About BHEL

Bharat Heavy Electricals Limited, or BHEL, is a state owned enterprise which

is an integrated power-plant equipment manufacturer and one of the oldest and
largest engineering and manufacturing companies in India .It is the 12th largest
power equipment manufacturer in the world. According to Forbes, in 2011
BHEL was ranked ninth most innovative company in the world.
BHEL, Bhopal, was established in on 29th August, 1956, with the technical
assistance of Associated Electronics(India) Ltd. which is a U.K. based
company.
Pt. Jawaharlal Nehru, the first Prime minister of India dedicated this plant to the
nation on 6th November, 1960

BHEL, Bhopal, is situated 5 kms from the Habibganj Railway Station, which is
also the nearest railway station from BHEL Bhopal. Bhopal Railway station is 7
kms and Raja Bhoj Airport is 18kms away from BHEL, Bhopal.

BHEL engages in designing, engineering, manufacturing, testing, and

servicing a wide range of products and services for the core sectors of economy
like Power, Transmission, Industry, Transportation, Renewable Energy, Oil &
Gas and Defence. It imports raw materials from other companies and processes
the material by performing different type of workshop activities to get the
finished part of the required dimension, which are then assembled to make
different components of a Power plant like a steam turbine, heat exchangers etc.
BHEL is affiliated with Siemens AG, which is a Europe based electronics and
electrical engineering company. BHEL is supplied with blueprints by Siemens
which BHEL uses to manufacture Steam Turbines.

BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is
moving towards excellence by adopting TQM as per EFQM / CII model of
Business Excellence. Heat Exchanger Division is accredited with ASME U

Stamp. With the slogan of Kadam kadam milana hai, grahak safal banana hai,
it is committed to the customers.

BHEL, Bhopal produces Hydro, Steam, Marine & Nuclear Turbines, Heat
Exchangers, Hydro & Turbo Generators, Transformers, and Switchgears,
Control gears, Transportation Equipment, Capacitors, Bushings, Electrical
Motors, Rectifiers, Oil Drilling Rig Equipment and Diesel Generating sets.

Some Products of BHEL, Bhopal

2.1 AC Motors & Alternators
BHEL is a leading AC Machines manufacturer and in the last four decades
have supplied more than20000 HT & LT A.C. Machines for various
applications to Indian as well as Export market. The applications include
Power Plants, Nuclear Energy, Petrochemicals, Fertilizers, Refineries, Cement
& Steel Industries, Irrigation Projects, Pipelines, etc.

2.2Turbines
1) Design, Manufacturing, Erection, Commissioning and Services of :

30 MW, 120 MW Steam Turbines

236 MW Nuclear Turbines.
15000 SHP Marine Turbines
210 MW Steam Turbines.
2) Supply of Spares and Repairs of above Steam Turbines.

3) R & M and Life assessment studies of BHEL & Non BHEL TG sets.
4) Repair and Supply of Spares of 210 MW and 500 MW KWU Turbines.

5) Repair and supply of Spares for Non BHEL TG Sets.

Diversified Projects
For IPR and ISRO: Manufacturing of various components.

2.3 Hydro generator

Hydro generator is a synchronous alternator driven by a hydraulic turbine.
Motor is synchronous motor to drive pump. BHEL Bhopal is a leading supplier
of large, medium & small hydro generators, motors, bulb generators and
related service

2.4 Heat Exchanger

Different types of auxiliary heat exchangers are being manufactured at BHEL.
Depending upon application these auxiliary Heat Exchangers are named as. Air Coolers (CACW)
. Oil Coolers (Shell & tube type / Frame and tube type
(Single tube &
concentric double tube construction) / OFAF), Plug in type
. Water Cooler (Shell & Tube type)
. Hydrogen Cooler etc. (Frame and tube type).
. Air Cooler CACA (Duct and tube type)
These coolers are accessories to main equipments such as Generator, Turbine,
and Transformer. To ensure long life of these coolers materials for different
components is decided carefully considering its application and water
chemistry. Constructionally these coolers are very easy to maintain.

