PROJECT REPORT

ON

MANUFACTURING OF STEAM & GAS

TURBINE
BY
HIMANSHU CHOUDHARY

UNDER ESTEEMED GUIDANCE OF

M RAJESHWARA CHARY
SR. ENGINEER
BHEL, R.C.PURAM, HYDERABAD
This is to certify that Mr. HIMANSHU CHOUDHARY, student of 2rd year
,B.Tech (Mechanical Engg.) of VELLORE INSTITUTE OF
TECHNOLOGY has undergone Internship training on
MANUFACTURING OF STEAM AND GAS TURBINE in BHEL,
Ramachandrapuram, Hyderabad-502 032. from 31/05/2016 To
29/06/216 he has prepared a project report on the above subject.

He has taken keen interest in all aspects of the training. He is very

sincere, intelligent, energetic and hard working. He has completed
Internship training efficiently and satisfactorily.

I wish him all success in his future endeavours.

( M. RAJESHWARA CHARY )
Sr. ENGINEER
BHEL,
Ramachandrapuram,
Hyderabad-502032
 ACKNOWLEDGEMENT
I would like to take this opportunity to express our
heartful thanks to all those who helped in the course of
my internship training

First of all, we would like to thank our parents for

providing the moral support needed to carry out the
project. Next we would like to thank our HOD
Dr. DEVENDRANATH RAMKUMAR for allowing
us to carry out training at BHEL.

We would like to thank our guide Mr. RAJESHWARA

CHARY for taking keen interest in our internship
training and giving us a chance to carry out this project
under his guidance and also for providing all the
required technical knowledge and support required for
this project.

We would also like to thank all the members of BHEL

for giving us a helping hand in the course of carrying
out my internship training.
 INDEX

INTRODUCTION
o BHEL INTRODUCTION
o PRODUCT AND PROCESSING IN BHEL
o MAIN SHOPS IN BHEL
STEAM TURBINE
o COMPOUNDING AND ITS TYPES
o IMPULSE STEAM TURBINE
o DESIGN FEATURES OF TURBINE
o TYPES OF STEAM TURBINE
o PARTS OF STEAM TURBINE

GAS TURBINE
o GAS TURBINE MAIN SECTION
o APPLICATION OF GAS TURBINE
o BHEL HYDERABAD GAS TURBINE

ROTOR
o MACHINING AND ASSEMBLY OF STEAM TURBINE ROTOR
o STEAM TURBINE ROTOR PARTS
o SEQUENCE OF OPERATIONS IN STEAM TURBINE ROTOR
MACHINING AND ASSEMBLY
o TYPES OF BLADES
o SEQUENCE OF OPERATIONS IN BLADING PLAN
MACHINING
o ROTOR MOUNTING
o IMPULSE AND REACTION TURBINE
 INTRODUCTION

At a time when energy is such an issue in our country, it may be

surprising to realize that the major technology involved in producing
electrical energy today was developed over a century ago by Charles G.
Curtis: the steam turbine. The aim of a steam turbine is to produce the
maximum amount of electrical energy in the minimum amount of space.
Today, steam turbines produce more electrical energy than any other
system. They comprise approximately 78 percent of all generation
capability in our country.

BHARAT HEAVY ELECTRICALS LIMITED is the largest engineering

and manufacturing enterprise in India in the energy related sector today.
BHEL was established more than 45 years ago when its first plant was
set up in Bhopal and was the genesis of the heavy electrical equipment
industry in India, a dream that has been more than realized with a well-
recognized track record of performance. It has been earning profits
continuously since 1971-72 and achieved a sales turnover of Rs. 7200
crores with a pre tax profit of Rs. 650 in 2006-2007

BHEL caters to the core sector of the Indian economy viz., Power
generation and Transmission, industry, Transportation,
Telecommunication, Renewable Energy, Defense, etc., the wide network
of BHELs 14 manufacturing divisions, 4 Power sector regional centers,
over 150 project sites, 8 service centers and 18 regional offices, enable
the company to promptly serve its customers and provide them with
suitable products, systems and services efficiently and at a competitive
price. BHEL has already ISO 9000 certification for quality management,
ISO 14001 CERTIFICATION for environment management. The
organization is against the process of implementing 6 sigma TQM
concepts in order to maintain Global Quality standardization.

