BHEL-PPT

GENERAL GENERAL AW AWARENESS ARENESS IN THE MANUFACTURING OF A STEAM TURBINE At BHEL-Haridwar

PRESENTED BY: ADITYA  ADITYA GUPTA GUPTA  A12405411013  A12405411013 7MAE-ASE  AMITY UNIVERSITY UNIVERSITY

FACUL ACULTY TY GUI GUIDE DE

• Mr. Mr. MAHENDRA MA HENDRA KUMAR VERMA (HOD-Mechanical HOD-Mechanical and Automation Engineering Department Amity School of Engineering Amity University, Uttar Pradesh)

INDUSTRIAL GUIDE

• Mr. JAIKESH KUMAR (ENGR-TUM-Plg, BL-3, BHEL-Haridwar)

ABOUT BHARAT HEAVY ELECTRICALS LIMITED •

Bharat Heavy Electricals Limited was established in 1964 and is one of the major manufacturing and engineering enterprise in INDIA.

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BHEL has its hands spread in telecommunication, renewable energy, power generation, etc.

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BHEL has been certified with ISO-9000 and ISO-14001 for quality management and environment management.

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BHEL manufactures products like 

steam turbines

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gas turbines

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hydro power plants, etc.

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BHEL has also won many INTERNATIONAL AWARDS and NATIONAL AWARDS:

BHEL, in the world, is the 7th largest power equipment manufacturer.

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The company received the National Intellectual Property Award 2014 and Award for Innovative Enterprises 2014.

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The company has also won the DSIJ Award 2013 for the Most Efficient Maharatna PSU.

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BHEL also won the Golden Peacock Award 2013 for Innovation Management.

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BHEL received the India Pride Award 2013 for Excellence in Heavy Industries.

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In 2013, the company won ICAI National Award for Excellence in Cost Management for the eighth consecutive year.

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The company received two Sustainability Award from the President of India in 2012.

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In 2011, BHEL was ranked 9th most innovative company in the world by US business magazine Forbes.

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The company was also placed at 4th place in Forbes Asia's Fabulous 50 List of 2010

BHEL-HARIDWAR •

BHEL’s unit in Haridwar is situated in the foot hills of Shivalik range.

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There are two units in BHEL Haridwar as followed 1) Heavy Electrical Equipment Plant (HEEP) 2) Central Foundry Forge Plant (CFFP)

CLASSIFICATION OF BLOCK - 3 •

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BAY-1 

HEAVY MACHINE SHOP: work is done on different CNC machines such as centre lathe, boring and milling machines. Asia’s largest vertical boring machine is installed here.

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ASSEMBLY SECTION: here assembly of hydro turbine is done.

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OVERSPEED BALANCE TUNNEL: here balancing of rotors of steam turbine, gas turbines etc., are done.

BAY-2 

HEAVY MACHINE SHOP: manufacturing of only internal and external casings is done.

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ASSEMBLY SECTION: here assembly of steam turbines up to 1000MW is done.

OVERSPEED AND VACUUM BALANCING TUNNEL

STEAM TURBINE CASING AND ROTORS IN ASSEMBLY AREA

CLASSIFICATION OF BLOCK - 3

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BAY-3 

BEARING SECTION: here JOURNAL bearings are manufactured- used to overcome the vibrations.

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TURNING SECTION: here CNC lathes, turning, milling, boring and drilling machines are installed.

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GOVERNING SECTION: governors used in turbines for controlling the speed of rotor are manufactured.

BAY-4 

TURBINE BLADE MANUFACTURING SHOP: here blades of steam turbines are made. There is also a copying machine.

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TURNING SECTION: here CNC lathes, turning, milling, boring and drilling machines are installed.

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HEAT TREATMENT SHOP: here HARDNESS tests are performed on large

CNC ROTOR TURNING LATHE

STEAM TURBINES •

A device that converts chemical energy into mechanical energy is called a turbine.

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A device that converts the chemical energy of steam into mechanical energy is known as steam turbine.