2.5 Transportation Equipment

BHEL's involvement in the transportation sector has been marked with rapid
growth. Today over85% of Indian Railways, one of the largest railway
networks in the world is equipped with traction equipment built by BHEL.
The range includes traction motors, traction generators/alternators, transformers,
sub-station equipment, vacuum circuit breakers, locomotive bogies, smoothing
reactors, exciters, converters, inverters, choppers and associated control
equipment, viz. master controllers, HSCBs, chopper controllers brake and door
equipment, electronic controls including software based controls extending to
rolling stock and other transport applications.
2.6 Renovation and Maintenance of Equipment

the

BHEL is the largest producer of power generating equipment including

turbines, generators, boilers and auxiliaries in the country. BHEL has already
supplied thermal sets up to 500 MW rating and has the technology to go up to
800 MW. BHEL manufactured 500/236 MW Nuclear sets are also installed in
country.
The BHEL manufactured sets accounts for 65% of total installed capacity in
India. There is ample scope for improving the plant availability by cutting down
the shutdown period, by Renovation & modernization, Rehabilitation and by
timely arranging the spare parts and other services.

Overview of Steam Turbines

Definition: A steam turbine is a device that extracts thermal energy from
pressurized steam and uses it to do mechanical work on a rotating output shaft.

In a Thermal Power Plant, coal is burned to produce heat which in turns boils
water to produce steam. This steam has very high pressure, which is used by
the turbine to rotate the rotor which turns the generator to produce electricity.

There are many ways to produce high pressured steam which can be used .There
are:
1. Conventional Methods
a. Hydro Power Plant
b. Thermal Power Plant
c. Nuclear Power Plant

2. Non-Conventional Methods
a. Solar Energy
b. Wind Power
c. Bio-Mass
d. Tidal Energy

As India is a country rich in coal, Thermal power plant are preferred over other
power generating methods. Power produced by coal covers 58% of the total
power produced in India, followed by Hydro Power (27%), then Gas turbine
(11%), and then Nuclear Power (3%).

Components of a Thermal Power Plant

1. Boiler: A boiler is a closed vessel in which water or

other fluid is heated. The heat vaporizes the fluid and as
the fluid changes state, pressure increases in the boiler
chamber.

2. Turbine: A turbine is a rotary mechanical device that

extracts energy from a fluid flow and converts it into
useful work.

3. Condenser: Condenser is a heat exchanger which

convert steam from its gaseous state to its liquid at a
pressure below atmospheric pressure.

4. Pump: The pressure in the boiler when water is

boiling is very high. Pump pressurizes the
condensed water to the required pressure so that
the water does not backflow. The usual pressure
provided by the pump is about120% of the
pressure in the boiler.
5. Generator: An Electric Generator is a device which
converts mechanical energy to electrical energy. When
the rotor of a steam turbine moves, the shaft of the
generator which is coupled with the rotor, also rotates.
This in turn produces electricity using the principle of
electromagnetic induction.

Types of Steam Turbines

Steam turbines are made in a variety of sizes ranging from small <0.75 kW
(1< hp) units (rare) used as mechanical drives for pumps, compressors and other
shaft driven equipment, to1,500,000 kW(2,000,000 hp) turbines used to
generate electricity. Steam Turbines are classified into 3 types:
On the basis of Steam Supply and Exhaust Condition.
Casing or Shaft Arrangement
Two-Flow Rotors

1) On the basis of steam supply and exhaust conditions

These types include condensing, Noncondensing, 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.

Extracting type turbines are common in all applications. In an extracting type

turbine, steam is released from various stages of the turbine, and used for
industrial process needs or sent to boiler feed water heaters to improve overall
cycle efficiency. Extraction flows may be controlled with a valve, or left
uncontrolled.
Induction turbines introduce low pressure steam at an intermediate stage to
produce additional power.

2) On the basis of Casing or shaft arrangements

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 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.

3) 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.
As the steam flows through the nozzle its pressure falls from inlet pressure to
the exit pressure(atmospheric pressure, or more usually, the condenser
vacuum). Due to this higher ratio of expansion of steam in the nozzle the steam
leaves the nozzle with a very high velocity.
The steam leaving the moving blades has a large portion of the maximum
velocity of the steam when leaving the nozzle. The loss of energy due to this
higher exit velocity is commonly called the "carry over velocity" or "leaving
loss".

4) 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 rotor, with no net
change in steam velocity across the stage but with a decrease in both pressure
and temperature, reflecting the work performed in the driving of the rotor.

Working principle of Steam Turbine

1. Steam at high pressure & temperature is made to pass through a row of fixed
blades or nozzles mounted on stationary body in Casing.
2. There will be drop in pressure of the steam across the fixed blade resulting to
very high steam velocity at the exit of fixed blade
3. The high velocity steam then impinges on another row of rotating
blades
4. The impingement
high velocity steam generates driving force on
mounted
on the rotor of
shaft
these
5.rotating
A set ofblades
fixed which
blades rotate
and rotating
the rotor.
blades mounted on rotor is called stage of
turbine. Depending on steam condition and power output, number of stages in
steam turbine is decided.

