1

BHARAT HEAVY ELECTRICALS

LIMITED

BHOPAL
SUMMER INDUSTRIAL TRAINING
Department: STEAM TURBINE MANUFACTURING (STM)

Under The Guidance Of:

Shri. Anup Khare, AGM, STM
From: 2nd June to 29th June 2016

Submitted By:
Anurag Sharma
Jaypee University of Engineering & Technology (JUET)
Guna
Mechanical Engineering
Token No: VT-450/16

CERTIFICATE
This is to certify that Anurag Sharma student of 3rd year
B.Tech., Mechanical Engineering (MEC), Jaypee University of
Engineering And Technology (JUET), Guna (M.P.) have
successfully completed their Vocational Training at BHEL,
Bhopal for four weeks from 2nd June 2016 to 29 June 2016. He
has completed the whole training as per the training report
submitted by them.
Training incharge
BHEL, Bhopal

ACKNOWLEDGEMENT
Gratitude is the hardest emotion to express and often one does
not find adequate words to express one feeling. I express my
deep gratitude and deep indebtedness for the HRD department
for granting me the permission as summer in-plant training.
I own my gratitude to BHEL BHOPAL for providing me the
opportunity to undergo training and allowing me to gain vast
knowledge about the industry and the other aspects of the
organisation during our training period.
It is my foremost duty to express my deep sense of gratitude
and respect to Mr Anup Khare (DGM/AME) for his valuable
guidance as well as uplifting tendency and inspiring me for
taking up training and completing it successfully
I am also very thankful to all staff members of BHEL BHOPAL
who gave their support during the training.

DECLARATION
I, Anurag Sharma, student of B. TECH. III year, studying at
Jaypee University of Engineering & Technology, Guna,
hereby declare that the vocational training report on Steam
Turbine Engineering is submitted to BHEL, Bhopal.
The information and data given in the report is authentic to the
best of my knowledge.
This vocational training report is not being submitted to any
other University for award of any other Degree, Diploma and
Fellowship.

Signature of guide
Signature of Candidate

MR. ANUP KHARE

ANURAG SHARMA

TRAINING AT BHEL, BHOPAL

I was appointed to do four weeks training at this esteemed
organization from 2 June 2016 to 29 June 2016. We were assigned
to visit various division of plant, which were:
Block 6
Block 2
Block 1
These four weeks of training was a very educational adventure
for me. It was really amazing to see the manufacturing of
motors and comprises of huge components manufactured by
BHEL and learns how massive, an elemental component could
be, and is produced. This report has been made by my
experience at BHEL, Bhopal.
The material in this report has been gathered from textbook,
trainers manuals and journals provided by training
department. The specification and principles are as learned by
me from the employees of each division of plant.

CONTENT

1. About Project
2. A brief introduction of BHEL
3. BHEL Bhopal Profile
4. Steam Turbine
5. Turbine Efficiency
a) Impulse Turbine
b) Reaction Turbine
6. Steam Turbine Construction
7. Working of a Steam Turbine
8. Rankine Cycle
9. Conclusion

TITLE OF PROJECT
To understand the design and working of Steam Turbine.

OBJECTIVE To classify steam turbines based on their working.

To understand various components of the steam turbine.

METHODOLOGY
Following methodology are being used for the preparation of
this project report:
a. Visited every section of the unit.
b. Analytical and comparative study of various resources
available in the unit.
c. Discussion with the various workers and engineers.

ACTIVITIES TO BE CARRIED OUT TO COMPLETE

THE PROJECTFollowing are the activities to be carried out to complete the
projectACTIVITY 1- Contact and meeting with project guide Mr Anup
Khare and discuss about the project.
ACTIVITY 2- Study of different types of steam turbines from
different manuals, training documents of BHEL and tutorials
websites.
ACTIVITY 3- Discuss among BHEL engineers about motors.
ACTIVITY 4- Analysis of information gathered & prepared draft
of the project report.
ACTIVITY 5- After finalising the project by my project guide it
will be submitted.

A BRIEF INTRODUCTION OF BHEL: BHEL is a Maharatna Govt. undertaking company. BHEL is the
largest engineering and manufacturing enterprise of India in
the energy & infrastructure related sectors. BHEL is amongst
worlds rarest few who have capability to manufacture entire
range of power plant equipment.

