BHARAT HEAVY ELECTRICALS LIMITED is the largest engineering

and manufacturing enterprise in India in energy-related and infrastructure sector which includes Power, Railways, Telecom, Transmission and Distribution, Oil and Gas Sectors and many more. BHEL was established more than 50 years ago, ushering in the indigenous Heavy Electrical Equipment industry in India. The company has been earning profits since 1971-72 and paying dividends since 1976-77. BHEL is one of Indias nine largest Public Sector Undertakings or PSUs, known as the NAVRATNAS or the nine jewels. BHEL manufactures over 180 products under 30 major product groups and caters to core sectors of the Indian economy viz., Power Generation and Transmission, Industry, Transportation, Telecommunication, Renewable Energy, etc. The wide network of BHELs 14 manufacturing divisions, four Power Sector regional centers, over 100 project sites, 8 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. Over 65% of power generated in India comes from BHELsupplied equipments. Overall it has installed power equipment for over 90000MW .It also among Indias fastest growing Industries.

MANUFACTURING UNITS AND PRODUCT PROFILE:

NAME OF PLANT PLACE

PRODUCT

Steam less plant.

Tiruchirappali (Tiruchy).

Steam less steel tubes, Sriral fin welded tubes.

Boiler auxiliaries.

Ranipet.

Electrostatic precipitation , Air pre-heater , Fans , Wind electric generators , Desalination plants.

Industrial valves plant .

Govindwal.

Industrial valves and Fabrication.

Heavy electrical Hardwar. equipment plant.

Steam turbines , Hydro turbines ,

Gas turbine

Turbo generators , Control panels, Light aircrafts , Electrical machines.

Central plant.

foundry

forge Hardwar.

Heavy casting and forging.

Heavy electrical plant.

Bhopal.

Steam turbines , Turbo generators , Hydro sets , Switch gear controllers,

Transformer plant.

Jhansi.

Transformers , Diesel shunt less , AC locos , AC EMU.

Heavy power equipment Hyderabad. plant.

Power generating set , Industrial turbo sets, Compressors , Pumps and heaters , Bow mills , Heat exchangers oil rings , Gas turbines , Switch gears.

Electronic division.

Bangalore .

Energy meters , Water meters , Control equipment , Capacitors , Photovoltaic panels and Electronic private automatic branch exchange.

Insulator plant.

Jagdishpur.

Insulators and bushing.

Electronic system Bangalore. division, electronic city.

Simulator, Telecommunication system , Other advanced micro processor based control system.

Electro division.

porcelain Bangalore.

Insulator and bushing , Ceramic liners.

Component plant .

fabrication Rudrapur.

Windmill , Solar water heating system .

Amerphass silicon solar Guragaon. cell plant.

Solar cells , Solar lanterns chargers , Solar clocks.

Heavy electrical Varanasi. equipment repair plant.

Repair shop for power generating equipment.

Electrical machine repair Mumbai. shop .

Repair of electrical machines.

HARIDWAR PLANT

BHARAT HEAVY ELECTRICALS LTD.

HARDWAR
HEEP (HEAVYEL ECTRICAL EQUIPMENT PLANT)
HARDWAR

CFFP (CENTRAL FOUNDARY FORGED PLANT)

BLOCK-1: ELECTRICAL MACHINE SHOP

BLOCK-2: HEAVY FABRICATION SHOP

BLOCK-3: TURBINE MANUFACTURING BLOCK

BLOCK-4: CIM (COILS & INSULATION MANUFACTURING) BLOCK BLOCK-5: CONDENCER FABRICATION & FORGR BLOCK

BLOCK-6: FABRICATION SHOP, DIE SHOP STAMPING SHOP) BLOCK-7: CARPANTARY SHOP & HEAT TREATMENT SHOP

BLOCK-8: HEAT EXCHANGER SHOP

HEEP PRODUCT PROFILE

1. THERMAL SETS : Steam turbines and generators up to 500 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. Reheaters / separators. Heat exchangers and pressure vessels.

5. ELECTRICAL MACHINES : DC general purpose and rolling mill machines from 100 to 19000KW suitable for provided with STDP, totally enclosed and

operation on voltage upto 1200V. These are duct ventilated enclosures . DC auxiliary mill motors .

210 MW THRI-108/39 TYPE GENERATOR STATOR

6. CONTROL PANEL: Control panel for voltage up to 400KW and control desks for generating stations and EMV substations. 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 PROCEDURE : Naval guns with collaboration of Italy.

