Vocational Training Report

Turbine Blade Shop-Block 3

Bharat Heavy Electricals Limited
RanipurHarid!ar "#ttrakhand$
Submitted By Submitted To
Satyendra %umar
B-Tech 3
rd
year
1
JP Institute Of Engineering & Technology,Meerut (U.P)
2
Declaration
I Satyendra Kumar student of b-tech 3
rd
year of JP institute of engineering and
technology hereby declare that the training report entitled Turbine blade
shopis an original !or" and the same has not been submitted to any other
institute#
3

&ckno!ledgement
It gi$es me immense pleasure to present my Pro%ect &eport before
you# I than"fully ac"no!ledge the staff of '()*+ (arid!ar
for gi$ing me so much co-operation and taught lots of ne! things
to me+ !hich I am sure !ill help me in my !ar future#
, special than"s to -r S#(aldar for his support during my Industrial
Training# I pay my sincere regards to him# .ithout his support I !as
not able to accomplish my training# I also than"s to all the !or"ing
staff of fabrication bloc" for their helpful guidance and support
during the period#I e/tend my than"s to my college for gi$ing me
such an opportunity under the super$ision of -r 0arman ,"htar
1Training and Placement 2fficer3!ho is also an e/perienced person#
4
'#(#)#*- ,n 2$er$ie!
'()* or the 'harat (ea$y )ngineering *imited is one of the largest
engineering and manufacturing organi5ations in the country and the
BHEL, Haridwar is their gift to 6ttaranchal# .ith t!o large
manufacturing plants+ '()* in (arid!ar is among the leading
industrial organi5ations in the state# It has established a (ea$y
)lectrical )7uipment Plant or ())P and a 8entral 0oundry 0orge
Plant or 800P in (arid!ar#
The (ea$y )lectrical )7uipment Plant in (arid!ar designs and
manufactures turbo generators+ ,8 and 98 motors+ gas turbines and
huge steams# The 8entral 0oundry 0orge Plant in (arid!ar deals !ith
steel castings and manufacturing of steel forgings#
The '()* plants in (arid!ar ha$e earned the IS2 - :;;1 and :;;2
certificates for its high 7uality and maintenance# These t!o units ha$e
also earned the IS2 - 14;;1 certificates# Situate in &anipur near
(arid!ar+ the 'harat (ea$y )ngineering *imited employs o$er <+;;;
people#
'()* is an integrated po!er plant e7uipment manufacturer and one of the
largest engineering and manufacturing companies in India in terms of
turno$er# '()* !as established in 1:=4+ ushering in the indigenous (ea$y
)lectrical )7uipment industry in India - a dream that has been more than
reali5ed !ith a !ell-recogni5ed trac" record of performance# The company
has been earning profits continuously since 1:>1->2 and paying di$idends
since 1:>=->> #'()* is engaged in the design+ engineering+
manufacture+ construction+ testing+ commissioning and ser$icing of a
!ide range of products and ser$ices for the core sectors of the
economy+ $i5# Po!er+ Transmission+ Industry+ Transportation+
&ene!able )nergy+ 2il ? @as and 9efence#'()* has 1A
A
manufacturing di$isions+ t!o repair units+ four regional offices+ eight
ser$ice centres+ eight o$erseas offices and 1A regional centres and
currently operate at more than 1A; pro%ect sites across India and
abroad# '()* places strong emphasis on inno$ation and creati$e
de$elopment of ne! technologies# 2ur research and de$elopment
1&?93 efforts are aimed not only at impro$ing the performance and
efficiency of our e/isting products+ but also at using state-of-the-art
technologies and processes to de$elop ne! products# This enables us
to ha$e a strong customer orientation+ to be sensiti$e to their needs
and respond 7uic"ly to the changes in the mar"et#
The high le$el of 7uality ? reliability of our products is due to adherence to
international standards by ac7uiring and adapting some of the best
technologies from leading companies in the !orld including @eneral )lectric
8ompany+ ,lstom S,+ Siemens ,@ and -itsubishi (ea$y Industries *td#+
together !ith technologies de$eloped in our o!n &?9 centres# -ost of our
manufacturing units and other entities ha$e been accredited to Buality
-anagement Systems 1IS2 :;;1C2;;<3+ )n$ironmental -anagement
Systems 1IS2 14;;1C2;;43 and 2ccupational (ealth ? Safety -anagement
Systems 12(S,S 1<;;1C2;;>3#
'()* has a share of around A:D in IndiaEs total installed generating capacity
contributing =:D 1appro/#3 to the total po!er generated from utility sets
1e/cluding non-con$entional capacity3 as of -arch 31+ 2;12# .e ha$e been
e/porting our po!er and industry segment products and ser$ices for
appro/imately 4; years# .e ha$e e/ported our products and ser$ices to more
than >; countries# .e had cumulati$ely installed capacity of o$er <+A;; -.
