PRESENTATION

ON
SUMMER INDUSTRIAL TRAINING
AT

Submitted to: Submitted by:

Mr. Hitendra Bankoti Yuganter Rawat

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CONTENTS
Introduction
Over view at Haridwar Plant
Layout of Block-3
Details of Bay 1(Assembly, Machine shop and OSBT)
Details of Bay 2(Gas turbine section and rotor
assembly)
Details of Bay 3(Governing and Broad
specifications of major machines)[CNC & Non CNC]
Bay 4( Blade and Heat treatment shop)

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INTRODUCTION
BHEL is the largest engineering and
manufacturing enterprise in India in the
energy field today. It was established more
than 40 years ago and has been earning the
profits since 1971.
It has very wide network over 150 project
sites, 8 service centers and 18 regional
offices and Headquarters in New Delhi. More
over it is one of the navratna of government
of India. 75% of electricity in India is
produced with the help of BHEL equipments.
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OVERVIEW AT HARIDWAR PLANT
Vision :World class, innovative, competitive,
and profitable engineering enterprise
providing total business solutions.
Mission :The leading engineering enterprise
providing quality product systems and
services in the field of energy, transportation,
infrastructure and other potential areas.
Manpower :Total strength is more than 10000
which includes around 3000 qualified
engineers and technicians, 5200 skilled
artisans and the rest in other categories.
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LAYOUT OF BLOCK :3
Bay 1 Assembly, Heavy machine shop, OSBT

Bay 2 Gas turbine assembly, Rotor assembly

Bay 3 Governing section, Light machine shop

Bay 4 Blade shop, Heat treatment shop

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THE SECTIONAL VIEW OF THE TURBINE
ARRANGEMENT AS IN A POWER PLANT

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PART A: - ASSEMBLY
The final assembly of the turbine is done in
bay 1. Main assembly parts:
1. High pressure steam turbine
2. Intermediate pressure steam turbine
3. Low pressure steam turbine
4. Bearing pedestals
5. Control valves

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HIGH PRESSURE STEAM TURBINE:-
This is the smallest of the three turbines. It
consists of two shells namely inner inner and
outer outer. Inner inner part is the part on
which guide blades are placed and outer
outer part mainly works as a casing of the
turbine. HP outer outer lower half is placed
on bed and leveling is done; now upper half
is assembled and alignment is done; now GBC
is aligned with respect to centre.
Final alignment is checked and turbine is
dispatched in the assembled conditions.

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INTERMEDIATE PRESSURE
TURBINE

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INTERMEDIATE PRESSURE
TURBINE
Capacity 210/250 MW
Main components
IP outer casing
Inner casing
GBC
Shaft seals
Rotor

Descriptions In outer casing, lower half is placed on bed and

leveling is done. U/H is assembled and alignment is done now
inner casing is placed and it is aligned with help of keys and
pokers. Rotor is placed and alignment of rotor is done, now
axial and radial gap between inner casing and rotor are
checked (flow path). The studs are heat tightened to achieve
elongation. Turbine is dispatched in assembled conditions.
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LOW PRESSURE TURBINE
Capacity 210/250/500MW
Main components:
LP inner outer
LP inner inner
LP outer outer
LP GBC
Rotor

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DESCRIPTIONS
LP I/O lower half is placed on bed and
leveling is done. Now upper half is assembled
and alignment is done. Now GBC is aligned
with respect to centre then GBC 2 and GBC 3
are aligned. Then inner core is aligned with
help of adjustment pokers.
Now projection pipes are welded then
diffusers are aligned. Final alignment is
checked and turbine is dispatched in
disassembled condition

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LP ROTOR OF 500MW STEAM
TURBINE

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BEARING PEDESTALS
Front HP/IP/LP, 210/250/500MW pipelines
are hydraulically tested. Then bearing is
aligned with help of phins, and pinning is
done. Assembly is completed and dispatched
in assembled conditions.