Components of a Steam Turbine

Main Components:
1. Fixed/Guide blades
2. Moving Blade
3. Cylinder
4. Rotor
5. Gland Seals
6. Bearing and bearing Pedestal
7. Coupling
8. Stop and control valves
9. Governing system
10.Control and Instrumentation

Guiding Blades : These blades are fixed to the casing of the turbine. They are
positioned at an angle to the direction of the incoming steam, so that the steam
impinges the moving blades in such a way that amount of energy transfer in the
form of kinetic to mechanical is maximum. Different types of turbines engage
different type of blades. There is a difference in their size, shape, design and
mechanical properties to withstand the different physical conditions the blade is
subjected to by the turbine.
Guiding blade requires various features such as dimensional accuracy,
durability, functional accuracy and trouble-free operations.

Guiding Blades

A set of fixed blades and rotating blades mounted on rotor is called stage of
turbine. Depending on steam condition and power output, number of stages in
steam turbine is decided.

Moving Blades: These are the blades which are connected to the rotor. As
the steam impinges on these blades, they are forced to move, which causes the
rotor to rotate and produce energy in the generator. They are also designed
especially for obtaining the maximum power transfer.

Moving blade requires

Sturdy construction
Corrosion resistance
High efficiency
Abrasion resistance

Moving Blades

The material used to make the blade depends on the type of turbine it is going to
be used in. For instance, HP and IP stage blades are generally made from 12Cr
martensitic stainless steels. However, blades used in high temperature (> 450 C)
HP or IP applications may be made of austenitic stainless steels because they
have better mechanical properties at high temperatures. LP blades are often, but
not exclusively, made from12Cr stainless steels also. Common types of
stainless steel used in LP sections include AISI types 403, 410, 410-Cb, and
630; the exact type of steel chosen for a particular LP application depends on
the strength and corrosion resistance required. Since the 1960s, titanium alloys,
especially Ti-6Al-4V, have also been used for LP turbine stages. These alloys
are particularly suited to LP stages for a number of reasons.
Other important requirements of material for blades of steam turbine HP and IP Guide Blades
Weld ability.
High creep and fatigue strength.
Good resistance to the oxidation and corrosion at the same temperature.
High quality surface finish to ensure smooth steam flow and to avoid
subsequent pressure drop.
Adequate ductility to accommodate cumulative strain due to thermal
fatigue and creep during the service life.
Low Pressure Guide Blades
Weld ability / Cast ability.
Good room temperature proof strength.
Good fatigue strength.
Adequate rupture ductility.

 High quality surface

finish.
High
creepIPstrength
fatigue strength.
HP And
Movingand
Blades
Good resistance to oxidation and corrosion.
Moderate damping capacity.
Good fracture and impact toughness.
Good surface finish.
LP Moving Blades
Good corrosion and emission resistance.
Good Vibration damping capacity.
Good room temperature, fatigue strength and proof strength.
Good surface finish.
Adequate notch rupture ductility.

There are four sides to a blade:

The blade can be right handed or left handed:

Nomenclature of a Cylindrical Blade:

If

a blade is referred to as
T4 is the type of profile
25 is the rhomboid width

55 is the stagger angle of the profile

Some types of cylindrical blade profiles are:

T4-25-55, then it means

Steam Turbine Rotor:

The moving steam imparts both a tangential and axial thrust on the turbine
shaft, but the axial thrust in a simple turbine is unopposed. To maintain the
correct rotor position and balancing, this force must be counteracted by an
opposing force. Either thrust bearings can be used for the shaft bearings, or the
rotor can be designed so that the steam enters in the middle of the shaft and
exits at both ends. The blades in each half face opposite ways (as shown), so
that the axial forces negate each other but the tangential forces act together. This
design of rotor is called two-flow or double-exhaust. This arrangement is
common in low-pressure casings of a compound turbine.

1. HP, IP AND LP rotor forgings were imported earlier but now Hp and IP
rotor are manufactured at CFFP Haridwar.
2. Earlier all rotors has boroscopic hole at the centre due to forging
technological constraint.
3. BHEL Bhopal all turbine rotors are with integral disc.
4. 210MW Russian design rotors manufactured at haridwar and 110 MW
Czechoslovakia design rotors manufactured at Hyderabad have shrunk
fitted disc on IP and LP rotors.
5. Rotors forging are machined in STM shop. Various type of disc heads are
machined to suit the corresponding blade roots.
6. Various blade roots are troot, fire-tree, fork and pin, axial entry and
curved axial entry.
7. 2-tier Blade is used in 720MW due to Baumann exhaust.
8. Large Difference in temperature of various parts during starting/shutdown
may cause rubbing, distortion, bend and other serious problems.

