A Training report

On
At
BHEL HARIDWAR

Submitted in partial fulfillment of requirements for the degree of

Bachelor of Technology
In
MATERIAL SCIENCE WITH SPECILIZATION IN NANOTECHOLOGY

Submitted by: Akriti Agrawal

Guided by:-

ACKNOWLEDGEMENT

Inspiration and motivation have always played a key role in the success of any
venture.
A vocational training is a golden opportunity for learning and self development. I
consider myself very lucky and honored to have so many wonderful people lead
me through in completion of this project.
I am also grateful to the management of Bharat Heavy Electrical limited
(BHEL),Haridwar for permitting me to have training during May 21st to June 20th
2015.
My thanks and appreciations also go to my co-trainees at BHEL who have
willingly helped me out with their abilities and their constructive feedback. For
their friendly support that created an environment in which work was very
enjoyable.
Lastly, I thank almighty, my parents for their constant encouragement without
which this assignment would not be possible.
The direction, advice, discussion and constant encouragement given
them has been so help full in completing the work successfully

by

Contents
1.

INTRODUCTION.................................................................................................................6
1.1. Working areas.....................................................................................................................6
1.1.1.

Power generation.....................................................................................................6

1.2.2. Power transmission & distribution (T& D)...............................................................6

1.2.3. Industries......................................................................................................................7
1.2.4. Transportation.............................................................................................................7
1.2.5. Telecommunication......................................................................................................8
1.2.6. Renewable energy........................................................................................................8
1.2.7. International operations..............................................................................................8
1.3Human resource development institute..........................................................................8
2. STEAM TURBINE..................................................................................................................10
2.1 INTRODUCTION.............................................................................................................10
2.2. Advantages:-......................................................................................................................13
2.3 Disadvantages:-..................................................................................................................13
2.4 Steam turbines the mainstay of BHEL............................................................................13
3. TYPES OF STEAM TURBINE..............................................................................................14
3.1Impulse turbine...................................................................................................................14
3.2 The impulse principle........................................................................................................15
3.3 Reaction principle..............................................................................................................15
3.4Impulse turbine staging......................................................................................................15
4. TURBINE PARTS....................................................................................................................16
4.1 Turbine blades....................................................................................................................16
4.2 Turbine casing....................................................................................................................16
4.3 Turbine rotors....................................................................................................................17
5. BLADING MATERIALS........................................................................................................17
6. MANUFACTURING PROCESS............................................................................................18
6.1Introduction.........................................................................................................................18
6.2 classification of manufacturing processes........................................................................18
6.2.1 Primary shaping processes.........................................................................................18
6.2.2 Secondary or machining processes............................................................................18

7. BLOCK 3 LAY-OUTS.............................................................................................................19
7.1 Classification of block 3.....................................................................................................19
8. BLADE SHOP..........................................................................................................................22
8.1 Types of blades...................................................................................................................23
8.2 Operations performed on blades......................................................................................23
8.3 Machining of blades...........................................................................................................23
8.4 New blade shop..................................................................................................................24
10. CONCLUSION......................................................................................................................24

Figure 1- Rotating Steam Turbine.................................................................................................11

Figure 2- Steam turbine rotor........................................................................................................12
Figure 3- Impulse turbine..............................................................................................................15
Figure 4-Reaction turbine..............................................................................................................16
Figure 5-steam turbine casing and rotors I assembly area.............................................................22
Figure 6-CNC rotor turning lathe..................................................................................................22
Figure 7- types of blades................................................................................................................23
Figure 8- Schematic diagram of a CNC machine..........................................................................24

1. 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 companys 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. There are two units in BHEL Haridwar as followed: Heavy Electrical
Equipment Plant (HEEP), Central Foundry Forge Plant (CFFP).

