BHARAT HEAVY ELECTRICALSLIMITED, BHOPAL MAJOR TRAINING REPORT ON "FABRICATION DIVISION" UNDER THE GUIDANCE OF : SUBMITTED BY: NAME:MR. TUSHAR YADAV JANARDAN KUMAR STAFF NO: 1296132 VT-2526/25 DESIGNATION:Sr. ENGINEER MECHANICAL ENGINEERING DEPARTMENT: FGM SUBMITTED TO: VT SECTION HRDC, BHEL BHOPAL. 1 ACKNOWLEDGEMENT It’s a great pleasure to acknowledge those people who have contributed to the successful completion of my training .The successful completion of my training has been made possible through the direct and indirect cooperation of the various people towards whom I would like to express my appreciation and heartfelt gratitude. First of all I would like to thank HRDC BHEL,BHOPALfor permitting us to undergo this training. I would like to express my sincere thanks toMR. TUSHAR YADAVfor their valuable guidance& kind support . His guidance and help were instrumental in all stages of my training at BHEL. I am thankful to you sir for your precious time and knowledge imparted to me. I extend my special thanks to all the technical staff of BHEL, BHOPAL for providing me a deeper insight into the system and sharing their invaluable suggestions and support during the training period. Their wise advices and great understanding always made my complex task manageable. 2 CERTIFICATE This is to certify that Mr JANARDAN KUMARstudent of JAI NARAIN COLLEGE OF TECHNOLOGY,BHOPAL 3rd year MECHANICAL ENGINEERING branch has completed his major training of 3weeks in the duration of 03/08/2015 to 22/08/2015 from BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL in FABRICATION DIVISON under the guidance of MR. TUSHAR YADAVas under the university curriculum. GUIDED BY: MR. TUSHAR YADAV Sr. ENGINEER (FGM) 3 B.NO CONTENT PAGE NO. HYDRO TEST LABORATORY 18 8.E. MOISTURE SEPERATOR 27 12. MISCELLANEOUS FLASH TANKS.H. BLOCK 1: WATER TURBINE MANUFACTURING 11 4. TYPES OF VALVES MANUFACTURED AT BHEL 21 10. AN INTRODUCTION TO B. MOISTURE SEPERATOR RE-HEATER. MACHINES SHOP OF HYDROTURBINE SECTION 19 9.INDEX SR. KAPLAN TURBINE 15 7.L: AN OVERVIEW 7 3. RUBBER EXPANSION JOINTS. PELTON WHEEL TURBINE 11 5. FRANCIS TURBINE 13 6.L.H. MISCELLANEOUS STORAGE TANKS 28 4 .E. HEAT EXCHANGER 24 11. 1. 5 2. H.000 MW of power generation. Dec. The company has been earning profits continuously since 1971-72 and paying dividends since 1976-77. and Jan. ushering in the indigenous Heavy Electrical Equipment industry in India . Hyderabad with Czechoslovakian and Soviet Union assistance in May 1956.for Utilities. The high level of quality & reliability of its products is due to the emphasis on design.AN INTRODUCTION TO B. today. with a view to reach self sufficiency in industrial products and power equipments. Today B. engineering and manufacturing to international standards by acquiring and adapting some of the best technologies from leading companies in the world. BHARAT HEAVY ELECTRICALS LMITED was set up in Bhopal in August.H. BHELwas established more than 40 years ago.00. BHEL has: Installed equipment for over 1. This plan was setup in collaboration with M/S AEJ.E. Captive and Industrial users.L.a dream that has been more than realized with a well-recognized track record of performance. 1965. More plants were setup at Tiruchi. 5 . 1967 respectively. 1956. Its headquarter is located at New Delhi.E. U. BHEL is the largest engineering and manufacturing enterprise in India in the energy-related/infrastructure sector.L. together with technologies developed in its own R&D centres. has become the largest engineering plant employing over 45000 employees.K. Supplied over one million Valves to Power Plants and other Industries.000 kms Railway network. BHEL's vision is to become a world-class engineering enterprise. namely Power. Supplied Traction electrics and AC/DC locos to power over 12.including Transmission. Steel. Supplied over 25.000 MVA transformer capacity and other equipment operating in Transmission & Distribution network up to 400 kV (AC & DC). Transportation and Renewable Energy . Petrochemicals. BHEL's operations are organised around three business sectors. Continuous training and retraining.and Overseas Business. quality and responsiveness.25. This enables BHEL to have a strong customer orientation. 6 . The company is striving to give shape to its aspirations and fulfill the expectations of the country to become a global player. Industry . Cement plants. Refineries. Fertilizer. a positive work culture and participative style of management all these have engendered development of a committed and motivated workforce setting new benchmarks in terms of productivity. career planning. The greatest strength of BHEL is its highly skilled and committed 45.000 Motors with Drive Control System to Power projects. etc. Every employee is given an equal opportunity to develop himself and grow in his career.505 employees. to be sensitive to his needs and respond quickly to the changes in the market. Aluminum. Supplied over 2. committed to enhancing stakeholder value. 