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•Bharat Heavy Electricals Limited one of the top engineering companies in India
ranks among the top 12 Power Equipment manufacturers in the world. Setup in mid
fifties, BHEL has diversified its product base over the years and today every key sector
of the economy is served by BHEL.
•BHEL’s products cater to a wide spectrum of customers in various fields like power
generation and transmission, oil exploration and production, transportation, steel &
metals, fertilizer, petro-chemicals, refineries, cement plants, engineering industries, non
conventional energy sources, defense etc.
•More than 65% of installed capacity for electrical power in India is contributed by
BHEL. With 14 manufacturing units and over 63,000 skilled manpower, BHEL has built
up tremendous engineering strength.
BHEL-Hyderabad manufactures almost all critical high technology products requires for
Power Sector viz. Gas Turbine, Steam Turbine, Generator, Steam Generator, Heat
Recovery Steam Generators, Pumps & Compressors, Heat Exchangers, Control
equipment etc. IN the factory area of BHEL there are altogether broadly 8 workshops in
which all the major work is done. They are:
1.ELECTRICAL MACHINES-Electrical equipment like generators, transformers are
produced and tested here.
2.TC >-Turbines, compressors and gas turbines are produced here. This work area is
further divided into sub sections for undertaking different operations like Heavy Machine
shop, light machine shop, rotor shop, blade shop, testing and assembly area.
Radial compressors are also produced and tested here. Several other operations like
forging, welding (small scale) are done. GT components are also done and assembled
separately. This project was done in this workshop.
Basic workshop operations like tapping, drilling etc. are done on the vertical drilling
machine. For different materials different coolants are used. Various specifications for processes are
1. Reaming-shell type or normal type reamers are the tools used.M-10,M-20…denote the
type of thread. They have their own characteristics like pitch ,drill dia, etc.
2. Drilling-According to requirement, the size of drill tool is selected. Radial drilling is used
to drill holes sideways.
3. Tapping-this operation is used for threading. There are many types of threads like gas
threads, NPT (National Pipe Taper), BSW, BSF etc. one example is shown below.
•The use of taper pins in assembling two parts is that it does not allow their
separation.
There is a design section adjoining the work area where analysis of the process is
done. Actual drawing sheets for various components are made here.
3.FOUNDRY - Input to this shop are details like drawing, temp. of boring,
allowances etc. Here the moulding process takes place. Exhaust roots, bearing
pedestal ,guide wheels are manufactured.
4. FORGING – the various welding operations are shielded metal arc welding, termite
welding etc. Closely related to this workshop is the metallurgical testing lab where the
composition of the metal is monitored. This is done by UV (ultraviolet) testing and
chemical analysis.
Mechanical testing lab is used for determining the properties of the metals. Here the
various tests done on are UTM (Universal testing machine), various hardness tests
like Brinnell, vicker etc.
5. SURFACE TREATMENT WORKSHOP- In most of the cases heat treatment is done here. Tempering ,nitriding and
other processes are made here.
Steam turbines-introduction
• The steam turbine is a prime mover in which the potential energy of the steam is
transformed into kinetic energy, and later in turn transformed into mechanical energy of
rotation of the turbine shaft
• The steam passes through the main steam connection, the steam strainer and
the emergency stop valve before the servo valves into the inlet part of the
outer casing. After opening of the servo valves, the steam flows into the
steam chamber, to pass through the jet groups into the expansion area of the
turbine, by giving off its energy capacity and expanding up to the final pressure
in the exhaust part.
•In a steam turbine the force exerted by the blades is due to the velocity of the steam.
This is due to fact that the curved blades by changing the direction of the steam receive a
force of impulse. The action of steam in this case is said to be dynamic in a steam
turbine.
General layout of a steam turbine plant TURBINE
STEAM
BOILER CONDENSER
HEAT
SUPPLIED
HEAT
REJECTED
FEED HOT
WELL EXTRACTION
PUMP
PUMP
.
Machining of casing:
• STEAM CHAMBER: The steam chamber represents the connection
between the control valve bores in the outer casing and the nozzle groups of the
control stage.
• The steam chamber contains the nozzle groups for the control stage(3),provision
for stem flow(2),inner shaft gland(5).
•Movable L-rings seal the steam path between the steam chamber and the
outer casing so as to permit thermal movement.
•The detailed design is as shown below---
•OUTER CASING:
• The turbine casing is divided into an admission and exhaust section. Back
pressures as well as condensing turbines have admission sections of
identical design. Depending on the inlet steam conditions, the admission
sections of comparable size are designed with casings of different wall
thickness. The admission section will be completed by an exhaust section of
adequate size.