With an export presence in more than 60 countries,

BHEL is truly Indias industrial ambassador to the world.
This list is intended as a general guide and does not
represent all of BHEL's products and systems.
Thermal Power Plants
Steam turbines and generators of up to 800MW capacity for
utility and combined-cycle applications; capability to
manufacture steam turbines with super critical steam cycle
parameters and matching generator up to 1000 MW unit size.

Gas based Power Plants

Gas turbines of up to 260MW (ISO) rating.
Gas turbine based co-generation and combined-cycle systems
for industry and utility applications.

Hydro Power Plants

Custom-built conventional hydro turbines of Kaplan, Francis
and Pelton types with matching generators, pump turbines with
matching motor-generators. Mini/micro hydro sets.
Spherical, butterfly and rotary valves and auxiliaries for hydro
station

DG Power Plants
HSD, LDO, FO, LSHS, natural-gas/biogas based diesel power
plants, unit rating up to 20MW and voltage up to 11kV, for
emergency, peaking as well as base load operations on turnkey
basis.

Industrial Sets
Industrial turbo-sets of ratings from 1.5 to 120MW.
Gas turbines land matching generators ranging from 3 to
260MW (ISO) rating.
Industrial stream turbines and gas turbines for drive
applications and co-generation applications.

Boilers and Auxiliaries

Steam generators for utilities, ranging from 30 to 800MW
capacity, using coal, lignite, oil, natural gas or a combination of
these fuels: capability to manufacture boilers with super critical
parameters up to 1000 MW unit size.
Steam generators for industrial applications, ranging from 40
to 450t/hour capacity using coal, natural gas, industrial gases,
biomass, lignite, oil, bagasse or a combination of these fuels.
Pulverized fuel fired boilers.
Stoker boilers.
Pressure vessels.

Heat Exchangers and Pressure Vessels

Air-cooled heat exchangers.

Surface condensers.
Steam jet air ejectors.
LPG/propane storage bullets.
Feed water heaters.

Power Station Control Equipment

Microprocessor-based distributed digital control systems.

Sub-station controls with SCADA.
Static excitation equipment/automatic voltage regulator.
Electro-hydraulic governor control.
Turbine supervisory system and control.
Controls for electrostatic precipitators.
Controls for HP/LP bypass valves.

Switchgears
Switchgear of the various types for indoor and outdoor
applications and voltage ratings up to 400 kV.
Minimum oil circuit breakers (66K 132kV).
SF6 circuit breakers (132 kV 400 kV).

10

Vacuum circuit breakers (3.3 kV 33 kV).

Gas insulated switchgears (36 kV).

Transformers
Power transformers for voltage up to 400 kV.
HVDC transformers and reactors up to + 500 kV rating.
Series and shunt reactors of up to 400 kV rating.
Current transformers up to 400 kV.
Electro-magnetic voltage transformers up to 220 kV.
Capacitor voltage transformers up to 400 kV.
Special transformers: earthing; furnace; rectifier; electrostatic
precipitator; freight loco and AC EMU and traction transformers.

Insulators
Disc/suspension insulators for AC/DC applications, ranging
from 45 to 400 kn electromechanical strength, for clean and
pollute atmospheres.
Pin insulators of up to 33 kV.
Hollow porcelains of up to 400 kV.
Solid core insulators of 25 kV rating (both porcelain and
hybrid) for railways.
Disc insulators for 800 kV AC and HVDC transmission lines
(BHEL is the first Indian manufacturer to supply such
insulators).

Capacitors
Power capacitors for industrial and power systems of up to
250 kVAr rating for application up to 400 kV, Coupling/CVT
capacitors for voltages up to 400 kV.
Low Tension Thyristor Switched Capacitors (LTTSC) for
dynamic power factor
Correction.

Energy Meters
Single Phase, Poly Phase and Special-purpose electromechanical and electrical meters.