BLOCK-3

BAY-1

BAY-2

BAY-3

BAY-4

HMS (Heavy Machine shop)

HMS

BEARING SECTION

BLADE SHOP

ASSEMBY SECTION

ASSEMBLY SECTION

TURNING SECTION

TURNING SECTION HEAT TREATMEN-T SECTION

OSBT

ASSEMBLY SECTION

GOVERNING SECTION

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. Assembly Section (of hydro turbines) - In this section assembly of hydro turbines are done. Blades of turbine are Ist 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 whish purchased it by B.H.E.L. 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 tor. 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. `

For balancing and over speed testing of rotors up to 320 tones in weight, 1800 mm in length and 6900 mm diameter under vacuum conditions of 1 Torr.
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. Assembly section In this section assembly of steam turbines up to 1000 MW are assembled. Ist moving blades are inserted in the grooves cut on circumferences of rotor, then rotor is balanced in balancing tunnel in bay-1. After it final assembly operation is done in whish 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 whish are used in turbines to overcome the vibration & rolling friction by providing the proper lubrication. 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. Governing section In this section governors are manufactured. These governors are used in turbines for controlling the speed of rotor within the certain limits. Ist 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.

Turning section- Same as the turning section in Bay-3, there are several small machines like lathes machines, milling, boring, grinding machines etc.

Heat treatment shop- In this section there are several tests performed for checking the hardness of different components. Tests performed are Sterelliting , Nitriding ,DP test

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.

TYPES OF BLADES
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 2 nd generation blades.

Then it was replaced by TX, BDS (for HP TURBINE) & F shaped blades. The most modern blades are F & Z shaped blades.

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

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 *- Digital read output type

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 m/c- with- 6 axis CNC c2ontrol CNC shaping machine

CNC SHAPING MACHINE

STEAM TURBINES

INTRODUCTION
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 and/or heat are needed for processes. These include: pulp mills, refineries, petrochemical plants, food processing plants, desalination plants and district heating plants.

Advantages include
1. 2. 3. 4. 5. 6. 7. 8. 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.

Disadvantages are
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 600 oC. Turbines are built on the building block system, consisting of modules suitable for a range of output and steam parameters.

APPLICATION RANGE OF STEAM TURBINE

SERIES TYPE OF SPEED POWER MAIN STEAM REHEAT STEAM OUTPUT CONDITION STEAM GENERATOR RPM CONDITION O O MW BAR C BAR C
Fossil Fuel Steam Generator Pressurized Light Water Reactor Heat recovery Steam Generator 3000 100-1000 130- 500-540 30-70 500-600 250

BACK PRESSURE MBAR

20-300

Turbines for Fossil Fuel Power Plants Turbines for Nuclear Power Plants Turbines for Combined Cycle Applications

3000

Upto 1000 40-70 250-300 8-15 200-250

20-300

3000

Upto 300

30140

500-540 30-50 500-540

20-300

For a desired output and steam parameters appropriate turbine blocks can be selected.

TYPES OF TURBINES
CONDENSING TURBINES
With the condensing turbine, the steam exhausts to the condenser and the latent heats of the steam is transferred to the cooling water. The condensed steam is returned to the boiler as feed water.

CONDENSING BLEEDER TURBINES

The condensing bleeder turbine reduces the condenser losses as steam is bled off at several points of the turbine. The bleed-steam is used for feed water heating up to 20% of the total steam flow may be bled off.

BACK-PRESSURE TURBINES
Back-pressure turbines are often used in industrial plants; they act as a reducing station between boiler and process steam header. The process steam pressure is kept constant and the generator output depends on the demand for process steam. The backpressure turbine may also have bleed points and is then called a back-pressure-bleeder-turbine.

TOPPING TURBINES
Topping turbines have been used when old boilers are replaced with new high pressure boilers. The turbine is a backpressure turbine exhausting to the old boiler header still supplying steam to the old lower pressure turbines.

MIXED PRESSURE TURBINES

Mixed pressure turbines are used where excess steam from process is available for the low pressure part of the turbine, while steam at boiler pressure may be added to the high pressure part of the turbine when more loads is applied to the turbine.

OPERATING PRINCIPLE
IMPULSE TURBINE
The principle of the impulse steam turbine consists of a casing containing stationary steam nozzles and a rotor with moving or rotating buckets. The steam passes through the stationary nozzles and is directed at high velocity against rotor buckets causing the rotor to rotate at high speed. The following events take place in the nozzles: 1. 2. 3. 4. 5. The steam pressure decreases. The enthalpy of the steam decreases. The steam velocity increases. The volume of the steam increases. There is a conversion of heat energy to kinetic energy as the heat energy from the decrease in steam enthalpy is converted into kinetic energy by the increased steam velocity.