POWER GENERATION:
Power generation sector comprises thermal, gas, hydro and nuclear
power plant business, as of 31-03-2001, BHEL supplied sets account for
nearly 64,737 MW, which works out to 65% of the total installed capacity
of 99,146 MW in the country, against nil till 1969-70.
BHEL has proven turkey capabilities for executing power projects from
concepts to commissioning. It possesses the technology and capabilities
to produce thermal sets with super critical parameters up to 1,000MW
unit rating and gas turbine- generator sets of up to 240MW unit rating.
The company manufactures 235MW nuclear turbine generator set, and
has commenced production of 500MW nuclear turbine generator sets,
custom made hydra sets of Francis, Elton and Kaplan type of different
heats discharge combination and also engineered and manufactured by
BHEL.

POWER TRANSMISSION AND DISTRIBUTION (T&D):

BHEL offers wide range products and systems for T&D
applications. Products manufactured include power transformers,
instrument transformers, dry-type transformer, series and shunt reactors,
capacitors banks, and vacuum and SF6 circuit breakers, gas insulated
switchgear and insulators.

INDUSTRIES:
 Since inception in 1982, the industry sector business has grown at
an impressive rate and today, contributes significantly to BHELs
turnover. BHEL is the major contributor of equipment and system to
industries: Cement, Sugar, Fertilizers, Refineries and Petrochemical,
Paper, Oil, Gas, Metallurgical and other process industries. The range of
systems and equipment supplied includes: Captive power plants, DG
power plants, Industrial Steam Turbines, Industrial Boilers and axillaries,
Waste heat recovery boilers, gas turbine, heat exchangers and
pressure vessels, centrifugal compressors electrical machines, pumps,
valves, seamless steel tubes, electrostatic precipitators, fabric filters,
reactors, fluidized de combustion boiler, chemical recovery boilers and
process controls.

FUTURE:
As a large number of Gas/Naphtha-based combined cycle power
plants are likely to be set up in the future by NTPC, the plant proposes
to take up the manufacture of large Gas Turbine (70MW to 140MW) and
Aero-derivative Gas Turbine, along with matching generators.

OBJECTIVES:
The objectives of BHEL are
1) Growth: To ensure steady growth by enhancing the competitive
edge BHEL in existing business, new areas and international
operations.
2) Profitability: To provide reasonable and adequate return on capital
employed primarily through improvements in operational efficiency
capacity utilization and productivity and general adequate internal
resources to finance the companys growth.
3) Customer focus: To build a high degree of customer confidence
by providing increased value for his money through international
standards of products quality, performance and superior customer
service.
People orientation: To enable each employee to achieve his
potential and improve his capabilities; perceive his role,
responsibilities and success of the company.
Technology: To achieve technological excellence in operations by
developments of indigenous technologies and efficient adaptation
of imported technologies to suit business needs and priorities and
provide a competitive advantage to the company.
Image: To fulfill the expectations which shareholders like Govt. as
owner employees, customers and the company at large have from
BHEL.

BHEL-RAMCHANDRAPURAM UNIT HYDERABAD

 In the early sixties, BHEL, Ramchandrapuram took shape in the
outskirts of the city of Hyderabad with this idea of Bringing power to the
people. BHEL Ramchandrapuram Unit is one of the major
manufacturing units of BHEL Corporation. It made its beginning in 1965
manufacturing 12MW, 60MW and 110MW capacity Steam Turbines,
Generators and auxiliaries for the Power and Industry sectors with
collaboration of Skoda of Czechoslovakia. Realising the need for
diversification, BHEL, Hyderabad soon ventured into other area
absorbing latest Technologies from world Leaders to meet emerging
challenges and needs of the country. Steam Turbines, Gas Turbines,
Turbo-generators, Compressors, Pumps, Switchgears, Oil field
equipment, Pulverising mills, Heat Exchangers including a host of
auxiliaries, all now form profile of products at BHEL, Hyderabad.
The success story of BHEL, Ramchandrapuram has its roots in its
commitment to the nations economic growth, towards which it has
standards for itself. Striving hard to take part in building of a strong and
self-reliant India.
The BHEL Started to manufacture 12MW, 60MW and 110MW
Turbo jets for Thermal projects. Earning in the process, a reputation for
quality in products, performance and services in the power sector,
Experimenting, innovation and Diversifying all the while BHEL, added to
its product manufacturing equipment. Thermal, Nuclear and Industrial
sector.
The product of profile encompasses TG sets UPTO 200MW,
Industrial TG sets, Gas Turbines, Turbo-compressors system, Oil rigs,
Heat exchanges, Switchgear etc., in keeping with the growing product
profile, induction of complex technologies, BHEL had to put the
equipment on its shop floor with advanced infrastructure.
PRODUCT AND PROCESSES :

