About BHELBharat Heavy Electricals Limited, or BHEL, is a state owned enterprise which is an integrated power-plant equipment manufacturer and one of the oldest and largest engineering and manufacturing companies in India .It is the 12th largest power equipment manufacturer in the world. According to Forbes, in 2011 BHEL was ranked ninth most innovative company in the world. BHEL, Bhopal, was established in on 29th August, 1956, with the technical assistance of Associated Electronics(India) Ltd. which is a U.K. based company. Pt. Jawaharlal Nehru, the first Prime minister of India dedicated this plant to the nation on 6th November, 1960 BHEL, Bhopal, is situated 5 kms from the Habibganj Railway Station, which is also the nearest railway station from BHEL Bhopal. Bhopal Railway station is 7 kms and Raja Bhoj Airport is 18kms away from BHEL, Bhopal. BHEL engages in designing, engineering, manufacturing, testing, and servicing a wide range of products and services for the core sectors of economy like Power, Transmission, Industry, Transportation, Renewable Energy, Oil & Gas and Defence. It imports raw materials from other companies and processes the material by performing different type of workshop activities to get the finished part of the required dimension, which are then assembled to make different components of a Power plant like a steam turbine, heat exchangers etc. BHEL is affiliated with Siemens AG, which is a Europe based electronics and electrical engineering company. BHEL is supplied with blueprints by Siemens which BHEL uses to manufacture Steam Turbines. BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving towards excellence by adopting TQM as per EFQM / CII model of Business Excellence. Heat Exchanger Division is accredited with ASME ‘U’ Stamp. With the slogan of “Kadam kadam milana hai, grahak safal banana hai”, it is committed to the customers. BHEL, Bhopal produces Hydro, Steam, Marine & Nuclear Turbines, Heat Exchangers, Hydro & Turbo Generators, Transformers, and Switchgears, Control gears, Transportation Equipment, Capacitors, Bushings, Electrical Motors, Rectifiers, Oil Drilling Rig Equipment and Diesel Generating sets. Some Products of BHEL, Bhopal 2.1 AC Motors & Alternators BHEL is a leading AC Machines manufacturer and in the last four decades have supplied more than20000 HT & LT A.C. Machines for various applications to Indian as well as Export market. The applications include Power Plants, Nuclear Energy, Petrochemicals, Fertilizers, Refineries, Cement & Steel Industries, Irrigation Projects, Pipelines, etc. 2.2Turbines 1) Design, Manufacturing, Erection, Commissioning and Services of : 30 MW, 120 MW Steam Turbines 236 MW Nuclear Turbines. 15000 SHP Marine Turbines 210 MW Steam Turbines. 2) Supply of Spares and Repairs of above Steam Turbines. 3) R & M and Life assessment studies of BHEL & Non BHEL TG sets. 4) Repair and Supply of Spares of 210 MW and 500 MW KWU Turbines. 5) Repair and supply of Spares for Non BHEL TG Sets. Diversified Projects For IPR and ISRO: Manufacturing of various components. 2.3 Hydro generator Hydro generator is a synchronous alternator driven by a hydraulic turbine. Motor is synchronous motor to drive pump. BHEL Bhopal is a leading supplier of large, medium & small hydro generators, motors, bulb generators and related service 2.4 Heat Exchanger Different types of auxiliary heat exchangers are being manufactured at BHEL. Depending upon application these auxiliary Heat Exchangers are named as. Air Coolers (CACW) . Oil Coolers (Shell & tube type / Frame and tube type (Single tube & concentric double tube construction) / OFAF), Plug in type . Water Cooler (Shell & Tube type) . Hydrogen Cooler etc. (Frame and tube type). . Air Cooler CACA (Duct and tube type) These coolers are accessories to main equipment’s such as Generator, Turbine, and Transformer. To ensure long life of these coolers materials for different components is decided carefully considering its application and water chemistry. Constructionally these coolers are very easy to maintain. HSCBs. traction generators/alternators. Rehabilitation and by timely arranging the spare parts and other services. master controllers. Today over85% of Indian Railways. smoothing reactors. . vacuum circuit breakers. generators. There is ample scope for improving the plant availability by cutting down the shutdown period. choppers and associated control equipment. by Renovation & modernization. BHEL manufactured 500/236 MW Nuclear sets are also installed in country. The range includes traction motors. 