1.1. Working areas

1.1.1. Power generation
Power generation sector comprises thermal, gas, hydro and nuclear power plant business as of
31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the total installed
capacity of 99,146 MW in the country, as against nil till 1969-70.BHEL has
proven turnkey capabilities for executing power projects from concept to commissioning, it
possesses the technology and capability to produce thermal sets with super critical parameters up
to 1000 MW unit rating and gas turbine generator sets of up to 240 MW unit rating. Cogeneration and combined-cycle plants have been introduced to achieve higher plant efficiencies.
to make efficient use of the high-ash-content coal available in India, BHEL supplies
circulating fluidized bed combustion boilers to both thermal and combined cycle power
plants. The company manufactures 235 MW nuclear turbine generator sets and has commenced
production of 500 MW nuclear turbine generator sets. Custom made hydro sets of Francis, Pelton
and Kaplan types for different head discharge combination are also engineering and
manufactured by BHEL .In all, orders for more than 700 utility sets of thermal, hydro, gas and
nuclear
have
been placed on the
Company as
on date. The
power plant equipment manufactured by BHEL is based on contemporary technology
comparable to the best in the world and is also internationally competitive. The Company
has proven expertise in Plant Performance Improvement through renovation modernization and
upgrading of a variety of power plant equipment besides specialized know how of residual life
assessment, health diagnostics and life extension of plants.

1.2.2. Power transmission & distribution (T& D)

BHEL offer wide ranging products and systems for T & D applications. Products
manufactured include power transformers, instrument transformers, dry type transformers, series
and stunt reactor, capacitor tanks, vacuum and SF circuit breakers gas insulated switch gears
and insulators. A strong engineering base enables the Company to undertake turnkey delivery
of electric substances up to 400 kV level series compensation systems (for increasing power
transfer capacity of transmission lines and improving system stability and voltage regulation),
shunt compensation systems (for power factor and voltage improvement) and HVDC systems
(for economic transfer of bulk power). BHEL has indigenously developed the state-of-the-art
controlled shunt reactor (for reactive power management on long transmission lines). Presently
a 400 kV Facts (Flexible AC Transmission System) project under execution.

1.2.3. Industries
BHEL is a major contributor of equipment and systems to industries. Cement, sugar, fertilizer,
refineries, petrochemicals, paper, oil and gas, metallurgical and other process industries lines and
improving
system stability
and
voltage regulation,
shunt
compensation systems (for power factor and
voltage improvement) and
HVDC systems(for economic transfer of bulk power) BHEL has indigenously developed
the state-of-the-art
controlled shunt reactor
(for
reactive power
management on
long transmission lines).Presently a 400 kV FACTS (Flexible AC Transmission System) projects
is under execution. The range of system & equipment supplied includes: captive power
plants, co-generation plants DG power plants, industrial steam turbines, industrial boilers and
auxiliaries. Water heat recovery boilers, gas turbines, heat exchangers and pressure vessels,
centrifugal compressors, electrical machines, pumps, valves, seamless steel tubes, electrostatic
precipitators, fabric filters, reactors, fluidized bed combustion boilers, chemical recovery boilers
and process controls. The Company is a major producer of large-size thruster devices.
It also supplies
digital distributed
control systems
for process
industries, and
control & instrumentation systems for power plant and industrial applications.

1.2.4. Transportation
BHEL is involved in the development design, engineering, marketing, production,
installation, and maintenance and after-sales service of Rolling Stock and traction propulsion
systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000HP,
diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting duly
applications. BHEL is also producing rolling stock for special applications viz.,overhead
equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides traction propulsion
systems for in-house use, BHEL manufactures traction propulsion systems for other rolling stock
producers of electric locomotives, electrical multiple units and metro cars. The electric and
diesel traction equipment on India Railways are largely powered by electrical propulsion systems
produced by BHEL. The company also undertakes retooling and overhauling of rolling stock in
the area of urban transportation systems. BHEL is geared up to turnkey execution of electric
trolley bus systems, light rail systems etc.

1.2.5. Telecommunication
BHEL also caters to Telecommunication sector by way of small, medium and large switching
systems.

1.2.6. Renewable energy

Technologies that can be offered by BHEL for exploiting non-conventional and renewable
sources of energy include: wind electric generators, solar photo voltaic systems, solar lanterns
and battery-powered road vehicles. The Company has taken up R&D efforts for development
of multi-junction amorphous silicon solar cells and fuel based systems.