1. TURBINES & COMPRESSOR SHOP

a) Steam Turbines & Compressors
b) Gas Turbines & Compressors

2. TURBO GENERATORS
a) Steam Turbine Generators
b) Gas Turbine generators
3. SWITCH GEARS.
4. FERROUS FOUNDRY.
5. NON-FERROUS FOUNDRY.
6. HEAT EXCHANGERS.
7. TOOL ROOM.
8. HEAT TREATMENT.
9. PATTERN SHOP.
10. SPARES MANUFAC
11. TURING.
12. COAL PULVERIZERS.
13. PUMPS.
14. OILFIELD EQUIPMENT. (OIL RIGS)
 BHEL PRODUCTS AND COLLABORATION :

INDUSTRIAL TURBINES : SEMENS-WEST GERMANY

MARINE TURBINES : ENGLISH ELECTRIC CO. U.K

OIL RIGS : V.S.S.ENGINEERS AND

CONSULTANT U.S.A.

SWITCHGEARS : ASEA SWEDEN TURBO,

HYDRASETS MOTORS

FEED PUMPS : PROMA SHEAPORT U.S.S.R

MAIN SHOPS IN BHEL HYDERABAD UNIT

01 SHOP: GAS-STEAM TURBINES AND COMPRESSORS SHOP

It is the biggest shop floor with plinth area of 35,311 sq-m
(Approximately accommodates 1000 people). It contains nearly
25C Machines. The products are
a) Steam turbines:
i. Utility sets 60,110,120 MW
ii. Industrial sets 1.5 MW to 60MW
b) Gas turbines:
i. Frame-1 (5MW)
ii. Frame-3 (10MW)
iii. Frame-5B (25MW)
iv. Frame-6B (37 MW)
v. Frame-9E (123MW)
 vi. Frame-6FA (70MW)
vii. Frame-9FA (240MW)
c) Compressors:
Centrifugal compressors
Horizontal and vertical split type

02. SHOP: ELECTRICAL MACHINES (Turbo Generators) 18500

SQ.MTRS.

a) Turbo generators of capacity 1.5 MW to 210 MW and 500 MW

b) Synchronous condenser
c) Exciters
d) BXP Motor (Boiler feed pump)
e) Alternators

03. SHOP: SWITCHGEAR (17000SQ.MTRS)

i. Air blast circuit breaker
ii. Minimum oil circuit breaker
iii. Sulphur hex fluoride gas breaker
iv. Fuel Nozzles for gas turbines
v. Delta panel for bowl Mills
vi. Control panel for Electrical Machines
vii. Plasma coatings shows for turbines

04. SHOP: FERROUS FOUNDRY (GRAY IRON FOUNDRY)

42000SQ.MTRS.
All ferrous casting for plant production products and Castings of
Mill bases are Casted in this shop.
05. SHOPS: NON-FERROUS FOUNDRY
All non-ferrous (Aluminium & Copper) Casting required for the
plant is manufactured in this shop.

06. SHOP: HEAT EXCHANGERS AND FABRICATIONS

Heat Exchangers Fabrication
a) LP Heaters a) Stator frames
b) H.P. heaters b) Ball Mill shells
c) Deaerator c) Foundation frames
d) Ejectors
e) Condensers

07. SHOP: TOOL ROOM (1500 SQ.MTRS)

a) Figs and fixtures
b) Single and Multi point cutting tools
c) Press tools
d) Backing cone

08. SHOP: COMMON WORKSHOP (15000SQ.MTRS)

a) Heat treatment, Hardening, Tempering, Normalizing, stress-
relieving etc., for surface treatment in this section the following
operations are done.
b) Forgings (Mainly blades)
c) Electro plating, Picking, and timing etc.,
d) Babbiting
09. SHOP: PATTERN SHOP (15000SQ.MTRS)
All patterns required for Ferrous & Non-Ferrous shop are
manufactured in this shop.