11

BHEL BHOPAL
Different blocks and their productions:
1. Block 1 Hydro turbine and Fabrication
2. Block 1 A - Transformer radiator (oil cooling)
3. Block 1B Fabrication
4. Block 2 Rotating Machines(IMM,LEM,PLM,TEM)
5. Block 3 Transformer ,Bushing and Capacitors
6. Block 4 Switchgear, Control gear and Rectifier
7. Block 5 - Foundry
8. Block 6 - Steam Turbine
9. CIM- Coil and insulation
10. CRX- Raw material store
11. Block 9 Traction Motor
12. Block 10 Press shop
13. Block 11 Tool and Gauge manufacturing Block
14. Block New Transformer Block (Part of TRM Block)
15. Block Swarn Jayanti Block
16. Block Electroplating Block

AC Machines - BHEL Technology

Acquisition
Collaboration with AEI, UK (1956-1971)
Machines with class B Resiflex insulation system

Collaboration with Siemens, Germany TCA-I

(1980-1990)
Induction and synchronous machine up to 20 MW (4 pole) with
class F
MICALASTIC insulation system.

12

Collaboration with Siemens, Germany TCA-II

(1996-2006)
New H-compact motors & H-module induction motors.
H-moflex motors and alternators up to 25 MW. VFD and special
motors.

13

BHEL BHOPAL PROFILEHeavy Electrical Plant , Bhopal is the mother plant of Bharat
Heavy Electricals Limited, the largest engineering and
manufacturing enterprise in India in the energy related and
infrastructure sector, today. It is located at about 7 km. From
Bhopal Railway station, about 5 km. from Habibganj Railway
station and about 18 km from Raja Bhoj Airport. With technical
assistance from Associated Electricals (India) Ltd., a UK based
company; it came into existence on 29th of August, 1956. Pt.
Jawaharlal Nehru, first Prime minister of India dedicated this
plant to the nation on 6th of November, 1960.
BHEL, Bhopal with state-of-the-art facilities, manufactures wide
range of electrical equipment. Its product range includes 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. 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 has its own Laboratories for material testing and
instrument calibration which are accredited with ISO17025 by
NABL. The Hydro Laboratory, Ultra High Voltage laboratory and
Centre for Electric Transportation are the only laboratories of it
are in this part of the world.
BHEL Bhopals strength is its employees. The company
continuously invests in Human Resources and pays utmost
attention to their needs. The plant's Township, well known for
its greenery is spread over an area of around 20 sq. km and
provides all facilities to the residents like, parks, community
halls, library, shopping centres, banks, post offices etc. Besides,
free health service is extended to all the employees through
350 bedded (inclusive of 50 floating beds) Kasturba Hospital
and chain of dispensaries.

14

BHEL BUSINESS AREAS

Today is the largest Engineering Enterprise of its kind in India
with excellent track record of performance, making profits
continuously since 1971-72.
BHEL's operations are organized around three business sectors,
namely Power, Industry -including Transmission, Transportation,
Tele communication & Renewable Energy and Overseas
Business. This enables BHEL to have a strong customer
orientation, to be sensitive to his needs and respond quickly to
the changes in the market.

Power
Industry
Transportation
Transmission
Defences etc.

The greatest strength of BHEL is its highly skilled and

committed 42,600 employees. Every employee is given an
equal opportunity to develop himself and grow in his career.
Continuous training and retraining, career planning, a positive
work culture and participative style of management all these
have engendered development of a committed and motivated
workforce setting new benchmarks in terms of productivity,
quality and responsiveness.
MAJOR CUSTOMERS OF B.H.E.L
Supplied to all major utilities in India:
National Thermal Power Corporation (NTPC) PGCIL
NJPC NHPC NLC NPCIL NEEPCO
APTRANSCO APGENCO JPPCL
ALL State Electricity Boards (SEBs)
Abroad:

15

TNB, Malaysia PPC, Greece MEW, Oman OCC, Oman GECOL,

Libya Trinidad & Tobago, New Zealand, Tanzania etc.

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-toweight 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.