55. a dream that has been more than realized with a well-recognized track record of performance.L. Renewal energy defense etc. Power Generation and Transmission. Industry. 8 service centers . 4 Power sector regional centers.806 crore cash surplus as on 31st March 2010. The Debt Equity ratio of the Company is at 0%.H.B. Transportation. Bhopal) BHEL is the largest engineering and manufacturing enterprise in India in the energy related/infrastructure sector today. The wide network of BHEL 's.E..E.H. Debt Equity ratio and cash surplus.L: AN OVERVIEW (Bird’s Eye view of B. BHEL caters to core sector of Indian economy viz.18 regional office and a large numbers of project sites spread all over India and abroad enable the company to promptly serve its customer and provide them with suitable products. The Company’s cash surplus stood over Rs 38. BHEL was established more than 45 years ago when its first plant was set up in Bhopal ushering in the indigenous Heavy Electrical Equipment industry in India. system and services at competitive prices. 7 . 14 manufacturing divisions. The Company’s inherent financial strengths can be seen from its net worth. Telecommunication. refinery. Today BHEL supplied sets account for nearly 6473 MW or 68% of the total installed capacity of 99146 MW in company as against nil in 1969-70. POWER SECTOR: GENERATION: Power sector comprises of thermal. 8 . petrochemicals. INDUSTRY SECTOR: BHEL is a major contributor of equipment and systems to industries like cement.BHEL has already attained ISO 9000 and all the major units/divisions of BHEL have been upgraded to the latest ISO-9001: 2000 version quality standard certification for quality management. nuclear and hydro power plant business. etc. medium and large switching systems. insulator etc. capacitor. These include high voltage power and distributed transformer . TELECOMMUNICATION: BHEL also caters to the telecommunication sector by way of small. fertilizers. for economic transmission of bulk power over long distances High voltage Direct Current (HVDC) sys tems are supplied. TRANSMISSION: BHEL also provides a wide range of transmission products and systems of upto 400 KV class. All the major units/divisions of BHEL have been awarded ISO-14001 certification for environmental management systems and OHSAS-18001 certification for occupational health and safety management systems. TRANSPORTATION: Most of the trains operated by the India Railways including Metro in Kolkata are equipped with BHEL’s traction control equipment. lighting and heating systems. NATIONAL CUSTOMERS OF BHEL: PUNJAB STATE ELECTRICITY BOARD(PSEB) UTTAR PRADESH STATE ELECTRICITY BOARD(UPSEB) NATIONAL THERMAL POWER CORPORATION(NTPC) APPOLO TYRES BAKCO SAIL BIRLA TYRES AND BIRLA CEMENT GRASIM INDUSTRIES IOC ESSAR OIL ONGC NATIONAL CUSTOMERS OF BHEL(CONTD.RENEWABLE ENERGY: Technologies that can be offered by BHEL for its exploiting non-conventional and renewable sources of energy include: wind-electric generator.): LARSEN AND TURBO JK CEMENT 9 . INTERNATIONAL OPERATIONS: BHEL has over the years. established its reference in over 60 countries worldwide. ranging from the USA to New Zealand in the far east. solar power based water pumps. the institute has acquired proficiency in imparting training to professionals in the field of Strategic management. BHEL's investment in R&D is amongst the largest in the corporate sector in India. TECHNOLOGICAL UPGRADATION AND RESEARCH & DEVELOPMENT: To remain competitive and meet customers' expectations. SINGAPORE BIEJI PROJECT. BHEL invested Rs. Values Laboratory.10. BHEL's commitment to advancement of technology is reflected in its involvement in the development of futuristic technologies like fuel cells and superconducting generators. 