INDUSTRIAL TRAINING AT BHEL, HARIDWAR “TURBINE UNIT MANUFACTURING” SUBMITTED BY : ROHAN AZAD ROLL NO. : 0702740076

BHARAT HEAVY ELECRTICALS LIMITED BHEL is one of NAVRATANAS among NTPC, VSNL, ONGC, IOC, HPCL, SAIL, IPCL, BPCL & BHEL Featured in “FORTUNES INTERNATIONALS 500” among 12 top companies in world for manufacturing of variety of mechanical & electrical equipment for generation, transmission and electricity ISO 9000 certified for quality management, and ISO 14001 certified for environment management BHEL caters to power generation and transmission industry, transportation, telecommunication, renewable energy, defence etc. First plant was established in Bhopal in 1964; in Haridwar in January,1967 Today BHEL has 14 manufacturing divisions, 9 service centers, 4 power sector regional centre and about 150 project sites

MANUFACTURING UNITS AND PRODUCT PROFILE NAME OF PLANT PLACE PRODUCT Steamless plant. Tiruchirappali ( Tiruchy ). Steamless steel tubes, Sriral finwelded tubes. Boiler auxiliaries. Ranipet. Electrostatic precipitation , Air preheater , Fans , Wind electric generators , Desalination plants. Industrial valves plant . Govindwal. Industrial valves and Fabrication. Heavy electrical equipment plant. Hardwar. Steam – turbines , Hydro – turbines , Gas – turbine , Turbo generators , Control panels, Light aircrafts , Electrical machines.

MANUFACTURING UNITS AND PRODUCT PROFILE Central foundry forge plant . Hardwar . Heavy casting and forging. Heavy electrical plant. Bhopal . Steam turbines , Turbo generators , Hydro sets , Switch gear controllers,   Transformer plant . Jhansi . Transformers , Diesel shunt less , AC locos , AC EMU .

MANUFACTURING UNITS AND PRODUCT PROFILE Heavy power equipment plant . Hyderabad . Power generating set , Industrial turbo – sets, Compressors , Pumps and heaters , Bow – mills , Heat exchangers oil rings , Gas turbines , Switch gears . Electronic division . Banglore . Energy meters , Water meters , Control equipment , Capacitors , Photovoltaic panels and Electronic private automatic branch exchange . Insulator plant . Jagdishpur . Insulators and bushing .

MANUFACTURING UNITS AND PRODUCT PROFILE Electronic system division, electronic city. Banglore . Simulator, Telecommunication system , Other advanced micro –processor based control system. Electro –porcelain division . Insulator and bushing , Ceramic liners . Component fabrication plant Rudrapur . Windmill , Solar water heating system . Amorphous silicon solar cell plant . Guragaon . Solar cells , Solar lanterns chargers , Solar clocks .

MANUFACTURING UNITS AND PRODUCT PROFILE Heavy electrical equipment repair plant . Varanasi . Repair shop for power generating equipment . Electrical machine repair shop . Mumbai . Repair of electrical machines .

TECHNICAL COLLABORATORS NAMES OF COLLABORATOR FROM PRODUCT Seimens Germany Steam turbines , Generators , Lateral / Arial condensers. National oil well U.S.A. Christmas tree and Well head assembled. General electrical company. Gas turbines. Asian brown boveri Switzerland High voltage directs current system (HVDC). May & christe gumbh Dry type transformer. Seimens AG Large size gas turbines.

TECHNICAL COLLABORATORS   National oil well U.S.A. Composite block valves, Sub – sea well , Head assembly , Caring support machine suspension equipment. Nordex A/S . Denmark . Wind electric–generators. Energy technics . Germany. Bed combustion boiler. AG Siemens Germany . Electrical machines Melara SPA . Italy Super rapid gun mount

BHARAT HEAVY ELECTRICALS LTD. HARDWAR HEEP (HEAVYEL ECTRICAL EQUIPMENT PLANT) CFFP (CENTRAL FOUNDARY FORGED PLANT) BLOCK-2: HEAVY FABRICATION SHOP BLOCK-3: TURBINE MANUFACTURING BLOCK BLOCK-4: CIM (COILS & INSULATION MANU- FACTURING) BLOCK BLOCK-5: CONDENCER FABRICATION & FORGR BLOCK BLOCK-6: FABRICATION SHOP, DIE SHOP, STAMPING SHOP) BLOCK-7: CARPANTARY SHOP BLOCK-8: HEAT EXCHANGER SHOP BLOCK-1: ELECTRICAL MACHINE SHOP

