CONTENTS

1. Steam Turbine
2. Types
3. Principle of operation and Design
4. Gas Turbine
5. Theory of Operation
6. Advance in technology
7. How to works
8. Bhel profile of steam Turbine

STEAM TURBINE

A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts
it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in 1884. It has almost
completely replaced the reciprocating piston steam engine (invented by Thomas Newcomen and greatly
improved by James Watt) primarily because of its greater thermal efficiency and higher power-to-weight
ratio. Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical
generator about 80% of all electricity generation in the world is by use of steam turbines. The steam
turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency
through the use of multiple stages in the expansion of the steam, which results in a closer approach to the
ideal reversible process.

Parsons turbine from the Polish destroyer ORP Wicher II

Types
Steam turbines are made in a variety of sizes ranging from small 1 hp (0.75 kW) units (rare) used
as mechanical drives for pumps, compressors and other shaft driven equipment, to 2,000,000 hp
(1,500,000 kW) turbines used to generate electricity. There are several classifications for modern
steam turbines.

Steam Supply and Exhaust Conditions

These types include condensing, noncondensing, reheat, extraction and induction.
Noncondensing or backpressure turbines are most widely used for process steam applications.
The exhaust pressure is controlled by a regulating valve to suit the needs of the process steam
pressure. These are commonly found at refineries, district heating units, pulp and paper plants,
and desalination facilities where large amounts of low pressure process steam are available.
Condensing turbines are most commonly found in electrical power plants. These turbines exhaust
steam in a partially condensed state, typically of a quality near 90%, at a pressure well below
atmospheric to a condenser.
Reheat turbines are also used almost exclusively in electrical power plants. In a reheat turbine,
steam flow exits from a high pressure section of the turbine and is returned to the boiler where
additional superheat is added. The steam then goes back into an intermediate pressure section of
the turbine and continues its expansion.

Casing or Shaft Arrangements

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.

Principle of Operation and Design

An ideal steam turbine is considered to be an isentropic process, or constant entropy process, in
which the entropy of the steam entering the turbine is equal to the entropy of the steam leaving
the turbine. No steam turbine is truly isentropic, however, with typical isentropic efficiencies
ranging from 20%-90% based on the application of the turbine. The interior of a turbine
comprises several sets of blades, or buckets as they are more commonly referred to. One set of
stationary blades is connected to the casing and one set of rotating blades is connected to the
shaft. The sets intermesh with certain minimum clearances, with the size and configuration of
sets varying to efficiently exploit the expansion of steam at each stage.

Turbine Efficiency
To maximize turbine efficiency, the steam is expanded, generating work, in a number of stages.
These stages are characterized by how the energy is extracted from them and are known as
impulse or reaction turbines. Most modern steam turbines are a combination of the reaction and
impulse design. Typically, higher pressure sections are impulse type and lower pressure stages
are reaction type.
Impulse Turbines
An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets
contain significant kinetic energy, which the rotor blades, shaped like buckets, convert into shaft
rotation as the steam jet changes direction. A pressure drop occurs across only the stationary
blades, with a net increase in steam velocity across the stage.
Reaction Turbines
In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles.
This type of turbine makes use of the reaction force produced as the steam accelerates through
the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator.
It leaves the stator as a jet that fills the entire circumference of the rotor. The steam then changes
direction and increases its speed relative to the speed of the blades. A pressure drop occurs across
both the stator and the rotor, with steam accelerating through the stator and decelerating through

the 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.

GAS TURBINE

A gas turbine, also called a combustion turbine, is a rotary engine that extracts energy from a
flow of combustion gas. It has an upstream compressor coupled to a downstream turbine, and a
combustion chamber in-between. (Gas turbine may also refer to just the turbine element.)
Energy is added to the gas stream in the combustor, where air is mixed with fuel and ignited.
Combustion increases the temperature, velocity and volume of the gas flow. This is directed
through a nozzle over the turbine's blades, spinning the turbine and powering the compressor.
Energy is extracted in the form of shaft power, compressed air and thrust, in any combination,
and used to power aircraft, trains, ships, generators, and even tanks.

Theory of operation
Gas turbines are described thermodynamically by the Brayton cycle, in which air is compressed
isentropically, combustion occurs at constant pressure, and expansion over the turbine occurs
isentropically back to the starting pressure.
In practice, friction and turbulence cause:
1. non-isentropic compression: for a given overall pressure ratio, the compressor delivery
temperature is higher than ideal.
2. non-isentropic expansion: although the turbine temperature drop necessary to drive the
compressor is unaffected, the associated pressure ratio is greater, which decreases the expansion
available to provide useful work.
3. pressure losses in the air intake, combustor and exhaust: reduces the expansion available to
provide useful work.

