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REPORT OF INDUSTRIAL TRAINING IN BHARAT HEAVY ELECTRICALS LIMITED,HARIDWAR FOR B.TECH.

FINAL YEAR

SUBMITTED TO: Mr. N.K. BATRA HOD ME.

SUBMITTED BY: DEVASHISH PAUL B.TECH. ME(C3) 11082348

ACKNOWLEDGEMENT An engineer with only theoretical knowledge is not a complete engineer. Practical knowledge is very important to develop and apply engineering skills. It gives me a great pleasure to have an opportunity to acknowledge and to express gratitude to those who were associated with me during my training at BHEL. Special thanks to Mr. S. HALDHAR for providing me with an opportunity to undergo training under his able guidance. I am very great full to our training and placement officer Mr. LATHER for his support. I express my sincere thanks and gratitude to BHEL authorities for allowing me to undergo the training in this prestigious organization. I will always remain indebted to them for their constant interest and excellent guidance in my training work, moreover for providing me with an opportunity to work and gain experience. DEVASHISH PAUL

PREFACE

Training is an investment and hence should be able to get due returns in terms of better quality of workmen and Engineering for future. BHEL today is one of the major turbine producer industry, giving their best performing machines to their customers. As concerned with my Industrial training it is of my best opportunity during my Engineering to learn many things about turbine industry During my training I learn many things that would pay to me in my near future. I pay thanks to the training faculty of our college and to staff and operators of BHEL for their co-operation during my Industrial Training. DEVASHISH PAUL

CONTENTS Vision , mission ,values Overview of BHEL Bhel Haridwar Steam turbine operation Block 3 Steam turbine mfg. Mfg. process Blade shop Osbt Assembly of turbine Blade operations Overall assembly Molykote lubricant Specification of machines Conclusion pg 4 pg 6 pg 11 pg 12 pg 14 pg 15 pg 17 pg 18 pg 20 pg 21 pg 22 pg 23 pg 24 pg 26 pg 30

CORPORATE VISION, MISSION AND VALUES Vision A world class engineering enterprise committed to enhancing stakeholder value.

Mission TO be an Indian Multinational Engineering Enterprise providing total business solutions through quality products, systems and services in the field of energy, infrastructure, industry, transportation and other potential areas.

Values 1)Zeal to excel and Zest for change 2)Integrity and fairness in all matters. 3)Respect for dignity and potential of individuals. 4)Strict adherence to commitments. 5)Ensure speed of response. 6)Faster learning, creativity and team work. 7)Loyalty and pride in the company

Overview of B.H.E.L. Bharat Heavy Electricals Limited (B.H.E.L.) is the largest engineering and manufacturing enterprise in India. BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense and many more. BHEL has its setup spread all over India namely New Delhi,Gurgaon,Hardwar, Rudrapur, Jhansi, Bhopal, Hyderabad, Jagdishpur, Tiruchirapalli, Banglore and many more. BHEL business operations cater to core sectors of Indian Economy like. Power Industry Transportation Transmission Defenses etc. The greatest strength of BHEL is its highly skilled and committed 42,600 employees. Every employee is given an equal opportunity to develop himself and grow in his career. Continuous training and retraining, career planning, 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, quality and responsiveness.

POWER SECTOR As part of Indias largest Solar Power-based Island Electrification Project in India, Bharat Heavy Electricals Limited (BHEL) has successfully commissioned two Grid-Interactive Solar Power Plants of 100 KW each in Lakshadweep. With this, the company has commissioned a total of eleven Solar Power Plants in the Lakshadweep islands, adding over 1 MW of Solar Power to the power generating capacity of the coral islands in the Arabian Sea. BHEL has proven turnkey capabilities for executing power projects from concept to commissioning and manufactures boilers, thermal turbine generator sets and auxiliaries up to 500MW. It possesses the technology and capability to procure thermal power generation up to 1000MW. Co- generation and combined cycle plants have also been introduced. For the efficient use of high ash content coal BHEL supplies circulating fluidized boiler. BHEL manufacturers 235MW nuclear sets and has also commenced production of 500MW nuclear turbine generator sets.

