades. In reaction turbine steam first flows through the 
guide mechanism and then flows through the moving blades.
19
  
• In impulses turbine, steam strikes on the moving blades with kinetic 
energy only. But in the reaction turbine, the steam which glides over the 
moving blades possesses both pressure and kinetic energy.
20
  
4. TURBINE PARTS 

4.1 NOZZLE: 

The nozzle expands steam of comparatively low velocity and high static 
pressure within considerable increase in velocity. The nozzle is so positioned 
as to direct the flow of steam into the rotor passage. 

4.2 DIFFUSER: 

It is a mechanical device that is designed to control the characteristics of 

steam at the entrance to a thermodynamic open system. Diffusers are used 
to slow the steam's velocity and to enhance its mixing into the surrounding 
steam. 

4.3 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. 

4.4 GUIDE BLADES​: 

Often  a  turbine  is  arranged  with  a  series  of  rotor  flow  passages.  Intervening 
between  the  blades  comprising  the  rotor  passages  are  rows  of  stationary 
guide  blades.  The  purpose  of  this  guide  is  to  reverse  the  direction  of  steam 
leaving  the  preceding  moving  blade  row  so  that  general  direction  of  steam 
leaving the preceding moving blade rows is similar. If guide blades were not 

21
 
provided, opposing force would be exerted on the rotor which would largely 
negate each other. 

4.5. TURBINE CASING: 

The  turbine  enclosure  is  generally  called  the  casing  although  the  other  two 
names  are  in  common use. The nozzle and guide are fixed on casing, which in 
addition  to  confining  the  steam  serves  as  support for the bearings. 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  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. 

4.6. SHAFT, ROTOR, SPINDLE: 

These terms are applied to the rotating assembly which carries the blades. 

22
 
4.7 TURBINE GOVERNING SYSTEM: 

Mechanical governor: 

The  purpose  of  a  mechanical  governor  is  to  maintain  the speed of the turbine 

at  a  desired  value  when  the  generator  is  disconnected  from  the  power 
supply. Main parts of mechanical governor: 

Flyweights 

Bracket Spring 

etc. 

Mechanism: 

When  the  turbine  shaft  rotates,  the  governor  flyweights  respond  to  the 
centrifugal  forces  created  by  the  rotations.  As  turbine  speed  increases,  the 
centrifugal  force  increases,  causing  the  flyweights  to  move  outward, 
overcoming the tension of the spring. 

23
 

5. FEATURES OF A BLADE 

Blades are the heart of a turbine, as they are the principal elements that 
convert the energy of working fluid into kinetic energy. Efficiency of the 
turbine depends on the following parameters. 

• Inlet and outlet angle of the blade

• Surface finishing of the blade

• Profile of the 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.

5.1. Blade Material: - 

Among the different materials typically used for blading are 403 stainless 
steel, ​422 stainless steel, A286, and and titanium alloy. 

The ​403 stainless​ steel is essentially the industry’s 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. 
24
 
The ​422 stainless​ steel material is applied only on high temperature stages 
(between 370 and 480°C), where its higher yield, endurance, creep and 
rupture strengths are needed. 

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. Blades are made of alloy steel which mainly contains carbon, 
chromium, nickel, molybdenum. 

5.2. H.P. BLADE PROFILES 

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  and  an  identical  point  on  the  next 
blade. 

25
 

5.3. 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.  The  Steam  turbines 
use  the  impulse  profiles  for  the  control  stage  (1st  stage),  and  the  reaction 
profiles for subsequent stages. 

5.4. 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. The 
roots  are  T-root and Fork-root. The fork root has a higher load-carrying capacity 
than  the  T-root  the  typical  roots  used  for  the  HP  moving  blades  for  various 
steam turbine applications are shown in the following figure: 

T- ROOT
T- ROOT WITH SIDE GRIP

26
  
BLOCK 3 LAY-OUT 

6. CLASSIFICATION OF BLOCK 3 

6.1. 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.  Asia’s  largest  vertical  boring  machine  is  installed  here  and  CNC 
horizontal boring milling machines from Skoda of Czechoslovakia. 
27
 

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. 
28
 
6.2. BAY –2 IS DIVIDED IN TO 2 PARTS: 

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. 

6.3. 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. 

29
 
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. 

6.4. 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. 

Fig 5. Steam Turbine Casing & Rotors in Assembly Area 

30
 
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. 
31
  
7. 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  center  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. 

7.1. TYPES OF BLADES 

• HP BLADES (high pressure blades)

• IP BLADES (intermediate pressure blades)

• LP BLADES (low pressure blades)

Constructional Features of Blades​: 

High pressure blades are mainly divided into three parts: 

a) Profile​: The profile which converts thermal energy of steam into kinetic 
energy and with certain efficiency depending on the shape of profile. 
 
 
b) Root:​ The root which fixes into the turbine rotor which gives the proper 
anchor to the blade and transmitting the kinetic energy of blade to the rotor. 
Different kinds of roots of blades used are 
 
• T-root

• Double T-root

• Fork root

• Firtree root

• Dove tail root

c) Shroud: ​The dampening element which reduces the vibration the 
​ ccurs in the blade which forms due to the flowing of high pressure 
vibration​ o
steam 

32
 
through the blades. This dampening element may be integral with the blade or 
that may be separate element mounted between the blades. 

3 Dimensional  Cylindrical Profile  Twisted Profile 

3DS Blade  TX Blade  F Blade 

HP/IP Initial Stages  HP/IP Intermediate stages  HP/IP  Rear 

Stages 
& LP Initial 

Fig. 7 Types of Blades 

7.2. OPERATIONS PERFORMED ON BLADES 

Some of the important operations performed on blade manufacturing are: - 

• Blank Cutting. (length cutting o/p)

• Width Milling o/p.

• Surface Grinding o/p.

• Angular/Orbital/Rhomboid Milling o/p. (angular shape)

• Angular/Orbital/Rhomboid Grinding.

• Profile Cutting.

• Root making.
33
 
7.3. 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.

7.4. 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 horizontal boring machine with 6 axis CNC control.

• CNC shaping machine.

34
 
8. BHEL in year 2016-17 at a glance. 
35
 

9. END NOTE. 

Gone  through  rigorous  4  Weeks  training  under  the  guidance  of  capable 
engineers  and  workers  of  BHEL  Haridwar  in  Block-3  “TURBINE 
MANUFACTURING” 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  and 
machining processes which was shown on heavy to medium machines. 

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. 
36
 

10. REFRENCES: - 
 
▪
BHEL Annual Report. (2016-17, 
2015-16) 
▪

▪
BHEL Official Website. 
International Refereed Journal of 
Engineering and Science (IRJES) 
 
37
 
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