10. SPARES CENTER

a) Product spares
b) Machine reconditioning center
c) Rewinding section
d) Refrigeration & Air conditioning

PULVERISERS & OIL FEED EQUIPMENT

Oil feed equipment

i. Hoisting & Rotating Equipment.

Coal Pulverizes
i. Bowl Mills
ii. Table Mills (Ball Mills)

Manpower in this shop is 583; turnover for 94-95 is 166 crores.

70. SHOP

i. Boiler feed Pumps (Capacity 210MW-500MW)

ii. Condensate Pumps
iii. Oil pumps
iv. Cooling Water Pumps
 In keeping with the growing product profile, introduction of complex
technologies and international standards, BHEL had equipped its shop
floors with advanced facilities and infrastructure that represents program
of R & D at its neighboring facility to introduce better and more effective
methods and processes all the time.
The unit has been divided into many divisions to facilitate the
smooth production flow. Each division is self-contained with the
personnel, Finance material management. Production and Commercial
functions attached it.
BHEL also got ISO 9001 Certification from BHEL in 1992/93.

STEAM TURBINES
A steam turbine is a prime mover which converts heat energy into mechanical
energy. In a conventional steam turbines cycle, water is used as the working
fluid. The water is heated in a boiler by burning fuel. It evaporates into steam
which is expanded in a turbine where mechanical power is generated. The
steam generated is of high temperature and high pressure. The temperature is
often in the 450 to 540 degrees centigrade range. The pressure ranges between
60 and 120 bar.
The essential parts of all steam turbines are similar, consisting of nozzles
through which steam flows and expands (dropping in temperature and gaining
kinetic energy) and the blades against which the swiftly moving steam exerts
pressure. The blades are mounted on rotor drum, and an outer casing confines
the steam to the turbine.
Both temperature and pressure fall as the steam passes through the
turbine. The greater the pressure drop, the more energy can be captured from
the steam. The more efficient power plants condense the steam back to water at
the end of the turbine.
The theoretical maximum efficiency of a steam turbine- based power
plant is determined by the difference between the temperature at which steam
enters the high pressure turbine and the temperature at which it exits the low
pressure turbine. The greater the temperature difference, the more energy can be
extracted.
 Steam turbines are finding greater use in process industries (like steel and
chemicals) producing large quantities of waste heat. The waste heat produced
can be used to generate steam as well as power. The capital cost of such plants
can be slightly higher but the generation of power represents a useful by-
product when the waste must be burnt in any case.
Steam turbines can also be deployed advantageously in industries with
greater requirements of both steam and power. They are used in cogeneration or
combined heat and power applications where process steam is also used in the
turbine to generate electricity. This also results in substantial improvements in
overall process efficiency.

TOWARDS HIGHER EFFICIENCY :

More efforts are being made to improve the efficiency of steam turbines. The
areas are
1. Super critical technology advances aiming for 50 percent efficiency.
2. Renovating and Upgrading for more value for money.
3. Combined Heat and Power for low cost, more flexibility.
4. Steam turbines in Combined Cycle, a new market
5. Clean coal technologies FBC, PFBC, IGCC etc to improve the overall
efficiency and to reduce the pollution level.

INTEGRATED GASIFICATION COMBINED CYCLE

COMPOUNDING OF STEAM TURBINES

 Steam jet does maximum work with good economy when the blade speed
is just half the steam speed. Due to very large rate of expansion, the steam
leaves the nozzle at a very high velocity ( Supersonic, since the pressure ratio
exceeds the critical pressure ratio and the nozzle thus used is Converging
Diverging ) of about 1000 m/sec. Even though the rotor diameters are kept
fairly small the rotational speed of 30000 rpm may be obtained. Such high
speeds can be used to drive the machines only with a large reduction gearing
arrangement. In actual De-Laval turbine the velocity of steam leaving the blade
is also quite appreciable resulting in energy loss. This amount to as high as 10-
12 percent of the steam.