The nozzles may be convergent nozzles or they may be convergent-divergent nozzles. Convergent nozzles are used for smaller pressure drops where the minimum exit pressure is 0.577 x the inlet pressure (the critical pressure for nozzles). If the exit pressure is less than 0.577 x inlet pressures, eddy-currents are developed and the exit velocity will be less than calculated. The convergent-divergent nozzles prevent eddy-currents and the calculated velocity will be obtained even at large pressure drops.

The Impulse Principle

If steam at high pressure is allowed to expand through stationary nozzles, the result will be a drop in the steam pressure and an increase in steam velocity. In fact, the steam will issue from the nozzle in the form of a high-speed jet. If this high steam is applied to a properly shaped turbine blade, it will change in direction due to the shape of the blade. The effect of this change in direction of the steam flow will be to produce an impulse force, on the blade causing it to move. If the blade is attached to the rotor of a turbine, then the rotor will revolve. Force applied to the blade is developed by causing the steam to change direction of flow (Newtons 2 nd Law change of momentum). The change of momentum produces the impulse force. The fact that the pressure does not drop across the moving blades is the distinguishing feature of the impulse turbine. The pressure at the inlet to the moving blades is the same as the pressure at the outlet from the moving blades.

Reaction principle
A reaction turbine has rows of fixed blades alternating with rows of moving blades. The steam expands first in the stationary or fixed blades where it gains some velocity as it drops in pressure. It then enters the moving blades where its direction of flow is changed thus producing an impulse force on the moving blades. In addition, however, the steam upon passing through the moving blades again expands and further drops in pressure giving a reaction force to the blades. This sequence is repeated as the steam passes through additional rows of fixed and moving blades.

Special Aspects of Reaction Turbines

There is a difference in pressure across the moving blades. The steam will therefore tend to leak around the periphery of the blades instead of passing through them. Blade clearances therefore must be kept to a minimum. Also, due to be developed upon rotor and some arrangement must be made to balance this.

Impulse Turbine Staging

In order for the steam to give up all its kinetic energy to the moving blades in an impulse turbine, it should leave the blades at zero absolute velocity. This condition will exist if the blade velocity is equal to one half of the steam velocity. Therefore, for good efficiency the blade velocity should be about one half of steam velocity. In order to reduce steam velocity and blade velocity, the following methods may be used: 1. Pressure compounding. 2. Velocity compounding. 3. Pressure-velocity compounding. 4. Pressure Compounding

TURBINE PARTS
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 Free standing LP moving blades
o

Tip sections with supersonic design

o o

Fir-tree root Flame hardening of the leading edge Tapered and forward leaning for optimized mass flow distribution Suction slits for moisture removal

Banana type hollow guide blade

o o

COMPUTATIONAL MESH FOR 3D ANALYSIS

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.

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 the shaft. 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. 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. The end cover is made with a shrink fit and welded of 600-700 *10^6 Pascal.

TUEBINE SEALS
Blade seals The efficiency of reaction turbines depends to a large extent on the blade seals; radial as well as axial seals are often part of the shroud with the seal clearances kept as small as possible. As protection for the axial seals some manufacturers apply an adjustable thrust bearing. The whole thrust block is able to be axially adjusted. During startup the thrust block is pushed against a stop in the direction of exhaust of exhaust for maximum seal clearances. When turbine is heated up and has been on load for a short time the thrust block is pulled forward against a forward stop for minimum seal clearance and maximum blade efficiency. Shaft Seals Shaft seals must be provided in order to prevent or at least reduce steam leakage where the shafts extend through the casings. Also when low pressure turbines are under vacuum the seals must prevent air from leaking into the casing. Ordinary soft packing may be used for shaft sealing in small turbines. Carbon rings are also very common for small turbines. The carbon ring is made up of three segments butting together tightly under the pressure of a garter spring. The ring has a few hundreds of millimeter clearance around the shaft and is prevented from turning by a locking pin. The ring has a slight side clearance in the housing allowing it to move freely in radial directions. Carbon rings are self-lubricating but have a tendency to corrode the shaft when the turbine is shut down. Water Seal The water seal cannot operate properly at low speed and gland steam must be applied for sealing during start-up until the turbine speed is approximately 2000rev/mm. Water seals are supplied with clean cool condensate from the extraction pump. It may be supplied directly or via a head tank with automatic level-control.