2. The BHEL manufactured sets accounts for 65% of total installed capacity in India. sub-station equipment. transformers. chopper controllers brake and door equipment. locomotive bogies. inverters. converters.5 Transportation Equipment BHEL's involvement in the transportation sector has been marked with rapid growth.6 Renovation and Maintenance of Equipment the BHEL is the largest producer of power generating equipment including turbines. one of the largest railway networks in the world is equipped with traction equipment built by BHEL. BHEL has already supplied thermal sets up to 500 MW rating and has the technology to go up to 800 MW. exciters. boilers and auxiliaries in the country. viz. electronic controls including software based controls extending to rolling stock and other transport applications.2. Power produced by coal covers 58% of the total power produced in India. then Gas turbine (11%). coal is burned to produce heat which in turns boils water to produce steam. . In a Thermal Power Plant. Thermal power plant are preferred over other power generating methods. Solar Energy b.Overview of Steam Turbines Definition: A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating output shaft. This steam has very high pressure. which is used by the turbine to rotate the rotor which turns the generator to produce electricity. Bio-Mass d. Thermal Power Plant c. Nuclear Power Plant 2. Non-Conventional Methods a. Tidal Energy As India is a country rich in coal.There are: 1. Conventional Methods a. Wind Power c. and then Nuclear Power (3%). followed by Hydro Power (27%). Hydro Power Plant b. There are many ways to produce high pressured steam which can be used . Turbine: A turbine is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. The heat vaporizes the fluid and as the fluid changes state.Components of a Thermal Power Plant 1. 2. Condenser: Condenser is a heat exchanger which convert steam from its gaseous state to its liquid at a pressure below atmospheric pressure. . pressure increases in the boiler chamber. Boiler: A boiler is a closed vessel in which water or other fluid is heated. 3. This in turn produces electricity using the principle of electromagnetic induction.4. the shaft of the generator which is coupled with the rotor. The usual pressure provided by the pump is about120% of the pressure in the boiler. 5. Generator: An Electric Generator is a device which converts mechanical energy to electrical energy. Pump pressurizes the condensed water to the required pressure so that the water does not backflow. . also rotates. When the rotor of a steam turbine moves. Pump: The pressure in the boiler when water is boiling is very high. compressors and other shaft driven equipment. These are commonly found at refineries.500. Condensing turbines are most commonly found in electrical power plants. The steam then goes back into an intermediate pressure section of the turbine and continues its expansion. Casing or Shaft Arrangement Two-Flow Rotors 1) On the basis of steam supply and exhaust conditions These types include condensing. .000. Reheat turbines are also used almost exclusively in electrical power plants. reheat. Noncondensing. pulp and paper plants. and desalination facilities where large amounts of low pressure process steam are available. In a reheat turbine. Non-condensing or backpressure turbines are most widely used for process steam applications.75 kW (1< hp) units (rare) used as mechanical drives for pumps. The exhaust pressure is controlled by a regulating valve to suit the needs of the process steam pressure.000 kW(2. extraction and induction.Types of Steam Turbines Steam turbines are made in a variety of sizes ranging from small <0. to1. Steam Turbines are classified into 3 types: On the basis of Steam Supply and Exhaust Condition. at a pressure well below atmospheric to a condenser. district heating units. typically of a quality near 90%.000 hp) turbines used to generate electricity. These turbines exhaust steam in a partially condensed state. steam flow exits from a high pressure section of the turbine and is returned to the boiler where additional superheat is added. tandem compound and cross compound turbines. Tandem compound are used where two or more casings are directly coupled together to drive a single generator. and used for industrial process needs or sent to boiler feed water heaters to improve overall cycle efficiency. In an extracting type turbine. or left uncontrolled.Extracting type turbines are common in all applications. A cross compound turbine is typically used for many large applications. . A cross compound turbine arrangement features two or more shafts not in line driving two or more generators that often operate at different speeds. Single casing units are the most basic style where a single casing and shaft are coupled to a generator. steam is released from various stages of the turbine. Extraction flows may be controlled with a valve. 