1. Outer casing
2. Exhaust steam part sealing shells
3. Support blocks
9. Webs to accommodate the blade
carriers
11 Mounts for rear bearing
6 Main steam line connection
12 Exhaust steam flange
Initial machining operations:
•The overall length is adjusted by cylindrical or conical spacer rings. The outer diameter
at the inlet and exhaust are measured.
•It is general practice to let the thickness of walls and flanges decrease from inlet- to
exhaust-end.
•Rough machining by a Gantry machine is done. Shoulder milling operation is done for
machining circular surfaces.
•On the inside, the outer casing has surrounding webs and contact cams to
accommodate blade carriers, the inner case or the steam chamber. By means of these
webs, the outer case is split into several sectors of differing pressure, out of which
tappings can be obtained to suit requirements
Scaling fins which are used for arresting the steam leakage ,and create more back
pressure so that the steam enters the guide vanes in the right way, are embedded
into the portion of the rotor between the grooves.
ROTOR ASSEMBLY.
•Actual assembly consists of individually inserting the blades into the grooves and
locking their positions using a small metal piece between the base of blade and the
rotor groove.
•This is done for all the stages except LP blades which have fork-root base.
•For the last blade in assembling a row of the blades, the base part remains
. solid (no root milling is done). It is marked and used for conducting some of the
performance tests like rotor insensitivity test etc
•Shrouding operation is done on the projecting side of all the rows of moving blades.
This is done so that steam does not escape out of the blades (rotor part).
•The moving blades have integral shrouding, with the moving blades of one row forming
a closed, tightly fitting blade assembly at the shrouds.
•The turbine case is axially split; the top and bottom of the case are held together by
reduced-shaft or solid shaft bolts. The outer faces of the casing parts possess webs to
accommodate the sealing shells and cast-in channels with affiliated flange connections
to remove leaking steam or to supply sealing
• A closed, tightly fitting blade assembly is obtained at the shrouds when the
stationary blade carrier halves are bolted together during final assembly.
The stationary blade carriers are suspended in the outer casing (5) so as to
allow for thermal expansion. If required, a stage drain can be provided
upstream of the last stationary blade stage to draw off any water that may
accumulate on the blade vanes into the condenser.
•Now the rotor is placed onto the one half of casing.
Final assembly operations
SEALING:
Task
• The sealing shells serve the purpose of sealing between the outer casing and rotor
on the steam end. Besides sealing against internal excess pressures, the ingress of
ambient air in the event of an internal partial vacuum must be reliably prevented.
Structure
•The sealing shell is axially split, and the halves are bolted to one another. On
the outer circumference of the sealing shell body, there is a surrounding slot
with which the shell is fixed radially and axially in the outer casing.
• Work input to the turbine is needed to start rotating the shaft. During start-ups
50-60% of energy is consumed by the compressor. The self-sustaining speed
is taken as 40-45% of max. speed. The motor is cutoff from rotating the shaft.
• A Brayton Cycle is characterized by two very significant parameters: pressure
ratio and firing temperature. The pressure ratio of the cycle is the pressure at
point 2 divided by the pressure at point 1. The firing temperature point 3 on
the fig., is the highest temperature reached in the cycle. The thermodynamic
cycle efficiency and Power output of a Gas Turbine depends on these two
parameters
• The efficiency of gas turbine is in the range of 40-46% which is low compared
to a steam power plant. But, further refinement to the cycle is at the cost of
simplicity and not feasible. The high temperature of the exhaust gases can be
used to heat steam for steam turbine application.
• The advantages of gas turbine are:
Efficient
Compact
Reliable
Eco-Friendly
…Rotary Internal Combustion Engine
• Self contained
• Light weight
• High Power Density
• Low installation time
• Quick start
• Black Start Capability
NOTES: 1)Though the Otto cycle is more efficient it has many inherent disadvantages
like knocking, not practicable for high output applications.
2)As it is an IC engine it does not require any external inputs as in the case
of steam turbine. Hence the installation is quite easy
3)Hence it occupies very less space. In steam turbines for generating the
same 125 MW of power coupled system is used.
4)Since air fuel mixture is 30:1 the exhaust gases do not contain high
concentration of pollutants.
COMPONENTS OF TURBINE.
The major components of a Gas Turbine are the compressor, combustion system and
turbine section. CDC stands for (compressor discharge casing). The various parts that
compose each individual section is dealt herewith.