POWER TRANSMISSION AND DISTRIBUTION (T&D) --BHEL offer wide-ranging products and systems for T & D applications Products manufactured include power transformers, instrument transformers, dry type transformers, series and shunt reactor, capacitor tanks, vacuum and SF circuit breakers gas insulated switch gears and insulators. A strong engineering base enables the Company to undertake turnkey delivery of electric substances up to 400 kV level series compensation systems (for increasing power transfercapacity of transmission lines and improving system stability and voltage regulation), shunt compensation systems (for power factor and voltage improvement) and HVDC systems (for economic transfer of bulk power). BHEL has indigenously developed the state-of-the-art

controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV Facts (Flexible AC Transmission System) project under execution.

INDUSTRY SECTOR BHEL is a major contributor of equipment and system to important industries like Cement Petrochemicals Fertilizers Steel papers Refineries Mining and telecommunication BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV FACTS (Flexible AC Transmission System) projects is under execution. The range of system and equipment supplied includes:Captive power plants High speed industrial drive turbines Industrial boilers and auxiliaries Waste heat recovery boilers Gas turbine pump, valves, seamless steel tubes Heat exchangers Process control etc. The Company is a major producer of large-size thruster devices. It also supplies digital distributed control systems for process industries, and control & instrumentation systems for power plant and industrial applications. BHEL is the only company in India with the capability to make simulators for power plants, defense

and other applications.The Company has commenced manufacture of large desalination plants to help augment the supply of drinking water to people.

TRANSPORTATION

BHEL is involved in the development design, engineering, marketing, production, installation, and maintenance and aftersales service of Rolling Stock and traction propulsion systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting duly applications. BHEL is also producing rolling stock for special applications viz., overhead equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use, BHEL manufactures traction propulsion systems for other rolling stock producers of electric locomotives, dieselelectric locomotives, electrical multiple units and metro cars. The electric and diesel traction equipment on India Railways are largely powered by electrical propulsion systems produced by BHEL. The company also undertakes retooling and overhauling of rolling stock in the area of urban transportation systems. BHEL is geared up to turnkey execution of electric trolley bus systems, light rail systems etc. BHEL is also diversifying in the area of port handing equipment and pipelines transportation systems.

Bharat Heavy Electricals Limited(B.H.E.L.),


Haridwar has two manufacturing plants:Heavy Electrical Equipment Plant(HEEP) Central Foundry Forge Plant(CFFP) H.E.E.P. Heavy Electrical Equipment Plant (HEEP) located in Hardwar is one of the major manufacturing plants of BHEL. The core business of HEEP includes design and manufacturing of large steam and gas turbines, turbo generators, hydro turbines and generators, large AC/DC motors and so on.

The various blocks in HEEP are as follows: Block-1: Turbo generator Shop Block-2: Fabrication Shop Block-3: Turbine Shop Block-4: Insulation Block Block-5: Forging Shop Block-6: Stamping Shop Block-7: Packing and Wood Working Shop Block-8: Condenser and Piping Shop New Blade Shop

BHEL-HARIDWAR

As a member of the prestigious 'BHEL family', BHEL-Haridwar has earned a reputation as one of its most important manufacturing units, contributing its lion's share in BHEL Corporation's overall business operations. The Haridwar unit was set up in 1963 and started its operations with manufacture of Turbo-generator sets and auxiliaries for 60 and 110 MW thermal utility sets. Over the years it has increased its capacity range and diversified its operations to many other areas. Today, a wide range of products are manufactured in this unit. Major products of this unit's manufacture include the following.

And many more.

