bhel hrd nts_ishant_me_titm

BHARAT HEAVY ELECTRICALS LIMITED, HARIDWAR

Presentation By:-

ISHANT GAUTAM B.TECH (M.E)ROLL N0. 1232140025TITM, MEERUT

VOCATIONAL TRAININGAt

NTS (NEW TURBINE SHOP)

BHEL, HARIDWAR(BLOCK-3)

BHEL was established in 1964. BHEL is one of the only 7 Public Sector Undertakings (PSUs) of

India clubbed under the esteemed 'Maharatna' status . On 1st February 2013, the Government of India granted Maharatna status to BHEL.

BHEL is engaged in the design, engineering, manufacture, construction, testing, commissioning and servicing of a wide range of products and services for the core sectors of the economy, viz. Power, Transmission, Industry, Transportation (Railway), Renewable Energy, Oil & Gas and defence.

BHEL has 15 manufacturing divisions, two repair units, four regional offices, eight service centers and 15 regional centers.

OVERVIEW OF BHEL

1. BHEL Bhopal (Madhya Pradesh )2. BHEL Ramachandrapuram, Hyderabad (Andhra Pradesh)3. Transformer Plant, BHEL Jhansi(Uttar Pradesh)4. High Pressure Boiler Plant and Seamless Steel Tube Plant,

Tiruchirapalli(Tamil Nadu) 5. Boiler Auxiliaries Plant, Ranipet (Tamil Nadu)6. ElectronicsDivision and Electro Porcelain

Division,Bangalore(Karnataka)7. Jagdishpur (Uttar Pradesh)8. Rudrapur (Uttrakhand)9. Industrial ValvesPlant, Goindwal (Punjab)10. BHEL Ranipur, Haridwar (Uttarakhand) 11. Bharat Heavy Plates and Vessels Limited(Vizag)

MAIN MANUFACTURING UNITS

Boiler(stream generator) Gas Generator Hydro Generator Steam turbine Gas turbine Hydro turbine Transportation Equipments Traction Machines Transformer Switchgear Oil field equipments OFE Boiler drum Water wall panel Wind mill Valve

PRODUCTS RANGE

BHEL or the Bharat Heavy Engineering Limited is one of the largest engineering and manufacturing organizations in the country and the BHEL, Haridwar is their gift to UTTARAKHAND With two large manufacturing plants. It has established a Heavy Electrical Equipment Plant or HEEP and a Central Foundry Forge Plant or CFFP in Haridwar.

The Heavy Electrical Equipment Plant in Haridwar designs and manufactures turbo generators, AC and DC motors, STEAM turbines, heat exchangers.

The Central Foundry Forge Plant in Haridwar deals with steel castings and manufacturing of steel forgings.

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

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

Situated in Ranipur near Haridwar, the Bharat Heavy Engineering Limited employs over 8,000 people.

BHEL HARIDWAR UNIT

1. BLOCK-1: Electrical Machine Shop

2. BLOCK-2: Heavy Fabrication Shop

3. BLOCK-3: Turbine Manufacturing Shop

4. BLOCK-4: CIM (Coils & Insulation Manuf.)

5. BLOCK-5: Condenser Fabrication & Forge Shop

6. BLOCK-6: Fabrication Shop & Die Shop

7. BLOCK-7: Carpentry & Heat Treatment Shop

8. BLOCK-8: Heat Exchanger Shop

HEAVY ELECTRICAL EQUIPMENT PLANT

(HEEP)

BLOCK 3 TURBINE SHOP

BAY 1 BAY 2 BAY 3

HEAVY MACHINE SHOP(HMS)

BEARING SECTION BLADE SHOP

ASSEMBLY SECTION TURNING SECTION TURNING SECTION

ASSEMBLY SECTION HEAT TREATMENT SHOP

GOVERNING SECTION

Block-3: TURBINE MANUFACTURING SHOP

A steam turbine works on the principle of conversion of High pressure & temperature steam into high Kinetic energy , thereby giving torque to a moving rotor.