BHEL HARIDWAR PRODUCT PROFILE THERMAL SETS Steam turbines and generator sets up to 500MW capacity capability to manufacture up to 1000 MW unit cycle GAS TURBINES Gas turbines for industry and utility application; range-3 to 200 MW (ISO). Gas turbines based co-generation and combined cycle system HYDRO – SETS Custom– built conventional hydro turbine of kaplan, Francis and Pelton with matching generators up to 250 MW unit size. Pump turbines with matching motor-generator Mini / micro hydro sets. Spherical butterfly and rotary valves and auxiliaries for hydro station .

BHEL HARIDWAR PRODUCT PROFILE EQUIPMENT FOR NUCLEAR POWER PLANTS Turbines and generators up to 500MW unit size. Steam generator up to 500MW unit size. Reheaters / separators . Heat exchangers and pressure vessels ELECTRICAL MACHINES DC general purpose and rolling mill machines from 100 to 19000KW suitable for operation on voltage up to 1200V. These are provided with STDP, totally enclosed and duct ventilated enclosures. DC auxiliary mill motors. CONTROL PANEL Control panel for voltage up to 400KW and control desks for generating stations and EMV sub–stations

BHEL HARIDWAR PRODUCT PROFILE CASTING AND FORGINGS Sophisticated heavy casting and forging of creep resistant alloy steels, stainless steel and other grades of alloy meeting stringent international specifications. AVIATION Light aircraft namely “SWATI DEFENCE PROCEDURE Naval guns with collaboration of Italy

CLASSIFICATION OF BLOCK-3

STEAM TURBINE A steam turbine is a prime mover in which rotary motion is obtained by gradual change of momentum of steam Modes of operation of steam turbine Impulse principle Reaction principle Stages of steam turbine H P ( High Pressure) I P ( Intermediate Pressure) L P ( Low Pressure)

MATERIAL Parameters of material selection Creep and rupture Hot yield (0.2% yield stress) Creep and rupture Relaxation properties Cyclic loading behaviour Fatigue failure Fracture toughness Rate of crack growth Resistance to scaling Material used currently 13% Cr. Stainless Steel Bars (C = 0.22%, Si = 0.5%, Mn = 0.8%, Cr = 13%, Ni = 0.8%, S = 0.020%, P = 0.030%)

BLADING Entire turbine is provided with reaction blading HP & IP blading as well as the initial stages of LP section are designed as reaction type stages Last stages of LP moving blades are designed as twisted blades

BEARINGS Journal bearing is being used in turbines to support the rotor HP rotor is supported by two bearings IP & HP rotors have a journal bearing each at end of the shaft

VALVES HP turbine is fitted with two initial steam stop and control valves IP turbine has two stop and control valves Stop valve is used to immediately stop the supply of steam (emergency valve) Control valve is used to control the steam flow rate by means of governor These valves are arranged at right angles to each other in a common body These valves are actuated by oil hydraulic mechanisms

GOVERNING SYSTEM The turbine has an electro-hydraulic governing system The governing system permits run up control of the turbine up to the rated speed and keep speed swings due to variation in load The electric system measures the variation in speed and output by means of sensors and send signals to electro-hydraulic converter. The electro hydraulic converter then operates servomotor by hydraulic means to control steam flow rate

OIL SUPPLY SYSTEM A single oil supply system lubricates and cools the bearings, governs the machine, operates the hydraulic actuators and safety and protective devices and drives the hydraulic turning gear The main pump driven by turbine shaft draws oil from the main oil tank Auxiliary oil pump maintains oil supply on start-up and shut down, during turbine gear operation and when the main oil pump is faulted

STEAM PARAMETERS PRESSURE (BAR) TEMPERATURE (0C) BEFORE E.S.V. 166.7 538 HP CYLINDER INLET 154.4 532.9 HP CYLINDER EXHAUST 44.9 340.9 IP CYLINDER STOP VALVE INLET 40.3 IP CYLINDER INLET 39.4 537.6 IP CYLINDER EXHAUST 7.3 291.4 LP CYLINDER INLET 7.1 293.3 LP CYLINDER EXHAUST 0.1013 46.1

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