PRACTICAL TRAINING REPORT

A TRAINING REPORT

Submitted by

HARSH SOLANKI

in partial fulfillment for the award of the degree

of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
At

JIET GROUP OF INSTITUTION

JODHPUR INSTITUTE OF ENGINEERING & TECHNOLOGY
NH-65, NEW PALI ROAD, MOGRA,
JODHPUR (RAJ)

RAJASTHAN TECHNICAL UNIVERSITY, KOTA

2016-2017
 BONAFIDE CERTIFICATE

This is to certify that Mr. / Ms. “HARSH SOLANKI” of Mechanical

Engineering Department, Jodhpur Institute of Engineering & Technology

having roll no. “13EJIME048” has completed his / her industrial training

during the academic year 2016-2017 as partial fulfillment of Bachelor of

Technology in Mechanical Engineering affiliated from Rajasthan Technical

University, Kota.

SIGNATURE SIGNATURE

PROF. M.R. BAID NAME OF THE GUIDE

Er. Rakesh Narawat

HOD – MECHANICAL ENGINEERING DESIGNATION
JIET, JODHPUR
SIGNATURE

NAME OF THE
TRAINING COORDINATORE

Er. Vivek Singh Shekhawat

DESIGNATION

Internal Examiner _____________________

External Examiner _____________________

 ACKNOWLEDGEMENT

“An engineer with only theoretical knowledge is not a complete engineer. Practical
knowledge is very important to develop and to 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.

Special thanks to PROF. M.R. BAID HOD–MECHANICAL ENGINEERING for

providing me with an opportunity to undergo training under his able guidance.

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.

Harsh Solanki
7th Semester,
B.Tech. Department of
Mechanical Engineering
 TABLE OF CONTENTS
1. Introduction
1.1 Introduction to Practical Training
1.2 Company Overview
1.2.1 Company Profile
1.2.2 Mission and vision statement
1.2.3 Quality Aspects
1.2.4 Organization chart
1.2.5 Types of services/ Products given/ Produces
2. The Project / Training
2.1 Training
2.2 BHEL units
2.3 Product profile
3. Steam turbine
3.1 Introduction
3.2 Advantage of Turbine
3.3 Disadvantage of Turbine
3.4 Types of steam Turbine
3.5 Reaction principle
3.6 Turbine compounding
4. Turbine parts
4.1 Turbine Blades
4.2 Turbine casing
4.3 Turbine Rotor
5. Blade profile and Root
5.1 HP Blade profile
5.2 HP Blade Root
5.3 LP Blade profile
5.4 LP Blade Root
6. Manufacturing processes
7. Shops
7.1 New Turbine shop
7.2 Stamping shop
7.3 Forge and Fabrication shop
8. Block -3
8.1 Bay-1
8.2 Bay-2
8.3 Bay-3
8.4 Bay-4
9. Blade shop
10. Conclusion
1.1 INTRODUCTION OF BHEL, HARIDWAR:

BHEL is the largest engineering and manufacturing enterprise in India in the energy
related infrastructure sector today. BHEL was established more than 52 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,
4 power Sector regional centers, over 150 project sites, 8 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 “MAHARATNAS”, which is supported by the government in their
endeavor to become future global players.

BHEL HARIDWAR:

There are two units in BHEL Haridwar as followed:

1) Heavy Electrical Equipment Plant (HEEP)

2) Central Foundry Forge Plant (CFFP)

1.2. COMPANY OVERVIEW:

• Bharat Heavy Electricals Limited (B.H.E.L.) is the largest engineering and

manufacturing enterprise in India. BHEL caters to core sectors of the
 Indian Economy viz., Power Generation's & Transmission, Industry,
Transportation, Telecommunication, Renewable Energy, Defense and
many more.

• Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960

in the area of Scientific, Technical and Industrial Cooperation.

• BHEL has its setup spread all over India namely New Delhi, Gurgaon,
Haridwar, Rudrapur, Jhansi, Bhopal, Hyderabad, Jagdishpur ,
Tiruchirapalli, Bangalore and many more.

• Over 65% of power generated in India comes from BHEL-supplied

equipment. Overall it has installed power equipment for over 90,000 MW.

• BHEL's Investment in R&D is amongst the largest in the corporate sector

in India. Turnover of the company in the year 2015-2016 was recorded as
30806 crore having a high of 62.00% in comparison to last year.