Control and Instrumentation:

Control and instrumentation is a very important area for proper functioning of a
steam turbine. The operator, by controlling the functioning of the turbine,
ensures the output given by the turbine and also control other important factors
like if the turbine is working in limits prescribed to be safe.
Through Instrumentation and Control us:
Monitor
Protect
Measure
The working of a turbine.

The scope of Control and Instrumentation is

Equipment functional requirement
Safety requirements
Customer specification requirements
Matching with the hardware platform
System Engineering
Customer/ consultants approval
H/W & S/W engineering by EDN
Primary Instrumentation Engg. By HWR

Governing System:
Turbine governing is the process of regulating the rotating speed of the output
shaft connected to the generator so that it remains constant. Variation in load
affects the performance, so an even speed is required. The primary objective in
the steam turbine operation is to maintain a constant speed of rotation
irrespective of the varying load. This can be achieved by means of governing in
a steam turbine.

Methods of Governing:

Throttle Governing
In throttle controlled turbines, steam flow is controlled by simultaneous opening
or closing of all control valves allowing the steam to flow to the group of
nozzles located on the entire periphery.

Throttle Governing

Throttle Governing
Nozzle Governing:
In nozzle controlled turbines, steam flow is controlled by sequential opening
and closing of control valves allowing steam to flow to associate nozzle
groups. In this method groups of two, three or more nozzles form a set and
each set is controlled by a separate valve. The actuation of individual valve

closes the corresponding set of nozzle thereby controlling the flow rate.

Nozzle Governing

Types of Governing system

Mechanical
Here the speed transmitter is mechanical centrifugal type speed governor
which actuates control valves through mechanical linkages. Pure
Mechanical governing systems are not used for utility turbines now a day.
Hydro-Mechanical
In hydro mechanical governing system speed transmitter is mechanical
centrifugal type speed governor. It is connected to a hydraulic system
either hydraulically or mechanically.
Hydraulic
In Hydraulic governing system, speed transmitter is centrifugal pump
whos Disch.PR. Is proportional to square of speed. The PR. Oil is sent to
hydraulic governor which generates a Hyd. Signal proportional to valve
opening/closure required.
Electro-Hydraulic
In Electro-Hydraulic governing system, speed transmitter is electrical
speed measuring device which sends an electrical signal to electronic
controller to a hydraulic system. The Hydraulic system is amplified as
that control valves servomotors can be actuated.

3.10 Vibrations/ Balancing/ Alignment of Steam Turbines

HP, IP and LP rotors and generators rotors are coupled together.
Each rotor is individually balanced about its own axis and has a residual
unbalance.
These rotors rotate about a common axis which is axis of rotation.
During assembly of stationary and rotating parts design radial and axial
clearances are achieved to ensure smooth running.
Vibration is the main criteria for the smooth running of the machine.
The increase in vibration level indicates that there is some problem.

Energy losses in Steam Turbines

In an ideal steam turbine, the process of expansion of steam is assumed to be
isentropic and the only loss which requires attention is carry over loss. In actual
turbine, apart from carry over loss, other loss creep in, as a result of friction and
turbulence in steam flow, due to leakage of steam through various clearances
etc.
Apart from this, turbine work is always accompanied by mechanical losses due
to friction in linkage mechanism and bearings. The above losses have different
characteristics and can be divided into two main groups, namely external and
internal losses.
Internal losses are connected with flow of steam through blade passages
and
accompanied with changes in the condition of steam.
External losses are those that do not directly influences steam conditions. In this
group, these are mechanical losses, which include losses in bearings and
reduction gearing.

3.8.1 Internal Losses

The internal losses can further be classified as Losses in regulating valves.
Losses in nozzles.
Losses in moving blades.
Carry over losses.
Losses due to disc friction and windage.
Losses due to wetness of steam.
Losses in exhaust load.
Losses due to axial and radial clearances.
3.8.2 External Losses
Mechanical losses

 Losses due to steam leakage through

seals.