One of the chief object in the development of steam turbines is to reduce

the high rotational speed of the rotor to practical limits. Several methods are
used to reduce this high rotor speed by absorbing the steam pressure or the
steam velocity in stages as it flows over the rotor blades. This is known as
Compounding.

TYPES OF COMPOUNDING :

1. Velocity Compounding ( Curtis principle )

2. Pressure Compounding
3. Mixed Compounding
 IMPULSE STEAM TURBINE

In impulse steam turbine, the overall transformation of heat into

mechanical work is accomplished in two distinct steps. The available energy
of steam is first changed into kinetic energy and this kinetic energy is then
transformed into mechanical work.
A nozzle is a passage of varying cross section area in which the potential
energy of the steam is converted into kinetic energy. The increase of velocity
of the steam jet at the exit of the nozzle is obtained due to decrease in total
heat content of the steam. The nozzle is so shaped that it will perform this
conversion of energy with minimum loss.
To overcome the feasibility of manufacturing convergent and divergent
profile, the nozzle is made in two parts and the passage between two
adjacent blades is of nozzle shape.
When the steam flows through a suitably shaped nozzle from zone of
high pressure to one at low pressure its velocity and specific volume will
both increase.
The equation of continuity
w=AV/v
Where w =Mass flow in Kg/sec
V =Velocity of steam in m/sec
A =Area of cross section in sq m
v =Specific volume in cubic m /Kg

The method of velocity staging is known as Curtis principle

DESIGN FEATURES OF BHEL STEAM TURBINES

BHEL, Hyderabad, one of four major manufacturing units of BHEL family,

is a pioneer in manufacturing of steam turbines in India. Steam turbines for
whole range of applications like cogeneration, captive power, utility, drive
and combined cycle plant applications are being manufactured under
continuing technical collaboration with Siemens, Germany. BHEL is fully
equipped to provide comprehensive solutions to customers, encompassing
system engineering, turnkey erection and commissioning including civil
 works. BHEL, with over 38 years of experience and over 540 turbines, has
perfected the art of steam turbine building in a comprehensive range,
covering every possible type of application.

In industrial applications, production process and thus the steam

parameters and flows decide the turbine selection. This makes each industrial
turbine design an individual solution, with very special design features. BHEL
has provided specific solutions with built in reliability for a wide spectrum of
industries using building block concept which is being continuously improved.
Range of capacities & Parameters of Steam Turbines :
The range of parameters cover wide spectrum encompassing all requirements of
industry.
Power Up to 150 MW
Inlet Pressure 4 ata to 140 ata
Inlet Temp 140 C to 540 0 C
0

Exhaust Up to 55 ata
Condensing Up to 0.05 ata
Speeds 3000 RPM to 15000 RPM
Types of steam turbines :

Extraction ( E series )
Back Pressure ( G series )
High pressure ( H series )
ECM Rotor ( M series )
Condensing ( K series )
Low pressure ( N series )
Double flow ( W series )
Extraction Back Pressure ( EG series )
Extraction Condensing ( EK series )
Back pressure turbines ( HG series )
Double flow condensing ( WK series )

Straight non-condensing turbine (Back Pressure turbine)

The most simple steam turbine configuration is the straight non-

condensing design. The output of the turbine is a function of the initial steam
conditions, the exhaust pressure, and the process steam demand. The power
production of this unit type is limited by the process demand.

Automatic Extraction non-condensing (Extraction back pressure turbine)

Industrial plants having steam demands at two or more pressure levels can
benefit from the use of these turbines. They provide the flexibility to
automatically respond to variations in steam demand at the extraction and the
exhaust.
Special features of steam turbines :

Building Block concept for optimum selection to suit any application

Impulse / Reaction blading for better efficiency over a range of loads
Individual design for optimum flow path
Standardized components with proven service record for high
reliability
Electronic governing system
Easy integration for cogeneration application
Wide choice of power & speeds to meet any specific requirements
Base frame design for smaller ratings

