INDUSTRIAL TRAINING PRESENTATION

ON

Bharat Heavy Electricals Limited

Ranipur, Haridwar ( Uttrakhand )
PRESENTED BYNISCHAL KHANNA
1314340068

Contents

INTRODUCTION OF B.H.E.L
CORE SECTORS
PHASES OF BHEL
TYPES OF STEAM TURBINE
PLANT LAYOUT
BLOCK-3
MANUFACTURING PROCESS
ROTORS AND BLADES
REFERENCES

INTRODUCTION OF BHEL

Bharat Heavy Electricals Limited (B.H.E.L.) is the power plant equipment

& largest engineering and manufacturing enterprise in India.
Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in
the area of Scientific, Technical and Industrial Cooperation.
BHEL has its setup spread all over India namely New Delhi, Gurgaon,
Haridwar, Rudrapur, Jhansi, Bhopal, Hyderabad, Jagdishpur , Tiruchirapalli,
Bangalore and many more.

BHEL has retained its market leadership position during 2015-16 with
74% market share in the Power Sector.

BHEL has already attained ISO 9000 certification for quality management,
and ISO14001 certification for environment management. Occupational
Health & Safety Management Systems (OHSAS 18001:2007).

It has been granted the prestigious Maharatna (big gem) status in 2013
by Govt of India for its outstanding performance

CONT

It has a network of 17 manufacturing units, 2 repair units, 4 regional

offices, 8 service centres , 8 overseas offices, 15 regional centres , 7 joint
ventures, and infrastructure allowing it to execute more than 150 projects
at sites across India and abroad.

Footprints in 78 countries with installed capacity of 10000MW including

Belarus, Bhutan, Egypt, Indonesia, Iraq , Malaysia ,New Zealand ,Oman.

HISTORY

BHEL was established in 1964 Heavy Electricals (India) Limited was

merged with BHEL in 1974.
In 1982, it entered into power equipment, to reduce its dependence on the
power sector.
1991, it was converted into a public limited company.
By the end of 1996, the company had handed over 100 Electric
Locomotives to Indian Railway and installed 250 Hydro-sets across India.

WORKING SECTORS

POWERGENERATION
TRANSMISSIONANDDISTRIBUTION
TRANSPORTATION
INDUSTRY
TELECOMMUNICATION
RENEWABLEENERGY

PRODUCT PROFILE
Thermal power plants
Nuclear power plants
Gas based power plants
Hydro based power plants
Dg power plants
Casting and Forging
Boilers
Boiler Auxiliaries
Piping system
Solar photovoltaic's
Defence

PHASES OF BHEL
1964-74- Laying Foundation for technology , Skills and
Knowledge
1974-84-Creating organization for engineering &technology .
1984-94-Development Phase.
1994-04-Consolidation Phase.
2004-14-R&D as a engine growth.

Manufacturing Plant
BHEL Haridwar has two manufacturing plants:

Heavy Electricals Equipment Plant (HEEP)

Central Foundry Forge Plant (CFFP).

It also has a Pollution Control Research Institute, PCRI.

The Heavy Electricals Equipment Plant is one of the major

manufacturing units of BHEL. The core business of HEEP includes
design and manufacture of large size steam and gas turbines, turbo
generators, heat exchangers, condensers and auxiliaries.

The Central Foundry Forge Plant (CFFP) is engaged in

manufacture of large size Castings and Forgings of various types of
steels like alloy steels, creep resistant steel and supercritical grade
steel.

The Pollution Control Research Institute (PCRI) provides services

in the field of Environmental Management and Pollution Control in
the areas of air, water, noise and solid waste.

BLOCKS OF HEEP
I)ElectricalMachine
II)FabricatedAssemblies
III)Turbines&Auxiliary
IV)Feeder
V)Fabrication
VI)FabricationStamping&DieManufacturing
VII)WoodWorking
VIII)Heaters&Coolers

BLOCKS UNDER CFFP

1. Foundry

2. Forging

3. Machine Shop

BLOCK 3 LAY-OUT

STEAM TURBINE
Steam turbines are heart of power plant, they are the devices
which transform thermal energy in fluid to mechanical
energy.When high energy fluid (high pressure and high
temperature) passes through series of rotor blades, it absorbs
energy from fluid and starts rotating, thus it transforms thermal
energy in fluid to mechanical energy.