2) On the basis of Casing or shaft arrangements These arrangements include single casing. Induction turbines introduce low pressure steam at an intermediate stage to produce additional power. The loss of energy due to this higher exit velocity is commonly called the "carry over velocity" or "leaving loss". A pressure drop occurs across only the stationary blades. . with a net increase in steam velocity across the stage. or more usually. convert into shaft rotation as the steam jet changes direction. Due to this higher ratio of expansion of steam in the nozzle the steam leaves the nozzle with a very high velocity. which the rotor blades. As the steam flows through the nozzle its pressure falls from inlet pressure to the exit pressure(atmospheric pressure. the condenser vacuum).3) Impulse turbines An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets contain significant kinetic energy. The steam leaving the moving blades has a large portion of the maximum velocity of the steam when leaving the nozzle. shaped like buckets. 4) Reaction turbines In the reaction turbine. The steam then changes direction and increases its speed relative to the speed of the blades. . It leaves the stator as a jet that fills the entire circumference of the rotor. with no net change in steam velocity across the stage but with a decrease in both pressure and temperature. with steam accelerating through the stator and decelerating through the rotor. This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. reflecting the work performed in the driving of the rotor. A pressure drop occurs across both the stator and the rotor. the rotor blades themselves are arranged to form convergent nozzles. . 2. number of stages in steam turbine is decided. There will be drop in pressure of the steam across the fixed blade resulting to very high steam velocity at the exit of fixed blade 3. The high velocity steam then impinges on another row of rotating blades 4. Depending on steam condition and power output.rotating A set ofblades fixed which blades rotate and rotating the rotor.Working principle of Steam Turbine 1. The impingement high velocity steam generates driving force on mounted on the rotor of shaft these 5. Steam at high pressure & temperature is made to pass through a row of fixed blades or nozzles mounted on stationary body in Casing. . blades mounted on rotor is called stage of turbine. Bearing and bearing Pedestal 7. Coupling 8. Different types of turbines engage different type of blades. functional accuracy and trouble-free operations. design and mechanical properties to withstand the different physical conditions the blade is subjected to by the turbine. durability. Moving Blade 3. shape. There is a difference in their size. Guiding blade requires various features such as dimensional accuracy.Control and Instrumentation Guiding Blades : These blades are fixed to the casing of the turbine. so that the steam impinges the moving blades in such a way that amount of energy transfer in the form of kinetic to mechanical is maximum. They are positioned at an angle to the direction of the incoming steam.Components of a Steam Turbine Main Components: 1. Governing system 10. . Fixed/Guide blades 2. Gland Seals 6. Cylinder 4. Rotor 5. Stop and control valves 9. Depending on steam condition and power output.Guiding Blades A set of fixed blades and rotating blades mounted on rotor is called stage of turbine. they are forced to move. As the steam impinges on these blades. They are also designed especially for obtaining the maximum power transfer. Moving Blades: These are the blades which are connected to the rotor. number of stages in steam turbine is decided. which causes the rotor to rotate and produce energy in the generator. Moving blade requires Sturdy construction Corrosion resistance High efficiency Abrasion resistance . Common types of stainless steel used in LP sections include AISI types 403. However. Good fatigue strength. made from12Cr stainless steels also. High creep and fatigue strength. Good room temperature proof strength. Other important requirements of material for blades of steam turbine HP and IP Guide Blades Weld ability. Adequate rupture ductility. Good resistance to the oxidation and corrosion at the same temperature. Low Pressure Guide Blades Weld ability / Cast ability. blades used in high temperature (> 450 C) HP or IP applications may be made of austenitic stainless steels because they have better mechanical properties at high temperatures. and 630. . 