Ancillary
base.
COMPRESSOR SECTION
• The axial-flow compressor section consists of the compressor rotor and the
enclosing casing, as also CDC.
• Within the compressor casing are the inlet guide vanes, 17 stages of rotor
and stator blading, and the exit guide vanes.
• Each compressor stage consists of a rotating row of blades (aerofoil) that
increases the velocity of the incoming air there by increasing its kinetic energy, followed
by stationary row of blades that act as diffusers, converting the kinetic energy to
pressure increase.
• The number of stages used for a particular gas turbine compressor depends
upon the design pressure ratio for that turbine. Typical pressure ratio ranges from 6:1 to
14.9:1.
• The compression efficiency is 85% that of the ideal isentropic process but handling
is easy. From stage to stage, the compressor ratio is n*o.85.(n approx 1.4)
NOTE:1) during startups ,50-60% of energy is consumed by compressor.
2)Some air is extracted from the intermediate stages to enable the rotor to rotate freely.
AT 95% of the full speed we close breed valve. Then compressor operates at full
efficiency.
PARTS OF COMPRESSOR:
• INLET GUIDE VANES (IGV’s):
•At the compressor inlet there is a row of stationary blades, called inlet guide
vanes (IGV's) that direct the incoming air on to the first rotating stage in a
smooth way. The flow angle of the IGV's can be changed to control the
volume of air being drawn into the compressor. The variable inlet guide vanes
(VIGV's) are used to ensure aerodynamically smooth operating compressor
throughout a large operating range.
Lower casing
• Movement of these guide vanes is accomplished by the
inlet guide vane control ring that turns individual pinion
gears attached to the end of each vane. The control ring
is positioned by a hydraulic actuator and linkage arm
assembly
ASSEMBLY
MACHINING:
Each wheel and the wheel portion of each stub shaft has slots machined
around its circumference. The rotor blades and spacers are inserted into these slots
and are held in axial position by staking at each end of the slot.
The blades are manufactured using the same process as in the case of a steam
turbine described earlier except that here the base profile is not a T-Root but an
inverted U.
STAKING is the process of inserting a thin metal piece between the compressor groove
and the sides of the blade base.
•The blades are not of the same size for all the stages,
but differ according to their position. Small size blades
are to be assembled at the front end of the rotor where COMPRESSOR
the pressure is more and large size blades are to be BLADES
assembled at the rear end of the rotor where pressure
is minimum.
ASSEMBLY:
• The wheels and stub shafts are assembled to each other with
mating rabbets for concentricity control and are held together with
tie bolts. Stub shaft is the protruding part of the connecting rod of
wheels of the compressor. They are two in number.
• Selective positioning of the wheels is made during assembly to
reduce balance correction. After assembly, the rotor is dynamically
balanced to a fine limit
CASING:
•The stator (casing) area of the compressor section is composed of four major
sections. They are inlet casing, forward compressor casing, aft compressor casing,
compressor discharge casing.
•These sections, in conjunction with the turbine shell, form the primary structure
of the gas turbine. They support the rotor at the bearing points and constitute the
outer wall of the gas path annulus. The casing bore is maintained to close
tolerances with respect to the rotor blade tips for maximum efficiency.
FORWARD CASING
FORWARD CASING
•The forward compressor casing contains
the first four compressor stator stages. It
also transfers the structural loads from the
adjoining casing to the forward support RING
SEGMENTS
which is bolted and doweled to this
compressor casing’s forward flange.
Note: The forward compressor casing is
equipped with two large integrally cast
trunnions which are used to lift the gas
turbine when it is separated from its base.
Bleed air from the fourth rotor stage can be
extracted through four ports which are
located at the aft section of the compressor
casing
BLADING ARRANGEMENT
The compressor stator blades are airfoil shape and are mounted by similar dovetails
into ring segments. The ring segments are inserted into circumferential grooves in
the casing and are held in place with locking keys.
AFT CASING
The aft compressor casing contains the 5 through 10 compressor stages. Extraction
ports in the casing permit removal of 5 and 11th-stage compressor air. This air is used
for cooling and sealing functions and is also for starting and shutdown pulsation control.
BLADING DESCRIPTION
NOTE:
As shown the grooves for fitting the blades
are of square dovetail shape
ASSEMBLY
•The compressor discharge casing consists of two cylinders, one being a continuation
of the compressor casings and the other an inner cylinder that surrounds the
compressor rotor.
•The two cylinders are concentrically positioned by twelve radial struts.