• BHEL has already attained ISO 9000 certification for quality

management, and ISO 14001 certification for environment management
and Occupational Health & Safety (ISO-18001).

• It is one of India's nine largest Public Sector Undertakings or PSUs, known

as the MAHARATNAS.

• The power plant equipment manufactured by BHEL is based on

contemporary technology comparable to the best in the world.

• The wide network of BHEL's 14 manufacturing divisions, 4 Power Sector

regional center, over 150 project sites, 8 Service Centre and 18 regional
offices, enables the Company to promptly serve its customers and provide
them with suitable products, systems and services efficiently.

1.2.1 COMPANY PROFILE:

The Company is an integrated power plant equipment manufacturer, which is

engaged in the designing, engineering, manufacturing, constructing, testing,
commissioning and servicing a range of products and services for various
sectors, such as power, transmission, industry, transportation, renewable energy,
oil and gas

1.2.2 MISSION AND VISSION

MISSION
Providing sustainable business solution in the field of engineering, Industry and
infrastructure.

VISSION
A global engineering enterprise providing solution for a better tomorrow.

1.2.3 QUALITY ASPECT :

Towards meeting its Quality Policy, BHEL is using the vehicle of Quality Management
Systems, which are certified to ISO 9001:2008 series of standards by internationally
acclaimed certifying agency, BVQI.

Corporate Quality and Unit level Quality structure enables requisite planning, control
and implementation of company-wide Quality Policy and Objectives which are linked
to the company's Vision statement.

Other than traditional Quality functions, today the focus is on

• Propagating Quality Management Systems and Total Quality Management

• Formulating, implementing and monitoring, "Improvement Plans" with focus on
internal and external Customer Satisfaction
• Investigations and preventive actions on critical quality issues
• Calibration and testing laboratories of BHEL are accredited under the National
Accreditation Board for Calibration and Testing Laboratories (NABL) scheme
of laboratory accreditation, which has got mutual recognition with Asia Pacific
Laboratory Accreditation Conference and International Laboratory
Accreditation Conference.

1.2.4 ORGANISATION CHART:

1.2.5 TYPES OF SERVICES/PRODUCTS GIVEN/PRODUCES:

It makes large size steam and gas turbines, turbo generators, heat exchangers,
condensers and auxiliaries, in the Heavy Electricals Equipment Plant .

Large size Castings and Forgings of various types of steels like alloy steels, creep
resistant steel and supercritical grade steel, in the Central Foundry Forge Plant.

And BHEL also do the work of maintenance of all these products, produces by it like
as Turbines, Generators, heat exchangers, condensers and auxiliaries.
2 TRAINING:

My 60 days training is competed from BHEL HARIDWAR.

There are two units in BHEL Haridwar as followed:

1) Heavy Electrical Equipment Plant (HEEP)
2) Central Foundry Forge Plant (CFFP)

There are 8 Blocks in HEEP:

Table-1

Blocks Work Performed in Block

I) Electrical Turbo Generator, Generator Exciter, Motor (AC and DC)
Machine

II) Fabrication Large Size Fabricated Assemblies or Components

III) Turbines & Steam, Hydro Turbines, Gas turbines, Turbine Blade, Special
Auxilary Tooling.

IV) Coils and Winding of TurboHydro Generators, Insulation for AC & DC

Insulation Motors

V) Fabrication Fabricated Parts of Steam Turbine, Water Boxes, Storage Tank,

Hydro
Turbine Parts

VI) Fabrication Fabricated Oil Tanks, Hollow Guide Blades, Rings, Stator
Stamping & Die Frames and Rotor Spindle, All Dies, Stamping for Generators
Manufacturing and Motor

VII) Wood Wooden Packing, Spacers

Working

VIII) Heaters & LP heaters, Ejectors, Glands, Steam and Oil Coolers, Oil Tank,
Coolers Bearing Covers
 There are 3 Sections in CFFP:
Table-2