History
The first device that may be classified as a reaction steam
turbine was little more than a toy, the classic Aeolipile,
described in the 1st century by Hero of Alexandria in Roman
Egypt. A thousand years later, the first impact steam turbine
with practical applications was invented in 1551 by Taqi alDin in Ottoman Egypt, who described it as a prime mover for
rotating a spit. Similar smoke jacks were later described by John

16

Wilkins in 1648 and Samuel Pepys in 1660. Another steam

turbine device was created by Italian Giovanni Branca in 1629.
The modern steam turbine was invented in 1884 by the
Englishman Sir Charles Parsons, whose first model was
connected
to
a dynamo that
generated
7.5
kW
of
electricity. Parson's steam turbine, making cheap and plentiful
electricity possible and revolutionizing marine transport and
naval warfare, the world would never be the same again. His
patent was licensed and the turbine scaled-up shortly after by
an American, George Westinghouse. A number of other
variations of turbines have been developed that work
effectively with steam. The de Laval turbine (invented
by Gustaf de Laval) accelerated the steam to full speed before
running it against a turbine blade. This was good, because the
turbine is simpler, less expensive and does not need to be
pressure-proof. It can operate with any pressure of steam. It is
also, however, considerably less efficient. The Parson's turbine
also turned out to be relatively easy to scale-up. Parsons had
the satisfaction of seeing his invention adopted for all major
world power stations. The size of his generators had increased
from his first 7.5 kW set up to units of 50,000 kW capacity. He
knew that the total output from turbo-generators constructed
by his firm C._A._Parsons_and_Company and by their licensees,
for land purposes alone, had exceeded thirty million horsepower. Within Parson's lifetime the generating capacity of a unit
was scaled-up by about 10,000 times.

17

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,
extraction and induction.

noncondensing,

reheat,

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.

18

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
intermediate stage to produce additional power.

at

an

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.

19

Turbine Efficiency

Schematic diagram outlining the difference between an impulse and a reaction

turbine

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.

20

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
steam chest pressure to condenser pressure (or atmosphere
pressure). Due to this relatively 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 is 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".

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.

21

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.

Steam
Turbine
Features

Constructional

GENERAL DESIGN FEATURES

The turbine is of tandem compound design with separate HP, IP
and LP cylinders. The HP turbine is of single flow type while IP
and LP turbines are of double flow type. The turbine is
condensing type with single reheat. It is basically engineered
on reaction principle with throttle governing. The stages are
arranged in HP, IP and LP turbines, driving alternating current
full capacity Turbo generators.
The turbine is capable of accepting variations from the rated
conditions within the limits as recommended by IEC-45.

22

MODULAR CONCEPT
The turbine is built on the well-proven design philosophy of
`Modular Principle' in steam turbine engineering field.
The
readily designed HP, IP and LP turbine modules are combined
and sized to required power output; steam parameters and
cycle configuration to give most economical turbine set.
This maneuverability is achieved without impairing the
reliability of the modules which is governed by the shape and
configuration of rotors, cylinder and distance between the
bearings.
These modules incorporate the design and
construction features which have proved their reliability in
service and ensure trouble-free operation over long operating
periods and at the same time ensuring high thermal
efficiencies. All the materials used for manufacture of various
parts are most suitable for the duty required and have been
selected after exhaustive research and long experience.

BARREL TYPE HP TURBINE

The
outer
casing of the HP turbine is of barrel
type
construction without any massive horizontal flange.
This
unique construction permits rapid start-up from any thermal
state and high rates of load changes of the turboset.
The
steam and metal temperature matching requirements are
also
less stringent
as there is no asymmetry of mass
distribution in transverse or longitudinal planes.
Although HP inner casing is with a horizontal split joint, yet it
represents itself like a thin thermal membrane. As the inner
casing is not subjected to large pressure drops, the horizontal
flange joint and bolts are made of thin
sections
thus
permitting large transverse temperature
changes.
Inner
casing is kinematically supported within the outer barrel.

23

The barrel type HP outer casing does not cause any problem
during overhauls and capital maintenance as the handling
fixtures supplied along with turbine, enables the disassembly
and assembly in relatively short time as compared to the
conventional design.

IP TURBINE
The IP turbine is double flow turbine with a horizontal split,
inner casing being kinematically supported within the outer
casing. IP inner and outer casings are suspended from top
halves so as to totally eliminate the effect of heating of
flanges on TG centre line. Although the casings are of
horizontal
split
design yet these do not
impose
any
constraints in start-up timings and rapid load fluctuations.