THE PARTS OF STEAM TURBINE

ROTOR

The rotor is the rotating part of the Turbine. The blading serves for
converting the thermal energy of the steam into mechanical energy. The turbine
rotor, as carrier of blades, transmits the mechanical energy impulses on the
running blades in the form of rotational energy to the driven machinery.
It rotors are made of forging of alloy steel material. The moving blades are
mounted in the grooves made on the rotor. The turbine utilizes moving and non-
moving blades. Non-moving blades are either attached directly to the turbine
casing or else they are located in the carriers. Short strips of metal, shrouding,
are attached to the outer edges of the non moving blades. This shrouding is used
to assist in maintaining rigidity of the blades. An impulse wheel at the
admission end of the rotor is equipped a different type of blading and serves as
the regulating stage or Impulse stage.
A tapped radial hole drilled into the stud of the front-bearing journal is
intended for housing the over speed monitor. Cams protruding from the
cylindrical surface of the stud at each side of the threaded hole serves as a
protection against excessive axial displacement of the rotor. Whenever such an
inadmissible axial shift of the rotor occurs during the operation of the turbine,
either of the two cams will engage with the lever of the emergency tripping
device and thus induce shutting off the steam supply.
A toothed wheel mounted by shrinking to the rear end of the rotor permits in
connection with a mechanical barring gear slow turning of the rotor by hand in
order to prevent warping.

ROTOR WITH TURBINE BLADES

Parts of steam turbine Rotor and mountings

A) Blading details
B) Front steam gland
C) Front oil gland
D) Front journal
E) Thrust collar
F) Over speed governor assembly
G) Toothed wheel
H) Rear steam gland
I ) Rear oil gland
J) Rear journal
L) Pinion for Hand barring wheel / Hydraulic barring wheel
 M) Coupling

CASING

The turbine casing is made of cast steel and is split horizontally, the joint being
level with the rotor axis. The turbine casing houses and supports the turbine
rotor, labyrinth seals, and bearings. The casing is cast in two halves and bolted
together with a metal to metal fit. The casing of back pressure turbine is
supported on separate bearing pedestals with the support surface level with the
rotor axis. This ensures the position of the casing relative to the rotor always
remains constant at all operating temperatures. The radial blade clearance thus
being unchanged. In order to permit unrestricted horizontal expansion of the
casing without moving it out center.

GUIDE BLADE CARRIERS / DIAPHRAGMS

The diaphragm is fixed to the cylinder casing contains the fixed nozzles and
serves to confine the steam flow to the moving nozzles fitted on the rotor.
 NOZZLES

EXHAUST HOOD
The exhaust hood is the portion of the casing, which collects and delivers the
exhaust steam to the condenser or exhaust pipe
CONDENSER :
The function of the condenser is to condense the steam leaving the turbine,
collect the condensate, and lower the turbine exhaust pressure.

STEAM CHEST
The steam chest, located on the forward, upper half of the HP turbine casing,
houses the throttle valve assembly. This is the area of the turbine where main
steam first enters the turbine. The throttle valve assembly regulates the amount
of steam entering the turbine. After passing through the throttle valve, steam
enters the nozzle block.

BEARING PEDESTALS
Two bearing pedestals, one on the front end other on the rear end
supports the casing including the rotor.

BEARINGS
In order to support the weight of the turbine and to maintain radial and
axial alignment, two different types of bearings are used. They are
housed in the bearing pedestals.

A) JOURNAL BEARING
Journal bearings maintain the radial alignment of the turbine and supports the
weight of the rotor. Bearings are spherically seated allowing for slight radial
misalignment during installation only. They are located on the forward and rear
end of turbine rotor. The bearings are internally lined with Babbitt, a metal alloy
usually consisting of tin, Copper and antimony.

High pressure oil is injected into the bearings to provide lubrication. The
oil is carefully filtered to remove solid particles.

B) THRUST BEARING
Thrust bearing is located in the front end bearing pedestal, and is meant to take
residual axial thrust present in the turbine which has not been eliminated by
balance piston as well as to the to maintain the axial position of the rotor in the
casing.
The thrust bearings are double acting, segment shoe, kingsbury type,
having the advantages of compactness and uniform pressure distribution on all
the thrust pads.