Thermal Power Station:

A thermal power station is a power plant in which the prime
mover is steam driven. Steam is produced in the boiler by heating water and as
the steam reaches a very high pressure, steam is released in the turbine. As the
high pressure steam hits the blades of the turbine, the heat energy of the steam is
converted into kinetic energy, and the rotor of the turbine rotates the generator
shaft which in turns produces electricity. After it passes through the turbine, the
steam is condensed in a condenser and recycled to where it was heated; this is
known as a Rankine cycle. The greatest variation in the design of thermal power
stations is due to the different fuel sources. Some prefer to use the term energy
centre because such
facilities
convert
forms
of heat energy into
electricity. Some thermal power plants also deliver heat energy for industrial
purposes, for district heating, or for desalination of water as well as delivering
electrical power. A large part of human CO2emissions comes from fossil fuelled
thermal power plants; efforts to reduce these outputs are various and
widespread.

Rankine Cycle:
The Rankine cycle is a cycle that converts heat into work. The heat is supplied
externally to a closed loop, which usually uses water. This cycle generates about
90% of all electric power used throughout the world, including virtually
all solar thermal, biomass, coal and nuclear power plants. It is named
after William John Macquorn Rankine, a Scottish polymath and Glasgow
University professor. The Rankine cycle is the fundamental thermodynamic
underpinning of the steam engine.

IDEAL RANKINE CYCLE-

4.4 Steam Cycles

Sub critical Cycles
- Pressure up to 200 bar
- Temperature 530 to 565 C
Supercritical Cycles
- Pressure up to 250 bar

- Temperature 540 to 565 C

Ultra supercritical Cycles
- Pressure > 250 bar
- Temperature > 565 C

4.5 Definition of critical conditions

Critical is a thermodynamic expression describing the state of a substance
beyond which there is no clear distinction between the liquid and gaseous
phase.
The critical pressure and temperature for water are
Pressure =225.56 kg/cm2
Temperature =374.15 o c

4.6 Advantages of Supercritical cycle

Steam Power plant efficiency increases with increase in steam pressure and
temperature.
With higher cycle efficiency, the supercritical cycle offers the advantage of
burn less fuel for the same output and lower emission. (Lesser Pollutants SOX, NOX & CO2)

4.7 Measures to improve Power Cycle Performance

Increase in Main & Reheat steam temperature.
Increase in main stream pressure.
Reduction in condenser back pressure.
Increase in final feed water temperature.
Double reheat.
Reducing the flue gas exit temperature.
Improving individual component efficiency.

Machines in Machine Shop

1) KREVHAN

ROTOR
ADJUSTING
(MACHINE No. -20/A/27)

LATHE

SPEED- 0.195-20 R.P.M

DISTANCE FROM CENTRE-7315 mm
MAXIMUM SWING OVER SPED-3048 mm
HEAD STOCK FACE PLATE DIAMETER- 1829 mm
FACE PLATE GRIPING CAPACITY-203-1575 km
2) WOTON CNC RAM BORAR
(MACHINE No. -20/A/2088)
CONTROL SYSTEM SIMENS 8-40-D
COLOUMN CROSS CONTROL- 8000 mm
HEAD STOCK VERTICAL TRAVEL-3500 mm
RAM TRAVEL-700 mm
SPINDEL TRAVEL-1000 mm
TABLE SIZE-2500 X 3000 mm
LONGITUDINAL TRAVEL- 2000 mm
3) BERTHIZ VERTICAL BORING AND TUNING
(MACHINE No. - 20/A/302)
SPEED- 6-60 RPM
FEED- 0.6-16 RPM
DIAMETER OF TABLE- 4000 mm
MAXIMUM TURNING DIAMETER-1600 mm
ARM LENGTH- 3700 mm

27.
4) PLANOMILING MACHINE
DIFFERENT PARTS:
TABLE, FRONT HEAD, SIDE
HEAD, WOVER ARM, SPINDLE, PANNEL etc.
PRINCIPLE:-THIS MACHINE WORKS ON HYDRAULICS
PRINCIPLE.
No. OF CUTTERS:-FACE CUTTER, MILL CUTTER, SLOTTED
DRILL CUTEER, T-SLOT CUTEER, FACING CUTEER, DRILLS.
PARTS MADE BY THIS MACHINE:1) STEAM TURBINE CASING
2) BUTTERFLY VALVE BODY MACHINING
3) TRUNINON SHAFT
4) TABLES
5) SPHERICAL PIECE
6) SPHERICAL SUPPORTS
7) BEARINGS
8) DOOR BODY
9) SEALING RING
10) TRUNION BLOCK
THEY USE CARBIDE TIP TO CUT THE JOB AND ITS VERY
COSTLY ALSO.
5) BERBIZ VERTICAL BORING AND TURNING MACHINE
(MACHINE No.-20/A/68)
SPEED-2.5-125 RPM
FEED-0.066-6 mm/round
DIAMETER OF TABLE-1800 mm
MAXIMUM DIAMETER TURNABLE-2900 mm