LP TURBINE
LP Turbine is also double flow type with exhaust area optimally
selected for the expected vacuum conditions. The casing of
LP turbine is connected with IP cylinder by two cross around
pipes, one on either side of the machine and level with the
floor. The horizontally split, fabricated LP casing is comprised
of three shells.
Special design measures have been adopted to remove the
moisture from last stages by reducing the thickness of water
film on guide blades. The axial clearances between guide and
moving blades have been so chosen as to reduce the droplet
sizes and attendant erosion of leading edges. Low pressure
extraction has been optimized not only from thermodynamic
considerations but to effectively drain out moisture also.
Free standing blades have been envisaged. The blades are

24

designed to permit continuous operation of machine in grid

frequency range from 47.5 Hz to 51.5 Hz.
Atmospheric relief diaphragms are provided in the upper part
of outer casing to protect the turbine against excessive
pressure. In the event of failure of the low vacuum trips ,the
pressure in the condenser rises to an excessively high level
until the force acting on the rupturing disc ruptures the
breakable diaphragm, thus providing a discharge path for the
steam. The diaphragm consists of a thin rolled lead plate. To
ensure that the remnants of the diaphragm and rupturing
disc are not carried along by the blow-off steam, brackets are
provided. As long as there is a vacuum in the condenser the
atmospheric pressure forces the blow-out diaphragm and the
rupturing disc against the supporting flange.

BLADING
In Steam Turbine, the blades transform the thermal energy
into mechanical energy. It is obvious that blading has got
direct impact on the efficiency and reliability of turbine.
Appropriate blade profile, with high aero thermodynamic
efficiency having sufficient mechanical strength to withstand
the steam forces, are determined after extensive research.
Particular care is taken to avoid resonance and to ensure that
the natural
frequencies of unshrouded free standing rotor blades are
compatible with the rotational frequency of the machine. A
final accurate check is made when the blades have been
fitted into the rotor. The opportunity is also taken to carefully
check the root fastening of the blades.

SHAFT GLANDS

25

Labyrinth-type glands seal the shaft where it passes through

the casing. In the case of HP and IP Turbine, in the area with
little relative expansion , consist of a series of sealing strips
alternatively caulked into the shaft and into stationary rings. In
the area with greater relative expansion on the exhaust side,
there are see-through seals with sealing strips opposite in
vernier arrangement. In case of the LP turbine glands sealing
strips are fitted in the stationary rings only. The pressure of
the steam leaking through the gland is reduced by
converting the pressure energy into velocity energy, which is
then dissipated as eddies as the steam passes through large
number of strips.
The
number of sealing strip rings used depends on the
pressure drop required. Each ring consist of six or eight
segments and is carried in grooves in the casing or inner casing
to allow radial movement. Each segment is held in position
against a shoulder by two helical springs. In the event of the
shaft coming into contact with the strips in the segments, the
affected segments will move away radially. A possible slight
contact between the shaft and the thin strips will generator
only a small amount of heat which cannot
lead to a
deformation.

ROTORS, COUPLINGS AND BEARINGS

The rotating elements consisting of three monoblock rotors of
HP, IP and LP turbines are coupled together by means of
integrally forged flanges thus in effect forming a single shaft
system. The critical speeds of the HP and IP rotors are
designed to be above the normal rated speeds. Each rotor is
subjected to 20% overspeed test. The HP rotor is carried in
two bearings a simple journal bearing at the free end of the
shaft and a combined journal and thrust bearing at the other
end directly adjacent to the coupling of the IP rotor. IP and LP

26

rotors each has a single journal bearing at the rear end. All
the bearings are independently supported on separate bearing
pedestals. This arrangement ensures maintenance of rotor
alignment under all operating conditions. The coupled rotors
are located to the stationary components by thrust bearing.

TURNING GEAR
Hydraulic motor turning gear is envisaged to ensure uniform
and rapid heating and cooling of the casings during start-up
and trip out respectively. The turning gear is located in front
bearing pedestal of HP turbine.
Manual turning gear is also provided in addition to the
hydraulic turning gear to enable the combined shaft system to
be rotated manually.

VALVES
HP turbine is fitted with 2 combined emergency stop and
control valves. Each combined valve consists of an emergency
stop valve and a control valve fitted in a common body with
the spindles at right angles and in the same plane. The two
valves operate with two separate servomotors independent of
each other. The valves are mounted on both the side of HP
turbine casing.
IP turbine is fitted with 2 combined reheat stop and control
valves with their separate independent servomotors. These
valves are located under the operating floor in front of
pedestal. These valves are of floating type.