As with all cyclic heat engines, higher combustion temperature means greater efficiency. The
limiting factor is the ability of the steel, nickel, ceramic, or other materials that make up the
engine to withstand heat and pressure. Considerable engineering goes into keeping the turbine
parts cool. Most turbines also try to recover exhaust heat, which otherwise is wasted energy.
recuperators are heat exchangers that pass exhaust heat to the compressed air, prior to
combustion. Combined cycle designs pass waste heat to steam turbine systems. And combined
heat and power (co-generation) uses waste heat for hot water production.
Mechanically, gas turbines can be considerably less complex than internal combustion piston
engines. Simple turbines might have one moving part: the shaft/compressor/turbine/alternativerotor assembly (see image above), not counting the fuel system.
More sophisticated turbines (such as those found in modern jet engines) may have multiple
shafts (spools), hundreds of turbine blades, movable stator blades, and a vast system of complex
piping, combustors and heat exchangers.
As a general rule, the smaller the engine the higher the rotation rate of the shaft(s) needs to be to
maintain top speed. Turbine blade top speed determines the maximum pressure that can be

gained,this produces the maximum power possible independent of the size of the engine. Jet
engines operate around 10,000 rpm and micro turbines around 100,000 rpm.

Types of gas turbines

Aeroderivatives and jet engines

Diagram of a gas turbine jet engine

Airbreathing jet engines are gas turbines optimized to produce thrust from the exhaust gases, or
from ducted fans connected to the gas turbines. Jet engines that produce thrust primarily from the
direct impulse of exhaust gases are often called turbojets, whereas those that generate most of
their thrust from the action of a ducted fan are often called turbofans or (rarely) fan-jets.
Gas turbines are also used in many liquid propellant rockets, the gas turbines are used to power a
turbopump to permit the use of lightweight, low pressure tanks, which saves considerable dry
mass.

Diagram of a high-pressure turbine blade

Amateur gas turbines

Increasing numbers of gas turbines are being used or even constructed by amateurs.
In its most straightforward form, these are commercial turbines acquired through military surplus
or scrapyard sales, then operated for display as part of the hobby of engine collecting. In its most
extreme form, amateurs have even rebuilt engines beyond professional repair and then used them
to compete for the Land Speed Record.
The simplest form of self-constructed gas turbine employs an automotive turbocharger as the
core component. A combustion chamber is fabricated and plumbed between the compressor and
turbine sections. More sophisticated turbojets are also built, where their thrust and light weight
are sufficient to power large model aircraft. The Schreckling design constructs the entire engine
from raw materials, including the fabrication of a centrifugal compressor wheel from plywood,
epoxy and wrapped carbon fibre strands.
Like many technology based hobbies, they tend to give rise to manufacturing businesses over
time. Several small companies now manufacture small turbines and parts for the amateur. Most
turbojet-powered model aircraft are now using these commercial and semi-commercial
microturbines, rather than a Schreckling-like home-build.

Auxiliary power units

Auxiliary power units (APUs) are small gas turbines designed for auxiliary power of larger
machines, such as those inside an aircraft. They supply compressed air for aircraft ventilation
(with an appropriate compressor design), start-up power for larger jet engines, and electrical and
hydraulic power.

Industrial gas turbines for electrical generation

GE H series power generation gas turbine. This 480-megawatt unit has a rated thermal efficiency of 60%
in combined cycle configurations.

Industrial gas turbines differ from aeroderivative in that the frames, bearings, and blading is of
heavier construction. Industrial gas turbines range in size from truck-mounted mobile plants to
enormous, complex systems. They can be particularly efficientup to 60%when waste heat
from the gas turbine is recovered by a heat recovery steam generator to power a conventional
steam turbine in a combined cycle configuration. They can also be run in a cogeneration
configuration: the exhaust is used for space or water heating, or drives an absorption chiller for
cooling or refrigeration. A cogeneration configuration can be over 90% efficient. The power
turbines in the largest industrial gas turbines operate at 3,000 or 3,600 rpm to match the AC
power grid frequency and to avoid the need for a reduction gearbox. Such engines require a
dedicated enclosure, both to protect the engine from the elements and the operators from the
noise.

