GENERAL AWARENWSS IN STEAM

TURBINE MANUFACTURING
By-: Abhinav Lakhera
Roll no-:13EAJME002

Aryabhatta College Of Engineering And Research Centre

Presentation sequence

Overview of BHEL

Steam turbine the mainstay of BHEL

Definition of steam turbine

Components of steam turbine

Stage

Working principle of steam turbine

Simple impulse turbine

Reaction turbine

Types of steam turbine and their rotors

Compounding of steam turbine

Manufacturing process

About block 3 of BHEL

Overview of BHEL

Bharat Heavy Electricals Limited (B.H.E.L.) is the largest engineering and

manufacturing enterprises in India.

Established in 1960s under the Indo-Soviet agreements of 1959 and 190 in the
area of scientific, technical and industrial cooperation.

Over 65-70% of power generated in India comes from BHEL supplied

equipment. Overall it has installed power equipment for over 90,000 MW.

BHEL has its setup spread all over India namely New Delhi, Gurgaon,
Haridwar, Rudrapur, Jhansi, Bhopal, Hyderabad, Jagdishpur, Tiruchirapalli,
Bangalore and many more.

It is one of Indias largest public sector undertakings or PSUs known as the

MAHARATNA.

Steam turbines the mainstay of BHEL

BHEL has the capability

to design, manufacture
and commission steam
turbines of up to 1000
MW rating of steam
parameters ranging
from 30bars to 300
bars pressure and
initial & reheat
temperature up to
600C.

Definition of steam turbine

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

Components of steam turbine

The main components are:

Turbine blades

1.

Cylindrical reaction blades for H.P., I.P. and L.P. turbine

2.

3-DS blades, in initial stage of H.P. and I.P. turbine to reduce secondary losses

Turbine casing

Turbine rotors

1.

Disc rotors

2.

Drum rotors

What is stage in steam turbine?

In an impulse turbine,
the stage is a set of
moving blades behind
the nozzle.

In a reaction turbine,
each row of blades is
called a "stage."

A single Curtis stage

may consist of two or
more rows of moving
blade.

Working principle of steam turbine

High pressure steam is fed through a set of fixed

nozzles in the turbine stator to the turbine rotor
(runner) and passes along the machine axis
through multiple rows of alternately fixed and
moving blades. From the steam inlet port of the
turbine towards the exhaust point.

The stator blades in each stage act as nozzles in

which the steam expands and emerges at an
increased speed but lower pressure. As the high
velocity steam impacts on the moving blades it
imparts some of its kinetic energy to the moving
blades.

There are two basic steam turbine types, impulse

turbines and reaction turbines, whose blades are
designed control the speed, direction and pressure
of the steam as is passes through the turbine.

Simple impulse turbine

If

the flow of steam through the nozzles and

moving blade of a turbine take place in such a
manner that the steam is expanded only in
nozzles and pressure at the outlet sides of
the blades is equal to the inlet side, such a
turbine is termed as impulse turbine because it
works on the principle of impulse. In other words
in impulse turbine, the drop in pressure of the
steam take place only in nozzles not in
moving blades. This is obtained by making the
blade passage of constant cross- section area.

As the general statement it may be

stated that energy transformation takes place
only in nozzles and moving blades (rotor)
only cause energy transfer.

Impulse
reaction turbine
In this turbine, the drop in the
pressure of the steam takes
place in fixed (nozzles) as well
as moving blade. The pressure
drop suffered by steam while
passing through the moving
blades cause a further
generation of kinetic energy
within the moving blades,
giving rise to reaction and adds
to the propelling force which is
applied through the rotor to the
turbine shaft. Since this turbine
works on the principle of
impulse and reaction both, so
it is called impulse-reaction
turbine.

Types of steam turbine and

there rotors

High pressure turbine or H.P. turbine

Intermediate pressure turbine or I.P. turbine

Low pressure turbine or I.P. turbine

Rotors:

High pressure rotor

Intermediate pressure rotor

Low pressure rotor

High pressure turbine

High pressure and temperature fluid at the inlet of the turbine

exit as lower pressure and temperature fluid.