TURBINE COUPLINGS
The purpose of couplings is to transmit power from the prime mover to the driven piece of machinery. For heavy loads the solid flange coupling is used. The flanges are generally integral parts of the shafts, but they may be separate parts for smaller turbines. In this case each coupling part has a tapered bore and keyway to fit the tapered end o f the shaft. Following the taper the shaft has a large thread allowing the coupling to be secured tightly with a large nut. The friction between the coupling halves and the shear force of the bolts transmits the power. For maximum shear stress the bolts must be fitted. The coupling bolts should be undercut, that is machined off to a diameter slightly less than the bottom diameter of the thread to avoid any strain on the thread. In some cases the couplings must compensate for axial expansion and contraction of the rotors and in this case a flexible coupling is applied. The outer half has internal gears, while the inner part has matching external gears. The coupling works like the spline on a driveshaft for a car. The couplings for very large shafts will need a large diameter if the bolts are used to transmit the power. The bolts can be much smaller if they are not allowed to transmit power. In the coupling shear pins carry the load. The area exposed to shear is the shear pins to be located at a large radius from the shaft centre. The coupling bolts are not fitted as they are exposed to tensile stress only.

GOVERNING OF STEAM TURBINE Governing of steam turbine is done through electro-hydraulic systems.

TURBINES WITH ADVANCED STEAM PARAMETERS

Application of higher parameters is the most direct way of increasing heat input

Steam parameters of 300 bar pressure and 600 oC temperature Six percent improvement in thermal cycle efficiency New materials for high temperature applications Impulse diagonal blading for the first stage HP and IP turbines Heat shield at inlet of IP turbine Increased wall sections for increased pressures.

to the cycle

SALIENT FEATURES

Turbines for both nozzle control as well as throttle control mode. Turbines can operate with any boiler and are suitable for i. ii. iii. Constant pressure as well as sliding pressure operation Base load as well as two-shift operation Sub critical as well as super critical parameters

All the rotors are monoblock HP & IP casings have double shell construction and LP has three-shell construction. IP turbines with single flow or with double flow. LP turbines are designed for normal as well as high back pressure conditions. Hollow guide blades with suction slits for moisture removal in last LP stage. Bearing pedestals isolated from turbine casings. Combined stop & control valves with individual servomotor. Sophisticated control and monitoring equipment such as Electro-hydraulic governing, automatic turbine run up system, turbine stress controller, automatic turbine tester etc. High operational flexibility i. ii. Fast start up and shut down Sharp load changes

Operation under wide frequency range (47.5 to 51.5 Hz)

TURBINE CONSTRUCTION

MANUFACTURING FACILITIES
The plant is fully equipped with the modern and sophisticated manufacturing and testing facilities to produce sets upto1000MW rating. These include:1. Blade shop for manufacture of both moving and stationary blades. 2. Special purpose CNC tools. 3. Over speed & Vacuum-Balancing Tunnel.

Some of special purpose CNC lathe machines are:-

MILLING OF BLADE ROOTS OF LP ROTOR ON KOPP MACHINE

ENGINEERING CAPABILITIS:
BHEL carries out life extension programs on steam turbines of various ratings, which forewarn the impending failure and help in reducing costly plant breakdowns by recommending replacement and up gradation of defective components.
Over the past two decades, BHEL has gained a vast experience in design, manufacture, erection and commissioning of various capacities of Turbine Generator sets ranging from 100 MW to 500 MW.

Many specific features to suit the customer requirements, layout & operation are taken care of. To name a few:

HP/LP bypass Turbine Stress Evaluator, hand Barring Gear and Automatic Turbine Runup System for 210 MW Russian Turbine. Base load/cycle /Two-shift operations Throttle /Nozzle governing Constant/Sliding pressure operation

RENOVATION & MODERNISATION (R&M)

Depending on the actual operating conditions, material properties of the components degrade as function of service life due to one or more time dependent material damage mechanisms such as creep, fatigue, corrosion, erosion, wear embattlement etc. Life extension programme (LEP) is a special package comprising systems and methodologies, which evaluates the residual life of components through sophisticated NDT, FEM stress analysis and metallurgical technique. Many improvements in material and design of critical components with state-of-art design is a part of the life extension process. Thus the performance, availability and efficiency of the plant may be improved by R&M Programs.

Technology / Collaborations
The technological base of BHEL in the area of Steam turbines and Turbo Generators has been created by acquiring technological information from the collaborators. Initially BHEL had collaboration with M/s LMW USSR for 100 and 210 MW sets. In 1976, BHEL entered into technical collaboration agreement with M/s Siemens-KWU, Germany to acquire the know-how and know-why for turbine generator sets upto 1000 MW. This collaboration still continues. This helps BHEL to keep pace with the worldwide technological progress and offer state of the art equipment to its customer. Under this collaboration agreement, BHEL has established strong design, manufacturing and servicing base for unit up to 500 MW ratings. BHEL PROGRESS REPORT CHART OF 2008-2009