Steam Turbines

Operation The expansion of steam through numerous stages in the turbine causes the turbine rotor to rotate. Steam expands through impulse stage or reaction stage. which known as the nozzle and rotor or moving blades rized by the that most or all enthalpy and hence pressure drop occurs in the nozzle. symmetrical and have entrance and exit angles around 20o. They are short and have constant cross sections At BHEL-Haridwar, compounded turbines are made as they are the most used by plants

available. eed. It will be higher as the enthalpy drop is higher. needs of bulky reduction gear turbine or pressure compounded turbine.

The Manufacture and Parts Casing The typical casing for an turbine consists of a cast high-pressure steam chest,an intermediate barrel section, and a separate exhaust casing. The barrel section is generally integral with the steam chest so that the vertical bolting joint is at one of the latter stages where internal pressures are very much reduced. The steam end, exhaust casing, nozzle ring, reversing blades and diaphragms are all split on the horizontal center line which allows for easy removal of the upper half of the turbine for internal inspection. The diaphragms are machined on the outside diameter and assembled into grooves accurately machined in the casing. Cap screws, secured by locking, fasten the nozzle ring to the steam chest, while the diaphragm halves are locked in position by stops located at the horizontal split in the casing. Steam chest passages, nozzle block partitions and the valve opening sequence are all carefully designed to ensure even and rapid heating of the casing after steam is first admitted to the turbine. The high-pressure end of the turbine is supported by the steam end bearing housing which is flexibly mounted to allow for axial expansion caused by temperature changes. The exhaust casing is centerline supported on pedestals that maintain perfect unit alignment while permitting lateral expansion. Covers on both the steam end and exhaust end bearing housings and seal housings may be lifted independently of the main casing to provide ready access to such items as the bearings, control components and seals. Rotors Rotors are precisely machined from solid alloy steel forgings. An integrally forged rotor provides increased reliability particularly for high speed applications. The complete rotor assembly is dynamically balanced at operating speed and overspeed tested in a vacuum bunker to ensure safety in operation. High speed balancing can also reduce residual stresses and the effects of blade seating.

Blades Blades are milled from stainless steel stock purchased within strict specifications for proper strength, damping and corrosion resistant properties. Disk profiles are designed to minimize centrifugal stresses, thermal gradient and blade loading at the disk rims. The blades have various shapes to achieve maximum performance and withstand any mechanical stresses.

TURBINE AND BLADE SHOP (BLOCK-3) GENERAL

1)Block 3 manufactures steam ,hydro and gas turbines and turbines blades. Special toolings for all products are also manufactured in the tool room located in the same block. Equipment layout plan is as per drawing, appended in section three.

2)the block consists of four bays namely bay 1 and 2 of size 400*36 and bay 3 and 4 are 400* 24. The block is equipped with facilties of crains ,compressed air overspeed balancing tunnel, rotors, indicating stand for steam turbine. Separate stand for testing of governing assemblies of steam and hydro turbines.

3) All the parts are conserved , painted and packed before dispatch.

STEAM TURBINES
The facilities and parts manufactured in the various sections of Steam Turbine manufacture are as follows: (a) Turbine casing Machining Section It is equipped with large size Planer, Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines etc. Fabrication work like casings, Pedestals etc. are received from Fabrication Block-II. (b) Rotor Machining Section It is equipped with large size machining tools like Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree Groove Milling Machine etc. Some rotor forgings are imported from Russia and Germany and some are indigenously manufactured at CFFP, BHEL Haridwar. (c) Rotor Assembly Section This is equipped with Indicating Stand, Small size Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and Discs. Machined Rotor, Discs and Blades are assembled here. Balancing and over speeding of Rotor is done on the dynamic balancing machine. (d) Turbine casing Assembly Section Machined casings are assembled and hydraulically tested by Reciprocating Pumps at two times the operating pressure. (e) Painting Preservation and Packing Section All the parts are painted, preserved and packed here for final dispatch. (f) Governing Machining Section This section is equipped with medium size and small size lathes, medium CNC lathe, Milling, Grinding, Drilling, Slotting and Honing Machines. Governing assembly parts are machined here. (g) Light machine shop In addition to normal conventional machine tools it is equipped with CNC Lathes, CNC Milling, CNC Vertical Boring, Precision Milling, planetary grinding machines etc. for manufacture of small and medium precision components of governing and other turbine parts.