outside of India in 21 countries+ including -alaysia+ Ira7+ the 6,)+ )gypt
and Fe! Gealand# 2ur physical e/ports range from turn"ey pro%ects to after
sales ser$ices#
'()* !or" !ith a $ision of becoming a !orld-class engineering enterprise+
committed to enhancing sta"eholder $alue#
2ur greatest strength is our highly s"illed and committed !or"force of o$er
4:+;;; employees# )$ery employee is gi$en an e7ual opportunity to de$elop
=
himself and gro! in his career# 8ontinuous training and retraining+ career
planning+ a positi$e !or" culture and participati$e style of management - all
these ha$e engendered de$elopment of a committed and moti$ated !or"force
setting ne! benchmar"s in terms of producti$ity+ 7uality and responsi$eness#
ST),- T6&'IF)
,
steam turbine is a mechanical de$ice that e/tracts thermal energy
from pressuri5ed steam+ and con$erts it into rotary motion# Its modern
manifestation !as in$ented by Sir 8harles Parsons in 1<<4# It has
almost completely replaced the reciprocating piston steam engine
1in$ented by Thomas Fe!comen and greatly impro$ed by James
.att3 primarily because of its greater thermal efficiency and higher
po!er-to-!eight ratio# 'ecause the turbine generates rotary motion+ it
is particularly suited to be used to dri$e an electrical generator H about
<;D of all electricity generation in the !orld is by use of steam
turbines# The steam turbine is a form of heat engine that deri$es much
of its impro$ement in thermodynamic efficiency through the use of
>
multiple stages in the e/pansion of the steam+ !hich results in a closer
approach to the ideal re$ersible process#
Types
These arrangements include single casing+ tandem compound and cross
compound turbines# Single casing units are the most basic style !here a single
casing and shaft are coupled to a generator# Tandem compound are used !here
t!o or more casings are directly coupled together to dri$e a single generator# ,
cross compound Steam turbines are made in a $ariety of si5es ranging from
small 1 hp 1;#>A ".3 units 1rare3 used as mechanical dri$es for pumps+
compressors and other shaft dri$en e7uipment+ to 2+;;;+;;; hp 11+A;;+;;; ".3
turbines used to generate electricity# There are se$eral classifications for
modern steam turbines#
Steam Supply and Exhaust Conditions
These types include condensing+ non-condensing+ reheat+ e/traction and
induction#
Fon-condensing or bac"pressure turbines are most !idely used for process
steam applications# The e/haust pressure is controlled by a regulating $al$e 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 !here large amounts of lo! pressure process steam are a$ailable#
8ondensing turbines are most commonly found in electrical po!er plants#
These turbines e/haust steam in a partially condensed state+ typically of a
7uality near :;D+ at a pressure !ell belo! atmospheric to a condenser#
&eheat turbines are also used almost e/clusi$ely in electrical po!er plants# In a
reheat turbine+ steam flo! e/its from a high pressure section of the turbine and
is returned to the boiler !here additional superheat is added# The steam then
goes bac" into an intermediate pressure section of the turbine and continues its
e/pansion#
Casing or Shaft Arrangements
<
Turbine arrangement features t!o or more shafts not in line dri$ing t!o or more
generators that often operate at different speeds# , cross compound turbine is
typically used for many large applications#
Priniple of !peration and "esign
,n ideal steam turbine is considered to be an isentropic process+ or constant
entropy process+ in !hich the entropy of the steam entering the turbine is e7ual
to the entropy of the steam lea$ing the turbine# Fo steam turbine is truly
