Submitted to:
Mr. Hitendra Bankoti
Submitted by:
Yuganter Rawat
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Introduction
 Over view at Haridwar Plant
 Layout of Block-3
 Details of Bay 1(Assembly, Machine shop and
OSBT)
 Details of Bay 2(Gas turbine section and rotor
assembly)
 Details of Bay 3(Governing and Broad
specifications of major machines)[CNC & Non
CNC]
 Bay 4( Blade and Heat treatment shop)

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 BHEL
is the largest engineering and
manufacturing enterprise in India in the
energy field today. It was established more
than 40 years ago and has been earning the
profits since 1971.
 It has very wide network over 150 project
sites, 8 service centers and 18 regional
offices and Headquarters in New Delhi. More
over it is one of the navratna of government
of India. 75% of electricity in India is
produced with the help of BHEL equipments.
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 Vision
:World class, innovative, competitive,
and profitable engineering enterprise
providing total business solutions.
 Mission :The leading engineering enterprise
providing quality product systems and
services in the field of energy,
transportation, infrastructure and other
potential areas.
 Manpower :Total strength is more than
10000 which includes around 3000 qualified
engineers and technicians, 5200 skilled
artisans and the rest in other categories.
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Bay 1
Assembly, Heavy machine shop, OSBT
Bay 2
Gas turbine assembly, Rotor assembly
Bay 3
Governing section, Light machine shop
Bay 4
Blade shop, Heat treatment shop
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 The
final assembly of the turbine is done in
bay 1. Main assembly parts:
 1. High pressure steam turbine
 2. Intermediate pressure steam turbine
 3. Low pressure steam turbine
 4. Bearing pedestals
 5. Control valves
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 This
is the smallest of the three turbines. It
consists of two shells namely inner inner and
outer outer. Inner inner part is the part on
which guide blades are placed and outer
outer part mainly works as a casing of the
turbine. HP outer outer lower half is placed
on bed and leveling is done; now upper half
is assembled and alignment is done; now GBC
is aligned with respect to centre.
 Final alignment is checked and turbine is
dispatched in the assembled conditions.
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Capacity 210/250 MW
Main components
IP outer casing
Inner casing
GBC
Shaft seals
Rotor
Descriptions In outer casing, lower half is placed on bed
and leveling is done. U/H is assembled and alignment is
done now inner casing is placed and it is aligned with help
of keys and pokers. Rotor is placed and alignment of rotor
is done, now axial and radial gap between inner casing and
rotor are checked (flow path). The studs are heat
tightened to achieve elongation. Turbine is dispatched in
assembled conditions.
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 Capacity
210/250/500MW
 Main components:
 LP inner outer
 LP inner inner
 LP outer outer
 LP GBC
 Rotor
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 LP
I/O lower half is placed on bed and
leveling is done. Now upper half is assembled
and alignment is done. Now GBC is aligned
with respect to centre then GBC 2 and GBC 3
are aligned. Then inner core is aligned with
help of adjustment pokers.
 Now projection pipes are welded then
diffusers are aligned. Final alignment is
checked and turbine is dispatched in
disassembled condition
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 Front
HP/IP/LP, 210/250/500MW pipelines
are hydraulically tested. Then bearing is
aligned with help of phins, and pinning is
done. Assembly is completed and dispatched
in assembled conditions.
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Valve seats are fitted in the casing by cooling in liquid oxygen. Pinning
of seats is done, welding of nipples and flanges is done and then
hydraulic testing with valves covers, now casing is sent for edge
preparation and the color of valve assembly and valve seat is checked.
Travel of valve is checked and locking is done. Then trial assembly of
s/m is done. Valve is dispatched in assembled condition.
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
In this, there are very costly and big machines
which are used to carry operation on large parts
of a turbine such as rotor, diffuser, casing etc.
1) Machine number 1-120
Center lathe machine CNC
 Job: HP Rotor (on that time)
 Operation: slotting
 Specifications of the machine: Main spindle bore: - 150mm
 Distance between centers: - 12000mm
 Turning dia. Over bed cover: - 1400mm
 Turning dia over carriage: - 1100mm
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2) Machine number 1-28
Horizontal boring machine (Russian)
 Operation performed: - tapping,
threading,drilling, boring, facing, milling
etc,except knurling
 Specifications
 Capacity: - 600mm (bore dia)
 Weight capacity: - 40 tonne
 Dia of spindle: - 150 mm
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Over speed balancing tunnel :
 This is the one of the most important section of the
turbine block. Here after the complete checking of
the rotor from the bay 1, rotor is bringing to get
check it in the working conditions. Here we rotate
our rotor in the vacuum condition on a very small
film of oil consisting of some microns; here the oil is
on very high pressure. Rotor is revolved on 3750 rpm,
while in the operating conditions rotor revolves at
3000rpm (500mw).
 The time being for which rotor is revolved is 3
minutes. The power required to rotate that much of
heavy rotor is very high which comes from the high
voltage line nearly of 11000 Volts, and the gear box
with the synchronize motor is used to get accurate
and desired speed
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Oil plays a very important role in the rotor checking
the oil comes from the underground tanks having a
capacity up to 30000 liters this is pumped with the
help of large pumps and a large quantity of oil is
supplied continuously so that oil film doesn’t break.
Here we use a number of filters on many stages so
that oil is checked out against dust particles or any
foreign particles the attention is paid during this
checking so that everything going OK. The full
control of OSBT is done with help of control system
which is in control room, each and every care is
taken during the complete testing. The complete
checking of rotor costs nearly 8 crore Rs. Which is a
very high cost and after this testing if we find there
is any loosening in the blades or any blade is out of
its position then the department of OSBT sends the
rotor to the BAY1 along with checking report and
every effort is now put on the rotor so that it pass
the checking in the OSBT only then rotor is
assembled with the casing and dispatched. film
doesn’t break.