HEIGHT AVALIBLE BENEATH THE ARM - 6.55-1660 mm

6) VERTICAL BORER
(MACHINE No.-20/A/2018)
DIAMETER OF TABLE- 1220 mm
MAXIMUM SWING- 1270 mm
MAXIMUM HEIGHT BENEATH CROSS SLIDE- 914 mm
VERTICAL FEED OF TOO BAR-510 mm
28.
7) KREVAHZ LATHE MACHINE
(MACHINE No. - 20/A/30)
SPEED-0.5-51 RPM
FEED-0.02-6.35 mm
DISTANCE FROM CENTRE-7620 mm
MAXIMUM SWING OVER-1676 mm
HEAD STOCK FACE PLATE DIAMETER-152 mm
FACE PLATE GRIPING CAPACITY- 203-1270 mm
LOAD- 80 TON
8) DRILING AND BORING MACHINE
(MACHINE No. -20/A/2080)
SPEED- 2.5-20 RPM
FEED- .03-69mm
SPINDLE DIAMETER-102 mm
LENGTH ABOVE SPINDLE CENTRE- MAX. 3175, MIN. 737
DEALING SLOT-89 mm
BORING CAPACITY- 457 mm
MILIMG CUTEER- 152 mm

9) HORIZONTAL BORING MACHINE

(MACHINE No. -20/A/2111)
SPINDLE DIAMETER- 127 mm
FACING HEAD- 1524 mm
WIDTH OF TABLE- 1524 mm
MAX. DIAMETER OF BORING- 158.80 mm
29.
10) RICHARD VERICAL BORING AND TUNING MACHINE
(MACHINE No. -20/A/11)
SPEED-0.48-13 RPM
FEED-0.501-102.51 mm/round
VERTICAL DISTANCE- 4877 mm
MAXIMUM TURNING DIAMETER- 4955 mm
MAX. HEIGHT BETWEEN RAM TOOL-3352 mm
11) MORENDO LATHE MACHINE
(MACHINE No.-20/A/2012)
SPEED- 1.5-200 RPM
FEED-0.5-200 RPM
HEIGHT OF CENTRE- 770 mm
DISTANCE BETWEEN CENTRE-6000 mm
SWING BED-1520 mm
MAX. WEIGHT ON CENTRE-30
TON
MAX. WEIGHT ON PLATE-60 TON
FEATURES:12) CNC MAIN
LATHE:-

1) CENTRE TO CENTRE DISTANCE- 10mm

2) CAPACITY 85 TON-80 TON
3) DIAMETER TURNABLE -2750 mm
4) MAX. RPM - 175
5) SEMI MACHINED JOB COMES HERE
13) PLANER MACHINE
TABLE WORKING SURFACE- 7924 X 2895 mm
MAX. WIDTH FROM ABOVE- 3124 mm
CROSS SLIDE MAX. HEIGHT- 3048 mm

14) HORIZONTAL BORING MILING AND TAPING MACHINE

(MACHINE No. - 20/A/61)
SPEED- 4-500 RPM
FEED- 1.27-508 mm/round
SPINDLE DISPLACEMENT-1828 mm
MAX. BORING CAPACITY- 1524 mm
TABLE- 3657 X 1828
SPINDLE DIAMETER- 127 BOZE TAPER M T -7
15) ACSIWTH R G 2 HORIZONTAL BORING AND THREDING
SPEED- 10-410 RPM
FEED-0.14- 686 mm/round
MAX. DRILING CAPACITY- 75 mm
MAX. BORING CAPACITY-180 mm
COLOUMNS HORIZONTAL DISPLACEMENT-7620 mm

SPINDLE HEADSVERTICAL DISPLACEMENT- 3040 mm

16) INOCENTI MILING BORING COLOUMN
MACHINE No. - 20/A/2002
TOTAL DISPLACEMENT OF BORING SPINDLE- 3000 mm
DISPLACEMENT OF HORIZONTAL COLOUMN ON BED- 27600
mm
TOTAL LENGTH OF BED- 40800 mm
VERTICAL DISPLACEMENT SPEED OF SPINDLE- 5000 mm
A) MAIN BORING AND MILING SPINDLE- 3-5-500 RPM
B) HIGH SPEED SPINDL 65-2200 RPM
FEED- 0.64-1700 mm

7. MAJOR DEVELOPMENTS IN BHEL BHOPAL.

Renovation and modernization and life assessment studies of BHEL
make TG sets.
Shot peening facility for steam turbine blades.
Surface condenser for 500MW Bhusawal TPS.
LP (Low Pressure) heaters for 500MW Bhusawal TPS.
HP (High Pressure) heaters for 462 kg/cm2 for 250 Neyveli TPS.
Turbine oil coolers for 500MW Bhusawal TPS.