Blocks Work Performed In Block

1. Foundry Casting of Turbine Rotor, Casing and Francis Runner

2. Forging Forging of Small Rotor Parts

3. Machine Shop Turning, Boring, Parting off, Drilling etc.

2.1 BHEL UNITS:

Table -3

UNIT TYPE PRODUCT

1. Bhopal Heavy Electrical Part Steam Turbines, Turbo Generators,

Hydro
Sets,
Switch Gear Controllers
2. Haridwar Hydro Turbines, Steam Turbines, Gas
Turbines, Turbo Generators, Heavy
HEEP Heavy Electrical Castings and Forging, Control Panels,
Equipement Light Aircrafts, Electrical Machines.
CFFP Plant
Central Foundry Forge Plant
3. Hyderabad Industrial Turbo-Sets, Compressor
Pumps and Heaters, Bow Mills, Heat
HPEP Heavy Power Equipement Exchangers Oil Rings, Gas Turbines,
Plant Switch Gears, Power Generating Sets.
4. Trichy
Seamless Steel Tubes, Spiral Fin
HPBP High Pressure Boiling Plant Welded Tubes.
5. Jhansi
Transformers, Diesel Shunt Less AC
TP Transformer Plant locos and EC EMU.
6. Bangalore Energy Meters, Watt Meters, Control
Equipement, Capacitors, Photo Voltic
EDN Electronics Division Panels, Simulator, Telecommunication
System, Other Advanced
EPD Electro Porcelains Devision Microprocessor based Control System,
Insulator and Bushing, Ceramic Liners
7. Ranipet Electrostatic Precipitator, Air Pre-
Heater, Fans, Wind Electric
BAP Boiler Auxilary Plant Generators, Desalination Plants.

8. Goindwal Industrial Valves Plant Industrial Valves & Fabrication

9. Jagdishpur High tension ceramic, Insulation Plates
and Bushings
IP Insulator Plant
10. Rudrapur Component Fabrication Windmill, Solar Water Heating system
Plant
11. Gurgaon Amorphous Silicon Solar Solar Photovoltaic Cells, Solar
Cell Lanterns,
Plant. Chargers ,Solar clock

2.3 HEEP PRODUCT PROFILE :

2.3.1 THERMAL SETS:

• Steam turbines and generators up to 500 MW capacity for utility and
combined cycle applications
• Capability to manufacture up to 1000 MW unit cycle.

2.3.2 GAS TURBINES:

• Gas turbines for industry and utility application range 3 to 200 MW (ISO).
• Gas turbines based co-generation and combined cycle system.
2.3.3 EQUIPMENT FOR NUCLEAR POWER PLANTS:
• Turbines and generators up to 500MW unit size.
• Steam generator up to 500MW unit size.

• Re-heaters / Separators.
• Heat exchangers and pressure vessels.

2.3.4 ELECTRICAL MACHINES:

a. 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.
b. DC auxiliary mill motors.

2.3.5 CONTROL PANEL:

Control panel for voltage up to 400KW and control desks for

generating stations and EMV sub–stations.

2.3.6 CASTING AND FORGINGS:

Sophisticated heavy casting and forging of creep resistant alloy

steels, stainless steel and other grades of alloy meeting stringent
international specifications.

2.3.7 DEFENCE:
Naval guns with collaboration of Italy.
STEAM TURBINE:

2.1 INTRODUCTION:
A turbine is a device that converts hydrullic 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 turbine’s
rotor turns, the rotating shaft can work to accomplish numerous applications,
often electricity generation.

Fig.1 Sectional View of a Steam Turbine

In a steam turbine, the steam’s energy is extracted through the turbine and the
steam leaves the turbine at a lower energy state. High pressure and temperature
fluid at the inlet 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.

Fig.2 Flow Diagram of a 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 wind’s 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 currently
being designed for and demonstrated in river and tidal applications. Turbines can
be designed to work well in a variety of 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 turbine still provides power, but a compressor and
combustor are required to make a self-contained 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.

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 600ºC.
 • 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:

There are complicated methods to properly harness steam power that give rise
to the two primary turbine designs: impulse and reaction turbines. These
different designs engage the steam in a different method so as to turn the rotor

3.1 IMPULSE 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.

3.2 THE IMPULSE PRINCIPLE:

Fig.3 Impulse Turbine

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 (Newton’s 2nd Law – 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.

3.4 IMPULSE 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.
ARRANGEMENT OF HP, IP & LP STEAM TURBINE IN A POWER
PLANT:

Flow Chart

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.

GENERATION OF BLADE:
 Fig. 4 Generation of Blades

• 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.

4.2 TURBINE CASING:

Casings or cylinders are of the horizontal split type. This is not ideal, as the heavy
flanges 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 exhaust-end. 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.

Fig 3. Casing of IP Turbine

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 saft. This construction requires a disc rotor.
Basically, there are two types of rotor:

DISK 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 they easily are slid along the shaft and
located in the correct position on the shaft and shaft key. A small clearance
between the discs prevents thermal stress in the shaft.