Manufacturing Process of Steam Turbine Processes carried out in various sections of steam turbine manufacture are based on following main phases:

1) Machine section casting, forging, welded structures and other blanks are delivered to this section. The manufacturing process is based on the use of high efficiency carbide tipped tools, high speed and high feed machining techniques with maximum utilization of m/c tool capacity and quick acting jigs and fixtures. 2) Assembly section casing and governing assemblies are hydraulically tested for leakage on special test bed. Assembled units are tested on governing test bed. 3) Painting, preservation and packing after testing the turbine, it is disassembled and inspected. Then the parts are painted, conserved and packed for final dispatch.

BLADE SHOP 1)INTRODUCTION: Major parts of turbine blade machining shop is located in bay 4 . In this shop various types of steam and gas turbine blades are machined from bar stock,drawn profile , precision forgings. It is a batch production shop comprising of various cnc machines and machining centres,besids various special purpose and general purpose m/c. The layout of equipment is as per technological sequence of mfg process. Blade shop implements various online quality control techniques through run and control chart.This shop is divided into four distinct areas.detalis of facilities are given in various schedules. 2) MANUFACTURING FACILITIES a) Plain milling section It prepares accurate reference surfaces on the blade blanks by milling and grinding operation. It also manufactures the brazed type blades by induction brazing of drawn profile and machined spacers. This section carries out banking by bandsaus ,rhomboid grinding on duplex grinding machines and thickness grinding on surface grinders. b)COPY MILLING SECTION The semi blanks prepared from plain milling section are further machined by copy milling machines ,cnc machines for concave convex profile forms , for expansion angles. Compound taper is carried out by surface grinders. c)LP SECTION This area deals with all types of free standing and forged blades for steam turbine compressor. The free standing

blades are carrobend casted in boxes to hold the blade with respect to profile. There is a five station 360 degree circular copy milling machine for machining the profile of envelope forged blades/stocks for steam and gas turbine blades. The inlet edge of last stage of low pressure turbine moving blades are hardened on a special purpose flame hardening m/c. d)POLISHING SECTION Blade contours are ground and polished to achieve the desired surface finish and other aerofoil requirements. Ther e are also other small sections eg. Fitting section, tool and cutter grinding, tooling repair section in blade shop. e)INSPECTION DEVICE 3D cordinate measuring machines for taper and rhomboid checking,real time frequency analyser for checking frequency of free checking blades f)MISCELLANEOS There are other imp. Facilties such as agv(automated guided vehicle),jib crains for material movement.

OSBT(OVER SPEED BALANCING TUNNEL) High speed rotor balancing is done at actual operating speeds, where rotor vibrations are excited by its residual unbalance. It eliminates residual stresses which eliminates residual stresses. It results in balanced rotor that will run smoothly in operation.

ADVANTAGES:

1)It reveals unbalances which occur in the rotor. 2)Sensitivity is increased. 3)Calculated rotor response is verified.

ASSEMBLY OF TURBINE

Major parts of assembly are: 1)lower casing 2)rotor 3)upper casing 4)tight with stud pin 5)rotor given side movements for proper alignment 5)all parts are again ressembled and packed

MAJOR BLADES OPERATIONS


1)Sizing to rectangular shape: horizontal milling machine 2)grinding: surface grinding 3)convex and concave profile:horizontal copy milling machine 4)root chamfer:t root machine 5)taper:surface taper machine 6)cutting of drawn profile:horizontal milling machine 7)pin turning: pin turning machine 8)hole drilling: cnc lathe 9)root machinig: root machine