1.2.7. International operations

BHEL has, over the years, established its references in around 60 countries of the world, ranging
for the United States in the west to New Zealand in the Far East. these references encompass
almost the entire product range of BHEL, covering turnkey power projects of thermal,
hydro and gas-based types, substation projects, rehabilitation projects, besides a wide variety
of products, like transformers, insulators, switchgears, heat exchangers, castings and forgings,
valves, well-head equipment, centrifugal compressors, photo-voltaic equipment etc. apart
from over 1110mw of boiler capacity contributed in Malaysia, and execution of four prestigious
power projects in Oman, some of the other major successes achieved by the company have been
in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan,
Sri Lanka, Iraq etc.

1.2 Technology up gradation and research & development

To remain competitive and meet customers' expectations, BHEL lays great
emphasis
on
the continuous up gradation of products and related technologies, and development of new
products. 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 Corporate R&D Division at Hyderabad, spread over a 140 acre
complex, leads BHEL's research efforts in a number of areas of importance to BHEL's product
range. Research and product development centers at each of the manufacturing divisions play a
complementary role. BHEL's Investment in R&D is amongst the largest in the corporate sector in
India.

1.3Human resource development institute

The most prized asset of BHEL is its employees. The Human ResourceDevelopment
Institute
and other HRD centers of the Company help in not only keeping their skills updated and finely
honed but also in adding new skills, whenever required. Continuous training and retraining,

positive, a positive work culture and participative style of management have engendered
development of a committed and motivated workforce leading to enhanced productivity and
higher levels of quality.

1.4. Health, safety and environment management

BHEL, as an integral part of business performance and in its endeavor of becoming a worldclass organization and sharing the growing global concern on issues related to
Environment. Occupational Health and Safety, is committed to protecting Environment in and
around its own establishment, and to providing safe and healthy working environment to all its
employees. For fulfilling these obligations, Corporate Policies have been formulated as:

1.4.1. Environmental policy

Compliance with applicable Environmental Legislation/Regulation;
Continual Improvement in Environment Management Systems to protect our natural
environment and Control Pollution;
Promotion of activities for conservation of resources by Environmental Management;
Enhancement of Environmental awareness amongst employees, customers and suppliers.

1.4.2. Occupational health and safety policy

Compliance with applicable Legislation and Regulations;
Setting objectives
and targets
to
eliminate/control/minimize risks
due to
Occupational and Safety Hazards;
Appropriate structured training of employees on Occupational Health and Safety (OH&S)
aspects;
Formulation and maintenance of OH&S Management programs for continual
improvement;
Periodic review of OH&S Management System to ensure its continuing
suitability,
adequacy and effectiveness;
Communication of OH&S Policy to all employees and interested parties.

1.4.3. Principles of the "global compact"

HUMAN RIGHTS
1. Business should support and respect the protection of internationally proclaimed human
rights;
2. Make sure they are not complicit in human rights abuses.
LABOUR STANDARDS

3. Business should uphold the freedom of association and the effective recognition
of the right to collective bargaining
4. The elimination of all form of forces and compulsory labor.
5. .The effective abolition of child labor, and6.Eliminate discrimination.
ENVIRONMENT
7. Businesses should support a precautionary approach to environmental challenges.
8. Undertake initiatives to promote greater environmental responsibility.
9. Encourage the development and diffusion of environmentally friendly technologies.

2. STEAM TURBINE
2.1 INTRODUCTION
A turbine is a device that converts chemical energy into mechanical energy, specifically when a
rotor of multiple blades or vanes is driven by the movement of a fluid or gas. In the case of a
steam turbine, the pressure and flow of newly condensed steam rapidly turns the
rotor. This movement is possible because the water to steam conversion results in a rapidly
expanding gas. As the turbines rotor turns, the rotating shaft can work to accomplish numerous
applications, often electricity generation.
In a steam turbine, the steams energy is extracted through the turbine and the steam leaves
the turbine at a lower energy state. High pressure and temperature fluid at the in let
of the turbine exit as lower pressure and temperature fluid. The difference is energy converted
by the
turbine to
mechanical rotational energy, less any aerodynamic
and
mechanical inefficiencies incurred in the process. Since the fluid is at a lower pressure at the exit
of the turbine than at the inlet, it is common to say the fluid has been expanded
across the turbine. Because of the expanding flow, higher volumetric flow occurs at
the turbine exit (at least for compressible fluids) leading to the need for larger turbine exit areas
than at the inlet. The generic symbol for a turbine used in a flow diagram is shown in Figure
below. The symbol diverges with a larger area at the exit than at the inlet. This is how
one can tell a turbine symbol from a compressor symbol. In Figure, the graphic is colored to
indicate the general trend of temperature drop through a turbine. In a turbine with a high inlet
pressure, the turbine blades convert this pressure energy into velocity or kinetic energy, which
causes the blades to rotate. Many green cycles use a turbine in this fashion, although the inlet
conditions may not be the same as for a conventional high-pressure and temperature
steam turbine. Bottoming cycles, for instance, extract fluid energy that is at a lower pressure and
temperature than a turbine in a conventional power plant. A bottoming cycle might be
used to extract energy from the exhaust gases of a large diesel engine, but the fluid in
a bottoming cycle still has sufficient energy to be extracted across a turbine, with the energy
converted into rotational energy.