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.

MATERIAL USED IN A STEAM TURBINE PARTS:

 Material of construction:
• HP Outer Casing: 15Cr1Mo1V
• LP Outer Casing: 10CrMoVNb
• LP Rotor/Discs: 12CrMoVNbN
• HP Rotor/Discs: 26NiCrMoV115
• Bolting: Nimonic 80A
• Vanes/Blades: 10CrMoVNbN
• HP Shaft: 25Cr1Mo1V
• IP Shaft: 25Cr1Mo1V
• LP Shaft: 26CrNi3Mo2V

CONSTRUCTIONAL FEATURES OF A BLADE:

The blade can be divided into 3 parts:

• Profile, which converts the thermal energy of steam into kinetic energy,
with a certain efficiency depending upon the profile shape.
 • Root, which fixes the blade to the turbine rotor, giving a proper anchor to the
blade, and transmitting the kinetic energy of the blade to the rotor.

• Shroud, It is the upper most part of blade, It is also called Head of Blade.

Fig.4 Nomenclature of a Steam Turbine Blade

5.1 H.P. BLADE PROFILES:
In order to understand the further explanation, a familiarity of the terminology
used is required. The following terminology is used in the subsequent sections.
If circles are drawn tangential to the suction side and pressure side profiles of a
blade, and their centers are joined by a curve, this curve is called the camber line.
This camber line intersects the profile at two points A and B. The line joining
these points is called chord, and the length of this line is called the chord length.
A line which is tangential to the inlet and outlet edges is called the bitangent line.
The angle which this line makes with the circumferential direction is called the
setting angle. Pitch of a blade is the circumferential distance between any point
on the profile and an identical point on the next blade.

5.2 CLASSIFICATION OF PROFILES:

There are two basic types of profiles - Impulse and Reaction. In the impulse type
of profiles, the entire heat drop of the stage occurs only in the stationary blades.
In the reaction type of blades, the heat drop of the stage is distributed almost
equally between the guide and moving blades. Though the theoretical impulse
blades have zero pressure drop in the moving blades, practically, for the flow to
take place across the moving blades, there must be a small pressure drop across
the moving blades also. Therefore, the impulse stages in practice have a small
degree of reaction. These stages are therefore more accurately, though less
widely, described as low-reaction stages. The presently used reaction profiles are
more efficient than the impulse profiles at part loads. This is because of the more
rounded inlet edge for reaction profiles. Due to this, even if the inlet angle of the
steam is not tangential to the pressure-side profile of the blade, the losses are
low. However, the impulse profiles have one advantage. The impulse profiles
can take a large heat drop across a single stage, and the same heat drop would
require a greater number of stages if reaction profiles are used, thereby increasing
the turbine length. The Steam turbines use the impulse profiles for the control
stage (1st stage), and the reaction profiles for subsequent stages. There are four
reasons for using impulse profile for the first stage:
a) Most of the turbines are partial arc admission turbines. If the first stage is are
action stage, the lower half of the moving blades do not have any inlet steam,
and would ventilate. Therefore, most of the stage heat drop should occur in the
guide blades.
b) The heat drop across the first stage should be high, so that the wheel chamber
of the outer casing is not exposed to the high inlet parameters. In case of -
4turbines, the inner casing parting plane strength becomes the limitation, and
therefore requires a large heat drop across the 1st stage.
c) Nozzle control gives better efficiency at part loads than throttle control.

d) The number of stages in the turbine should not be too high, as this will increase
the length of the turbine.

There are exceptions to the rule. Turbines used for CCPs, and BFP drive turbines
do not have a control stage. They are throttle-governed machines. Such designs
are used when the inlet pressure slides. Such machines only have reaction stages.
However, the inlet passages of such turbines must be so designed that the inlet
steam to the first reaction stage is properly mixed, and occupies the entire 360
degrees. There are also cases of controlled extraction turbines where the L.P.
control stage is an impulse stage. This is either to reduce the number of stages to
make the turbine short, or to increase the part load efficiency by using nozzle
control, which minimizes throttle losses.