10 . During the year 2010-11. IRAQ LMZ. BHEL lays great emphasis on the continuous upgradation of products and related technologies. and development of new products.21% higher than the previous year.050 Million on R&D efforts. Research. HUMAN RESOURCE DEVELOPMENT: BHEL's Human Resource Development Institute (HRDI) has skills in the areas of Management training. Project management. etc. Contract management. INTERNATIONAL CUSTOMERS OF BHEL: M/S ESBARA CORPORATION. etc. RUSSIA. GERMANY SIEMENS. Activity based costing. Over the years. USA SIMMCO INTERNATIONAL SIEMENS. Marketing management. JAPAN M/S ZEECO IN CORPORATION. Consultancy. KIRLOSKAR SIEMENS. Emotional Intelligence. Organizational Development and Manpower Planning. Performance management. Human Resource management. BLOCK 1: WATER TURBINE MANUFACTURING A hydraulic turbine is a machine. It uses the potential and kinetic energy of water and sets the rotor in motion by dynamic action of water flowing from a high level or head. Leadership Development. BHEL is a leading engineering enterprise which supplies all types of equipment for hydro power generation. And a leading turbine manufacturer offering a wide range of Hydro Turbine. which converts hydraulic energy into mechanical energy. PELTON WHEEL TURBINE Pelton turbines are impulse turbines. Turbine and Station Auxiliary systems.Human-process Laboratory. Following types of hydro turbines are designed and manufactured in BHEL Bhopal: 1. Governors. 3. Trainer Development. Team Building. This rotary motion is then utilized by turbo generator to produce electricity in Hydro Power Plants. Kaplan Turbine. Valves. Francis Turbine. 2. These are generally used for sites having 11 . Pelton Wheel Turbine. Balance of plants for Hydro Power Station and related Services. and other functional andbehavioral areas of management. Features: High head and low discharge. Double jet horizontal .5 to The about turbine quantity having in the 51RPM. d) Casing. Four jet vertical. Supplied in following configurations. Single jet horizontal. c) Runner and Buckets. b) Jet Deflector. 12 .high head and relatively low discharge. Control mechanism with nozzle. Deflector. Following are the parts of Pelton wheel turbine: a) Nozzle and Flow Regulating mechanism. head is high 300 m and the handles low of water specific speed range 8. Bearing pad and cover . Francis turbines are the most common water turbine in use today. Medium size and larger Francis turbines are most often arranged with a vertical shaft. 10. 3. Therefore. Because water and most liquids are nearly incompressible. 2. almost all of the available energy is extracted in the first stage of the hydraulic turbine. Regulating ring. unlike gas turbines that operate with compressible fluid. Francis in Lowell. The buckets of a Pelton wheel are designed so as to split the flow in half. Draft tube. 8. 4. 13 . and turn the flow nearly 180° around (with respect to a frame of reference moving with the bucket). It is an inward-flow reaction turbine that combines radial and axial flow concepts. 5. 6. FRANCIS TURBINE The Francis turbine is a type of water turbine that was developed by James B. Turbine shaft . Stay vane and Scroll case.e) Braking jet. Massachusetts. 9. Turbine cover. 7. Runner and runner cone. Servomotor. Guide vane. Main Components: 1. Link. Pelton wheels have only one turbine stage. radius of the runner. Guide vanes direct the water tangentially to the turbine wheel. There is a draft tube attached to the central exit of the runner. The inlet is spiral shaped. which means that the working fluid changes pressure as it moves through the turbine. giving up its energy. A casement is needed to contain the water flow. curvature of channel. The runner is encircled by a ring of stationary channels called as guide vanes. Theory of operation: The Francis turbine is a reaction turbine. the plate with channels is collectively called as the runner. The turbine is located between the high-pressure water source and the low-pressure water exit. This circular plate has curved channels on it. known as a runner. angle of the vanes and the size of the turbine as a whole depend on the available head and type of application altogether. Guide vanes are housed in a spiral casing called as a volute.Design of Francis Turbine: Francis Turbine has a circular plate fixed to the rotating shaft perpendicular to its surface and passing through its centre. The exit of the Francis turbine is at the centre of the runner plate. This radial flow acts on the runner 14 . usually at the base of a dam. The design parameters such as. a runner servomotor. The guide vanes (or wicket gate) may be adjusted to allow efficient turbine operation for a range of water flow conditions.and the blade operating rod inside the shaft etc. the ball spins faster due to the conservation of angular momentum. further acting on the runner. imagine swinging a ball on a string around a circle. causing the runner to spin. This property. 