INDUSTRIAL TRAINING REPORT

(JUNE – JULY 2016)

On

General Awareness of Steam Turbine Manufacturing

Submitted in partial fulfilment of the requirements

Of the degree of

Bachelor of Technology

In

Mechanical Engineering

By

(ASHUTOSH SHARMA)

(1301440010)

(Shri Ram Murti Smarak College of Engineering and Technology)

Bareilly, 243202.

ACKNOWLEDGEMENT

“An engineer with only theoretical knowledge is not a complete Engineer.

Practical knowledge is very important to develop and apply engineering skills”.

It gives me a great pleasure to have an opportunity to

acknowledge and to express gratitude to those who were associated with me during

my training at BHEL.

I am very grateful to Mr. VIMAL KUMAR for providing me with an opportunity

to undergo training under his able guidance.

Last, but not the least, I would also like to acknowledge the support of my college

friends, who pursued their training with me. We shared some unforgettable

moments together.

I express my sincere thanks and gratitude to BHEL authorities for allowing me to

undergo the training in this prestigious organization.

I will always remain indebted to them for their constant interest and excellent

guidance in my training work, moreover for providing me with an opportunity to

work and gain experience.

THANK YOU

ABSTRACT

In the era of Mechanical Engineering, Turbine, A Prime Mover (Which uses the

Raw Energy of a substance and converts it to Mechanical Energy) is a well-known

Machine most useful in the field of Power Generation. This Mechanical energy is

used in running an Electric Generator which is directly coupled to the shaft of

turbine. From this Electric Generator, we get electric Power which can be

transmitted over long distances by means of transmission lines and transmission

towers.

In my Industrial Training in B.H.E.L., Haridwar I go through all sections in

Turbine Assembly. First management team told me about the history of industry,

Area, Capacity, Machines installed & Facilities in the Industry.

After that they told about the Steam Turbine its types, parts like Blades, Casing,

Rotor etc. Then they told full explanation of constructional features and procedure

along with equipment used. Step by Step arrangement of machines in the block

with a well-defined proper format.

I would like to express my deep sense of Gratitude and thanks to MR. VIMAL

KUMAR in charge of training in Turbine Block in B.H.E.L., Haridwar. Without

the wise counsel and able guidance, it would have been impossible to complete the

report in this manner. Finally, I am indebted to all who so ever have contributed in

this report and friendly stay at Bharat Heavy Electricals Limited (BHEL).

INDEX

SR. NO. TOPIC

1. INTRODUCTION

2. BHEL-AN OVERVEIW

3. STEAM TURBINE

4. TYPES OF STEAM TURBINE

5. BHEL UNITS

6. BHEL HARIDWAR

7. MANUFACTURING PROCESS

8. HEAVY DUTY MACHINES

9. FUTURE SCOPE

10. CONCLUSION.

INTRODUCTION

BHEL is the largest engineering and manufacturing enterprise in India in the

energy related infrastructure sector today. BHEL was established more than 40

years ago when its first plant was setup in Bhopal ushering in the indigenous

Heavy Electrical Equipment Industry in India a dream which has been more than

realized with a well-recognized track record of performance it Has been earning

profits continuously since1971-72.

BHEL caters to core sectors of the Indian Economy viz., Power Generation's &

Transmission, Industry, Transportation, Telecommunication, Renewable Energy,

Defense, etc. The wide network of BHEL's 14 manufacturing division, four

power Sector regional centers, over 150 project sites, eight service centers and 18

regional offices, enables the Company to promptly serve its customers and provide

them with suitable products, systems and services – efficiently and at competitive

prices. BHEL has already attained ISO 9000 certification for quality management,

and ISO 14001certification for environment management. The company’s inherent

potential coupled with its strong performance make this one of the

“NAVRATNAS”, which is supported by the government in their endeavor to

become future global players

B.H.E.L- AN OVERVIEW

BHEL or the Bharat Heavy Engineering Limited is one of the largest engineering

and manufacturing organizations in the country and the BHEL, Haridwar is their

gift to Uttarakhand. With two large manufacturing plants, BHEL in Haridwar is

among the leading industrial organizations in the state. It has established a Heavy

Electrical Equipment Plant or HEEP and a Central Foundry Forge Plant or CFFP in

Haridwar.

The Heavy Electrical Equipment Plant in Haridwar designs and Manufactures

turbo generators, AC and DC motors, gas turbines and huge steams. The Central

Foundry Forge Plant in Haridwar deals with steel castings and manufacturing of

steel forgings.