5.3 H.P. BLADE ROOTS:

The root is a part of the blade that fixes the blade to the rotor or stator. Its design
depends upon the centrifugal and steam bending forces of the blade. It should be
designed such that the material in the blade root as well as the rotor / stator claw
and any fixing element are in the safe limits to avoid failure. The roots are T-root
and Fork-root. The fork root has a higher load carrying capacity than the T-root.
It was found that machining this T-root with side grip is more of a problem. It
has to be machined by broaching, and the broaching machine available could not
handle the sizes of the root. The typical roots used for the HP moving blades for
various steam turbine applications are shown in the following figure:
 Table 4 Blade Roots

T-ROOT

T-ROOT WITH SIDE GRIP

FORK ROOT

5.4 L.P. BLADE PROFILES:

The LP blade profiles of moving blades are twisted and tapered. These blades
are used when blade height-to-mean stage diameter ratio (h/Dm) exceeds 0.2.

5.5 LP BLADE ROOTS:

The roots of LP blades are as follows:

1) Blading:
a. The roots of both the LP stages in –2 type of LP Blading are T-
roots.

2) Blading:
a. The last stage LP blade of HK, SK and LK blades have a fork-root.
SK blades have4-fork roots for all sizes. HK blades have 4-fork
roots up to 56 size, where modified profiles are used. Beyond this
size, HK blades have 3 fork roots. LK blades have 3-forkroots for
 all sizes. The roots of the LP blades of preceding stages are of T-
roots.

5.6 DYNAMICS IN BLADE:

The excitation of any blade comes from different sources. They are

• Nozzle-passing excitation: As the blades pass the nozzles of the stage,

they encounter flow disturbances due to the pressure variations across
the guide blade passage. They also encounter disturbances due to the
wakes and eddies in the flow path. These are sufficient to cause
excitation in the moving blades. The excitation gets repeated at every
pitch of the blade. This is called nozzle-passing frequency excitation.
The order of this frequency =no. of guide blades x speed of the machine.
Multiples of this frequency are considered for checking for resonance.
• Excitation due to non-uniformities in guide-blades around the periphery.
These can occur due to manufacturing inaccuracies, like pitch errors,
setting angle variations, inlet and outlet edge variations, etc.
For HP blades, due to the thick and cylindrical cross-sections and short blade
heights, the natural frequencies are very high. Nozzle-passing frequencies are
therefore necessarily considered, since resonance with the lower natural
frequencies occurs only with these orders of excitation. In LP blades, since the
blades are thin and long, the natural frequencies are low. The excitation
frequencies to be considered are therefore the first few multiples of speed, since
the nozzle passing frequencies only give resonance with very high modes, where
the vibration stresses are low.
The HP moving blades experience relatively low vibration amplitudes due to
their thicker sections and shorter heights. They also have integral shrouds. These
shrouds of adjacent blades butt against each other forming a continuous ring.
This ring serves two purposes – it acts as a steam seal, and it acts as a damper
for the vibrations. When vibrations occur, the vibration energy is dissipated as
friction between shrouds of adjacent blades.
For HP guide blades of Wesel design, the shroud is not integral, but a shroud
band is riveted to a number of guide blades together. The function of this shroud
band is mainly to seat the steam. In some designs HP guide blades may have
integral shrouds like moving blades. The primary function remains steam
sealing.
In industrial turbines, in LP blades, the resonant vibrations have high amplitudes
due to the thin sections of the blades, and the large lengths. It may also not always
be possible to avoid resonance at all operating conditions. This is because of two
reasons. Firstly, the LP blades are standardized for certain ranges of speeds, and
turbines may be selected to operate anywhere in the speed range. The entire
design range of operating speed of the LP blades cannot be outside the resonance
range. It is, of course, possible to design a new LP blade for each application,
but this involves a lot of design efforts and manufacturing cycle time. However,
with the present-day computer packages and manufacturing methods, it has
become feasible to do so. Secondly, the driven machine may be a variable speed
machine like a compressor or a boiler-feed-pump. In this case also, it is not
possible to avoid resonance. In such cases, where it is not possible to avoid
resonance, a damping element is to be used in the LP blades to reduce the
dynamic stresses, so that the blades can operate continuously under resonance
also. There may be blades which are not adequately damped due to
manufacturing inaccuracies. The need fora damping element is therefore
eliminated. In case the frequencies of the blades tend towards resonance due to
manufacturing inaccuracies, tuning is to be done on the blades to correct the
frequency. This tuning is done by grinding off material at the tip (which reduces
the inertia more than the stiffness) to increase the frequency, and by grinding off
material at the base of the profile (which reduces the stiffness more than the
inertia) to reduce the natural frequency.