Radial gas turbines

Main article: Radial turbine

In 1963, Jan Mowill initiated the development at Kongsberg Vpenfabrikk in Norway. Various
successors have made good progress in the refinement of this mechanism. Owing to a
configuration that keeps heat away from certain bearings the durability of the machine is
improved while the radial turbine is well matched in speed requirement.

Advances in technology
Gas turbine technology has steadily advanced since its inception and continues to evolve;
research is active in producing ever smaller gas turbines. Computer design, specifically CFD and
finite element analysis along with material advances, has allowed higher compression ratios and
temperatures, more efficient combustion and better cooling of engine parts. On the emissions
side, the challenge in technology is increasing turbine inlet temperature while reducing peak
flame temperature to achieve lower NOx emissions to cope with the latest regulations.
Additionally, compliant foil bearings were commercially introduced to gas turbines in the 1990s.

They can withstand over a hundred thousand start/stop cycles and eliminated the need for an oil
system.

Advantages and disadvantages of gas turbine engines

Advantages of gas turbine engines

Very high power-to-weight ratio, compared to reciprocating engines;

Smaller than most reciprocating engines of the same power rating.

Moves in one direction only, with far less vibration than a reciprocating engine.

Fewer moving parts than reciprocating engines.

Low operating pressures.

High operation speeds.

Low lubricating oil cost and consumption.

Disadvantages of gas turbine engines

Cost is much greater than for a similar-sized reciprocating engine since the materials must be
stronger and more heat resistant. Machining operations are also more complex;

Usually less efficient than reciprocating engines, especially at idle.

Delayed response to changes in power settings.

These disadvantages explain why road vehicles, which are smaller, cheaper and follow a less
regular pattern of use than tanks, helicopters, large boats and so on, do not use gas turbine
engines, regardless of the size and power advantages imminently available.

SPECIFICATIONS OF MACHINES AVAILABLE IN BLOCK-III:

Vertical Boring Machine :

Max diameter of work piece accommodated

Max height of work piece
Diameter of table

:10000mm to 12500mm
:5000mm
:8750mm

Max travel of vertical tool head RAM slides

Max travel of vertical tool heads from centre of
Table
Max weight of work piece

Diameter of boring spindle of combined head

Travel of boring spindle
Taper hole of boring spindle

:3200mm
:5250mm
:200 T
For N<=6rpm;100T for any speed
:160mm
:1250mm
:100metric

Centre Lathe :(Biggest of all BHEL)

Max diameter over bed

Max diameter over saddle
Length between centers
Max weight of work piece
Spindle bore

:3200mm
:250mm
:16m
:100 T
:96mm

CNC Lathe :

Manufacturer: Safop, Italy

Swing over carriage
Centre distance
Weight capacity
Spindle power
External chucking range
Hydrostat steady range
Max spindle rpm
CNC system

:3500mm
:9000mm
:120 T
:196KW
:250-2000mm
:200-1250mm
:200
: SINUMERIK 840D

CNC Indicating stand :

Manufacturer : Heinrich Georg, Germany

Turning diameter
Turning length
Weight capacity

CNC Vertical Borer :

Manufacturer : M/S Pietro Carnaghi, Italy

:5.3m
:15m
:160 T

Machine model
Table diameter
Max turning diameter
Min boring diameter
Max height for turning and milling
Table Speed
Table load capacity
Milling spindle speed
Spindle taper
CNC system

:AP 80TM-6500
:6500mm
:8000mm
:660mm
:7000mm
:0.2-50 rpm
:200 T
:3.4-3000 rpm at 40KW
:BT 50
:SINUMERIK 840D

CNC Facing Lathe : KH-200-CNC

Swing over bed

Swing over carriage
Max distance between faced plate and carriage
Max weight of job held in chuck
Face plate diameter
Spindle speed
Main spindle drive

:2300mm
:1800mm
:2000mm
:6000kg
:1800mm
:1.4-400rpm
:95.5KW

Step boring Machine :

Max boring diameter

Min boring diameter
Table
Max weight of job
Headstock travel

:2500mm
:625mm
:4000mmx4000mm
:100 T
:4000mm

Double Column Vertical Borer :

Table diameter
Max travese of cross rail
Max weight of work piece
Max weight of job

:4000mm
:4250mm
:4200mm
:50 T

CNC Skoda Horizontal Borer :