isentropic+ ho!e$er+ !ith typical isentropic efficiencies ranging from 2;D-
:;D based on the application of the turbine# The interior of a turbine comprises
se$eral sets of blades+ or buc"ets as they are more commonly referred to# 2ne
set of stationary blades is connected to the casing and one set of rotating blades
is connected to the shaft# The sets intermesh !ith certain minimum clearances+
!ith the si5e and configuration of sets $arying to efficiently e/ploit the
e/pansion of steam at each stage#
Turbine Effiieny
To ma/imi5e turbine efficiency+ the steam is e/panded+ generating !or"+ in a
number of stages# These stages are characteri5ed by ho! the energy is e/tracted
from them and are "no!n as impulse or reaction turbines# -ost modern steam
turbines are a combination of the reaction and impulse design# Typically+ higher
pressure sections are impulse type and lo!er pressure stages are reaction type#
#mpulse Turbines
,n impulse turbine has fi/ed no55les that orient the steam flo! into high speed
%ets# These %ets contain significant "inetic energy+ !hich the rotor blades+ shaped
li"e buc"ets+ con$ert into shaft rotation as the steam %et changes direction# ,
pressure drop occurs across only the stationary blades+ !ith a net increase in
steam $elocity across the stage#
$eation Turbines
In the reation turbine+ the rotor blades themsel$es are arranged to form
con$ergent no55les# This type of turbine ma"es use of the reaction force
produced as the steam accelerates through the no55les formed by the rotor#
:
Steam is directed onto the rotor by the fi/ed $anes of the stator# It lea$es the
stator as a %et that fills the entire circumference of the rotor# The steam then
changes direction and increases its speed relati$e to the speed of the blades# ,
pressure drop occurs across both the stator and the rotor+ !ith steam
accelerating through the stator and decelerating through the rotor+ !ith no net
change in steam $elocity across the stage but !ith a decrease in both pressure
and temperature+ reflecting the !or" performed in the dri$ing of the rotor#
SPECIFICATIONS OF MACHINES AVAILABLE IN BLOCK-III:
%ertial Boring &ahine '
-a/ diameter of !or" piece accommodated C1;;;;mm to
12A;;mm
-a/ height of !or" piece CA;;;mm
9iameter of table C<>A;mm
-a/ tra$el of $ertical tool head &,- slides C32;;mm
-a/ tra$el of $ertical tool heads from centre of
Table CA2A;mm
-a/ !eight of !or" piece C2;; T
0or FIJ=rpmK1;;T for any speed
9iameter of boring spindle of combined head C1=;mm
Tra$el of boring spindle C12A;mm
Taper hole of boring spindle C1;;metric
Centre Lathe '(Biggest of all BHEL)
-a/ diameter o$er bed C32;;mm
-a/ diameter o$er saddle C2A;mm
*ength bet!een centers C1=m
1;
-a/ !eight of !or" piece C1;; T
Spindle bore C:=mm
C*C Lathe '
-anufacturerC Safop+ Italy
S!ing o$er carriage C3A;;mm
8entre distance C:;;;mm
.eight capacity C12; T
Spindle po!er C1:=K.
)/ternal chuc"ing range C2A;-2;;;mm
(ydrostat steady range C2;;-12A;mm
-a/ spindle rpm C2;;
8F8 system CSIF6-)&IK
<4;9

C*C #ndiating stand '
-anufacturer C (einrich @eorg+ @ermany
Turning diameter CA#3m
Turning length C1Am
.eight capacity C1=; T
C*C %ertial Borer '
-anufacturer C -LS Pietro 8arnaghi+ Italy
-achine model C,P <;T--
=A;;
Table diameter C=A;;mm
11
-a/ turning diameter C<;;;mm
-in boring diameter C==;mm
-a/ height for turning and milling C>;;;mm
Table Speed C;#2-A; rpm
Table load capacity C2;; T
-illing spindle speed C3#4-3;;; rpm at4;K.
Spindle taper C'T A;
8F8 system CSIF6-)&IK <4;9
C*C +aing Lathe ' ,H-.//-C*C
S!ing o$er bed C23;;mm
S!ing o$er carriage C1<;;mm
-a/ distance bet!een faced plate and carriage C2;;;mm
-a/ !eight of %ob held in chuc" C=;;;"g
0ace plate diameter C1<;;mm
Spindle speed C1#4-4;;rpm
-ain spindle dri$e
C:A#AK.