15 . The runner blade operating mechanismconsists of a pressure oil head. its spinning radius decreases. The turbine's exit tube is shaped to help decelerate the water flow and recover the pressure. and there is little drop in efficiency due to head variation or load. leaving with no swirl and very little kinetic or potential energy. For an analogy.As a result of recent advances. As the water moves through the runner. if the string is pulled short. helps Francis and other inward-flow turbines harness water energy efficiently. water acts on cup-shaped runner features. in addition to the water pressure. KAPLAN TURBINE Kaplan turbine is most appropriate for operation witha low head and a large amount of discharge. the range of KaplanTurbine applications has been greatly improved. the constructionof Kaplan turbine becomes naturally a bitcomplicated.vanes. whichfavours numerous undeveloped hydro sourcespreviously discarded for economic or environmentalreasons.As having adjustable runner blades. Owingto adjustable runner blades it offers the significantadvantage to give high efficiency even in the range ofpartial load. At the exit. Draft tube. Turbine bearing. Co-operation of regulating the runner blades and guide vanes. 4. 16 . 8. Covers. 10. 2. 9. 11. Scroll casing and stay ring. 7. 5. Runner. Runner blade servo motor. 3. 6.Runner chamber.Main components: The Kaplan turbines have the following main components:1. Guide apparatus. Turbine shaft. 12.Shaft sleeve and seal box. Regulating mechanism of the runner blades. Unlike the Francis Turbine which has guide vanes at the periphery of the turbine rotor (called as runner in the case of Francis Turbine). The shape of the passage is such that the flow which enters the passage in the radial direction is forced to flow in axial direction. there is a passage between the guide vanes and the rotor of the Kaplan Turbine. Kaplan Turbine also has a ring of fixed guide vanes at the inlet to the turbine.Design Of Kaplan Turbine: To generate substantial amount of power from small heads of water using Kaplan Turbine it is necessary to have large flow rates through the turbine. Similar to the Francis Turbine. The rotor of the Kaplan Turbine is similar to the propeller of a ship. The rotor blades are attached to the central shaft of the turbine. Except the alignment of the blades the construction of the Kaplan Turbine is very much similar to that of the Francis Turbine. The overall path of flow of water through the Kaplan Turbine is from radial at the entrance to axial at the exit. Kaplan Turbine is designed to accommodate the required large flow rates. 17 . The blades are connected to the shaft with moveable joints such that the blades can be swiveled according to the flow rate and water head available. The whole assembly is covered with spiral casing. 2. Their mechanism is installed inside the runner hub. the link crosshead and so on. Electric-hydraulic control system provides automatic operating and closing of the shut-off valve during normal operation and shut off valve closing in case of emergency. emergency and maintenance shut-off device. The special packings are installed between the runner hub and blade stem to prevent both water intrusion from the outside of the runner hub and leakage of lubricant oil to the outside. For heads ranging from 45 to 230 m – butterfly valves. containing the runner blade and stem. HYDRO TEST LABORATORY The hydro model test laboratory is equipped with sophisticated universal test 18 . A high quality lubricating oil is filled inside the runner hub to lubricate the mechanism interior. Outside the assembly there is a shut off valve which is discussed below. For heads ranging from 170 m to 800 m – spherical valves.The shut off valves are mounted on the penstock upstream of the spiral case and serve as an operating. Shaft-off valves of two types are used: 1.Assembly Of Kaplan Turbine: The runner blades are operated to smoothly adjust their blade angles by a link mechanism. The oil for operation of the control system and actuating mechanisms is fed from the separate or from the turbine oil pressure system. Head. Constant Efficiency curve. 3. thyristor drive and control.rigs. It may be noted that the pressure head in the testing lab is generated by using the pumps. CNC machines for manufacture of hydro turbine scale models. ensuring high accuracy of measurement as per international standards. Richard’s drill machine. automatic data acquisition and analysis system. The laboratory also conducts field efficiency tests at hydro power houses to confirm efficiency guarantees of hydro turbines. 6. The laboratory has modern facilities as soft wares for computerized analysis of fluid dynamics. 2.Tests are done on the models designed to satisfy customer needs such as efficiency. c. b. 4. Main characteristic curve or constant head curve. Axial & Radial thrust test. Index test: plot of Discharge vs. power developed etc. MACHINES SHOP OF HYDROTURBINE SECTION BHEL WATER TURBINE MANURACTURING DIVISION IS EQUIPPED WITH FOLLOWOING MACHINES: HEAVY MACHINE SHOP Vertical planer machine. This testing laboratory has in situ calibration set up for all measuring equipments. 