The BHEL plants in Haridwar have earned the ISO - 9001 and 9002 certificates for

its high quality and maintenance. These two units have also earned the ISO - 14001

certificates. Situate in Ranipur near Haridwar, the Bharat Heavy Engineering

Limited employs over 8,000 people.

BHEL is an integrated power plant equipment manufacturer and one of the largest

engineering and manufacturing companies in India in terms of turnover. BHEL

was established in 1964, ushering in the indigenous Heavy Electrical Equipment

industry in India - a dream that has been more than realized with a well-recognized

track record of performance. The company has been earning profits continuously

since 1971-72 and paying dividends since 1976-77 .BHEL is engaged in the

design, engineering, manufacture, construction, testing, commissioning and

servicing of a wide range of products and services for the core sectors of the

economy, viz. Power, Transmission, Industry, Transportation, Renewable Energy,

Oil & Gas and Defense. BHEL has 15 manufacturing divisions, two repair units,

four regional offices, eight service centers, eight overseas offices and 15 regional

centers and currently operate at more than 150 projects sites across India and

abroad. BHEL places strong emphasis on innovation and creative development of

new technologies. Our research and development (R&D) efforts are aimed not only

at improving the performance and efficiency of our existing products, but also at

using state-of-the-art technologies and processes to develop new products.

This enables us to have a strong customer orientation, to be sensitive to their needs

and respond quickly to the changes in the market.

The high level of quality & reliability of our products is due to adherence to

international standards by acquiring and adapting some of the best technologies

from leading companies in the world including General Electric Company, Alstom

SA, Siemens AG and Mitsubishi Heavy Industries Ltd., together with technologies

developed in our own R&D centers. Most of our manufacturing units and other

entities have been accredited to Quality Management Systems (ISO 9001:2008),

Environmental Management Systems (ISO 14001:2004) and Occupational Health

& Safety Management Systems (OHSAS 18001:2007).

BHEL has a share of around 59% in India's total installed generating capacity

contributing 69% (approx.) to the total power generated from utility sets

(excluding non-conventional capacity) as of March 31, 2012. We have been

exporting our power and industry segment products and services for approximately

40 years. We have exported our products and services to more than 70 countries.

We had cumulatively installed capacity of over 8,500 MW outside of India in 21

countries, including Malaysia, Iraq, the UAE, Egypt and New Zealand. Our

physical exports range from turnkey projects to after sales services.

BHEL work with a vision of becoming a world-class engineering enterprise,

committed to enhancing stakeholder value. Our greatest strength is our highly

skilled and committed workforce of over 49,000 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.

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 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.

ADVANTAGES:-

-free operation.

usts steam.

DISADVANTAGES:-

For slow speed application reduction gears are required. The steam turbine cannot

be made reversible. The efficiency of small simple steam turbines is poor.

STEAM TURBINES THE MAINSTAY OF BHEL:-

steam turbines of up to 1000 MW rating for steam parameters ranging

from 30 bars to 300 bars pressure and initial & reheat temperatures up to

600ºC.

system, consisting of modules

suitable for a range of output and steam parameters.

for a desired output and steam parameters appropriate turbine blocks

can be selected.

Types

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

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, non-condensing, reheat, extraction and Induction.

Non-condensing 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

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.

BHEL HARIDWAR

1. LOCATION

It is situated in the foot hills of Shivalik range in Haridwar. The main

administrative building is at a distance of about 8 km from Haridwar.

2. ADDRESS

Bharat Heavy Electrical Limited (BHEL)

Ranipur, Haridwar PIN- 249403

3. AREA

BHEL Haridwar consists of two manufacturing units, namely Heavy Electrical

Equipment Plant (HEEP) and Central Foundry Forge Plant (CFFP), having area

HEEP area: - 8.45 sq. km

CFFP area: - 1.0 sq. km

The Heavy Electricals Equipment Plant (HEEP) located in Haridwar, is one of the

major manufacturing plants of BHEL. The core business of HEEP includes design

and manufacture of large steam and gas turbines, turbo generators, hydro turbines

and generators, large AC/DC motors and so on.