410. the exact type of steel chosen for a particular LP application depends on the strength and corrosion resistance required. have also been used for LP turbine stages. especially Ti-6Al-4V. HP and IP stage blades are generally made from 12Cr martensitic stainless steels. LP blades are often.Moving Blades The material used to make the blade depends on the type of turbine it is going to be used in. 410-Cb. For instance. Since the 1960s. High quality surface finish to ensure smooth steam flow and to avoid subsequent pressure drop. but not exclusively. Adequate ductility to accommodate cumulative strain due to thermal fatigue and creep during the service life. titanium alloys. These alloys are particularly suited to LP stages for a number of reasons. fatigue strength and proof strength. HP And Movingand Blades Good resistance to oxidation and corrosion. Adequate notch rupture ductility. Good fracture and impact toughness. Good surface finish. Good room temperature. High creepIPstrength fatigue strength. Good Vibration damping capacity. LP Moving Blades Good corrosion and emission resistance. . Moderate damping capacity. High quality surface finish. Good surface finish. There are four sides to a blade: The blade can be right handed or left handed: . Nomenclature of a Cylindrical Blade: If a blade is referred to as T4 is the type of profile 25 is the rhomboid width 55 is the stagger angle of the profile Some types of cylindrical blade profiles are: T4-25-55. then it means . . so that the axial forces negate each other but the tangential forces act together. or the rotor can be designed so that the steam enters in the middle of the shaft and exits at both ends. but the axial thrust in a simple turbine is unopposed. This arrangement is common in low-pressure casings of a compound turbine. To maintain the correct rotor position and balancing. this force must be counteracted by an opposing force. This design of rotor is called two-flow or double-exhaust. The blades in each half face opposite ways (as shown). Either thrust bearings can be used for the shaft bearings.Steam Turbine Rotor: The moving steam imparts both a tangential and axial thrust on the turbine shaft. 8. HP. Various blade roots are troot. 2. fire-tree. 210MW Russian design rotors manufactured at haridwar and 110 MW Czechoslovakia design rotors manufactured at Hyderabad have shrunk fitted disc on IP and LP rotors. 2-tier Blade is used in 720MW due to Baumann exhaust. distortion. axial entry and curved axial entry. 5. Earlier all rotors has boroscopic hole at the centre due to forging technological constraint. 6. IP AND LP rotor forgings were imported earlier but now Hp and IP rotor are manufactured at CFFP Haridwar. 4. . Large Difference in temperature of various parts during starting/shutdown may cause rubbing. 7. 3. fork and pin. bend and other serious problems. BHEL Bhopal all turbine rotors are with integral disc.1. Various type of disc heads are machined to suit the corresponding blade roots. Rotors forging are machined in STM shop. Through Instrumentation and Control us: Monitor Protect Measure The working of a turbine. . The operator. by controlling the functioning of the turbine. ensures the output given by the turbine and also control other important factors like if the turbine is working in limits prescribed to be safe.Control and Instrumentation: Control and instrumentation is a very important area for proper functioning of a steam turbine. By HWR .The scope of Control and Instrumentation is Equipment functional requirement Safety requirements Customer specification requirements Matching with the hardware platform System Engineering Customer/ consultants approval H/W & S/W engineering by EDN Primary Instrumentation Engg. steam flow is controlled by simultaneous opening or closing of all control valves allowing the steam to flow to the group of nozzles located on the entire periphery. Methods of Governing: Throttle Governing In throttle controlled turbines. . Variation in load affects the performance. This can be achieved by means of governing in a steam turbine. The primary objective in the steam turbine operation is to maintain a constant speed of rotation irrespective of the varying load.Governing System: Turbine governing is the process of regulating the rotating speed of the output shaft connected to the generator so that it remains constant. so an even speed is required. In this method groups of two. three or more nozzles form a set and each set is controlled by a separate valve.Throttle Governing Throttle Governing Nozzle Governing: In nozzle controlled turbines. steam flow is controlled by sequential opening and closing