19 . Cavitation Test: Cavitation is defined as the phenomenon of formation of vapour bubbles of a flowing liquid in a region where the pressure of liquid falls below its vapour pressure and the sudden collapsing of these bubbles in a region of higher pressure. Following Are Some Tests Conducted: 1. 5. Guide vane torque Estimation. thus a variety of heads can be developed. Operating characteristics curves at constant speed. For cavitation negative or suction head is also generated using this method. Heavy vertical plano milling machine. Run away test: speed is determined for zero efficiency. Performance Test : a. Bench lathe (small size 5 set). CNC operated vertical boring machine. Horizontal milling machine. CNC lathe (heavy machine). Horizontal floor boring machine. Radial drill machine (3set). Vertical turret lathe. Here specifications of some of the machines are given below: a) Horizontal table borer Spindle diameter – 152 mm Revolving table size – 2286*2286 mm^2 Sliding table size – 3657*1981 mm^2 Max face diameter – 1524mm b) Horizontal floor boring machine Spindle diameter – 152 mm Max tower of column – 1658 mm Vertical tower of slide – 2438 mm Spindle tower slide – 1219 mm c) Slotting machine Max stroke – 530 m Face to face width – 1040mm d) Cravens bros vertical boring machine Table diameter -6705 mm Max job diameter -7696 mm Max load capacity – 90 ton Distance between uprights – 7696 mm Down feed below cross slide – 4267 mm Max height below holder -3969 mm 20 . Vertical boring machine (3set). Slotting machine. Portable drill machine(3 set). PICTURE SHOWS THE BOARING OPERATION ON FRANCIS RUNNER TYPES OF VALVES MANUFACTURED AT BHEL BUTTERFLY VALVE 21 . features a slight offset in the way the disc is positioned. the disc is turned so that it completely blocks off the passageway. Unlike a ball valve.Large butterfly valve A butterfly valve is a valve which can be used for isolating or regulating flow. the disc is rotated a quarter turn so that it allows an almost unrestricted passage of the fluid. 22 . When the valve is fully open. meaning less support is required. When the valve is closed. The disc is positioned in the center of the pipe. A butterfly valve is from a family of valves called quarter-turn valves. the disc is always present within the flow. The resilient butterfly valve. therefore a pressure drop is always induced in the flow. The "butterfly" is a metal disc mounted on a rod. The closing mechanism takes the form of a disk. Butterfly valves are generally favored because they are lower in cost to other valve designs as well as being lighter in weight. There are different kinds of butterfly valves. The high performance butterfly valve. Operation is similar to that of a ball valve. Rotating the actuator turns the disc either parallel or perpendicular to the flow. The valve may also be opened incrementally to throttle flow. regardless of valve position. which allows for quick shut off. which uses the flexibility of rubber. The valve best suited for highpressure systems is the triple offset butterfly valve. used in slightly higher-pressure systems. which makes use of a metal seat and is therefore able to withstand a greater amount of pressure. has the lowest pressure rating. each adapted for different pressures and different usage. which increases the valve's sealing ability and decreases its tendency to wear. passing through the disc is a rod connected to an actuator on the outside of the valve. shutting off the flow. butterfly valves are used on firefighting apparatus and typically are used on larger lines. through the middle 23 . It is a very well-known and well used design. The sphere has a hole. or port. The valve is similar in operation to a ball valve. used to make a fluid start or stop flowing through a section of pipe. Rotating the handle turns the plate either parallel or perpendicular to the flow of water. including eccentric and high-performance valves. 