Step boring &ahine '
-a/ boring diameter C2A;;mm
-in boring diameter C=2Amm
Table C4;;;mm/4;;;mm
-a/ !eight of %ob C1;; T
(eadstoc" tra$el C4;;;mm
"ouble Column %ertial Borer '
Table diameter C4;;;mm
-a/ tra$ese of cross rail
C42A;mm
12
-a/ !eight of !or" piece C42;;mm
-a/ !eight of %ob CA; T
C*C S0oda Hori1ontal Borer '
Spindle diameter C2;;mm
Taper spindle C'T A;
&,- si5e C4A;/4A;mm
&,- length C1=;;mm
Spindle length C2;;;mm
(eadstoc" CA;;;mm
Table C4;;;/3A;;mm
8F8 system CSI-)FS <A;mm
Job C I#P# 2uter
Hori1ontal Borer ' LST2 3//4
Spindle diameter C2A;mm
(eight of machining bed C=;;mm
-a/ boring depth !ith spindle C2;;;mm
-a/ e/tension of &,- C1=;;mm
.idth of bed guide !ays C2A;;mm
,ctual length of headstoc" !ith $ertical lift C21A;mm
,ctual length of column hori5ontal feed C1A;;;mm
*o!est position of spindle a/is upon bed guide!ays C14>Amm
-achine !eight !ith electrical e7uipments C14; T
(eight of machine C1;#3m
C*C Lathe ' 5-5./
-anufacturer C &a$ensburg
-ain spindle bore C1A;mm
9istance bet!een centers C12m
Turning diameter o$er bed co$er C14;;mm
Turning diameter o$er carriage C11;;mm
.or"piece !eight unsupported C4;;;"g
.or"piece !eight bet!een centers C2; T
13
Centre Lathe ' 5-.6
-anufacturer C K3T8+ 6SS&
-a/ diameter o$er bed C12A;mm
-a/ diameter o$er saddle C:;;mm
*ength bet!een centers C=3;;mm
-a/ !eight of !or" piece C2A T
Spindle bore C<;mm
-achine !attage CAAK.
Hori1ontal Boring &ahine ' 5-.3
9iameter of spindle C1A;mm
.or"ing surface of table C22A;/12A;mm
-a/ tra$el of table C12;;mm
-a/ $ertical tra$el of headstoc" C2;;;mm
Hori1ontal Boring &ahine '
'oring spindle taper C'TA;
'oring spindle diameter C1=;mm
(eadstoc" $ertical tra$el C3;;;mm
*ongitudinal &,- tra$el C>;;mm
*ongitudinal spindle tra$el C1;;;mm
8olumn cross tra$el C1;m
&otary table tra$el C3;;;mm
Table load C4; T
Hori1ontal Boring &ahine ' 5-55
'oring spindle internal taper material C2;;
'oring spindle diameter C32;mm
-a/ spindle tra$el
C2A;;mm
Mertical head tra$el C=;;;mm
Trans$erse column tra$el
C=;;;mm
-a/ longitudinal column tra$el C<;;mm
-achine !attage C:;K.
14
"ouble Column $otary Table %ertial Borer '
-a/ diameter of !or" piece accommodated C1;mL12#Am
-a/ height of !or" piece accommodated CAm
9iameter of table C<#>Am
-a/ tra$el of $ertical tool head &,- slides C3#2m
-a/ tra$el of $ertical tool head from centre of table CA#2Am
-a/ !eight of !or" piece C2;;T for FIJ<rpmK1;;T for any speed
9iameter of boring spindle of combined head C1=;mm
Tra$el of boring spindle C12A;mm
Taper hole of boring spindle C1;;mm
Hori1ontal borer ' 5-.
Spindle diameter C22;mm
.or"ing surface C<1;; / A;;;mm
-a/ $ertical tra$el C3mm
-a/ trans$erse tra$el of column C=m
-a/ longitudinal tra$el of column C=m
-a/ longitudinal tra$el of spindle C1#<m
C*C Lathe ' .-64/
-anufacturer C (oesch
-a/ load C32; T
-a/ length bet!een centers C1<m
S!ing o$er bed C3#2m
Hori1ontal Borer ' .-573
Spindle diameter C22;mm
-a/ $ertical tra$el C3m
-a/ trans$erse tra$el of column C=m
-a/ longitudinal tra$el of column C=m
-a/ longitudinal tra$el of spindle C1#<m
.or"ing surface C1<;;/A;;mm
Creep +eed 2rinding &ahine '
9iameter of %ob C2m
Job height C2#4m
Table rpm C1;rpm1ma/3
1A
Table diameter C2;A;mm
S!ing diameter C2A;;mm
8F8 control CSI)-)FS-3@@
Broahing &ahine '