Spindle diameter

:200mm

Taper spindle
RAM size
RAM length
Spindle length
Headstock
Table
CNC system
Job

:BT 50
:450x450mm
:1600mm
:2000mm
:5000mm
:4000x3500mm
:SIMENS 850mm
: I.P. Outer

Horizontal Borer : LSTG 8006

Spindle diameter
:250mm
Height of machining bed
:600mm
Max boring depth with spindle
:2000mm
Max extension of RAM
:1600mm
Width of bed guide ways
:2500mm
Actual length of headstock with vertical lift
:2150mm
Actual length of column horizontal feed
:15000mm
Lowest position of spindle axis upon bed guideways:1475mm
Machine weight with electrical equipments
:140 T
Height of machine
:10.3m

CNC Lathe : 1-120

Manufacturer : Ravensburg

Main spindle bore

Distance between centers
Turning diameter over bed cover
Turning diameter over carriage
Workpiece weight unsupported
Workpiece weight between centers

:150mm
:12m
:1400mm
:1100mm
:4000kg
:20 T

Centre Lathe : 1-23

Manufacturer : K3TC, USSR

Max diameter over bed

Max diameter over saddle
Length between centers
Max weight of work piece

:1250mm
:900mm
:6300mm
:25 T

Spindle bore
Machine wattage

:80mm
:55KW

Horizontal Boring Machine : 1-28

Diameter of spindle
Working surface of table
Max travel of table
Max vertical travel of headstock

:150mm
:2250x1250mm
:1200mm
:2000mm

Horizontal Boring Machine :

Boring spindle taper

Boring spindle diameter
Headstock vertical travel
Longitudinal RAM travel
Longitudinal spindle travel
Column cross travel
Rotary table travel
Table load

:BT50
:160mm
:3000mm
:700mm
:1000mm
:10m
:3000mm
:40 T

Horizontal Boring Machine : 1-11

Boring spindle internal taper material

Boring spindle diameter
Max spindle travel
Vertical head travel
Transverse column travel
Max longitudinal column travel
Machine wattage

:200
:320mm
:2500mm
:6000mm
:6000mm
:800mm
:90KW

Double Column Rotary Table Vertical Borer :

Max diameter of work piece accommodated

:10m/12.5m
Max height of work piece accommodated
:5m
Diameter of table
:8.75m
Max travel of vertical tool head RAM slides
:3.2m
Max travel of vertical tool head from centre of table:5.25m
Max weight of work piece
:200T for N<=8rpm
;100T for any speed

Diameter of boring spindle of combined head

Travel of boring spindle
Taper hole of boring spindle

:160mm
:1250mm
:100 metric

Horizontal borer : 1-2

Spindle diameter
Working surface
Max vertical travel
Max transverse travel of column
Max longitudinal travel of column
Max longitudinal travel of spindle

:220mm
:8100 x 5000mm
:3mm
:6m
:6m
:1.8m

CNC Lathe : 2-360

Manufacturer : Hoesch

Max load
Max length between centers
Swing over bed

:320 T
:18m
:3.2m

Horizontal Borer : 2-198

Spindle diameter
Max vertical travel
Max transverse travel of column
Max longitudinal travel of column
Max longitudinal travel of spindle
Working surface

:220mm
:3m
:6m
:6m
:1.8m
:1800x500mm

Creep Feed Grinding Machine :

Diameter of job
Job height
Table rpm
Table diameter
Swing diameter
CNC control

Broaching Machine :

:2m
:2.4m
:10rpm(max)
:2050mm
:2500mm
:SIEMENS-3GG

Broaching capacity
Broaching stroke
Broaching slide width
Broaching specific cutting stroke
Broaching specific return stroke
Max diameter of disc
Max move of table
Helix angle/skew angle setting
Cone angle

:32 T
:10.3m
1500mm
:1.25m/min
:60m/min
:2300mm
:600mm
:+45/-45
:0-20

CNC Lathe :

Manufacturer : Innse Berardi, Italy

Swing over carriage
Swing over bed
Capacity
Cost
CNC system

:1500mm
:2000mm
:30 T
:16 crore
:SINUMERIK 840D

Over Speed Balancing of Turbines :

Main features :

Type of pedestials
Rotor weight
Rotor diameter
Rotor journal diameter
Bearing centre distance
Balancing speed
Min vibration limit
Max vacuum

:DH 90/DH 12
:Min 4 MT, Max 320 MT
:Max 6900mm
:Min 250mm,Max 950mm
:Min 3000mm,Max 15700mm
:180-3600rpm
:1 micron
:1 torr

Tunnel Features :

Tunnel length
Tunnel diameter
Max thickness of tunnel
Steel plate thickness
Cost of balancing equipment(FE)
Total cost of balancing tunnel

:19000mm
:6900mm
:2500mm
:32mm
:444 lakhs
:770 lakhs

Main Features of Drive :

Drive motors (2 no.)