Figure 1- Rotating Steam Turbine

Turbines also extract energy in fluid flow where the pressure is not high but where the fluid has
sufficient fluid kinetic energy. The classic example is a wind turbine, which converts the winds
kinetic energy to rotational energy. This type of kinetic energy conversion is common in green
energy cycles for applications ranging from larger wind turbines to smaller hydrokinetic
turbines. Turbines can be designed to work well in variety fluids, including gases and liquids,
where they are used not only to drive generators, but also to drive compressors or pumps .One
common (and somewhat misleading) use of the word turbine is gas turbine, as in a gas
turbine engine. A gas turbine engine is more than just a turbine and typically includes a
compressor, combustor and turbine combined to be a self-contained unit used to provide shaft or
thrust
power.
The turbine
component
inside
the
gas
turbinestill provides power, but a compressor and combustor are required to make a selfcontained system that needs only the fuel to burn in the combustor. An additional use for turbines
in industrial applications that may also be applicable in some green energy systems is to cool a
fluid. As previously mentioned, when a turbine extracts energy from a fluid, the fluid
temperature is reduced. Some industries, such as the gas processing industry, use turbines as
sources of refrigeration, dropping the temperature of the gas going through the turbine. In other
words, the primary purpose of the turbine is to reduce the temperature of the working fluid as
opposed to providing power. Generally speaking, the higher the pressure ratio across a
turbine, the greater the expansion and the greater the temperature drop. Even where turbines are
used to cool fluids, the turbines still produce power and must be connected to a power absorbing
device that is part of an overall system. Also note that turbines in high inlet-pressure applications
are sometimes called expanders. The terms turbine and expander can be used
interchangeably for most applications, but expander is not used when referring to kinetic energy
applications, as the fluid does not go through significant expansion.

Turbines are of 3 types1. High pressure

2. Low pressure
3. Intermediate pressure

Figure 2- Steam turbine rotor

High pressure the high pressure turbine is a multi-layer, multi block structure that only
converts water steam into shaft power. It is more efficient than the turbine and can support higher
steam pressure input. High pressure turbine requires a high amount of water steam to operate
efficiently and requires ramp up time for the lower end fins.

Single flow
Small size
Double shell casing
Inner casing vertically
Outer casing bored type and axially divided
Mono block rotor
1st stage diagonal blading
Casing mounted valves
Main steam pressure 247 ATA
Main steam temperature 565 c
Outlet steam pressure 54 ATA
Number of stages -19
Power generated in HPT 197 MW

Intermediate Pressure

Double flow
Double casing design with horizontal split
Inlet from lower half
Single exhaust from upper half
Extractions connections from lower half
Admission blade ring with cooling
Reheat steam pressure 54ATA

Reheat steam temperature 593 c

Steam outlet pressure : 6.0ATA
Power generation in IPT 262 MW

Low turbine

Double flow
Big size
Double shell casing
Single admission from top half
Outer casing and condenser rigidly connected
Push rod arrangement to minimize axial clearness
Mono block rotor
Inner outer casing fabricated
Inlet steam pressure 5.97 ATA
Inlet steam pressure 282. 12 c
Outlet steam pressure 0.1047ATA
Power generated in LPT 210 MW

After the steam has passed through the HP stage, it is returned to the boiler to be re- heated to its
original temperature .Although the pressure remains greatly reduced. The reheated steam then
passes through the IP stage and finally to the IP stage of the turbine. A single shaft or several
shafts coupled together may be used.