'roaching capacity C32 T
'roaching stro"e C1;#3m
'roaching slide !idth 1A;;mm
'roaching specific cutting stro"e C1#2AmLmin
'roaching specific return stro"e C=;mLmin
-a/ diameter of disc C23;;mm
-a/ mo$e of table C=;;mm
(eli/ angleLs"e! angle setting CN4AL-4A
8one angle C;-2;
C*C Lathe '
-anufacturer C Innse 'erardi+ Italy
S!ing o$er carriage C1A;;mm
S!ing o$er bed C2;;;mm
8apacity C3; T
8ost C1= crore
8F8 system CSIF6-)&IK <4;9
!8er Speed Balaning of Turbines '
&ain features '
Type of pedestials C9( :;L9( 12
&otor !eight C-in 4 -T+ -a/ 32; -T
&otor diameter C-a/ =:;;mm
&otor %ournal diameter C-in 2A;mm+-a/ :A;mm
'earing centre distance C-in 3;;;mm+-a/ 1A>;;mm
'alancing speed C1<;-3=;;rpm
-in $ibration limit C1 micron
-a/ $acuum C1 torr
Tunnel +eatures '
Tunnel length C1:;;;mm
1=
Tunnel diameter C=:;;mm
-a/ thic"ness of tunnel C2A;;mm
Steel plate thic"ness C32mm
8ost of balancing e7uipment10)3 C444 la"hs
Total cost of balancing tunnel C>>; la"hs
&ain +eatures of "ri8e '
9ri$e motors 12 no#3 C:A;M 98+ A;;rpm+3#A
-. each
Total dri$e po!er C> -.12/3#A3
&2 set of "ri8e '
Synchronous motors C11 KM+:-.+A;(5+A;;rpm
98 @enerator 12 no#3 C:A;M+A;;rpm+3#<-. each
3d coordinate measuring machine in new blade shop:
-odel refrenceC 2212: *I)TG @ermany
Plan no 3-;=<
-easuring rangeC
O a/is 22;;mm
P a/is 12;;mm
G a/is :;; mm
Molumetric errorC 1ma/3 1#A micron
&esolutionC ;#;A micron
-a/ !eight of %obC 22A; "g
,ccuracyC 1#AN*L3A; micron
,pplicationC dimensional and profile
management of turbine mo$ing and guide blades
HOW IT WORKS
1>


1<

1:

*P rotor !ith mo$ing blades $arious blade profiles
2;
STEA& +L!9 TH$!:2H STEA& T:$B#*E

21

22

23

24

2A
&oderni1ation of +ailities'
8F8 *athe for *P &otor from S,02P+ IT,*P
8F8 (ori5ontal 'oring machine for machining of casing from
P,-,+ IT,*P
8F8 Indicating Stand for *P &otor 'lade machining from @)2&@+
@)&-,FP
8F8 0ir Tree &oot -illing machine
8F8 @antry -illing machine
&a;or +ailities for *ew Turbine Shop'
8F8 M 'orer-Table diameter->A;;mm
8F8 M 'orer-Table diameter-4;;;mm
8F8 ( 'orer Spindle 9iameter-2;;mm+1=;mm
2=
8F8 *athe capacity-12; T+<;T
8F8 0ir Tree &oot -illing machine
8F8 @antry -illing machine
Highlights'
#mported Substitutions '
(ybrid burner for gas turbine
) ring for gas turbine
9eep hole drilling in (P outer casing supplied by -achine
Shop+ 800P
Proess #mpro8ement '
Slitting of casing+ thrust rings+ @T rings on 'and Sa!
milling machine+ thus sa$ing the time on critical machines
such as &am 'orers
6sing K2-)T drilling systems+ the producti$ity in %oint
plane drilling of casing and *P &otors has increased
Seeing the congestion on K22P milling machine+ a ne!
!or" center machine called &,-'(2& machine1Fo#
24>3
Tool Brands'
Wiia
!an"ic#
!eco
2>
Isear
$isson
%uhring
Inian tools
Mitutoyo
Tool #nstruments'
Die ring s&anner
'ac# sa" fra(e
)urr cutter
!oli ta& (car*ie)
'an ta&
2rinding Cutters'
+o(*ination cutter,-./0./((
1illet cutter,-2/034((
'an (ill cutter
En (ill cutter
Internal &rofile cutter
!hell en (ill cutter,2305/((
)all nose
!la* (ill
500 MW Steam Turbie:
HP Turbine:
Moule 6'3/,-//,4
!tea( Pressure 6-7/8g9s:.c(
!tea( te(&erature 6;37 eg.cel
2<
<eheating te(&erature 6;37 eg.cel
Weight 652.// 8g
=ength of <otor 6..2-(
'eight 64.-;(
LP Turbine:
Moule 6>3/,40-/s:.(
Weight 63.; T
=ength of <otor 65.7(
With 6-/.7(
'eight 6..2(
IP Turbine:
=ength 6...4;(
With 6;(
'eight 6..5(
!tea( &ressure 6.-8g9s:.c(
!tea( te(&erature 6;37 eg.cel
&illing Cutters'
-) !ie en face (illing cutter
4) Interloc#ing sie an face (illing cutter
3) !hell en (ill cutter
.) Metal slitting sa"
;) !ingle angle (illing cutter
2) Dou*le une:ual angle (illing cutter
2:
7) Dou*le e:ual angle (illing cutter
5) 8ey"ay (illing cutter
?) Milling cutter for chain "heels
-/) !ingle corner rouning (illing cutter
--) +on@e0 (illing cutter
-4) +onca@e (illing cutter
-3) T slot (illing cutter "ith &lane &arallel shan#
-.) T slot (illing cutter "ith Morse ta&er shan# ha@ing ta&ere en
-;) +ylinrical (illing cutter
-2) !lot (illing cutter "ith &arallel shan#
-7) En (ill "ith &arallel shan#
-5) )all nose en (ill "ith &arallel shan#
-?) 1lat en ta&ere ie sin#ing cutter "ith &lane &arallel shan#
4/) )all nose ta&er ie sin#ing cutter "ith &lane &arallel shan#
4-) !lot (illing cutter "ith (orse ta&ere shan# ha@ing tange en
44) En (ill "ith (orse ta&ere shan# ha@ing tange en
43) )all nose en (ill "ith (orse ta&ere shan# ha@ing tange en
4.) 1lat en ta&ere ie sin#ing cutter "ith (orse ta&ere shan# ha@ing ta&&e
en
4;) )all nose ta&ere ie sin#ing cutter "ith (orse ta&ere shan# ha@ing
ta&&e en
42) !lot (illing cutter "ith (orse ta&ere shan# ha@ing ta&&e en
47) En (ill (orse ta&ere shan# ha@ing ta&&e en
45) )all nose (ill (orse ta&ere shan# ha@ing ta&&e en
4?) <oughing en (ill "ith &arallel shan# finishing ty&e
3/) <oughing en (ill "ith &arallel shan# roughing ty&e
3-) !lot (illing cutter "ith 794. ta&er shan#
34) En (ill "ith 794. ta&er shan#
3;
33) )all nose en (ill "ith 794. ta&er shan#
3.) Wooruff #ey slot (illing cutter "ith &arallel shan#
3;) !cre"e shan# slot rill
Ma!"r C"m#"et$ "% Steam Turbie:
=P <otor
=P Inner +asing U&&er 'alf
=P Inner +asing =o"er 'alf
=P Outer +asing U&&er 'alf
=P Outer +asing =o"er 'alf
IP <otor
IP Inner +asing U&&er 'alf
IP Inner +asing =o"er 'alf
IP Outer +asing U&&er 'alf
IP Outer +asing =o"er 'alf
31
'P <otor
'P Inner +asing U&&er 'alf
'P Inner +asing =o"er 'alf
'P Outer +asing U&&er 'alf
'P Outer +asing =o"er 'alf
Diffuser
%)+ (%uie )lae +arrier)
IA+A (Interce&t Aal@e +ontrol Aal@e)
E!A+A (E(ergency !to& Aal@e +ontrol Aal@e)
Auxiliary Parts of Steam Turbine'
-) Aal@e !eal
4) U,<ing
3) Piston <o
.) )ase Plate
;) !ealing <ing
2) =iner
7) %uie <ing
5) Aal@e +o@er
?) %uie )laes 6
1i0e )laes
Mo@ing )laes
-/) !u&&ort
--) )earing
-4) )earing !hell
-3) $ngle <ing
-.) !lee@e
32
-;) Pin Ta&er (4;0-./)
-2) Journal )earing !hell
-7) +asing
-5) %uie *ush
-?) Piston (;//MW)
4/) Aal@e +one
4-) Bo#e
44) Manrel
43) !u&&ort <ing
4.) Thrust <ing
4;) $Custing <ing
42) !haft !ealing +o@er
T&#e$ "% B'a(e$:
T4 *laes
T. *laes
TD *laes
3D! *laes
1, *laes
%T,+o(&ress *laes
)raEe *laes
<ussian esign *laes
F,!hrou *laes
+o(&ressor *laes (!er(ental coate)
=P Mo@ing *lae ;//MW
Ne) B'a(e S*"#:
33
First Generation Blades :
T4 Profile )laes
+ylinrical Profile )laes (-?7/)
Second Generation Blades :
T. Profile )laes
+ylinrical Profile )laes ( late -?5/)
-G %ain in !tage Efficiency o@er T4 Profile )laes
TX Profile Blades
+ylinrical Profile )laes ( late -??/)
2ains '
<euces Profile =osses