Central Foundry Forge Plant (CFFP) is engaged in manufacture of Steel Castings:

Up to 50 Tons per Piece Wt. & Steel Forgings: Up to 55 Tons per Piece

4. UNITS

There are two units in BHEL Haridwar as followed:

1) Heavy Electrical Equipment Plant (HEEP)

2) Central Foundry Forge Plant (CFFP)

LAYOUT OF BLOCK 3

MANUFACTURING PROCESS

INTRODUCTION

Manufacturing process is that part of the production process which is directly

concerned with the change of form or dimensions of the part being produced. It

does not include the transportation, handling or storage of parts, as they are not

directly concerned with the changes into the form or dimensions of the part

produced. Manufacturing is the backbone of any industrialized nation.

Manufacturing and technical staff in industry must know the various

manufacturing processes, materials being processed, tools and equipment’s for

manufacturing different components or products with optimal process plan using

proper precautions and specified safety rules to avoid accidents. Beside above, all

kinds of the future engineers must know the basic requirements of workshop

activities in term of man, machine, material, methods, money and other

infrastructure facilities needed to be positioned properly for optimal shop layouts

or plant layout and other support services effectively adjusted or located in the

industry or plant within a well-planned manufacturing organization. Today’s

competitive manufacturing era of high industrial development and research, is

being called the age of mechanization, automation and computer integrated

manufacturing. Due to new researches in the manufacturing field, the advancement

has come to this extent that every different aspect of this technology has become a

full-fledged fundamental and advanced study in itself. This has led to introduction

of optimized design and manufacturing of new products. New developments in

manufacturing areas are deciding to transfer more skill to the machines for

considerably reduction of manual labor.

CLASSIFICATION OF MANUFACTURING PROCESSES

For producing of products materials are needed. It is therefore important to know

the characteristics of the available engineering materials. Raw materials used

manufacturing of products, tools, machines and equipment in factories or

industries are for providing commercial castings, called ingots. Such ingots are

then processed in rolling mills to obtain market form of material supply in form of

bloom, billets, slabs and rods. These forms of material supply are further subjected

to various manufacturing processes for getting usable metal products of different

shapes and sizes in various manufacturing shops. All these processes used in

manufacturing concern for changing the ingots into usable products may be

classified into six major groups as

Primary shaping processes

Secondary machining processes

Metal forming processes

Joining processes

Surface finishing processes and

Processes effecting change in properties

PRIMARY SHAPING PROCESSES

Primary shaping processes are manufacturing of a product from an amorphous

material. Some processes produces finish products or articles into its usual form

whereas others do not, and require further working to finish component to the

desired shape and size. The parts produced through these processes may or may

not require undergoing further operations. Some of the important primary shaping

processes is:

Casting

Powder metallurgy

Plastic technology

Gas cutting

Bending and

Forging

SECONDARY OR MACHINING PROCESSES

As large number of components require further processing after the primary

processes. These components are subjected to one or more number of machining

operations in machine shops, to obtain the desired shape and dimensional accuracy

on flat and cylindrical jobs. Thus, the jobs undergoing these operations are the

roughly finished products received through primary shaping processes. The

process of removing the undesired or unwanted material from the work-piece or

job or component to produce a required shape using a cutting tool is known as

machining. This can be done by a manual process or by using a machine called

machine tool (traditional machines namely lathe, milling machine, drilling, shaper,

planner, slotter). In many cases these operations are performed on rods, bars and

flat surfaces in machine shops. These secondary processes are mainly required for

achieving dimensional accuracy and a very high degree of surface finish. The

secondary processes require the use of one or more machine tools, various single

or multi-point cutting tools (cutters), jobholding devices, marking and measuring

instruments, testing devices and gauges etc.

Some of the common secondary or machining processes are:

Turning

Threading

Knurling

Milling

Drilling

Boring

Planning

Shaping

Slotting

Sawing

Broaching

Hobbing

Grinding

Gear Cutting

Thread cutting and

BLOCK 3 (BAY-1)

BAY-1 IS DIVIDED INTO THREE PARTS

1. HMS

In this shop heavy machine work is done with the help of different NC &CNC

machines such as center lathes, vertical and horizontal boring & milling machines.

Asia’s largest vertical boring machine is installed here and CNC horizontal boring

milling machines from Skoda of Czechoslovakia.

2. Assembly Section (of hydro turbines)

In this section assembly of hydro turbines are done. Blades of turbine are1st

assemble on the rotor & after it this rotor is transported to balancing tunnel where

the balancing is done. After balancing the rotor, rotor &casings both internal &

external are transported to the customer. Total assembly of turbine is done in the

company which purchased it by B.H.E.L.