2.2. Advantages:

Ability to utilize high pressure and high temperature steam.

High efficiency.
High rotational speed.
High capacity/weight ratio.
Smooth, nearly vibration-free operation.
No internal lubrication.
Oil free exhausts steam.

2.3 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.

2.4 Steam turbines the mainstay of BHEL

BHEL has the capability to design, manufacture and commission 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 600C.Turbines are built on the building block system, consisting of
modules suitable for a range of output and steam parameters.

3. TYPES OF STEAM TURBINE

3.1Impulse turbine
The
principle
of the impulse
steam
turbine
consists of a
casing containing
stationary steam nozzles
and
a
rotor
with
moving
or rotating
buckets. The steam passes through the stationary nozzles and is directed at high velocity against
rotor buckets causing the rotor to rotate at high speed.
The following events take place in the nozzles:
1. The steam pressure decreases.
2. The enthalpy of the steam decreases.
3 The steam velocity increases.
4. The volume of the steam increases.
5. There is a conversion of heat energy to kinetic energy as the heat energy from the decrease in
steam enthalpy is converted into kinetic energy by the increased steam velocity.

Figure 3- Impulse turbine

3.2 The impulse principle

If steam at high pressure is allowed to expand through stationary nozzles, the result will be a
drop in the steam pressure and an increase in steam velocity. In fact, the steam will issue from
the nozzle in the form of a high-speed jet. If this high steam is applied to a properly shaped
turbine blade, it will change in direction due to the shape of the blade. The effect of this
change in direction of the steam flow will be to produce an impulse force, on the blade causing
it to move. If the blade is attached to the rotor of a turbine, then the rotor will revolve. Force
applied to the blade is developed by causing the steam to change direction of flow (Newtons
2ndLaw change of momentum). The change of momentum produces the impulse force. The
fact that the pressure does not drop across the moving blades is the distinguishing feature
of the impulse turbine. The pressure at the inlet to the moving blades is the same as the pressure
at the outlet from the moving blades.

3.3 Reaction principle

A reaction turbine has rows of fixed blades alternating with rows of moving
blades. The steam expands first in the stationary or fixed blades where it gains some velocity as
it drops
in pressure. It then enters the
moving
blades where its direction of flow
is
changed thus producing an impulse force on the moving blades. In addition, however, the
steam upon passing through the moving blades again expands and further drops in
pressure giving a reaction force to the blades. This sequence is repeated as the steam passes
through additional rows of fixed and moving blades.

3.4Impulse turbine staging

In order for the steam to give up all its kinetic energy to the moving blades in an impulse
turbine, it should leave the blades at zero absolute velocity. This condition will exist
if the blade velocity is equal to one half of the steam velocity. Therefore, for good efficiency
the blade velocity should be about one half of steam velocity. In order to reduce steam velocity
and blade velocity, the following methods may be used:
1. Pressure compounding.
2. Velocity compounding.
3. Pressure-velocity compounding.

Figure 4-Reaction turbine

4. TURBINE PARTS
4.1 Turbine blades
Cylindrical reaction blades for HP, IP and LP Turbines
3-DS blades, in initial stages of HP and IP Turbine, to reduce secondary losses.
Twisted blade with integral
shroud,
in last stages of
HP,
IP
and initial
stages of LP turbines, to reduce profile and Tip leakage losses
Free standing LP moving blades Tip sections with supersonic design
Fir-tree root
Flame hardening of the leading edge
Banana type hollow guide blade
Tapered and forward leaning for optimized mass flow distribution
Suction slits for moisture removal

4.2 Turbine casing

Casings or
cylinders
are of the horizontal
split
type.
This
is
not
ideal, as the heavyflanges of the joints are slow to follow the temperature changes of the cylinder
walls.However, for assembling and inspection purposes there is no other solution. The casing is
heavy in order to withstand the high pressures and temperatures. It is general practice to let the

thickness
of walls
and
flanges
decrease
from inlet- to
exhaustend. The casing joints are made steam tight, without the use of gaskets, by matching the flange
faces very exactly and very smoothly. The bolt holes in the flanges are drilled for smoothly
fitting bolts, but dowel pins are often added to secure exact alignment of the flange joint. Double
casings are used for very high steam pressures. The high pressure is applied to the inner casing,
which is open at the exhaust end, letting the turbine exhaust to the outer casings.