The difference is energy converted by the turbine to mechanical

rotational energy, less any aerodynamic and mechanical in
efficiencies incurred in the process.

The fluid is at a lower pressure at the exit of the turbine than at

the inlet, it is common to say the fluid has been expanded across
the turbine.

High pressure rotor

High pressure
rotor has less in size
and diameter.

The R.P.M of the

high pressure rotor
is less in comparison
to other rotor.

Intermediate pressure turbine

After expansion of steam in HP turbine, the exhaust steam of HP Turbine is

reheated at constant pressure, increasing its temperature.

This steam is then fed to IP turbine, pressure 56 bar. The steam expands in IP
turbine, and is then fed to low pressure turbines.

Intermediate pressure turbine having more pressure than low pressure and
less than the high pressure turbine.

Its blade is larger than high pressure turbine.

Intermediate pressure rotor

It has mediate size and

diameter of H.P. and I.P.
rotor.

R.P.M. of intermediate
pressure rotor is between
high pressure and low
pressure rotor.

Low pressure turbine

LP turbine is designed to be a dual flow turbine.

Steam enters the center of the turbine from the crossover

pipe and flows across the reaction blading in two opposite
directions.

This configuration reduces axial thrust on the turbine and

allows for a smaller turbine installation.

On ships where space is not a concern, a single flow

turbine is used.

Low pressure rotor

It has much
bigger size and
diameter
comparison to H.P.
and I.P. rotor.

It has high R.P.M

to other rotor.

Compounding of steam turbine

Compounding of steam turbine is the method in which

energy from the steam is extracted in a number of
stages rather than a single stage in a turbine single
stage in a turbine.

A compounded steam turbine has multiple stages i.e.

it has more than one set of nozzles and rotors, in
series, keyed to the shaft or fixed to the casing, so
that either the steam pressure or jet velocity is
absorbed by the turbine in number of stages.

The leaving loss also will then be less.

There are three main types

Pressure-compounded impulse turbine.
Velocity-compounded impulse turbine.
Pressure and velocity compounded impulse turbine.

Manufacturing process

Manufacturing processes are the steps through which raw materials are
transformed into a final product.

The manufacturing process begins with the creation of the materials from
which the design is made.

These materials are then modified through manufacturing processes to

become the required part.

Classification of manufacturing process

Primary shaping process

Secondary machining process

Metal forming process

Joining process

Surface finishing process

Process effecting change in properties

Layout of turbine block (block 3) at

BHEL, Haridwar

Bay-1

Bay-1 is further divided into three parts

HMS (Heavy Machine Section)

In this section heavy machine work is done with the help of different NC &
CNC machines, vertical and horizontal boring machine. Asias largest vertical
boring machine is installed here.

Assembly section

In this section assembly of steam turbine is done. Blades of turbines are first
assemble on rotor & and after it this rotor is transported to balancing tunnel.

OSBT (over speed balancing tunnel)

In this section all types of turbine like LP, HP, IP rotors are balanced.

Bay-2

Bay-2 is divided into 2 parts

HMS

In this shop several components of steam turbine like LP, HP & IP rotors ,
internal and external casing are manufactured with the help of different
operations carried out through different NC & CNC machines.

Assembly section

Steam turbine up to 1000MW is assembled.

Bay-3 & Bay-4

Bay-3 is divided into three parts

Bearing section

In this section journal bearing are manufactured.

Turning section

Governing section

In this section governors are manufactured. These governors are used in turbine for
controlling the speed of rotor with in certain limits.

Bay-4 is divided into four parts

TBM (Turbine Blade Manufacturing)

Turning section

Heat treatment shop

Blade shop

Blade shop is an important shop . Blades of all the stages of turbine are made
in this shop only

Types of blades

3 dimensional 3DS blade (HP/IP Initial stage)

Cylindrical profile TX blade (HP/IP intermediate stage & LP initial stage)

Twisted profile F blade (HP/IP rear stages)

Operation performed on blade

Milling

Blank cutting

Grinding of both surfaces

Cutting

Root milling

Conclusion

Summer training gives the idea of general awareness in steam turbine

manufacturing & its process. It provides practical idea to manufacturing
several components of turbine.

THANKYOU