27

GOVERNING SYSTEM
The turbine is equipped with electro-hydraulic governing
system backed up with hydro- mechanical system ensuring
stable operation under any grid fluctuations and load throw
off conditions. The electro-hydraulic system has a number of
advantages, not the least of which are its high accuracy, high
operating speed and sensitivity. It permits governed run up
to
rated speed. The
linear
power
output/frequency
characteristic can be adjusted between close limits even
while the machine is in operation.

TURBINE STRESS CONTROLLER

The turbine stress evaluator continuously scans the critical
sections of stop valves, HP and IP turbines and provides
temperature margin based on the fatigue life of the material
and state of thermal stresses at that particular instant. This
ensures a stress consistent start-up and operation. Hence,
when there is temperature rise, the outer casing of the HP
turbine expand from their from their fixed points towards front
pedestals. Casing of IP Turbine expand from its fixed point
towards the generator.
LP Casing expands from its fixed point at front end ,towards the
generator.

Rotor Expansion
The Hp turbine rotor expands from the thrust bearing towards
the front bearing pedestal of the HP turbine and the Ip turbine
Rotor from the thrust bearing towards the generator.

28

The LP turbine rotor is displaced towards the generator by the

expansion of the shaft assembly ,originating from the thrust
bearing.

DIFFERENTIAL EXPANSION
Differential expansion between rotors and casings results from
the difference between the expansion of rotor and casing
originating from the HP-IP pedestal.
Differential expansion between rotor and casing of the IP
turbine results from the difference between the expansion of
the shaft assembly, originating from thrust bearing and casing
expansion ,which originates from the fixed points on the LP
turbine longitudinal beams.

SHAFT SEAL and BLADE TIP SEALING

All shaft seals, which seal the steam in the casing against
atmosphere, are axial-flow type. They consists of a large
number of thin seal strips which, in the HP and IP turbines are
caulked alternately into grooves in the shafts and the
surrounding seal rings.

TURBINE CONTROL SYSTEM

The Turbine has an electrohydraulic control system. An electric
system measures speed and output and controls them by
controlling
the
control
valve
hydraulically
via
an
electrohydraulic converter.

29

The linear power frequency droop characteristic can be

adjusted in fine steps even when the turbine is running

TURBINE MONITORING SYSTEM

In addition to measuring and display instruments for pressure,
temperatures, valve lifts and speed ,the monitoring system also
includes following parameters:
1.Rotor expansion measured at the rear bearing pedestal of LP
turbine.
2.Axial Shift measured at the HP-IP pedestal
3.Bearing pedestal vibration
4.Shaft vibration measured at all turbine bearings.

OIL SUPPLY SYSTEM

A common oil supply system lubricates and cools the bearings.
The main oil pump is driven by the turbine shaft and draws oil
from the main oil tank. Auxiliary oil pumps maintain the oil
supply on start-up and shutdown, during turning gear operation
and when the main oil supply is faulted.
A jack oil pump forces high pressure oil under the shaft journals
to prevent boundary lubrication during turning gear operation.
The Lubricating and cooling oil is passed through oil coolers
before entering the bearings.

30

WORKING OF A STEAM TURBINE:

Introduction
A steam turbine is a mechanical device that converts thermal
energy in pressurized steam into useful mechanical work. The
original steam engine which largely powered the industrial
revolution in the UK was based on reciprocating pistons. This
has now been almost totally replaced by the steam turbine
because the steam turbine has a higher thermodynamic
efficiency and a lower power-to-weight ratio and the steam
turbine is ideal for the very large power configurations used in
power stations. The steam turbine derives much of its better
thermodynamic efficiency because of the use of multiple stages
in the expansion of the steam. This results in a closer
approach
to
the
ideal
reversible
process.
Steam turbines are made in a variety of sizes ranging from
small 0.75 kW units used as mechanical drives for pumps,
compressors and other shaft driven equipment, to 1,500,000kW
turbines used to generate electricity. Steam turbines are widely
used for marine applications for vessel propulsion systems. In
recent times gas turbines , as developed for aerospace
applications, are being used more and more in the field of
power generation once dominated by steam turbines.