of control valves allowing steam to flow to associate nozzle groups. The actuation of individual valve . Nozzle Governing .closes the corresponding set of nozzle thereby controlling the flow rate. The Hydraulic system is amplified as that control valves servomotors can be actuated. Pure Mechanical governing systems are not used for utility turbines now a day. speed transmitter is electrical speed measuring device which sends an electrical signal to electronic controller to a hydraulic system. IP and LP rotors and generators rotors are coupled together.PR. speed transmitter is centrifugal pump who’s Disch. The increase in vibration level indicates that there is some problem. It is connected to a hydraulic system either hydraulically or mechanically. During assembly of stationary and rotating parts design radial and axial clearances are achieved to ensure smooth running. Hydro-Mechanical In hydro mechanical governing system speed transmitter is mechanical centrifugal type speed governor. Hydraulic In Hydraulic governing system. 3. Each rotor is individually balanced about its own axis and has a residual unbalance. Vibration is the main criteria for the smooth running of the machine. The PR. Is proportional to square of speed. Electro-Hydraulic In Electro-Hydraulic governing system. These rotors rotate about a common axis which is axis of rotation. Oil is sent to hydraulic governor which generates a Hyd. .10 Vibrations/ Balancing/ Alignment of Steam Turbines HP. Signal proportional to valve opening/closure required.Types of Governing system Mechanical Here the speed transmitter is mechanical centrifugal type speed governor which actuates control valves through mechanical linkages. 8. 3. Losses in nozzles. due to leakage of steam through various clearances etc.1 Internal Losses The internal losses can further be classified as Losses in regulating valves. which include losses in bearings and reduction gearing. namely external and internal losses. Losses due to disc friction and windage. other loss creep in. In this group. turbine work is always accompanied by mechanical losses due to friction in linkage mechanism and bearings.Energy losses in Steam Turbines In an ideal steam turbine. as a result of friction and turbulence in steam flow. Internal losses are connected with flow of steam through blade passages and accompanied with changes in the condition of steam. The above losses have different characteristics and can be divided into two main groups. External losses are those that do not directly influences steam conditions. In actual turbine. these are mechanical losses.2 External Losses Mechanical losses . the process of expansion of steam is assumed to be isentropic and the only loss which requires attention is carry over loss. Losses in moving blades. 3. apart from carry over loss. Apart from this. Carry over losses. Losses due to axial and radial clearances.8. Losses in exhaust load. Losses due to wetness of steam. The greatest variation in the design of thermal power stations is due to the different fuel sources. and the rotor of the turbine rotates the generator shaft which in turns produces electricity. Steam is produced in the boiler by heating water and as the steam reaches a very high pressure. Some prefer to use the term energy centre because such facilities convert forms of heat energy into electricity. Thermal Power Station: A thermal power station is a power plant in which the prime mover is steam driven. the heat energy of the steam is converted into kinetic energy. Some thermal power plants also deliver heat energy for industrial purposes. Losses due to steam leakage through seals. this is known as a Rankine cycle. efforts to reduce these outputs are various and widespread. . or for desalination of water as well as delivering electrical power. As the high pressure steam hits the blades of the turbine. A large part of human CO2emissions comes from fossil fuelled thermal power plants. steam is released in the turbine. the steam is condensed in a condenser and recycled to where it was heated. for district heating. After it passes through the turbine. biomass. coal and nuclear power plants. . including virtually all solar thermal. which usually uses water. The heat is supplied externally to a closed loop. a Scottish polymath and Glasgow University professor. The Rankine cycle is the fundamental thermodynamic underpinning of the steam engine. This cycle generates about 90% of all electric power used throughout the world. It is named after William John Macquorn Rankine.Rankine Cycle: The Rankine cycle is a cycle that converts heat into work. Temperature 530 to 565 °C Supercritical Cycles .Pressure