STEAM TURBINES engineering

At

(S.T.E Department)
BHOPAL (M.P.)

15/12/2013 to 4/1/2014

Prepared and submitted by

Krishna pratap singh
0131me111o34
Department of mechanical engineering
Jai narain college of technology Bhopal (m.p)

CERTIFICATE

This is to certify that the vocational training on Steam Turbine

Engineering has been carried out by KRISHNA PRATAP
SINGH, 0131ME111034, JAI NARAIN COLLEGE OF
TECHNOLOGY at Bharat Heavy Electricals Limited
(BHEL) Bhopal (M.P.) under my guidance in partial
fulfillment for the award of
(BACHELOR OF
TECHNOLOGY) in (MECHANICAL ENGINEERING),
during the academic year 2014-15.

Training Coordinator
Mr. HARIOM PIPLE
(H.R.D.Department)
BHEL, Bhopal (M.P.)

ACKNOWLEDGEMENT
My first experience of training has been successful, a special thanks to the
supporting staff, many friends, family & colleagues with gratitude. I wish to
acknowledge all of them. However, we wish to make special mention of the
following.
First of all I am thankful of Mr. HARIOM PIPLE (HRD),
of B.H.E.L Bhopal, under the guideline of whom I were able to complete my
training. I am wholeheartedly thankful to them for giving us there valuable time
& attention & for providing us a systematic channel for completing my training
in time.
I am also very thankful to B.H.E.L Bhopal, which gave us an opportunity to
learn and firm our concepts in our desired field of interest.

KRISHNA PRATAP SINGH

0131ME111034
Mechanical Engineering Department
J.N.C.T, BHOPAL (M.P)

CONTENTS
1. Introduction of BHEL Bhopal
2. Some products which BHEL Bhopal Manufacture
3. Overview of Steam Turbine
3.1 Components Of A Thermal Power Plant
3.2 Types Of Steam Turbine
3.3 Working Principle
3.4 Main Components
3.5 Blade Terminology and Material
3.6 Blade Profile
3.7 Turbine Rotor
3.8 Control And Instrumentation
3.9 Governing Of Steam Turbine
3.10 Vibration and Balancing
3.11 Energy Losses
4. Thermal Power Plant
4.1 Introduction
4.2 Rankine Cycle
4.3 Cycles with different unit ratings
4.4 Steam Cycles
4.5 Critical Conditions
4.6 Advantages of Supercritical Cycle
4.7 Measure to improve Performance
5. Other workshops visited
5.1 Hydro turbine
5.2 foundry
6. Machines in S.T.M Unit BHEL, Bhopal
7. Major Development in BHEL Bhopal

TYPES OF TOOLS USED

1. BASED ON METAL OF THE TOOL
Three types of tools are used in the machine shop of the workshop of steam
turbine department in BHEL, Bhopal.
1 CARBIDE TOO
Carbide tool is the hardest tool available for machining process in the
workshop. It is basically used to operate on jobs manufactured from
hard metals like alloy steel or stainless steel. The carbide cutting tool
can be either a carbide metal cutting tip brazed on mild steel shank or
a carbide metal bid bolted over a mild steel shank.

2. HIGH SPEED STEEL TOOL

HSS are used in metals which are relatively softer than above metals.
The tool is single piece high speed steel having one cutting edge

2. BASED ON CUTTING EDGES OF THE TOOL

Based on the number of cutting edges tools are of three types.

1. Single point cutting tool

Example: Cutting tool conventional lathe machines.

2. Multipoint cutting tool

Example: Drill beat, milling cutter, grinding wheel etc.

Note: The coolant used in the metal removal processes is the solution of the
cutting oil in water either in the oil to water ratio of
1:10 or 1:20
depending on the need of the amount of coolant required.

OTHER WORKSHOPS VISITE

1 HYDRO TURBINES DEPARTMEN
Broadly, a hydro turbine converts the potential energy of water into
the rotational energy of the turbine and eventually to electrical energy.
The main parts of a hydro turbine are:
1 PIVOT RING: its primary objective is to support the guide
vane.
2 GUIDE VANES: Primary objective of the guide vanes/ stay
vanes is to convert the pressure energy of the fluid into the
momentum energy. They also serve to direct the flow at design
angles to the runner blades.