The damping in any blade can be of any of the following types:

a) Material damping: This type of damping is because of the inherent

damping properties of the material which makes up the component.

b) Aerodynamic damping: This is due to the damping of the fluid which

surrounds the component in operation.

c) Friction damping: This is due to the rubbing friction between the

component under consideration with any other object.
Out of these damping mechanisms, the material and aerodynamic types of
damping are very small in magnitude. Friction damping is enormous as
compared to the other two types of damping. Because of this reason, the damping
elements in blades generally incorporate a feature by which the vibrational
energy is dissipated as frictional heat. The frictional damping has a particular
characteristic. When the frictional force between the rubbing surfaces is very
small as compared to the excitation force, the surfaces slip, resulting in friction
damping. However, when the excitation force is small when compared to the
frictional force, the surfaces do not slip, resulting in locking of the surfaces. This
condition gives zero friction damping, and only the material and aerodynamic
damping exists. In a periodically varying excitation force, it may frequently
happen that the force is less than the friction force.
During this phase, the damping is very less. At the same time, due to the locking
of the rubbing surfaces, the overall stiffness increases and the natural frequency
shifts drastically away from the individual value. The response therefore also
changes in the locked condition. The resonant response of a system therefore
depends upon the amount of damping in the system (which is determined by the
relative duration of slip and stick in the system, i.e., the relative magnitude of
excitation and friction forces) and the natural frequency of the system (which
alters between the individual values and the locked condition value, depending
upon the slip or stick condition).

5.7 BLADING MATERIALS:

Among the different materials typically used for blading are 403 stainless steel,
422 stainless steel, A-286, and Haynes Satellites Alloy Number 31 and
titanium alloy. The403 stainless steel is essentially the industry’s 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 material is applied only on high
temperature stages (between 700 and 900°F or 371 and 482°C), 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 1150°F (482 and 621°C).
The Haynes Satellites Alloy Number 31 is a cobalt-based super alloy and is used
on jet expanders when precision cast blades are needed. The Haynes Satellite
Number 31 is used at stage temperatures between 900 and 1200°F (482 and
649°C). 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:

6.1 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 equipments 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.

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. 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

6.2.1 PRIMARY SHAPING PROCESSES:

Primary shaping processes are manufacturing of a product from an amorphous

material. Some processes produce 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 to undergo further operations. Some of the important primary shaping
processes are:

• Casting
• Powder metallurgy
• Plastic technology
• Gas cutting
• Bending and
• 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. 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. forgetting desired dimensional
control and required degree of surface finish on the work-pieces. The example
of parts produced by machining processes includes hand tools machine tools
instruments, automobile parts, nuts, bolts and gears etc. Lot of material is wasted
as scrap in the secondary or machining process. 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
• Unconventional machining processes namely machining with
Numerical control (NC) machines tools or Computer Numerical
Control (CNC) machine tool using ECM, LBM, AJM, USM setups.

NEW TURBINE SHOP (MACHINE SHOP):

This shop is a part of BHEL in which Turbine rotor and Governor are manufacture and
repair,(maintenance work)
1.CNC lathe (for light duty job):
It is use for stud threading, Bolt threading and also for turning, facing among others
purpose.

Machine Specifications:
 Max. Diameter to be hold in chuck is-250mm.
 Max length of the job to be made is-1000mm.
 Max RPM =1200
 Size of Chuck =500mm.
 Centre Distance=1000mm
 Insert type of tool used in this machine, It is made up of Carbide or Tungsten
Carbide.

2.CNC Lathe (for medium duty job):

It is used for turning, facing etc.

Mostly this machine use for making turbine valve seats, which is used in turbine
assembly.

It is not used for milling purpose.

Machine Specifications:

 Chuck Diameter-1000mm.
 Centre Distance-5000mm.
 Tool material- High Speed Steel.
 Coolant used- 1:20(1liter oil,20liter water)
 Max. feed- 10mm.
 Normal feed- 2-3mm.
 Maximum Capacity-15 ton.
 Fig.5 Lathe for medium duty job

3.CNC Shunt Lathe (for heavy duty job):

It is used for mass production of long cylindrical objects.
Generally, it is used for maintenance of HP, IP and LP turbine rotor, where from-Italy.
Machine Specifications:
 Weight capacity-80 ton.
 Max. swing over carriage-1800mm.
 Max. Swing over bad-3000mm.
 Centre Distance-10,000mm.
 Tool material-Insert type Carbide tip
 Object material-Steel alloy
 Tool used:-
 T1-Right Hand turning tool.
 T2-Left Hand turning tool.
  T3-Radious tool.
 T8-Pluging tool.
 T10-Face Turning tool.
 T13-Internal Turning grooving tool.