up to 250 bar .4 Steam Cycles Sub critical Cycles .IDEAL RANKINE CYCLE- 4.Pressure up to 200 bar . Increase in final feed water temperature.15 o c 4. Reduction in condenser back pressure.56 kg/cm2 Temperature =374. (Lesser Pollutants SOX.Temperature > 565 °C 4.Temperature 540 to 565 °C Ultra supercritical Cycles .7 Measures to improve Power Cycle Performance Increase in Main & Reheat steam temperature.Pressure > 250 bar . The critical pressure and temperature for water are Pressure =225.5 Definition of critical conditions “Critical” is a thermodynamic expression describing the state of a substance beyond which there is no clear distinction between the liquid and gaseous phase.6 Advantages of Supercritical cycle Steam Power plant efficiency increases with increase in steam pressure and temperature. Increase in main stream pressure. NOX & CO2) 4. . the supercritical cycle offers the advantage of ‘burn less fuel for the same output’ and lower emission. With higher cycle efficiency. Improving individual component efficiency.. Reducing the flue gas exit temperature. Double reheat. 1829 mm FACE PLATE GRIPING CAPACITY-203-1575 km 2) WOTON CNC RAM BORAR (MACHINE No.20/A/302) SPEED.2000 mm 3) BERTHIZ VERTICAL BORING AND TUNING (MACHINE No. -20/A/27) LATHE SPEED. -20/A/2088) CONTROL SYSTEM SIMENS 8-40-D COLOUMN CROSS CONTROL.4000 mm MAXIMUM TURNING DIAMETER-1600 mm ARM LENGTH.M DISTANCE FROM CENTRE-7315 mm MAXIMUM SWING OVER SPED-3048 mm HEAD STOCK FACE PLATE DIAMETER.6-16 RPM DIAMETER OF TABLE.P.6-60 RPM FEED.0.8000 mm HEAD STOCK VERTICAL TRAVEL-3500 mm RAM TRAVEL-700 mm SPINDEL TRAVEL-1000 mm TABLE SIZE-2500 X 3000 mm LONGITUDINAL TRAVEL.3700 mm . .195-20 R.Machines in Machine Shop 1) KREVHAN ROTOR ADJUSTING (MACHINE No.0. WOVER ARM. OF CUTTERS:-FACE CUTTER. PRINCIPLE:-THIS MACHINE WORKS ON HYDRAULIC’S PRINCIPLE. 4) PLANOMILING MACHINE DIFFERENT PARTS: TABLE. SLOTTED DRILL CUTEER. T-SLOT CUTEER. FRONT HEAD.-20/A/68) SPEED-2. SPINDLE.066-6 mm/round DIAMETER OF TABLE-1800 mm MAXIMUM DIAMETER TURNABLE-2900 mm . 5) BERBIZ VERTICAL BORING AND TURNING MACHINE (MACHINE No. No. SIDE HEAD. MILL CUTTER.5-125 RPM FEED-0.27. FACING CUTEER. PANNEL etc. DRILLS. PARTS MADE BY THIS MACHINE:1) STEAM TURBINE CASING 2) BUTTERFLY VALVE BODY MACHINING 3) TRUNINON SHAFT 4) TABLES 5) SPHERICAL PIECE 6) SPHERICAL SUPPORTS 7) BEARINGS 8) DOOR BODY 9) SEALING RING 10) TRUNION BLOCK THEY USE CARBIDE TIP TO CUT THE JOB AND ITS VERY COSTLY ALSO. 152 mm .914 mm VERTICAL FEED OF TOO BAR-510 mm 28.MAX. 737 DEALING SLOT-89 mm BORING CAPACITY.35 mm DISTANCE FROM CENTRE-7620 mm MAXIMUM SWING OVER-1676 mm HEAD STOCK FACE PLATE DIAMETER-152 mm FACE PLATE GRIPING CAPACITY.5-51 RPM FEED-0..HEIGHT AVALIBLE BENEATH THE ARM . -20/A/2080) SPEED.203-1270 mm LOAD.5-20 RPM FEED.80 TON 8) DRILING AND BORING MACHINE (MACHINE No. .20/A/30) SPEED-0.02-6. 3175.55-1660 mm 6) VERTICAL BORER (MACHINE No. 7) KREVAHZ LATHE MACHINE (MACHINE No.-20/A/2018) DIAMETER OF TABLE.6.2.457 mm MILIMG CUTEER.03-69mm SPINDLE DIAMETER-102 mm LENGTH ABOVE SPINDLE CENTRE.1220 mm MAXIMUM SWING.1270 mm MAXIMUM HEIGHT BENEATH CROSS SLIDE. MIN. 1524 mm MAX.9) HORIZONTAL BORING MACHINE (MACHINE No.4877 mm MAXIMUM TURNING DIAMETER. DIAMETER OF BORING.501-102.158. -20/A/2111) SPINDLE DIAMETER.80 mm 29.-20/A/2012) SPEED.5-200 RPM FEED-0.5-200 RPM HEIGHT OF CENTRE.1524 mm WIDTH OF TABLE. 10) RICHARD VERICAL BORING AND TUNING MACHINE (MACHINE No. -20/A/11) SPEED-0.4955 mm MAX. HEIGHT BETWEEN RAM TOOL-3352 mm 11) MORENDO LATHE MACHINE (MACHINE No.127 mm FACING HEAD.1.770 mm DISTANCE BETWEEN CENTRE-6000 mm SWING BED-1520 mm MAX. WEIGHT ON CENTRE-30 TON MAX. WEIGHT ON PLATE-60 TON FEATURES:12) CNC MAIN LATHE:- .48-13 RPM FEED-0.51 mm/round VERTICAL DISTANCE. 3048 mm 14) HORIZONTAL BORING MILING AND TAPING MACHINE (MACHINE No.10-410 RPM FEED-0.7924 X 2895 mm MAX. BORING CAPACITY-180 mm COLOUMNS HORIZONTAL DISPLACEMENT-7620 mm .3124 mm CROSS SLIDE MAX.10mm 2) CAPACITY 85 TON-80 TON 3) DIAMETER TURNABLE -2750 mm 4) MAX.175 5) SEMI MACHINED JOB COMES HERE 13) PLANER MACHINE TABLE WORKING SURFACE. . DRILING CAPACITY. RPM .4-500 RPM FEED.27-508 mm/round SPINDLE DISPLACEMENT-1828 mm MAX.20/A/61) SPEED.1.686 mm/round MAX.14.75 mm MAX.127 BOZE TAPER M T -7 15) ACSIWTH R G 2 HORIZONTAL BORING AND THREDING SPEED.1524 mm TABLE.3657 X 1828 SPINDLE DIAMETER. HEIGHT. WIDTH FROM ABOVE.1) CENTRE TO CENTRE DISTANCE. BORING CAPACITY. Renovation and modernization and life assessment studies of BHEL make TG sets. Shot peening facility for steam turbine blades. . LP (Low Pressure) heaters for 500MW Bhusawal TPS. Surface condenser for 500MW Bhusawal TPS.3000 mm DISPLACEMENT OF HORIZONTAL COLOUMN ON BED.0.20/A/2002 TOTAL DISPLACEMENT OF BORING SPINDLE. Turbine oil coolers for 500MW Bhusawal TPS.64-1700 mm 7. MAJOR DEVELOPMENTS IN BHEL BHOPAL. HP (High Pressure) heaters for 462 kg/cm2 for 250 Neyveli TPS.3040 mm 16) INOCENTI MILING BORING COLOUMN MACHINE No.5000 mm A) MAIN BORING AND MILING SPINDLE.SPINDLE HEADSVERTICAL DISPLACEMENT.3-5-500 RPM B) HIGH SPEED SPINDL 65-2200 RPM FEED.27600 mm TOTAL LENGTH OF BED.40800 mm VERTICAL DISPLACEMENT SPEED OF SPINDLE. . P.E Department) BHOPAL (M.T.STEAM TURBINES engineering At (S.p) .) 