OVERALL

ASSEMBLY

Power station steam turbines are divided into individual and separate high pressure ( HP ) and low pressure ( LP ) turbines, connected only by their rotating shafts. This is done to enhance the efficiency of the steam turbine ... The HP turbine if the first compartment of the steam turbine to receive the superheated steam, the superheated steam is at boiler pressure and high temperature. The steam leaving the HP steam turbine is at a lower pressure and temperature, as steam energy has been transferred to the turbine blades in the form of mechanical energy. As the steam entering the LP turbine is at a lower pressure a larger surface area is required to extract the steam energy, and hence the diameter of the LP turbine is larger than the HP turbine. The LP steam turbine may itself be divided into a number of smaller low pressure steam turbines, each having larger blade diameters. The steam finally exits the LP steam turbine and enters the condenser.

The overall construction of a typical steam turbine is well shown in the figure below. The HP section of the steam turbine is the extreme bottom, while the LP sections extend from the HP section upwards. Notice the scale of steam turbine - compare to one of the working engineers!

MOLYKOTE

LUBRICANT

It is used in the blade assembly . There are two types of blades in rotor : guide , moving and locking blade. These have different shape as guide blades guide the steam, moving blade moves the rotor and locking blades are used to lock the other blades as it is used in the last of blade assembly.

This lubricant is applied on lock blade of each stage for better lubrication, so that the last blade will fit easily because it is the tightest of all blades in the groove.

LUBRICTING

OIL

The lubricant consists of 20 l water and 1 l soluble oil(cutting oil). It also acts as coolant for extreme machining.

Eg. Commadril cutting tool

BROAD SPECIFICATION OF MAJOR MACHINE TOOLS AND MACHINES First of all the major suppliers of the machines: 1)CNC MACHINES; WOTN,GERMANY HOESCH,GERMANY SAFOP,ITALY HMT,INDIA BATLIBOI,INDIA MIH,JAPAN OSAKA,JAPAN SCHIESS,GERMANY 2)NON CNC MACHINES; SCHENK,GERMANY

1)CNC HORIZONTAL BORERS

Model Supplier Cnc system Spindle dia. Table Max. load Power Weight of m/c Traverse Rpm

: : : : : : : : : :

rapid 6c wotn,germany fanuc 12m 200mm 4000*4000mm 100t 90kW 111t x=2000,y=5000,z=1400mm 0.5-90

2) CNC

VERTICAL

BORER

Model Supplier

: :

w200 hb skoda : : : 200mm x=1250,y=5000,z=2000mm FANUC 88kW

Spindle dia. Traverse CNC POWER :

Machine wt. : 100t Load capacity Rpm : : 70t

.2-30 rpm

3)CNC Model :

LATHES hoesch,germany : sinumerik : : 8000mm 0-125rpm 92kW :124t 110 t

Cnc system

Swing over bed Spindle speed Power :

Weight of m/c Weight of job :

NON-CNC MACHINE 1)HEAVY DUTY LATHE Swing : 2000mm

Bore dia. : 1500mm Dia. Of spindle bore : 80mm : 20t

Max. wt. of of workpiece Length Height : 14000mm

: 2800mm

CONCLUSION

Here, in the end, where I would like to conclude my whole report with some short sign. I must say that, to rise in the field of Mechanical Engineering, one must have the good knowledge of all the manufacturing processes. The most important thing is to study the drawings and make the route sheet, planning, shop floor management of the consequent operations. And in that way I prefer myself to get training at B.H.E.L, Haridwar. Because B.H.E.L is growing in the field of Manufacturing and is a very big manufacturing unit so its very good to learn at this place the mechanical and the strategies of management too. Electric power has always been an important part of the world's power supply, providing reliable, cost effective electricity, and will continue to do so in the future. The future of turbines will depend upon future demand for electricity and the future is very bright as we have no source to produce without turbines, be it Hydro Turbine, Steam Turbine or Gas Turbine. In this report, you will find some very refined data, which is referenced from a number of books and manuals and websites. This is just an effort to make my report more efficient.

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