A SUMMER TRAINING PRESENTATION

ON

STUDY OF TURBINE MANUFACTURING

AT
BHEL, HARIDWAR
PRESENTED BY
PRASHANT PATEL
1109140067

JSS MAHAVIDYAPEETHA
JSS ACADEMY OF TECHNICAL EDUCATION, NOIDA
DEPARTMENT OF MECHANICAL ENGINEERING
Session 2013-2014

BHEL An Introduction
BHEL is one of the only 7 PSUs of India put under the
'Maharatna' status.
It is the 12th largest power equipment manufacturer in the
world.
BHEL has a share of 59% in Indias total installed generating
capacity contributing 69% (approx.) to the total power generated
from utility sets as of March 31, 2012.
BHEL is engaged in the design, manufacturing, testing and services for the core
sectors like Power Industries, Railways, Oil & Gas and Defence sectors.

BHEL has 15 manufacturing divisions, 2 repair units, 4 regional offices, 8 service

centers and currently operate at more than 150 project sites across India and abroad.
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BHEL Ranipur Plant

Started in 1964 with the help of Russia and Czechoslovakia.

It has two plantsHEEP- Heavy Electrical Equipment Plant

CFFP- Central foundry Forge Plant
Spread in about 5000 acres.
Mainly produce turbine parts and the
generator parts, heat exchangers etc.

Block Details
1. BLOCK-1: Electrical Machine Shop
2. BLOCK-2: Heavy Fabrication Shop
3. BLOCK-3: Turbine Manufacturing Shop
4. BLOCK-4: CIM (Coils & Insulation Manuf.)

5. BLOCK-5: Condenser Fabrication & Forge Shop

6. BLOCK-6: Fabrication Shop & Die Shop
7. BLOCK-7: Carpentry & Heat Treatment Shop
8. BLOCK-8: Heat Exchanger Shop
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Block 3 - Turbine Shop

Steam Turbines, Gas Turbines and Turbines Blades are produced.
Special Tooling for all products in the Tool Room located in the same block.
Consists of four BaysBay-I of size 36x378 sqm
Bay- II of Size 36x400 sqm.
Bay-III of size 24x402 sqm.
Bay IV of Size 24x381 sqm.
Facilities of Cranes, Over speed Balancing Tunnel, stands for steam turbine rotors,
one Test stand for testing 210 MW steam turbines .

Steam Turbine
Turbine is a hydraulic device that converts energy of fluid into useful mechanical
energy .
Steam turbine depends completely upon the dynamic action of the steam.
These are classified intoa- Impulse Turbine and Reaction Turbine.
b- Axial Flow, Mixed Flow and Radial Flow Turbines.

Working Of Steam Turbine

1- Impulse Turbine: Steam is expanded only in nozzles.
Blade passage of constant cross-section
area.
2- Reaction Turbine:

Pressure drop in fixed & moving blade.

Blade passage of varying cross-section
area.

Rotor And Casing Of Steam Turbine

HP (High Pressure) 54 atm
IP (Intermediate Pressure)- 6. 08 atm

LP (Low Pressure)- 2 atm

Steam Turbines Manf. Facilities

The facilities and parts manufacturing of Steam Turbine are as follows:
TURBINE CASING MACHINING SECTION: Equipped with large size
Planer, Drilling, Horizontal Boring, Vertical Boring machines.
ROTOR MACHINING SECTION: Equipped with large size machining tools
like Turning Lathe, CNC Lathes, Horizontal Boring Machines etc.
ROTOR ASSEMBLY SECTION : Equipped with Indicating Stand, Small size
Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors
and Discs.
TURBINE CASING ASSEMBLY SECTION : Machined casings are assembled
and hydraulically tested by Reciprocating Pumps at two times the operating
pressure.
OVER SPEED VACUUM BALANCING TUNNEL: Vibration and frequency
of rotor shaft is tested at very high speed of 4500rpm.
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Blade Shop
Turbine Blade Machining Shop is located in Block-IV.
It consists of plain milling section, polishing section, testing sections.

The blade are prepared of alloy steels consisting of Cr, Ni, V etc.
The blades are very accurately manufactured and tested.

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Blades Manufacturing
Operations Performed On Blades:
Cutting
Milling
Grinding on both the surface

Inspection

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 Mostly 500MW turbine blades are manufactured in this shop.

Basically the design of blades is classified according to the stages of turbine.
The size of LP Turbine blades is generally greater than of HP Turbine blades

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Over Speed Balancing Tunnel

Features:
Max. thickness of tunnel :

2500 mm

9000 mm
1 micron
2500 to 4500 rpm
600 MW

Tunnel diameter
Min. vibration limit
Over speed limit
Rotor balancing of max.
rating

:
:
:
:

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Gas Turbine
Gas turbine have been used for electricity generation.
The gas turbine obtains its power by utilizing the energy of burnt gases & air
which are at high Pressure and Temperature.
For electricity generation, it is known as power turbine.
For propulsion unit in aircraft, it is called aircraft turbine.

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THANK YOU
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