4.3 Turbine rotors

The design of
a turbine rotor
depends on the operating principle of
the turbine.
The
impulse turbine with pressure drop across the stationary blades must have seals between
stationary blades and the rotor. The smaller the sealing area, the smaller the leakage; therefore
the stationary blades are mounted in diaphragms with labyrinth seals around the shaft. This
construction requires a disc rotor. Basically there are two types of rotor:

DISC ROTORS

All larger disc rotors are now machined out of a solid forging of nickel steel; this should give the
strongest rotor and a fully balanced rotor. It is rather expensive, as the weight of the final rotor is
approximately 50% of the initial forging. Older or smaller disc rotors have shaft and discs made
in separate pieces with the discs shrunk on the shaft. The bore of the discs is made 0.1%smaller
in diameter than the shaft. The discs are then heated until them easily are slid along the shaft and
located in the correct position on the shaft and shaft key.

DRUM ROTORS

The first reaction turbines had solid forged drum rotors. They were strong,
generally
well balanced as they were machined over the total surface. With the increasing size of turbines
the solid rotors got too heavy pieces. For good balance the drum must be machined both outside
and inside and the drum must be open at one end. The second part of the rotor is the drum end
cover with shaft.

5. BLADING MATERIALS
Among the different materials typically used for blading are 403 stainless steel, 422
stainless steel, A-286, and Haynes Stellite Alloy Number 31 and titanium alloy. The403 stainless
steel is essentially the industrys standard blade material and, on impulse steam turbines, it is
probably found on over 90 percent of all the stages. It is used because of its high yield strength,
endurance limit, ductility, toughness, erosion and corrosion resistance, and damping. It is used
within a Brinell hardness range of 207 to 248 to maximize its damping and corrosion resistance.
The 422 stainless steel materials is applied only on high temperature stages (between 700 and
900F or 371 and 482C), where its higher yield, endurance, creep and rupture strengths are
needed. The A-286 material
is a nickel
based super alloy that is generally used in hot gas
expanders with stage temperatures between 900 and 1150F (482 and 621C). The
Haynes Stellite Alloy Number 31 is a cobalt-based super alloy and is used on jet expanders when
precision cast blades are needed. The Haynes Stellite Number 31 is used at

stage temperatures between 900 and 1200F (482 and 649C). Another blade material is
titanium. Its high strength, low density, and good erosion resistance make it a good candidate for
high speed or long-last stage blading.

6. MANUFACTURING PROCESS
6.1Introduction
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.

6.2 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 equipments 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. 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

6.2.1 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 primaries shaping processes are:
(1)Casting(2)Powder metallurgy(3)Plastic technology(4)Gas cutting(5)Bending and(6)Forging.

6.2.2 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. 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

Unconventional machining processes namely machining with Numerical control (NC) machines
tools or Computer Numerical Control (CNC) machine tool using ECM, LBM, AJM,
USM setups.

7. BLOCK 3 LAY-OUTS
7.1 Classification of block 3
Bay 1- Size- 36*378 meters
Bay 2- Size 36*400 meters
Bay 3- Size - 24*402 meters
Bay 4- Size- 24*381 meters respectively
BAY-1 IS FURTHER 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. Asias 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.

FIG.4 OVERSPEED AND VACCUM BALANCING TUNNEL

BAY 2 IS DIVIDED IN TO 2 PARTS:
1. HMS- In this shop several components of steam turbine like LP, HP & IP rotors, Internal
& external casing are manufactured with the help of different operations carried out through
different NC & CNC machines like grinding, drilling, vertical & horizontal milling and boring
machines, center lathes, planer, Kopp milling machine.
2. Assembly section- In this section assembly of steam turbines up to 1000 MWIs assembled. 1st
moving blades are inserted in the grooves cut on circumferences of rotor, then rotor is balanced
in balancing tunnel in bay-1.After is done in which guide blades are assembled inside the internal
casing &
then rotor is fitted inside this casing. After it this internal casing with rotor is
inserted into the external.
BAY 3 IS DIVIDED INTO 3 PARTS:
1. Bearing section In this section Journal bearings are manufactured which are used in
turbines to overcome the vibration & rolling friction by providing the proper lubrication.