15/12/2013 to 4/1/2014 Prepared and submitted by Krishna pratap singh 0131me111o34 Department of mechanical engineering Jai narain college of technology Bhopal (m. Bhopal (M. 0131ME111034.) .CERTIFICATE This is to certify that the vocational training on Steam Turbine Engineering has been carried out by KRISHNA PRATAP SINGH. during the academic year 2014-15.Department) BHEL. Training Coordinator Mr.R.P.) under my guidance in partial fulfillment for the award of (BACHELOR OF TECHNOLOGY) in (MECHANICAL ENGINEERING).P.D. JAI NARAIN COLLEGE OF TECHNOLOGY at Bharat Heavy Electricals Limited (BHEL) Bhopal (M. HARIOM PIPLE (H. family & colleagues with gratitude. First of all I am thankful of Mr. I wish to acknowledge all of them. many friends.E.E.N.P) . I am wholeheartedly thankful to them for giving us there valuable time & attention & for providing us a systematic channel for completing my training in time. However.T. a special thanks to the supporting staff. which gave us an opportunity to learn and firm our concepts in our desired field of interest.L Bhopal. we wish to make special mention of the following. of B.H.L Bhopal.C. under the guideline of whom I were able to complete my training. KRISHNA PRATAP SINGH 0131ME111034 Mechanical Engineering Department J.ACKNOWLEDGEMENT My first experience of training has been successful. I am also very thankful to B. HARIOM PIPLE (HRD). BHOPAL (M.H. 11 Energy Losses 4.2 Types Of Steam Turbine 3.7 Turbine Rotor 3. Introduction of BHEL Bhopal 2.1 Components Of A Thermal Power Plant 3. Thermal Power Plant 4.3 Working Principle 3.10 Vibration and Balancing 3. Bhopal 7. Overview of Steam Turbine 3.1 Introduction 4.8 Control And Instrumentation 3.4 Steam Cycles 4.2 Rankine Cycle 4.T.M Unit BHEL.4 Main Components 3. Machines in S. Other workshops visited 5. Some products which BHEL Bhopal Manufacture 3. Major Development in BHEL Bhopal .2 foundry 6.5 Critical Conditions 4.7 Measure to improve Performance 5.9 Governing Of Steam Turbine 3.1 Hydro turbine 5.CONTENTS 1.6 Blade Profile 3.6 Advantages of Supercritical Cycle 4.5 Blade Terminology and Material 3.3 Cycles with different unit ratings 4. 1 CARBIDE TOO Carbide tool is the hardest tool available for machining process in the workshop. Multipoint cutting tool Example: Drill beat. BASED ON CUTTING EDGES OF THE TOOL Based on the number of cutting edges tools are of three types. The carbide cutting tool can be either a carbide metal cutting tip brazed on mild steel shank or a carbide metal bid bolted over a mild steel shank. The tool is single piece high speed steel having one cutting edge 2. Bhopal. It is basically used to operate on jobs manufactured from hard metals like alloy steel or stainless steel. HIGH SPEED STEEL TOOL HSS are used in metals which are relatively softer than above metals.TYPES OF TOOLS USED 1. Single point cutting tool Example: Cutting tool conventional lathe machines. 1. Note: The coolant used in the metal removal processes is the solution of the cutting oil in water either in the oil to water ratio of 1:10 or 1:20 depending on the need of the amount of coolant required. . milling cutter. 2. grinding wheel etc. 2. BASED ON METAL OF THE TOOL Three types of tools are used in the machine shop of the workshop of steam turbine department in BHEL. OTHER WORKSHOPS VISITE 1 HYDRO TURBINES DEPARTMEN Broadly. They also serve to direct the flow at design angles to the runner blades. 2 GUIDE VANES: Primary objective of the guide vanes/ stay vanes is to convert the pressure energy of the fluid into the momentum energy.The kinetic energy is converted to the rotational energy. All throughout its length it has numerous openings at regular intervals to allow water to impound on the blades of the runner. (The runners perform most efficiently at specific head and pressure) (High tensile stainless steel runners are excellent for large systems or abrasive water conditions) 4 SPIRAL CASING: Spiral casing around the runner of the turbine is also known as volute. 