31

Steam Turbine Principle

The steam energy is converted mechanical work by expansion
through the turbine. The expansion takes place through a
series of fixed blades (nozzles) and moving blades each row of
fixed blades and moving blades is called a stage. The moving
blades rotate on the central turbine rotor and the fixed blades
are concentrically arranged within the circular turbine casing
which is substantially designed to withstand the steam
pressure.
On large output turbines the duty too large for one turbine and
a number of turbine casing/rotor units are combined to achieve
the duty. These are generally arranged on a common Centre
line (tandem mounted) but parallel systems can be used called
cross compound systems.

Impulse Blading
The impulse blading principle is that the steam is directed at
the blades and the impact of the steam on the blades drives
them round. The day to day example of this principle is the

32

pelton

wheel

Turbines.

In this type of turbine the whole of the stage pressure drop

takes place in the fixed blade (nozzle) and the steam jet acts on
the moving blade by impinging on the blades.

Blades of an impulse turbine

Velocity diagram impulse turbine stage

z represents the blade speed , V r represents the relative

velocity, V wa & V wb- represents the tangential component of
the
absolute
steam
in
and
steam
out
velocities
The power developed per stage = Tangential force on blade x
blade

33

Reaction Blading
The reaction blading principle depends on the blade diverting
the steam flow and gaining kinetic energy by the reaction. The
Catherine wheel (firework) is an example of this principle. For
this turbine principle the steam pressure drop is divide between
the fixed and moving blades.

Velocity diagram reaction turbine stage

z represents the blade speed , V r represents the relative

velocity, V wa & V wb- represents the tangential component of
the
absolute
steam
in
and
steam
out
velocities
The power developed per stage = Tangential force on blade x
blade speed.
Power /stage= (V w a - V wb).z/1000 kW per kg/s of steam

The blade speed z is limited by the mechanical design and

material constraints of the blades.

34

Rankine Cycle
The Rankine cycle is a steam cycle for a steam plant operating
under the best theoretical conditions for most efficient
operation. This is an ideal imaginary cycle against which all
other real steam working cycles can be compared.
The theoretic cycle can be considered with reference to the
figure below. There will no losses of energy by radiation,
leakage of steam, or frictional losses in the mechanical
components. The condenser cooling will condense the steam
to water with only sensible heat (saturated water). The feed
pump will add no energy to the water. The chimney gases
would be at the same pressure as the atmosphere.

35

Within the turbine the work done would be equal to the energy
entering the turbine as steam (h1) minus the energy leaving
the turbine as steam after perfect expansion (h2) this being
isentropic (reversible adiabatic) i.e. (h1- h2). The energy
supplied by the steam by heat transfer from the combustion
and flue gases in the furnace to the water and steam in the
boiler will be the difference in the enthalpy of the steam leaving
the boiler and the water entering the boiler = (h1 - h3).

Basic Rankine Cycle

The ratio output work / Input by heat transfer is the thermal

efficiency of the Rankine cycle and is expressed as

Although the theoretical best efficiency for any cycle is the

Carnot Cycle the Rankine cycle provides a more practical ideal
cycle for the comparison of steam power cycles ( and similar
cycles ).
The efficiencies of working steam plant are

36

determined by use of the Rankine cycle by use of the relative

efficiency or efficiency ratio as below:
The various energy streams flowing in a simple steam turbine
system as indicated in the diagram below. It is clear that the
working fluid is in a closed circuit apart from the free surface of
the hot well. Every time the working fluid flows at a uniform
rate around the circuit it experiences a series of processes
making
up
a
thermodynamic
cycle.
The complete plant is enclosed in an outer boundary and the
working fluid crosses inner boundaries (control surfaces). The
inner
boundaries
defines
a
flow
process.
The various identifiers represent the various energy flows per
unit mass flowing along the steady-flow streams and crossing
the boundaries. This allows energy equations to be developed
for
the
individual
units
and
the
whole
plant.
When the turbine system is operating under steady state
conditions the law of conservation of energy dictates that the
energy per unit mass of working agent ** entering any system
boundary must be equal to the rate of energy leaving the
system
boundary.
**It is acceptable to consider rates per unit mass or unit time
whichever is most convenient

37

Turbine Vapour Cycle on T-h Diagram

Steady Flow Energy Equations

Boiler
The energy streams entering and leaving the boiler unit are as
follows:
F + A + h d = h 1 + G + hl

hence

F + A = G + h 1 - h d + hl

Turbine
The energy streams entering and leaving the boiler unit are as
follows:
h 1 = T + h 2 + hl