2. Turning section In this section small lathe machines, milling & boring machines, grinding
machines & drilling machines are installed. In this section small jobs are manufactured like
rings, studs, disks etc.
3. Governing section In these section governors are manufactured. These governors are used in
turbines for controlling the speed of rotor within the certain limits. 1st all components
of governor are made by different operations then these all parts are treated in heat treatment
shop for providing the hardness. Then these all components are assembled into casing. There are
more than 1000 components of Governor.
BAY-4 IS DIVIDED INTO 3 PARTS:
1. TBM (turbine blade manufacturing) shop- In this shop solid blade of both steam & gas
turbine are
manufactured. Several CNC & NC machines
are
installed
here such as Copying machine, Grinding machine, Rhomboid milling machine, Duplex milling
machine, T- root machine center, Horizontal tooling center, Vertical & horizontal boring

machine etc.
2. Heat treatment shop-In these sections there are several tests performed for checking
the hardness of different components. Tests performed are Sterilizing, Nit riding, DP test.

Stress relieving- consists of heating the steel to a temperature below the critical range to
relive the stresses resulting from cold working, shearing, or gas cutting. It is not intended
to alter the microstructure or mechanical properties as does annealing and normalizing.
Flame hardening is a surface hardening method that involves heating a metal with a
high temperature flame, followed by quenching. It is used on medium carbon, mild or
alloy steel or cast iron to produce a wear resistant surface. The result of the hardening is
controlled by four factors Design of the flame head
Duration of the heating
Target temperature of the head
Composition of the metal being treated

Gas nitriding It is a surface hardening process, where nitrogen is added to the surface of steel
parts using dissociated NH3 as the source. Gas nitriding develops a very hard case in a
component at relatively low temperature, without the need for quenching. It can be performed in
a pit furnace. It is also called ammonia nitriding .When ammonia comes into contact with heated
work piece it disassociates into nitrogen and hydrogen. The nitrogen then diffuses onto the
surface of the material creating a nitride layer.

Salt bath Nitriding Nitriding is a salt bath heat treatment process that diffuses nitrogen into
the surface of a metal at the ferritic stage to create a case hardened surface. Cyanide salt is used
in salt bath nitriding . Temperature- (550-570 c)

Advantages- quick processing time (4-6 hrs.)

Simple operation heats the salt and work pieces to temperature until the duration
has transpired.
Disadvantages- salts used are highly toxic.

Figure 5-steam turbine casing and rotors I assembly area

Figure 6-CNC rotor turning lathe

8. BLADE SHOP
Blade shop is an important shop of Block 3. Blades of all the stages of turbine are made in this
shop only. They have a variety of center lathe and CNC machines to perform the

complete operation of blades. The designs of the blades are sent to the shop and the
Respective job is distributed to the operators. Operators perform their job in a fixed interval of
time.

8.1 Types of blades

Basically the design of blades is classified according to the stages of turbine. The size of LP
TURBINE BLADES is generally greater than that of HP TURBINE BLADES .At the first T1,
T2, T3 & T4 kinds of blades were used, these were 2nd generation blades. Then it was replaced
by TX, BDS (for HP TURBINE) & F shaped blades. The most modern blades are F & Z shaped
blades.

Figure 7- types of blades

8.2 Operations performed on blades

Some of the important operations performed on blade manufacturing are:Milling

Blank Cutting
Grinding of both the surfaces
Cutting
Root milling

8.3 Machining of blades

Machining of blades is done with the help of Lathe & CNC machines. Some of the
machines are:-

Centre lathe machine

Vertical Boring machine
Vertical Milling machine
CNC lathe machine

Figure 8- Schematic diagram of a CNC machine

8.4 New blade shop

A new blade shop is being in operation, mostly 500mw turbine blades are manufactured in this
shop. This is a highly hi tech shop where complete manufacturing of blades is done using single
advanced CNC machines. Complete blades are finished using modernized CNC machines.
Some of the machines are: Pama CNC ram boring machine
Wotum horizontal machine with 6 axis CNC control
CNC shaping machine

10. CONCLUSION
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.