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SYSTEM TO CREATE VACCUM FOR THE OSBT,AT BHEL HARDWAR
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PART A: -Gas turbine section
The main thing that is done here is that the making of rotor for
the gas turbine, the rotor of gas turbine is very different from
that of the steam turbine, here the rotor is made in the form of
discs and after that the complete rotor is made by joining the
discs.
On a simple disc firstly the grooves are cut on the broaching
machine , very similar to the gear cutting process. Now after
cutting one groove the indexing is done and the machine is ready
to cut the another groove. after cutting the all grooves on the
periphery of the disc now the process is done to make teethes on
both the surfaces with the help of the grinding so that each disc
should mesh all the teethes and proper joining and the alignment
can be done, and similar process is done to all the other discs,
now before assembling the all the discs an very important
operation is done to check the accuracy of all the discs in
meshing, and the operation is named as the Colour matching.
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 Colour
matching It is the process to check
the complete meshing of the two joining
parts here the part on which we have to join
is colored and the mating part is put on it so
that complete transfer of color on the other
part could be done if there is not the equal
distributions of the color on the second part
then the portions are identified to be
machined so that complete and accurate
matching could be done.
 Now after checking all the discs the blades
are inserted in the respective grooves and
now the shrink fitting of these discs is done
on the solid shaft which would be passing
from each disc thoroughly.
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Shrink It is the process of joining two parts, one
part Is called male part and the other is called as
female part, the party on which we have to
insert other part is called as male part and
another would be female part.
 In this process the male part is cooled say in the
liquid oxygen so that it contracts and the female
part is expanded by heating and now both the
parts are superimposed and are subjected to
room temperature conditions and after some
time both parts are tightly joined. Here in the
gas turbine rotor the shaft is the male part and
the discs are called female part.
 In this way the complete rotor of the gas turbine
is prepared and the testing of the rotor as in the
case of steam turbine is carried out in the OSBT.
fitting
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In this section the rotor making is done for the steam turbine HP, LP, IP.
For the any steam turbine firstly the rotor is in the form of the shaft, the
procedure to make the complete rotor is explained here in the steps:The rotor shaft is placed on the centre lathe machine and turning and
taper turning is done according to the provided drawings.
Then grooves cutting is done for the blades fixing on all over the length
of the rotor accordingly as per in the drawing.
Now with the help of the crane the rotor is placed on the other machine
on which rotor is just revolved to do the indexing.
Talking about one groove a extra portion is cut so that blades can be
inserted in it easily.
Then a locking blade is fixed to get lock all the blades of one stage. Here
unlike in gas turbine a single blade is fixed but in the GT each and every
blade was fixed individually.
Sealing are placed on the portion in between two stages so that these
sailings match with the same sealing made on the casing so that leaking
of the fluid can be avoided from one stage to the other stage.
After doing all this work the rotor is now send to the Bay 1 so that final
inspection and the checking in OSBT could be done and the finally rotor
with proper alignment is assembled in the casing.
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Contents: - Governing section, light machine shop
Section 1:- Governing section
 Governing is the process of controlling the speed of
the rotor so that we can get constant frequency
under the fluctuating loads. This is done by
controlling the amount of fluid going inside the
turbine, means to say if the load is less that mean
speed of the rotor would tends to increase then we
make the less steam to enter inside so that rotor
speed come to desired value. Opposite thing Is done
in case of the heavy load when the speed of the
turbine is less more steam is made to enter inside the
turbine. To control this all, at the steam enterance
we use an electronic and mechanical system which
consists of oil pumps, servo motors pipes and many
indicators on the valve mouth.
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Section 2:- Machine shop
A. CNC machines
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CNC LATHE
CNC MILLING MACHINE
CNC VERTICAL BORER
CNC SURFACE BROACHING M/C
CREEP FEED GRINDING M/C
BROACH SHARPENING M/C
B. Non CNC machines
PRECISION HEAVY DUTY LATHE
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Sections
 1. Turbine blade manufacturing.
 2. Heat treatment
Blades of turbine:-
 Blades
are one of the most crucial parts of a
turbine. Blades are fitted in the grooves .The
shape of the blades is of aerofoil type
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There are two types of blades (i) Guide blades (ii) Moving
blades
 1. Guide blades:-These blades are remained fixed during
the motion of the runner so these are also called as
fixed blades .These blades are fitted in the grooves in
the casing. The sealing action is also done before putting
the blades in the grooves so that during working
conditions the leakage of fluid can be stopped. Guide
blades are put in guide blade carriers.
 2. Moving blades:-As the name suggests these blades
remain in moving condition for the whole life cycle of a
turbine. They are arranged so that they become
opposite to the direction of the fixed blades. This
arrangement will help in striking of the fluid on more
area of the moving blades and hence helps in I
 Material for blades: For steam turbines we mainly use the chrome steel, steel
with some % of V, W etc.
 For some special type of gas turbines we import blades
from other countries such as Germany, Russia etc.
ncreasing the efficiency of the turbine.
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 Importance
of wrang in blade shop: Due to the aerofoil type of shape of the
blades it is not easy to handle the blades
when we are performing various operations
on them, so a material with low melting
point (100 deg. Cel.) is used for this purpose.
For this a die is taken, the blade is put
between the wrang and various machining
operations are performed. To take the blades
outside the die with blade, we put the die in
boiling water, wrang melts and thus blade is
taken outside.
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 Working
of blades:-
The fluid coming from the boiler is highly energetic the guide blades
which are also called as fixed blades Are arranged so that they are in
oppposite direction to moving blades,it helps the maximum fluid to
strike on the moving blades and increases the efficiency of turbine.
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THANK YOU……….
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