1) Body 2) Sea3) Disc (ball) 4) Handle (Lever) 5) Stem A ball valve is a valve with a spherical disc. These are normally a type of valve that uses a flat plate to control the flow of water.STRUCTURE: Butterfly valves are valves with a circular body and a rotary motion disk closure member which is pivotally supported by its stem. BALL VALVE Cut-away view of a ball-valve mechanismCutaway view of a simple manual ball valve. A butterfly valve is also a type of flow control device. As well as this. A butterfly valve can appear in various styles. such as front and rear suction ports and tank to pump lines. the part of the valve which controls the flow through it. plastic or metal with a ceramic center. the hole is perpendicular to the ends of the valve. Ball valves are used extensively in industrial applications because they are very versatile. They are therefore an excellent choice for shutoff applications (and are often preferred to globe valves and gate valves for this purpose). The handle or lever will be in line with the port position letting you "see" the valve's position.so that when the port is in line with both ends of the valve.5 cm to 30 cm. The ball valve. Sizes typically range from 0. The body of ball valves may be made of metal. They do not offer the fine control that may be necessary in throttling applications but are sometimes used for this purpose. and flow is blocked. 24 . They are easy to repair and operate. supporting pressures up to 1000 bars and temperatures up to 200°C. along with the butterfly valve and plug valve. When the valve is closed. flow will occur. A ball-check valve is a type of check valve with a ball without a hole for a disc. are part of the family of quarter turn valves. Ball valves are durable and usually work to achieve perfect shutoff even after years of disuse. The ball is often chrome plated to make it more durable. and is not covered in this article. These coolers are accessories to main equipment’s such as Generator. hence special attention is given to make these coolers compact in design and for trouble free service. Water Water Cooler (Shell & Tube type). took place in year 1970) and started its production from year 1971 onwards. RELIANCE. Perception is collected through customer surveys. Plug in type. Product technology is continuously upgraded through in house development projects/ or Technical Collaboration. etc. new collaboration agreement with M/s BALCKE DURR. Miscellaneous storage tanks and Butterfly valves added in subsequent years. Air Cooler CACA ( Duct and tube type). BHEL-Bhopal Thermal group products manufactured and supplied all over India to different State Electricity Boards and exported to countries like LIBYA. Subsequently. IOCL. major customers of thermal equipments are State Electricity Boards and NTPC. OMAN etc. Azerbaizan. 4 & KAIGA 1. Auxiliary Heat Exchangers: Different types of auxiliary heat exchangers are being manufactured at BHEL. Flash Tanks. FEDO. Malaysia.K.Germany for Moisture Separator ReHeater (MSR) took place in 1987. ONGC. Hydrogen Cooler etc. etc. 2 and 500 MW TAPP 3&4 Nuclear plants. Transformer . Thermal group products are Technology intensive and therefore Technology development is of strategic importance. Oil Coolers (Shell & tube type / Frame and tube type (Single tube & Concentric double tube construction) / OFAF). GAIL. Turbine. All the Thermal products are tailor made and customer specific product. Depending upon application these auxiliary Heat Exchangers are named as Air Coolers (CACW).HEAT EXCHANGER Thermal group of BHEL-Bhopal was formulated in year 1968 (Initial collaboration with M/s AEI -U. Production of some of the other products like Rubber Expansion Joints. Bangladesh. MSR to this new design were manufactured and supplied for 236 MW RAPP 3. and Customer requirements are continuously captured through pre-tender and post tender discussions. (Frame and tube type). 25 . Motors. contract review etc. Similarly Industrial Heat Exchangers have been supplied to IFFCO. In Generators and Air Coolers . Feed Water Heaters: BHEL is manufacturing feed water heaters for power stations of Unit Rating up-to 250 MW Thermal Power Project since more than last 25 years. Oil coolers. Motors and Generators. material selection becomes an important criteria. etc. etc. Since different types of chemicals is involved in Industrial Heat Exchangers. end closing. The main components of shell and tube type heat exchangers are tube nest assembly. In turbine and oil coolers . These coolers play an important role in the smooth functioning of the main equipments. they are used to cool bearing oil or the oil which in turn cools the rotating parts. Water-Water coolers and Hydrogen Coolers act as accessories to Transformers. In general Heat Exchangers used are of shell and tube type construction. 