Operations: Jobs:
 Turning HP rotor
 Grooving LP rotor
 Offset Turning IP rotor

Fig.6 CNC Shunt Lathe

4.CNC Vertical Boring Machine:

It is used for light and medium duty job, Bush is made up by this machine, which is
used in turbine assembly.
 Fig.7 Vertical Boring Machine

5.Radial Drilling Machine:

It is used to drill a hole in a metal or non-metal plate.

Machine specifications:
 Spindle Diameter-110mm.
 Spindle Tapper-MT-6
 Spindle Travel-475mm.
 Max drill Capacity-100mm.
 Vertical Travel of Ram-1600.
 Radial Travel of Spindle-3400.
 Max/Min. Drilling Radius-4470mm/1000mm.
 Movement 360 Degree on its axis
 -y to +y direction
-x to +x direction.

Fig.8 Radial Drilling Machine

6.Hydrullic Press Machine:

Generally, it is used for pressing of metal plate to provide initial arc or bending with
the help of Template.

Template: It is a metal sheet which is used for arc measurement.

Types of Template :-
 Conical
 Radial
Template radius is varies from 250mm to 2000mm.
Template Representation

R1538, R1578 and R1438 etc.

 If any gap present between the template arc and arc this means band in sheet is
not proper.

Types of Hydraulic Press Machine:

Hydraulic press machines are define according to applying Load.

Hydraulic Press
1. CNC 1000 Ton: Max thickness of plate is 200mm to 250mm.
2. Manual 800 Ton: Max thickness of plate is 25mm to 170mm.
3. Manual 400 Ton: Max thickness of plate is 35mm to 95mm.
4. CNC 340 Ton: Max thickness of plate is 40mm to 80mm.

Applications of plate which are pressed:

 Plates (end shield)

 Conical half rings
 Inner rings
 Guide Blades

Following material plates are press on Hydraulic Machine:

 Mild steel
 Stainless steel
 Ductile material

Fig.9 CNC Hydraulic Press Machine (340 Ton)

Fig.10 CNC Hydraulic Press Machine (1000 Ton)

7. CNC Flame Cutting Machine:

This machine is used to cut row material thick plate, which is used on press machine to
provide initial arc and after that plate send to Rolling machine there roll the plate and
welded.

 Plates are used in HP, IP and LP Steam Turbine outer casing and Generator
casing.
 Generally, in this machine BMC (Bharat Metal Cutting) gas is used Because this
gas is low in cost, in comparison of Oxyacetylene gas.
 Dissolved Oxyacetylene gas also used in this machine in 1:1 ratio.

 To varies the Oxygen and Acetylene percentage and make these flames:-

1. Carburizing Flame:- C% is greater than O2 %.

2. Natural Flame:- C % is equal to O2%.
3. Oxidizing Flame:- C % is less than O2 %.

 Mostly Natural Flame is used as a cutting purpose of metal plates.

 Carburizing flame is used in Brazing.
 Oxidizing flame is not used because of rough finish of the job or object, By this
metal removal is more.
 Plasma arc cutting machine is used for Stainless steel and High Speed Steel
material, In this machine Argon-Hydrogen gas is used in 1:1 ratio for cutting
purpose.
 Nozzle material :-Copper Alloy ,
Temperature of nozzle at working condition is 3200 to 3300 degree celceus
 Tool tip Distance :- 5 to 10mm

 Mechanism of movement of machine is Rack and Pinion.

Movement of Nozzle:

Only in two directions:

 -x to +x Axis
-z to +z Axis

Fig.11 CNC Flame Cutting machine

STAMPING SHOP:

In this shop only work on sheet metal, thickness of the sheet is vary 0.65mm to 2.0mm.

In this shop first of all metal sheet cut in rectangular piece and then rectangular sheet
cut on Press machine with the help of die and punch.

All press machines are varies in load capacity:-

 125 Ton
 150 Ton
 200 Ton
 250 Ton
After that rectangular sheet is cut in the circular sheet, with the help of following
machines:-

1.CNC Notching Machine:

This machine is used to cut circular sheets with the help of notch and center plate,
circular sheet also called Blank.