Types of Steam
Turbine
Impulse Turbine

Process of complete expansion of

steam takes place in stationary nozzle
and the velocity energy is converted
into mechanical work on the turbine
blades.

Reaction Turbine

Pressure drop with expansion and

generation of kinetic energy takes place
in the moving blades.

Impulse Turbines :
The impulse arrangement is made up of a ring of nozzles followed by a ring of blades. The
high-pressure, high-energy steam is expanded in the nozzle to a lower-pressure, high-velocity
jet of steam. This jet of steam is directed into the impulse blades and leaves in a different
direction .
The changing direction and therefore velocity produces an impulsive force which mainly acts
in the direction of rotation of the turbine blades. There is only a very small end thrust on the
turbine shaft.

Flow Through Steam Turbine

Stage

Manufacturing Process
Steam Turbine
The facilities and parts manufacturing of Steam Turbine are as follows:
TURBINE CASING MACHINING SECTION: equipped with large size Planer,
Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring
machines .
ROTOR MACHINING SECTION : Equipped with large size machining tools like
Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree
Groove Milling Machine etc.
ROTOR ASSEMBLY SECTION : Equipped with Indicating Stand, Small size
Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and
Discs.

TURBINE CASING ASSEMBLY SECTION : Machined casings are assembled

and hydraulically tested by Reciprocating Pumps at two times the operating pressure.
TEST STATION : Equipped with condensers, Ejector, Oil Pumps, Oil containers
Steam Connections etc, required for testing.

OVER SPEED VACUUM BALANCING TUNNEL: Vibration and frequency of

rotor shaft is tested at very high speed of 4500rpm.

MANUFACTURING PROCESS
1.
2.

PRIMARY SHAPING PROCESS

SECONDARY MACHINING PROCESS

PRIMARY SHAPING PROCESS

Primary shaping processes are manufacturing of a product from an amorphous material. Some
processes produces finish products or articles into its usual form whereas others do not, and
require further working to finish component to the desired shape and size. The parts produced
through these processes may or may not require to undergo further operations. Some of the
important primary shaping processes are:
.

.
.
.
.
.

Casting
Powder metallurgy
Plastic technology
Gas cutting
Bending and
Forging

SECONDARY MACHINING PROCESS

As large number of components require further processing after the primary processes. These
components are subjected to one or more number of machining operations in machine shops, to
obtain the desired shape and dimensional accuracy on flat and cylindrical jobs. The process of
removing the undesired or unwanted material from the work-piece or job or component to produce
a required shape using a cutting tool is known as machining. This can be done by a manual process
or by using a machine called machine tool (traditional machines namely lathe, milling machine,
drilling, shaper, planner, slotter).
Some of the common secondary or machining processes are:

Turning
Threading
Knurling
Milling
Drilling
Boring
Planning
Shaping

STEAM TURBINE ROTORS

DISC ROTORS

Alllarger disc rotors are now machinedout

of a solid forging ofnickelsteel this should
give the strongest rotor and a fully balanced
rotor.It is rather expensive, as theweight of
the final rotor is approximately 50%
oftheinitial forging.

DRUM ROTORS
Thefirstreactionturbineshadsolidforged
drumrotors.Theywerestrong
generally
wellbalanced as they were machined over
the totalsurface.With the increasing size of
turbines the solid rotors got too heavy
pieces.

TURBINE BLADES
Cylindrical reaction blades for HP, IP and LP
Turbines
3-DS
blades,in
initial
stages
ofHPandIPTurbine,to reduce secondary
losses.
Twistedbladewithintegral
shroud,
inlaststagesof HP, IP andinitial stagesof
LPturbines, to reduce profile and
Tipleakage losses

RECENT DEVELOPMENTS

An improved focus on project execution enabled BHEL record its highest ever
commissioning/synchronization of 15059 MW of power plants in domestic and
international markets in 2015-16, marking a 59% increase over 2014-15. With the
all-time high commissioning of 15000 MW in a single year FY2015-16, BHEL has
exceeded 170 GW installed base of power generating equipments.

During the year 2012-13, the company invested about Rs. 1,252 Crore on R&D
efforts, which corresponds to nearly 2.50% of the turnover of the company,
focusing on new product and system developments and improvements in existing
products for cost competitiveness, higher reliability, efficiency, availability and
quality etc..

REFERENCES:

Wikipedia
Figures from manufacturing data web page BHEL.com.
Google
Report maintained during training.

Thank You
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