3. OSBT (Over Speed Balancing Tunnel)

In this section, rotors of all type of turbines like LP(low pressure), HP(high

pressure) & IP(Intermediate pressure) rotors of Steam turbine ,rotors of Gas &

Hydro turbine are balanced .In a large tunnel, Vacuum of 2 torr is created with the

help of pumps & after that rotor is placed on pedestal and rotted with speed of

2500-4500 rpm. After it in a computer control room the axis of rotation of rotor is

seen with help of computer & then balance the rotor by inserting the small

Balancing weight in the grooves cut on rotor.

HEAVY DUTY MACHINES

1) SINUMERIK CNC lathe Swing over carriage:3500mm

Centre distance :9000mm

Weight capacity:120 T

Spindle power:196KW

External chucking range:250-2000mm

Max spindle rpm:200

CNC system 840D:SINUMERIK

2) INNSE Horizontal CNC machine : Boring spindle diameter:160mm

Headstock vertical travel:3000mm

Longitudinal RAM travel:700mm

Longitudinal spindle travel:1000mm

Column cross travel:10m

Rotary table travel:3000mm

Table load:40 T

3) Tacchi heavy duty CNC lathe:

4) Skoda Vertical CNC lathe

Finishing machining casings including guide blade grooves are carried out in

vertical position on this lathe. The machine is provided with 840-C CNC

system.

Research and development

BHEL's investment in R&D is amongst the largest in the corporate sector in India.

During the year 2012-13, the company invested about Rs. 1,252 Crore on R&D

efforts, which corresponds to nearly 2.50% of the turnover of the company,

focusing on new product and system developments and improvements in existing

products for cost competitiveness, higher reliability, efficiency, availability and

quality etc. To meet customer expectations, the company has upgraded its products

to contemporary levels through continuous in-house efforts as well as through

acquisition of new technologies from leading engineering organizations of the

world. The IPR (Intellectual Property Rights) capital of BHEL grew by 21.5% in

the year, taking the total to 2170.

The Corporate R&D division at Hyderabad leads BHEL’s research efforts in a

number of areas of importance to BHEL’s product range. Research & product

development (RPD) Groups for each product group at the manufacturing divisions

play a complementary role. BHEL has established Centers of Excellence for

Simulators, Computational Fluid Dynamics, Permanent Magnet Machines, Surface

Engineering, Machine Dynamics, Centre for Intelligent Machines and Robotics,

Compressors & Pumps, Centre for Nano Technology, Ultra High Voltage

Laboratory at Corporate R&D; Centre of Excellence for Hydro Machines at

Bhopal; Power Electronics and IGBT & Controller Technology at Electronics

Division, Bengaluru, and Advanced Fabrication Technology and Coal Research

Centre at Tiruchirappalli.

BHEL has established four specialized institutes, viz., Welding Research Institute

(WRI) at Tiruchirappalli, Ceramic Technological Institute (CTI) at Bangalore,

Centre for Electric Traction (CET) at Bhopal and Pollution Control Research

Institute (PCRI) at Haridwar. Amorphous Silicon Solar Cell plant

at Gurugram pursues R&D in Photo Voltaic applications.

Significantly, BHEL is one of the only four Indian companies and the only Indian

Public Sector Enterprise figuring in 'The Global Innovation 1000' of Booz & Co., a

list of 1,000 publicly traded companies which are the biggest spenders on R&D in

the world.

Criticism

BHEL is to construct 1,320-megawatt coal power plant in Rampal which is close

to the Sundarban mangrove forest for Bangladesh-India Friendship Power

Company(Pvt.) Limited(joint venture between NTPC Limited and Bangladesh

Power Development Board). The project has faced criticism for the environmental

impact and the potential harm to the largest mangrove forest in the world.

CONCLUSION

Gone through 1 month training under the guidance of capable engineers and

workers of BHEL Haridwar in Block-3 “TURBINE MANUFACTURING” headed

by Senior Engineer of department Mr. VIMAL KUMAR situated in Ranipur,

Haridwar, (Uttarakhand). The training was specified under the Turbine

Manufacturing Department. Working under the department I came to know about

the basic grinding, scaling and machining processes which was shown on heavy to

medium machines. Duty lathes were planted in the same line where the specified

work was undertaken.

The training brought to my knowledge the various machining and fabrication

processes went not only in the manufacturing of blades but other parts of the

turbine.