Fig.12 CNC Notching Machine

Machine Specifications:
 Normal Force-160KN
 No. of Strockes-100-160 per minute
 Stroke of slide-40mm
 Slide Adjustment-30mm
 Machine Weight-5000kg
It is work on the Air Pressure punch is move up and down via air pressure. (5kg/cm2)
After that Master Grinder or Grinding machine is used to remove the burr from the
sheet surface

And then varnish the prepared Blank sheet on varnish machine and varnish sheet send
to heater to heat the sheet and dry.

 1hrs- 400 pieces are varnished.

FORGE AND FABRICATION SHOP:

Forging is a process in which the job is heated below the melting point and then force
applied with the help of Hammer to change the shape or to enlarged the job.

Fig.13 Heat Treatment Furnace (LPG Fired)

Forging shop is the place where all forging activities are done manually.

Mostly materials are used:-

 Plane Carbon Steel
 Alloy Steel
  Carbon Steel
 Stainless Steel

Furnaces are used in this shop for heating purpose:-

 300kg
 500kg
 1000kg
 3000kg

LPG (Liquefied Petroleum Gas) gas is used to heat the ingot in the furnace, LPG gas is
supplied from the CFFP plant.

In the furnace the ingot is heated at Red Hot Temperature 750 degree celsius, and
Maximum furnace temperature is1250 degree celsius.

Electric furnace is used to Reheat the ingot, Body of furnace is made up of Cast Iron.

Refractory bricks are used to prevent the heat dissipation through the furnace casing.

In this shop these Heat Treatment processes are used:-

1. Normalizing - In Furnace,
2. Tempering - In oil or water,
3. Annealing – In air.

Metal ingot is pressed by different types of Hammer:-

1. Electric hammer (500 and 1000 ton)

2. Hydraulic pressure hammer (5000 ton)
3. Air pressure hammer (3000 ton)
 Fig.14 Hydraulic hammer

Head of Hammer is made up of carbon steel and body of hammer is made up of Cast
iron.
Material used in Reciprocating shaft of hammer is E19 or S24.

CLASSIFICATION OF BLOCK 3

BAY-1 IS FURTHER DIVIDED INTO THREE PARTS:

1. HMS(Heavy Machine Shop):

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.

Fig. 15 Over speed & Vacuum Balancing Tunnel

For balancing and over speed testing of rotors up to 320 tons in weight, 1800
mm in length and 6900 mm diameter under vacuum conditions of 1 Torr.
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 MW Is 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 this 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.
 Fig.16 Steam Turbine 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.

Fig .17 Steam Turbine Casing & Rotors in Assembly Area

2. Turning Section
Same as the turning section in Bay-3, there are several small Machine like lathes
machines, milling, boring, grinding machines etc.

Fig 6. CNC Rotor Turning Lathe

3. Heat Treatment Shop
In this shop there are several tests performed for checking the Hardness of
different components. Tests performed are Sereliting, Nitriding, DP Test.

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 centre 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.

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, 3DS,
(for HP TURBINE) & F shaped blades. The most modern blades are F & Z
shaped blades.
 Fig.17 Types of Steam Turbine Blades
3 Dimesional Cylindrical Profile Twisted Profile
3DS Blade TX Blade F Blade
HP/IP Initial Stages HP/IP Intermediate stages HP/IP Rear
& LP Initial Stages

OPERATIONS PERFORMED ON BLADES:

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

• Blanking
• Marking
 • Grinding of both the surfaces
• Cutting
• Root milling

MACHINING OF BLADES:
Machining of blades is done with the help of CNC machines. These machines are: -

• CNC 3-Spindle 5-Axis Machine

• CNC Head Cutting Machine

5-Axies are:
X-Axis-Movement in -x to +x direction
Y-Axis-Movement in-y to +y direction
Z-Axis-Movement in -z to +z direction
A-Axis-Blade rotate with spindle
B-Axis-Blade rotate own its axis

3 Spindles which are hold 3 blades in one time

Fig 8. CNC 3-Spindle 5-Axis Machine

 Fig.19 CNC Head Cutting Machine

CONCLUSION:

Gone through rigorous 6 Weeks training under the guidance of capable engineers and
workers of BHEL Haridwar “NEW TURBINE SHOP” headed by Senior Engineer of
department Mr. Shatrughan Sharma 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.