These struts flair out to meet the larger diameter of the turbine shell, and are the
primary load bearing members in this portion of the gas turbine stator.
•The supporting structure for the No. 2 bearing is contained within the inner cylinder.
CDC-upper portion:
Spark plug
Arrangement of Combustion
chambers.
• TURBINE SECTION
•The three-stage turbine section is the area where energy, in the form of
high-temperature pressurized gas produced by the compressor and combustion
sections, is converted to mechanical energy.
•The major components of Gas turbine are the turbine rotor, turbine casing
exhaust frame, exhaust diffuser, nozzles and shrouds.
ROTOR
•The turbine rotor consists of two wheel shafts; the first, second, and third-stage turbine
wheels with buckets; and two turbine spacers.
•The 3-stage turbine wheels are manufactured in the following way:
The outer rim part consists of grooves for assembling the buckets. These rims are
forged onto a supporting circular shaft by heat treatment, forging.
•These wheels are held together with through bolts.
• The turbine rotor must be cooled to maintain reasonable operating temperatures and,
therefore, assure a longer turbine service life. Cooling is accomplished by a positive
flow of cool air radially outward through a space between the turbine wheel with
buckets and the stator, into the main gas stream. This area is called the wheelspace.
WHEELSPACE: There are three stages of wheelspaces according to their positions.
1. FIRST STAGE: The first –stage forward wheelspace is cooled by compressor discharge
air. High-pressure packing is installed at the end of the compressor rotor between the
rotor and the inner barrel of the compressor discharge casing.
2. SECOND-STAGE WHEELSPACES
The second-stage aft wheel space is cooled by air from the internal extraction
system. The air enters the wheel space through slots in the forward face of the spacer
3. THIRD-STAGE WHEELSPACES
The third-stage forward wheel space is cooled by leakage from the second-stage aft
wheel space through the inter stage labyrinth.
Inner Barrel
ALIGNMENT OF TURBINE CASE AND EXHAUST FRAME:
1. Pick up turbine case & shroud assembly and assemble on the height blocks with its
AFT face upwards. Clean AFT face free of burrs & high spots
2. Pick up exhaust frame. Clean the FWD face and assemble the exhaust frame on to
turbine case AFT face, aligning the horizontal parting plane of both frame and
turbine case.
3. Assemble the Frame to turbine case loosely with the above screws. They are
inserted into the holes drilled on the outer casing of turbine and exhaust.
4. Align the exhaust frame to turbine case by taking drop checks at 6 points.
5. Tighten the vertical flange bolting and recheck the alignment.
6. Using the quacken-bush drilling equipment and fixture drill and ream dia19H7
dowel pin holes.
7. Assemble correctly the dowel pins into the holes. Match mark the pins and holes.
8. Remove the pins and screws from vertical flanges and preserve. Dismantle the
exhaust frame from turbine case.
9. Reverse the turbine case and assemble it on height block such that FWD face is
up wards and repeat the operations.
Thus the exhaust frame is aligned with the turbine casing.
ALIGNMENT OF CDC WITH TURBINE:
1. Bring the compressor discharge casing assy. Loosen the support ring bolts all
around & tighten to a snug condition.
2. Assemble the C.D.C assy. on turbine casing. Rotate the casing to align the parting
planes closely
3.Assemble the two casings loosely with bolts move the alignment pole within 0.05,
maintaining horizontal joint alignment to turbine case.
4.
4.Bring the casing tube to horizontal position. Attach the FWD support fixture to FWD
COMP. casing.
5. Position the FWD & AFT support blocks. Lower the tube and rest it on the support
blocks. Ensure the tube is supported properly on blocks. Level the tube and release the
crane.
6. Bring the inlet casing including IGV assembly. Assemble the inlet casing to comp.
casing with bolts as before.
7. Assemble exhaust frame to turbine casing with sock screws, we should not tighten
the bolts.
ASSEMBLY OF ROTATING PARTS INTO CASING:
1. Before removing the top half of casing match mark all dowel pins and body bound
studs to matching holes in casing.
2. Remove the upper cover from variable I G V & control ring.
3. Remove the vertical bolting from combined compressor casing upper half. Remove
the
horizontal joint bolting.
4.Similarly unbolt the vertical and horizontal flange bolting of exhaust frame and remove
the upper half
5.These bolts and their order should be clearly demarcated. Now the rotating parts are
ready to be assembled into the corresponding stator parts.
ASSEMBLY OF EXHAUST
DIFFUSER INTO EXHAUST
FRAME