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 CV FOR 500MW STEAM TURBINE
AT BHEL,HARIDWAR
Valve seats are fitted in the casing by cooling in liquid oxygen. Pinning
of seats is done, welding of nipples and flanges is done and then
hydraulic testing with valves covers, now casing is sent for edge
preparation and the color of valve assembly and valve seat is checked.
Travel of valve is checked and locking is done. Then trial assembly of
s/m is done. Valve is dispatched in assembled condition.

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PART B: - HEAVY MACHINE SHOP
In this, there are very costly and big machines which are
used to carry operation on large parts of a turbine such
as rotor, diffuser, casing etc.

1) Machine number 1-120

Center lathe machine CNC
Job: HP Rotor (on that time)
Operation: slotting
Specifications of the machine:-
Main spindle bore: - 150mm
Distance between centers: - 12000mm
Turning dia. Over bed cover: - 1400mm
Turning dia over carriage: - 1100mm
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 2) Machine number 1-28
Horizontal boring machine (Russian)
Operation performed: - tapping,
threading,drilling, boring, facing, milling
etc,except knurling
Specifications
Capacity: - 600mm (bore dia)
Weight capacity: - 40 tonne
Dia of spindle: - 150 mm

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PART C: - OSBT
Over speed balancing tunnel :
This is the one of the most important section of the
turbine block. Here after the complete checking of the
rotor from the bay 1, rotor is bringing to get check it in
the working conditions. Here we rotate our rotor in the
vacuum condition on a very small film of oil consisting of
some microns; here the oil is on very high pressure.
Rotor is revolved on 3750 rpm, while in the operating
conditions rotor revolves at 3000rpm (500mw).
The time being for which rotor is revolved is 3 minutes.
The power required to rotate that much of heavy rotor is
very high which comes from the high voltage line nearly
of 11000 Volts, and the gear box with the synchronize
motor is used to get accurate and desired speed
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Oil plays a very important role in the rotor checking the
oil comes from the underground tanks having a capacity
up to 30000 liters this is pumped with the help of large
pumps and a large quantity of oil is supplied
continuously so that oil film doesnt break. Here we use
a number of filters on many stages so that oil is checked
out against dust particles or any foreign particles the
attention is paid during this checking so that everything
going OK. The full control of OSBT is done with help of
control system which is in control room, each and every
care is taken during the complete testing. The complete
checking of rotor costs nearly 8 crore Rs. Which is a very
high cost and after this testing if we find there is any
loosening in the blades or any blade is out of its position
then the department of OSBT sends the rotor to the
BAY1 along with checking report and every effort is now
put on the rotor so that it pass the checking in the OSBT
only then rotor is assembled with the casing and
dispatched. film doesnt break.
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SYSTEM TO CREATE VACCUM FOR THE OSBT,AT BHEL HARDWAR

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BAY 2
PART A: -Gas turbine section
The main thing that is done here is that the making of rotor for the
gas turbine, the rotor of gas turbine is very different from that of
the steam turbine, here the rotor is made in the form of discs and
after that the complete rotor is made by joining the discs.
On a simple disc firstly the grooves are cut on the broaching
machine , very similar to the gear cutting process. Now after
cutting one groove the indexing is done and the machine is ready
to cut the another groove. after cutting the all grooves on the
periphery of the disc now the process is done to make teethes on
both the surfaces with the help of the grinding so that each disc
should mesh all the teethes and proper joining and the alignment
can be done, and similar process is done to all the other discs, now
before assembling the all the discs an very important operation is
done to check the accuracy of all the discs in meshing, and the
operation is named as the Colour matching.