/.4G %ain in !tage Efficiency o@er T. Profile )laes
Appliations '
Mile !tage Of '.P. an I.P Tur*ine
Initial !tage of =.P. Tur*ine
3DS Blades :
Gains :
<euces !econary 1lo" =osses
/.; H -./G %ain in !tage Efficiency o@er TD Profile )laes
Appliation '
Initial !tage of '.P. an I.P Tur*ine
34
F- Blades
2ains '
<euces Inirect 1lo" =osses
/.; H -./G %ain in !tage Efficiency o@er TD Profile )laes
Appliations '
<ear !tage of '.P. an I.P Tur*ine
Mile !tage of =.P. Tur*ine
Se<uential operation for mahining of T= blades'
Operation ac!ine
-) )lan#ing
4) <ho(*oi (achining
)an sa"
+>+ rho(*oi (achine
cell
3) <e(o@al of tech allo"ance9&arting off *an sa"
.) <oot (achining +>+ high s&ee root (achining
;) Profile an e0&ansion angle(internal an
e0ternal)
+>+ hea@y9light uty (achine or
+>+ &rofile an fillet (achining
center
2) !hrou co&ying +>+ hea@y9light uty (achine
7) Ta&er grining +>+ cree& fee grining
(achine
5) %rining an &olishing Polishing (achine
?) 1inal fitting of *laes ,
-/)Ai*ro finishing of *laes Ai*ro finishing e:ui&(ent
--)1inal ins&ection ,
Se<uential operation for mahining of 6"S and + blades'
Operation ac!ine
-) )lan#ing 'and sa!
3A
4) Pre&aration of technological ens for "or#
&iece holing
+>+ (achining center
3) +o(&lete *lae (achining("ith nor(al
shrou9F shrou)
+>+ ; a0is (achining centre
.) Ins&ection 3D +MM
;) (illing off technological ens at root an
shrou raius (achining
+>+ (achining centre
2) 1itting ,
7) @i*ro finishing for surface finishing
i(&ro@e(ent
Ai*ro finishing e:ui&(ent
5) Ins&ection ,
"u#ber of ad$ance desi%n blades:
Blades &'() '(()
TD Profile *lae -/3?/ 254/
1 an 3D! *lae 3-// 45;4
1ree staning *lae 44. 4;4
"O"- D*ST+,-TI.* T*STI"G /Li0uid penetration 1#a%netic
fla23radio%rap!45
Failure of the turbine blades was one of the challenges addressed with the help of BHEL by modifications
of LP stage-5 blade, shroud modifications etc., and based on its success, the same techniue was used
for other plants to sort out inherent problems. !rid-induced "utages !rid disturbance induced outages
were o#ercome by house load schemes and in one-month #i$., %ay &''(, as many as &5) house load
operations too* place and units operated withstanding these transients. Healthiness of the control
system and other euipment to withstand e+ternal grid transients was remar*able. ,he sharp corner in
the root section of the blade causes the blade to crac*. Failure of the turbine blades was one of the
challenges addressed with the help of BHEL by modifications of HP stage-5 blade, shroud modifications
3=
etc., and based on its success, the same techniue was used for other plants to sort out inherent
problems. ,he material used was &-.r-%o martensitic steel,which is a #ery high temperature resistant
material. ,he microstructure was obser#ed was tempered martensitic structure. ,hese turbine blades
were collected from %adras /tomic Power 0tation 1%/P02 for analysis. ,hese blades were found to be
failed. ,hese blades were used for the

present in#estigation of defects using ultrasonic phased array and
3-ray radiography techniues. ,urbine blades are *nown to fail due to tempered martensite
embrittlement, fatigue, fretting, high temperature creep age hardening, firtree design, high residual
stresses etc.