3 RUNNER: . These openings convert the pressure . The shaft mounted gets rotated with the runner. a hydro turbine converts the potential energy of water into the rotational energy of the turbine and eventually to electrical energy. Blades/buckets depending on need captures most of the energy from water. The main parts of a hydro turbine are: 1 PIVOT RING: its primary objective is to support the guide vane. The runner and the shaft (mounted over the runner and coupled with the shaft of the generator) rotate in the casing (pivot ring.energy into the momentum energy just before the fluid impounds the blades of the runner. the cross sectional area constantly decreases. SPHERICAL VALVE : Takes more space Expensive setup Feasible for high pressure setup. The width of the stay ring is equal to the width of the guide vanes. then top cover. 6 STAY RING: The stay ring is the parent casing which holds the pivot ring. The shaft is coupled with the shaft of the generator which also rotates with the speed of the rotor. . along the circumference. The hydro power plant also uses valves to regulate the flow of water from the penstocks. BUTTERFLY VALVE : Takes less space Used in low pressure set ups 2. 5 TOP COVER: The top cover of the turbine sits over the upper portion of the STAY RING. then guide vanes. To maintain constant flow rate of water despite many openings. all mounted in the stay ring) without any friction coming in action between them and the casing. connected with the pivot ring with the help of bolts. the guide vanes and the top cover. It also supports the guide vanes. Two types of valves are used: - 1. In this video we will go through working principle and design aspects of Pelton turbine. The rotating shaft runs a generator and produces electricit 2 FRANCIS TURBINE hen high speed water jet injected through a nozzle hits buckets of Pelton wheel. 3. This force makes the turbine rotate. The rotating shaft runs a generator and produces electricity. FRANCIS TURBINE 3. When high speed water jet injected through a nozzle hits buckets of Pelton wheel. KAPLAN TURBINE 1. it induces an impulsive force. They work efficiently when there is a huge water flow available .TYPES OF HYDROTURBINES 1. This force makes the turbine rotate. when water energy is available at high head and low flow rate. PELTON TURBINE :Pelton turbines/wheels are suitable for power extraction. it induces an impulsive force. PELTON TURBINE 2. Kaplan turbines derive motive force from pure reaction. which can cause casting defects with high melting point metals. It also cannot be used with certain basic metal because it will chemically interact with the metal forming surface defect. thus. a lower purity sand can be used (between 94 and 98% pure). low cost (therein being its greatest advantage). Finally.760 °C (3. which can lead to unsound casting. HSS + binder + accelerator + hardener Used in critical and highly finished jobs . high silica sand is used in different forms. ilica (SiO2) sand is the sand found on a beach and is also the most commonly used sand. it causes silicosis in foundry worker Depending on the job require ent. and. The fusion point of pure silica is 1. such as steels. Silica sand is the most commonly used sand because of its great abundance. Its disadvantages are high thermal expansion. For high melting point casting. a minimum of 98% pure silica sand must be used.FOUNDRY SHOP The foundry shop in BHEL. however for lower melting point metals. such as beaches and river beds. It is made by either crushing sandstone or taken from natural occurring locations. and low thermal conductivity. Bhopal uses high silica sand as its moulding sand over the conventional use of the green sand. 1 IVP (Indian vegetable product) Here no backing/ air setting sand is used. such as cast iron and nonferrous metals.200 °F). however the sands used have a lower melting point due to impurities. The only difference being that zirconium oxide is water based whereas graphite oil is alcohol based. The carbon dioxide gas is passed through the vent holes. Successive oil films are coated over the mould to obtain very high finish. The graphite oil is first applied and then burnt to remove the alcohol present in it which hardens the oil film. . Similarly zirconium oxide is used for steel jobs. Graphite oil is used for cast iron.2 Coated sand HSS + resin + hardener (accelerator added in hardener) 3 Carbon dioxide sand HSS + binder {sodium silicate (6-7%)} + moisture (seasonable) Generally 1% 8% in dry season and Zero % moisture in rainy season. which on reacting with sodium silicate forms silica gel which acts as binder in the sand. 4 Green sand HSS + binder (dextrin powder) + bentonite powder (hardener) + moisture {3-4 % (seasonable)} In order to achieve high finishing. graphite oil and zirconium oxide oil are used.