3 RUNNER: - The kinetic energy is converted to the rotational

energy. The shaft mounted gets rotated with the runner.
Blades/buckets depending on need captures most of the energy
from water.
(The runners perform most efficiently at specific head and
pressure)
(High tensile stainless steel runners are excellent for large systems
or abrasive water conditions)
4 SPIRAL CASING: Spiral casing around the runner of the
turbine is also known as volute. All throughout its length it has
numerous openings at regular intervals to allow water to impound
on the blades of the runner. These openings convert the pressure

energy into the momentum energy just before the fluid impounds
the blades of the runner.
To maintain constant flow rate of water despite many
openings, the cross sectional area constantly decreases, along the
circumference.
5 TOP COVER: The top cover of the turbine sits over the upper
portion of the STAY RING, connected with the pivot ring with the
help of bolts. It also supports the guide vanes.
6 STAY RING: The stay ring is the parent casing which holds
the pivot ring, the guide vanes and the top cover. The width of the
stay ring is equal to the width of the guide vanes.
The runner and the shaft (mounted over the runner and coupled
with the shaft of the generator) rotate in the casing (pivot ring,
then guide vanes, then top cover, all mounted in the stay ring)
without any friction coming in action between them and the
casing.
The shaft is coupled with the shaft of
the generator
which also rotates with the speed of the rotor.
The hydro power plant also uses valves to regulate the flow of water from the
penstocks. Two types of valves are used: -

1. BUTTERFLY VALVE : Takes less space

Used in low pressure set ups

2. SPHERICAL VALVE : Takes more space

Expensive setup
Feasible for high pressure setup.

TYPES OF HYDROTURBINES
1. PELTON TURBINE
2. FRANCIS TURBINE
3. KAPLAN TURBINE

1. PELTON TURBINE :Pelton turbines/wheels are suitable for power extraction, when
water energy is available at high head and low flow rate. In this
video we will go through working principle and design aspects of
Pelton turbine. When high speed water jet injected through a
nozzle hits buckets of Pelton wheel; it induces an impulsive force.
This force makes the turbine rotate. The rotating shaft runs a
generator and produces electricit

2 FRANCIS TURBINE
hen high speed water jet injected through a nozzle hits
buckets of
Pelton wheel; it induces an impulsive force. This force makes the
turbine rotate. The rotating shaft runs a generator and produces
electricity.

3.
Kaplan turbines derive motive force from pure reaction.
They
work efficiently when there is a huge water flow available

FOUNDRY SHOP
The foundry shop in BHEL, Bhopal uses high silica sand as its moulding
sand over the conventional use of the green sand.
ilica (SiO2) sand is the sand found on a beach and is also the most
commonly used sand. It is made by either crushing sandstone or taken
from natural occurring locations, such as beaches and river beds.
The fusion point of pure silica is 1,760 C (3,200 F), however the sands
used have a lower melting point due to impurities. For high melting point
casting, such as steels, a minimum of 98% pure silica sand must be used;
however for lower melting point metals, such as cast iron and nonferrous metals, a lower purity sand can be used (between 94 and 98%
pure).
Silica sand is the most commonly used sand because of its great
abundance, and, thus, low cost (therein being its greatest advantage). Its
disadvantages are high thermal expansion, which can cause casting
defects with high melting point metals, and low thermal conductivity,
which can lead to unsound casting. It also cannot be used with certain
basic metal because it will chemically interact with the metal forming
surface defect. Finally, it causes silicosis in foundry worker
Depending on the job require ent, high silica sand is used in different
forms.

1 IVP (Indian vegetable product)

Here no backing/ air setting sand is used.

HSS + binder + accelerator + hardener

Used in critical and highly finished jobs

Coated sand
HSS + resin + hardener (accelerator added in hardener)

3 Carbon dioxide sand

HSS + binder {sodium silicate (6-7%)} + moisture (seasonable)
Generally 1%
8% in dry season and
Zero % moisture in rainy season.
The carbon dioxide gas is passed through the vent holes, which
on
reacting with sodium silicate forms silica gel which acts as binder in the
sand.

4 Green sand
HSS + binder (dextrin powder) + bentonite powder
(hardener) + moisture {3-4 % (seasonable)}

In order to achieve high finishing, graphite oil and zirconium oxide oil
are
used.
Graphite oil is used for cast iron. The graphite oil is first applied and then burnt
to remove the alcohol present in it which hardens the oil film. Successive oil
films are coated over the mould to obtain very high finish.
Similarly zirconium oxide is used for steel jobs. The only difference being that
zirconium oxide is water based whereas graphite oil is alcohol based.