8hemical compositions of the turbine bladeC
Element Weight %
Sulphur ;#;1: to ;#;3
Phosphorus ;#;1: to ;#;2<
8arbon ;#2; to ;#24
8hromium 12#< N 1#2
-anganese ;#4A to ;#A4
Si'i+"e 0,-0 t" 0,.-
Fic"el ;#4; to ;#A2
Manadium ;#;A
-olybdenum ;#1 to ;#13
Iron Balance
T:$B#*E &ATE$#ALS
In the case of turbine+ the ad$ancement in steam conditions mainly
affects its high pressure 1(P3 and intermediate pressure 1IP3
sections#,s a result+ the associated rotations as !ell as stationary parts
of these sections e/perience more se$ere ser$ice conditions than that
of con$entional sets# Since they operate !ell !ithin the creep range+
their design is based primarily on the long-term creep strength ofthe
material+ but the stress le$els during steady and non-steady operating
conditions+ particularly during A:3Q8 contemplate the use of 128r
steel rotor !ith steam cooling to bring the rotor temperature do!n
to A==Q8+ !here its creep strength is ade7uate to meet the design
pressure# (o!e$er+ presently se$eral super 128r steels !ith much
3>
superior creep resistance are a$ailable and they should also be
considered before a final decision is ta"en# ,bo$e A:3Q8 steam
temperature+ O128r-o.MFbF 1; 11 and austenitic stainless steel
must be considered# ,mongst the austenitic steels+ ,2<= and
O<8rFi-o'Fb 1= 1= offer better creep strength for an (P rotor of
ad$anced sets operating at =4:Q8# 2ne of the rotor-related problems is
the ma/imum si5e that can be produced from the 128r and austenitic
steels# 9ue to se$ere segregation in con$entional ingots+ the si5e of
the austenitic steel rotors used in earlier supercritical units !as limited
to small si5e+ as a result of !hich+ it became necessary to di$ide the
(P turbine into t!o stages# It is estimated that a large ad$anced plant
!ould re7uire a one-piece super-alloy (P rotor forging
!eighing 11+3;; "g !ith a barrel diameter of <:;mm# Similarly+ a
double-flo! reheat rotor made of 128r steel is e/pected to be about
11A;mm in diameter and 31+>A; "g in !eight+ !hich !ould
re7uire to start !ith an ingot si5e of =3+A;; "g # Significant progress
has been made+ in recent years+ in increasing the si5e as !ell as the
7uality of the forging by employing modern steel ma"ing techni7ues
such as lo! sulfur silicon deo/idation 1lo! S3+ $acuum o/ygen
decarburi5ation 1M293+ $acuum carbon deo/idation 1M893+ central
5one refining 18G&3+ electro slag hot topping 1)S(T3 and electro
slag remelting 1)S&3# 'y employing these techni7ues+ either
indi$idually or in combination+ production e/perience !ith lo!-alloy
ferritic R3:S+ 128r as !ell as austenitic steels R4+ 4;S demonstrate that
the rotors of the candidates materials can be made to the re7uired si5e
and 7uality !ithout e/periencing much
problems#
Blading
8on$entional 128r-oM steel blades are ade7uate to meet the steam
temperature at A==Q8# 'ut a !ide $ariety of high-temperature blade
materials !ith pro$en ser$ice performance in large gas turbines are
a$ailable+ and they should be considered for more ad$anced steam
conditions# These include super 128r steels+ austenitic steels+ Fimonic
<;,+ :;+ 1;A+ 11A+ In>1< and precision casting alloys such as 6dimet
A;; and IF >3<*8#
LP $otor
3<
The principal re7uirements of material for lo!pressure 1*P3 rotor are
high yield strength to !ithstand the high stress imposed on it by long
blades and high fracture toughness to minimi5e subcritical fla!
gro!th so as to a$oid the possibility of fast fracture# 3#AFi8r-oM
steel is !idely used for *P rotor throughout the po!er industry# To
a$oid temper embrittlement+ the ma/imum operating temperature of
the *P rotor made of this steel is generally limited to about 3A;Q8 R:S#
The inlet steam temperature to *P turbine of the supercritical
units+ on the other hand+ is dictated by the e/haust steam from the
second IP section# The IP-*P crosso$er temperature from ad$anced
supercritical units at steam temperatures of A:3Q8 and abo$e
!ould be 4;;-4AAQ8 R:S# To maintain the inlet steam temperature of
*P turbine at its present ma/imum allo!able limit+ it !ould be
necessary to cool the steam either through cooling of the rotor
or by adding an additional stage of e/pansion to the IP turbine# The
latter approach !ould be a difficult design tas"+ as it re7uires usage of
long blades at high temperature+ !hereas the former approach has to
sacrifice a part of the thermal efficiency# ,nother approach to the
problem !ould be to render *P rotor material more resistant to temper
embrittlement R41S# )fforts are+ therefore+ being made to impro$e the
fracture toughness of the IP rotor steel by impro$ed steel ma"ing
technology and closer control of chemical composition# The
interaction bet!een -n+ Si+ P and Sn !as sho!n to ha$e promoted
the degree of temper embrittlement# &esistance to temper
embrittlement of 3#AFi8r-oM rotor steel !ith lo! -n and lo! Si
contents !as found to ha$e greatly impro$ed as compared to
con$entional steel R:S# 'y utilising the modern steel ma"ing
technologies+ it is no! possible to decrease both -n and Si contents
to le$els of- ;#;;2D#
3:
4;
41
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