26 . Industrial Heat Exchangers: Industrial Heat Exchangers. Transformer Coolers are used to cool transformer oil by air or water. BHEL is manufacturing different types of shell and tube type heat exchangers for Industries like Refineries . as the name implies are used in industries dealing in various types of chemicals. shell assembly and types of enclosure i. At present feed heaters with stainless steel tube materials are being used for longer life expectancy. Similarly. turbines. Petrochemicals and Fertilizers.Technical Information/Application: Air coolers.e. they are used to cool the generator air which is a closed circuit air of maintained humidity and which in turn cools winding of the stator. Feed water heaters (both High pressure and Low pressure) are used in feed heating system of the regeneration cycle by heating feed water by steam extracted from suitable stages of the turbine. Technical Information/Application: The high pressure & Low pressure feed water heaters are employed to increase the overall efficiency of the regenerative cycle by heating the feed water by the steam extracted from suitable stages of the turbine. The feed water passes through the 'U' tubes and the steam/drain (condensed steam) passed over the tubes. SHOWS A HP WATER HEATER 27 . FIG. Both Horizontal and vertical type of heaters are manufactured with the highest standard of engineering to provide reliability in operation. These heaters are located in feed water heating cycle and feed water going to boilers is heated with steam extracted from different stages of turbine resulting in saving of energy and increased efficiency. The superheated steam contributes a net electric production gain and promotes extended turbine blade life. Moisture separator reheater (MSR) vessels are installed between the high pressure (HP) and low pressure (LP) steam turbines at a nuclear power plant.P Turbine steam becomes wet and water content is quite high in the order of 15% to 20%. After expansion in H. Steam enters these carefully arranged fine separators through coarse separator and dry steam is separated through steam outlet at top. Devices such as vortex 28 . Fig: Moisture Separator Re-heater MOISTURE SEPARATOR (MS) The quantity of water formed due to expansion of steam in the steam Turbine is considerably high in Nuclear Power plant and particularly in lower rating plants where steam entering H. while separating the high energy phases and exchanging heat. Removal of moisture becomes essential in these Turbines before further processing to increase efficiency and to avoid corrosion and erosion damages to turbine components. To separate the moisture content of this wet steam .MOISTURE SEPARATOR RE-HEATER (MSR) In Nuclear Turbines the Moisture separator re-heater is a thermo-hydraulic junction where two-phase (steam/ water) flows interact.P Turbine is of low pressure and temperature.Moisture separator is employed. These devices are utilized to remove water condensed from the process steam to maximize thermal efficiency of the LP turbine and minimize erosion/corrosion of steam loop piping. drain is collected through the connection at the bottom. This separator works on the principal of Loss of Kinetic energy and employs fine separators. Potable water tank. DMCW tanks.breaker. Pressure Balance type and Compensating type. For cooling water pump applications Ordinary type or Conventional type RE joints are used. MISCELLANEOUS FLASH TANKS Flash tanks are cylindrical tanks having end enclosures as flat heads or dished ends and are used in Feed heating cycle to allow drains of different temperatures and Pressures to "Flash " and mix to form a common stabilized drain and vent for feeding in Condenser. These individual drains. MISCELLANEOUS STORAGE TANKS Misc. Condensate surge tank. Service water tank etc. Clean oil tank and Oil unloading vessel. if allowed to enter the condenser directly will cause flashing inside Condenser leading to thermal imbalance which may cause damage to tubes and their internals. These Tanks always remain under high vacuum condition during operation. Turbines etc. level controller and water level gauges are suitably mounted for smooth operations and monitoring. Equipment cooling water tank. The designing of Flash tanks require utmost care that must be taken into account while calculating geometry of the tanks and special type of nozzle connections. There are two types of RE joints for Condenser CW pipe line applications i.e. 29 . are not affected by the thermal expansion. These tanks have adequate thickness based on design conditions . RUBBER EXPANSION JOINTS Rubber Expansion Joints (REJ) consists of Bare Rubber Bellows and are employed in cooling water pipe line of Condensers as well as pumps to absorb differential thermal expansion/movements so that the equipments such as Condenser . Tanks are important part of a TG or Auxiliary plants and may include different oil tanks such as Dirty oil tanks. These tanks are used for storage of different fluids and thus are required in s 30 . Thank you 31 . pecific capacity depending on volume of the fluid to be handled. 32 .