STEAM TURBINE

1.High pressure turbine (H.P. Turbine)

2.Intermediate pressure turbine (I.P. Turbine) 3.Low pressure turbine (L.P. Turbine)

TYPES OF STEAM TURBINE

• High pressure and temperature fluid at the inlet of the turbine exit as lower pressure and temperature fluid.

Specification of HP Turbine(500 MW)

Main Steam Temp- 537˚C main steam pressure- 170 kg/cm2

Reheat steam temp- 537˚C Length of Rotor - 4.61m Height -2.15m Weight -86400kg

HIGH PRESSURE TURBINE (H.P. Turbine)

HIGH PRESSURE TURBINE

The blades are responsible for extracting energy from the high temperature, high pressure steam produced by the  boiler.

H.P TURBINE BLADES

Intermediate pressure turbine having more pressure then L.P turbine and lass than the high pressure turbine(H.P) . Its blade is larger than high pressure turbine.

INTERMEDIATE PRESSURE TURBINE

The size of blades of I.P steam turbine is larger than H.P steam turbine , but smaller than L.P steam turbine.

BLADE OF I.P TURBINE

LP turbine is designed to be a dual flow turbine. Steam enters the centre of the turbine from the crossover pipe and flows across the reaction blading in two opposite directions. This configuration reduces axial thrust on the turbine and allows for a smaller turbine installation.

Specification of LP Turbine(500 MW)

Main Steam Temp- 320˚C Main steam pressure- 8 kg/cm2

Reheat steam temp- 320˚C Length of Rotor - 8.71m Height -10.7mWeight-345000kg.

Low Pressure Turbine

LP TURBINE

Low Pressure Turbine

Titanium alloys offer high strength to intermediate temperatures at a density almost half that of steel and nickel-based super alloys. As a result, they have been adopted widely in the fan and compressor stages of the gas turbine for both disc and blade applications..

LP blade is larger than HP & IP. 

L.P TURBINE BLADES

HEAVY DUTY MACHINES 

SINUMERIK CNC LATHE

Swing over carriage:3500mm

Centre distance :9000mm Weight capacity:120 T Spindle power:196KW External chucking

range:250-2000mm Max spindle rpm:200 CNC system

840D:SINUMERIK

INNSE HORIZONTAL CNC MACHINE:

Boring spindle diameter:160mm

Headstock vertical travel:3000mm

Longitudinal RAM travel:700mm

Longitudinal spindle travel:1000mm

Column cross travel:10m Rotary table travel:3000mm Table load:40 T

TACCHI HEAVY DUTY CNC LATHE:

Skoda Vertical CNC lathe

Finishing machining casings including guide blade grooves are carried out in vertical position on this lathe. The machine is provided with 840-C CNC system.

CASING SHELL OR CYLINDER

ASTM A 356 Grade 1 for cast carbon steel

 Nodular Cast Iron G40 The reason is that cast

carbon steel is weld repairable(LP turbine inner casing rings,)

1-2 Cr Mo steels –low temperature steam

Cast 9 Cr 1 –Mo- V –Nb alloys

9-12-cr Martensite /ferrite steel

Casing Materials

CASING

LOWER HALF (L/H) UPPER HALF (U/H)

Various operations consist in manufacturing of blades of steam turbine.

Check the raw material(Stainless Steel / Titanium Alloy)

Blanking-by blank saw m/c MILLING- width and thickness are maintained Mill Rhomboid –Rhomboid shape is provided by

Duplex milling machine Blanking of Rhomboid shape

BLADE SHOP

Rhomboid grinding-by CH-BACH M/c

Right angle-by Horizontal milling M/C

External profiling-by Hydraulic coping m/c or CNC Coping m/c

• Internal profiling

HYDRAULIC COPING M/C or CNC COPING M/C

Template (checking for external profile)

T –ROOT profiling is done by NC M/c at various station

STATION 1- Clamping the w/p on NC m/c .

STATION 2- Rough Tapering

STATION 3- T-ROOT Cutting, Chamfering

STATION 4- Stepping

STATION 5- Smoothing o/p(final milling).

RUSSIAN DESIGN BLADE

Summer Training gives the idea of ‘general

awareness in steam turbine manufacturing’, & its process. Its provides practical idea to manufacturing several components of turbine.

CONCLUSION