Total drive power

:950V DC, 500rpm,3.5 MW each

:7 MW(2x3.5)

MG set of Drive :

Synchronous motors
DC Generator (2 no.)

:11 KV,9MW,50Hz,500rpm
:950V,500rpm,3.8MW each

HOW IT WORKS

STEAM FLOW THROUGH STEAM

TURBINE

Modernization Of Facilities :

CNC Lathe for LP Rotor from SAFOP, ITALY

CNC Horizontal Boring machine for machining of casing from PAMA, ITALY
CNC Indicating Stand for LP Rotor Blade machining from GEORG, GERMANY
CNC Fir Tree Root Milling machine
CNC Gantry Milling machine

Major Facilities For New Turbine Shop :

CNC V Borer-Table diameter-7500mm

CNC V Borer-Table diameter-4000mm
CNC H Borer Spindle Diameter-200mm,160mm
CNC Lathe capacity-120 T,80T
CNC Fir Tree Root Milling machine
CNC Gantry Milling machine

Highlights :
Imported Substitutions :

Hybrid burner for gas turbine

E ring for gas turbine
Deep hole drilling in HP outer casing supplied by Machine Shop, CFFP

Process Improvement :

Slitting of casing, thrust rings, GT rings on Band Saw milling machine, thus
saving the time on critical machines such as Ram Borers
Using KOMET drilling systems, the productivity in joint plane drilling of
casing and LP Rotors has increased
Seeing the congestion on KOOP milling machine, a new work center
machine called RAMBHOR machine(No. 2473

Tool Brands :

Widia
Sandwick
Seco
Isear
Addisson
Guhring

Indian tools
Mitutoyo

Tool Instruments :

Die ring spanner

Hack saw frame
Burr cutter
Solid tap (carbide)
Hand tap

Grinding Cutters :

Combination cutter-140x40mm
Fillet cutter-160x32mm
Hand mill cutter
End mill cutter
Internal profile cutter
Shell end mill cutter-63x80mm
Ball nose
Slab mill

500 MW Steam Turbine :

HP Turbine:

Module
Steam Pressure
Steam temperature
Reheating temperature
Weight
Length of Rotor
Height

:H30-100-2
:170Kg/sq.cm
:537 deg.cel
:537 deg.cel
:86400 Kg
:4.61m
:2.15m

LP Turbine:

Module
Weight
Length of Rotor
Width
Height

IP Turbine:

:N30-2x10sq.m
:3.5 T
:8.7m
:10.7m
:4.6m

Length
Width
Height
Steam pressure
Steam temperature

:4.425m
:5m
:4.8m
:41Kg/sq.cm
:537 deg.cel

Gas Turbine V 94.2 :

ISO 159MW
Weight
Length
Breadth
Temperature of hot gas in turbine
Type of burner

:200 T
:10m
:2.5m
:1060 deg.cel
:Hybrid Burner

Milling Cutters :
1) Side end face milling cutter
2) Interlocking side and face milling cutter
3) Shell end mill cutter
4) Metal slitting saw
5) Single angle milling cutter
6) Double unequal angle milling cutter
7) Double equal angle milling cutter
8) Keyway milling cutter
9) Milling cutter for chain wheels
10) Single corner rounding milling cutter
11) Convex milling cutter
12) Concave milling cutter
13) T slot milling cutter with plane parallel shank
14) T slot milling cutter with Morse taper shank having tapered end
15) Cylindrical milling cutter
16) Slot milling cutter with parallel shank
17) End mill with parallel shank
18) Ball nosed end mill with parallel shank
19) Flat end tapered die sinking cutter with plane parallel shank
20) Ball nosed taper die sinking cutter with plane parallel shank
21) Slot milling cutter with morse tapered shank having tanged end
22) End mill with morse tapered shank having tanged end
23) Ball nosed end mill with morse tapered shank having tanged end
24) Flat end tapered die sinking cutter with morse tapered shank having tapped end
25) Ball nosed tapered die sinking cutter with morse tapered shank having tapped end
26) Slot milling cutter with morse tapered shank having tapped end
27) End mill morse tapered shank having tapped end
28) Ball nosed mill morse tapered shank having tapped end