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High pressure fluid at the inlet of the turbine (having high energy state) exits as lower pressure and temperature fluid (having low energy state).

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The difference in energy is converted into mechanical rotational energy.

ANOTHER USE OF STEAM TURBINE •

Industries such as the gas processing industry use turbines as a source of refrigeration, dropping the temperature of the gas going through the turbine.

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In other words, turbines can be used to reduce the temperature of the working fluid even while providing power.

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Higher the pressure ratio across a turbine means greater expansion and greater temperature drop.

TURBINE v/s GAS TURBINE •

The word “gas turbine” is one common, and somewhat misleading, use of the word “turbine”.

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A device that converts chemical energy into mechanical energy, specifically when a rotor of multiple blades is driven by the movement of fluid or gas, is called a turbine.

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A gas turbine engine is more than just a turbine. It typically includes a compressor, combustor and turbine combination which is used to provide shaft or thrust power.

ADVANTAGES OF STEAM TURBINES •

Ability to utilize the energy of high pressure and high temperature steam

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High efficiency

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High rotational speed

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High capacity/weight ratio

DISADVANTAGES OF STEAM TURBINES •

For slow speed applications reduction gears are required.

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The efficiency of small steam turbines is poor.

IMPULSE TURBINE •

The impulse turbine work on the principle that- if steam at high pressure is allowed to expand through stationary nozzles, it will result in the drop in the steam pressure and an increase in steam velocity.

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 The steam passes through the stationary nozzles and the high speed steam when applied to a turbine blade, will cause in the direction of steam to change due to blades.

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This will create an impulse force on the blades causing them to move, which will rotate the attached rotor.

REACTION TURBINE •

A reaction turbine has alternating rows of fixed blades and rows of rotating blades.

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Initially the steam expands in the fixed blades and gains some velocity with some drop in its pressure.

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It then enters the moving blades where its direction of flow is changed producing an impulse force on the moving blades.

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However, as the steam passes through the moving blades it expands again and further drop in pressure gives a reaction force to the blades.

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This process is repeated as the steam passes through alternating rows of fixed and moving blades.

PARTS OF A BLADE A blade can be divided into 3 parts for its constructional features. These parts are as follows: •

The profile: the thermal energy of the steam is converted into kinetic energy.

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The root: it fixes the blades to turbine rotor, giving a proper anchor to the blades, and transmitting the kinetic energy of the blade to the rotor.

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The damping element: the vibrations which occur in the blades, are reduced by the dampers, due to the steam flowing through the blades.

BLADES PROFILE HP BLADE PROFILE •

Camber line

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Chord

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Bitangent line

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Pitch of a blade is the circumferential distance between any point on the profile and an identical point on the next blade.

LP BLADE PROFILE •

These blades are twisted and tapered in the case of the L.P. blade profiles.

BLADE ROOTS •

A part of the blade that fixes to the rotor or stator is called root of the blade.

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There are two types of roots, namely Troot and Fork-root.

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The T-root has a lower load carrying capacity than the Fork-root.

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Machining the sides of a T-root with side grip is one more of a problem.

BLADING MATERIAL •

There are various materials used for making the turbine blades. Some of these are: 403-stainless steel, 422-stainless steel, A-286, etc.

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The 403 stainless steel is probably found over 90% of all the stages on impulse steam turbine. The 403 stainless steel is used because it has the following properties of the high yield strength, endurance limit, ductility, toughness, corrosion resistance and damping.

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At higher temperatures (between 700 and 900oF or 371 and 482oC) the 422 stainless steel material is used.

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The A-286 material is a nickel-based alloy that is generally used in hot gas expanders with stage temperatures between 900 and 1150oF (482 and 621oC).

CONCLUSION

Thus we have studied about the various parts, types and uses of a steam turbine. I would like to thank my industry guide Mr. Jaikesh Kumar and my faculty guide Mr. Mahendra Kumar Verma for their guidance and support in completing this project.

THANK YOU