Condenser Unit

hence

0 = T - h 1 + h 2 + hl

38

The energy streams entering and leaving the boiler unit are as
follows:
W i+ h 2= W o+ h

+ hl

hence

W i= W o+ h

- h 2 + hl

Feed Water System

The energy streams entering and leaving the Feed Water
System are as follows:
h

+ d e + d f= h d + hl

hence d e + d f = - h

+ h d + hl

The four equations on the right can be arranged to give the

energy equation for the whole turbine system enclosed by the
outer boundary

That is per unit mass the of working agent (water) the energy
of the fuel (F) is equal to the sum of
- the mechanical energy available from the turbine less that
used to drive the pumps (T - (d e+ d f)
- the energy leaving the exhaust [G - A] using the air
temperature as the datum.
- the energy gained by the water circulating through the
condenser [W o - W i]
- the energy gained by the atmosphere surrounding the
plant hl
The overall thermal efficiency of a steam turbine plant can be
represented by the ratio of the net mechanical energy available
to the energy within the fuel supplied as indicated in the
expressions below :

39

This cycle shows the stages of operation in a turbine plant.

The enthalpy reduction in the turbine is represented by A -> B
. The reversible process for an ideal isentropic (reversible
adiabatic) is represented by A->B'. This enthalpy loss would be
(h g1 - h 2 ) in the reversible case this would be (h g1 - h 2s ).
The heat loss by heat transfer in the condenser is shown as B>C and results in a loss of enthalpy of (h 2- h f2) or in the
idealized reversible process it is shown by B'-> C with a loss of
enthalpy of (h 2s- h f2).
The work done on the water in extracting it from the condenser
and feeding it to the boiler during adiabatic compression C-> D
is (h d - h f2 ) = length M
The energy added to the working agent by heat transfer across
the heat transfer surfaces in the boiler is (h g1 - h d ) which is
approx.( h g1 - h f2 )
The Rankine efficiency of the Rankine Cycle AB'CDEA is

The efficiency of the Real Cycle is

40

Following were some of the machines

used for the manufacturing of the
various parts of a steam turbine
Craven Lathe machine
No .20/A/30
Speed : .5-51 rpm
Distance from the centre : 7620 mm
Maximum swing over 1676 mm
Head stock Face Plate diameter : 1524 mm
Face Plate gripping Capacity: 203-1270mm
Load :90 tons (stades)

Horizontal Boring Machine:

41

No. 20/A/2111
Spindle diameter: 127mm
Fending head: 1524 mm
Width of table =1524 mm
Maximum diameter of boring bar = 158.80 mm
Feeds=129- 38 mm

Morando Boring Machine

No: 20/A/2012
Speed: 1.5- 200 rpm
Feed: .5-2000 mm/min
Centre Height: 770 mm
Distance between centres: 6000 mm
On Swing Bed: 1520 mm
Max Weight on Centre= 30 Tons
Max Weight on face plate= 60 Tons

Richard Vertical Boring and Turning

Machine
No: 20/A/11

42

Speed: .48- 13 rpm

Feed: .501 102.51 mm/min
Diameter: 4877 mm
Max Turning Diameter: 4955 mm

CONCLUSION
A strong system of quality inspection, design through software,
manufacturing through skilled technicians and testing through
calibrated instruments & equipments help BHEL to manufacture
quality product with zero defect. The data in the testing of
different products in BHEL reveal satisfactory performance.
In all the production sections about 60% of the manufactured
products show desired performance in first attempt.
Transformers of rating 33kV, 1MVA were the first range of
transformers under production in BHEL and now the largest
transformer in India (1200kV, 333MVA) is also being
manufactured in this pioneering industry. Traction motors of
foreign technology were used to be imported from other
countries which increased the expense of Indian Railways. Now
BHEL is utilizing this technology and manufacturing its own
traction motors and supplying to the Indian Railways.

43

STM Department helped us know about how the steam turbines

are constructed and also explained its working. Our theoretical
knowledge was easily viewed in a practical manner through
various shops and machines at BHEL, Bhopal.
All this helped us a lot to know about practical life in todays
world and how Mechanical students handle these kind of work
and maintenance of machines.