29)
30)
31)
32)
33)
34)
35)

Roughing end mill with parallel shank finishing type

Roughing end mill with parallel shank roughing type
Slot milling cutter with 7/24 taper shank
End mill with 7/24 taper shank
Ball nosed end mill with 7/24 taper shank
Woodruff key slot milling cutter with parallel shank
Screwed shank slot drill

Major Components of Steam Turbine :

LP Rotor
LP Inner Casing Upper Half
LP Inner Casing Lower Half
LP Outer Casing Upper Half
LP Outer Casing Lower Half
IP Rotor
IP Inner Casing Upper Half
IP Inner Casing Lower Half
IP Outer Casing Upper Half
IP Outer Casing Lower Half
HP Rotor
HP Inner Casing Upper Half
HP Inner Casing Lower Half
HP Outer Casing Upper Half
HP Outer Casing Lower Half
Diffuser
GBC (Guide Blade Carrier)
IVCV (Intercept Valve Control Valve)
ESVCV (Emergency Stop Valve Control Valve)

Auxiliary Parts of Steam Turbine :

1)
2)
3)
4)
5)
6)
7)
8)
9)

Valve Seal
U-Ring
Piston Rod
Base Plate
Sealing Ring
Liner
Guide Ring
Valve Cover
Guide Blades :

10) Support

Fixed Blades
Moving Blades

11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)

Bearing
Bearing Shell
Angle Ring
Sleeve
Pin Taper (25x140)
Journal Bearing Shell
Casing
Guide bush
Piston (500MW)
Valve Cone
Yoke
Mandrel
Support Ring
Thrust Ring
Adjusting Ring
Shaft Sealing Cover

Auxiliary Parts of Gas Turbine :

1)
2)
3)
4)
5)
6)

Spacer Ring
Oil Guard Ring V 94.2
Oil Projecting Ring
Plate
Coupling Bolt
Inlet Shell

Types of Blades :

T2 blades
T4 blades
TX blades
3DS blades
F- blades
GT-Compress blades
Brazed blades
Russian design blades
Z-Shroud blades
Compressor blades (Sermental coated)
LP Moving blade 500MW

New Blade Shop :

 First Generation Blades :

T2 Profile Blades
Cylindrical Profile Blades (1970)

Second Generation Blades :

T4 Profile Blades
Cylindrical Profile Blades ( late 1980)
1% Gain in Stage Efficiency over T2 Profile Blades

TX Profile Blades
Cylindrical Profile Blades ( late 1990)

Gains :
Reduces Profile Losses
0.2% Gain in Stage Efficiency over T4 Profile Blades
Applications :
Middle Stage Of H.P. and I.P Turbine
Initial Stage of L.P. Turbine

3DS Blades :
Gains :
Reduces Secondary Flow Losses
0.5 1.0% Gain in Stage Efficiency over TX Profile Blades

Application :
Initial Stage of H.P. and I.P Turbine

F- Blades
Gains :
Reduces Indirect Flow Losses
0.5 1.0% Gain in Stage Efficiency over TX Profile Blades

Applications :
Rear Stage of H.P. and I.P Turbine
Middle Stage of L.P. Turbine

Sequential operation for machining of TX blades :

Operation
1) Blanking
2) Rhomboid machining
3) Removal of tech
allowance/parting off
4) Root machining
5) Profile and expansion
angle(internal and external)
6) Shroud copying
7) Taper grinding
8) Grinding and polishing
9) Final fitting of blades
10) Vibro finishing of blades
11) Final inspection

Machine
Band saw
CNC rhomboid machine cell
band saw
CNC high speed root machining
CNC heavy/light duty machine or
CNC profile and fillet machining
center
CNC heavy/light duty machine
CNC creep feed grinding machine
Polishing machine
Vibro finishing equipment
-

Sequential operation for machining of 3DS and F blades :

Operation

Machine

1) Blanking

Band saw

2) Preparation of technological
ends for work piece holding
3) Complete blade machining(with
normal shroud/Z shroud)
4) Inspection
5) milling off technological ends at
root and shroud radius
machining
6) Fitting
7) vibro finishing for surface
finishing improvement
8) Inspection

CNC machining center

CNC 5 axis machining centre
3D CMM
CNC machining centre
Vibro finishing equipment
-

Number of advance design blades:

Blades

250MW

500MW

TX Profile blade
F and 3DS blade
Free standing blade

10390
3100
224

6820
2852
252