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 Colour matching It is the process to check
the complete meshing of the two joining
parts here the part on which we have to join
is colored and the mating part is put on it so
that complete transfer of color on the other
part could be done if there is not the equal
distributions of the color on the second part
then the portions are identified to be
machined so that complete and accurate
matching could be done.
Now after checking all the discs the blades
are inserted in the respective grooves and
now the shrink fitting of these discs is done
on the solid shaft which would be passing
from each disc thoroughly.
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 Shrink It is the process of joining two parts, one
part Is called male part and the other is called as
female part, the party on which we have to insert
other part is called as male part and another would
be female part.
In this process the male part is cooled say in the
liquid oxygen so that it contracts and the female
part is expanded by heating and now both the parts
are superimposed and are subjected to room
temperature conditions and after some time both
parts are tightly joined. Here in the gas turbine
rotor the shaft is the male part and the discs are
called female part.
In this way the complete rotor of the gas turbine is
prepared and the testing of the rotor as in the case
of steam turbine is carried out in the OSBT. fitting
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PART B: -ROTOR ASSEMBLY
SECTION
In this section the rotor making is done for the steam turbine HP, LP, IP. For the
any steam turbine firstly the rotor is in the form of the shaft, the procedure to
make the complete rotor is explained here in the steps:-
The rotor shaft is placed on the centre lathe machine and turning and taper
turning is done according to the provided drawings.
Then grooves cutting is done for the blades fixing on all over the length of the
rotor accordingly as per in the drawing.
Now with the help of the crane the rotor is placed on the other machine on which
rotor is just revolved to do the indexing.
Talking about one groove a extra portion is cut so that blades can be inserted in it
easily.
Then a locking blade is fixed to get lock all the blades of one stage. Here unlike
in gas turbine a single blade is fixed but in the GT each and every blade was fixed
individually.
Sealing are placed on the portion in between two stages so that these sailings
match with the same sealing made on the casing so that leaking of the fluid can
be avoided from one stage to the other stage.
After doing all this work the rotor is now send to the Bay 1 so that final inspection
and the checking in OSBT could be done and the finally rotor with proper
alignment is assembled in the casing.
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BAY 3
Contents: - Governing section, light machine shop
Section 1:- Governing section
Governing is the process of controlling the speed of the
rotor so that we can get constant frequency under the
fluctuating loads. This is done by controlling the amount of
fluid going inside the turbine, means to say if the load is
less that mean speed of the rotor would tends to increase
then we make the less steam to enter inside so that rotor
speed come to desired value. Opposite thing Is done in
case of the heavy load when the speed of the turbine is
less more steam is made to enter inside the turbine. To
control this all, at the steam enterance we use an
electronic and mechanical system which consists of oil
pumps, servo motors pipes and many indicators on the
valve mouth.
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 Section 2:- Machine shop
A. CNC machines
CNC LATHE
CNC MILLING MACHINE
CNC VERTICAL BORER
CNC SURFACE BROACHING M/C
CREEP FEED GRINDING M/C
BROACH SHARPENING M/C

B. Non CNC machines

PRECISION HEAVY DUTY LATHE

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BAY 4
Sections
1. Turbine blade manufacturing.
2. Heat treatment
Blades of turbine:-

Blades are one of the most crucial parts of a

turbine. Blades are fitted in the grooves .The
shape of the blades is of aerofoil type
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 There are two types of blades (i) Guide blades (ii) Moving blades
1. Guide blades:-These blades are remained fixed during the
motion of the runner so these are also called as fixed
blades .These blades are fitted in the grooves in the casing.
The sealing action is also done before putting the blades in
the grooves so that during working conditions the leakage of
fluid can be stopped. Guide blades are put in guide blade
carriers.
2. Moving blades:-As the name suggests these blades remain
in moving condition for the whole life cycle of a turbine. They
are arranged so that they become opposite to the direction of
the fixed blades. This arrangement will help in striking of the
fluid on more area of the moving blades and hence helps in I
Material for blades:-
For steam turbines we mainly use the chrome steel, steel with
some % of V, W etc.
For some special type of gas turbines we import blades from
other countries such as Germany, Russia etc. ncreasing the
efficiency of the turbine.

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 Importance of wrang in blade shop:-
Due to the aerofoil type of shape of the
blades it is not easy to handle the blades
when we are performing various operations
on them, so a material with low melting
point (100 deg. Cel.) is used for this purpose.
For this a die is taken, the blade is put
between the wrang and various machining
operations are performed. To take the blades
outside the die with blade, we put the die in
boiling water, wrang melts and thus blade is
taken outside.

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 Working of blades:-

The fluid coming from the boiler is highly energetic the guide blades
which are also called as fixed blades Are arranged so that they are in
oppposite direction to moving blades,it helps the maximum fluid to
strike on the moving blades and increases the efficiency of turbine.
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THANK YOU.

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