COUPLING
A) FLEXIBLE COUPLING: Transmits the torque from the turbines to
the reduction gears. The flexible couplings are designed so that any thrust
created in the turbines will not be transmitted to the reduction gears. They
also allow for slight radial misalignment and provide a means of
disconnecting the turbines from the main reduction gears.

GLANDS / SHAFT SEALS

The shaft seal on a turbine rotor consist of a series of ridges and grooves around
the rotor and its housing which present a long, tortuous path for any steam
leakage through the seal.
Glands with labyrinth seals are fitted at both ends where the shaft passes
through the turbine casing. The labyrinths consists of sealing strips in the
stationary part of the gland and grooves machined in the shaft. The leaking
steam is collected and returned to a low-pressure part of the steam circuit.
CONTROL VALVES / GOVERNING VALVES

The control valves regulate the amount of steam flowing to the turbine
according to the load. The cones of control valves are suspended from a beam.
The beam is supported by two spindles which are raised and lowered through a
system of levers by a servomotor arranged adjacent to the valves. The hanging
distance of each control valve is adjusted with reference to its valve seat on the
beam, so that when the beam is lifted, the valves open in a sequence and the
steam is admitted progressively to the various nozzle groups.

SERVO MOTOR

Servo motor is an activating mechanism for operating control valves of a steam

turbine. It mainly consists of two cylinders
A) Power cylinder B) Pilot valve

GOVERNING SYSTEM
The most important and vital part of the steam turbine is governing system. The
main purpose of the governing system is to maintain
- Constant speed at variable loads.
- Constant speed at varying steam inlet parameters.
- Constant speed at varying extractions and exhaust steam
Parameters / Conditions

The selection of Governors based on process requirements

- Speed / Frequency control
- Back pressure control
- Extraction pressure control
- Extraction back pressure control
- Boiler feed pump drive

The governing system should be simple in design, stable during operation

and highly reliable. The governing system consists of a number of basic
governing elements and protection. The reliability and availability of the
equipment depends on the type of governing system selected. The speed
governing elements are the speed sensor governor with the proper transformer
amplifier, servo motor and governing valves.

Types of Governors used on steam Turbines

- Centrifugal fly weight governor (Mechanical governor)
- Hydraulic governors
A) Hydro- Mechanical Governor
B) Hydro- Dynamic Governor
- Electro- Hydraulic (Electronic Governor)
- Electronic control

HAND BARRING DEVICE

HYDRAULIC BARRING DEVICE / TURNING GEAR

Steam turbines are equipped with turning gear to rotate the turbine rotor after
they have been shut down and while they are cooling. This evens out the
temperature distribution around the turbines and prevents bowing of rotors.
Large turbines are equipped with turning gear.
Turning gear:
A turning gear rotates the turbine rotor at slow speeds before startup and just
after shutdown. This minimizes the bowing of the rotor, that can cause uneven
temperature distribution in the covers and bases of the turbine. The turning gear
consists of an electric motor that gear drives the turbine rotor.
GEAR BOX

To get the required RPM for the drive and to achieve optimum efficiency.

VARIOUS AUXILIARY EQUIPMENTS

DUPLEX FILTER

Duplex filters occupy a unique position within the filter industry. They were
created to enable operators to change contaminated filter elements without
shutting down an active system. Duplex filters are popular for liquid and gas
fuel applications.

SOLENOID VALVE

The solenoid valve is intended for installation in the pressure oil circuit to the
automatic trip gear. When operated, it will interrupt the oil flow in that line. At
the same time, the trip oil circuit will be connected to the oil drain where by
emergency tripping is released. The solenoid valve is remote controlled
electrically ie it is either operated from the control room or by a protection
device.
AUTOMATIC LOW LOAD LIMITING DEVICE

QUICK CLOSING NON-RETURN VALVE

CHANGEOVER VALVE

The change over Valve limits the quantity of oil flowing to the swing
check valve during startup of the turbine.

STEAM JET AIR EJECTOR

VARIOUS MONITORING DEVICES , SAFETY AND PROTECTIVE

DEVICES

EMERGENCY STOP VALVE AND ITS TESTING DEVICE

 The emergency stop valve is the fundamental shut-off organ in the live
steam line between steam generator and the turbine. The emergency stop valve
is provided at the steam inlet to turbine. It is directly mounted on the casing
with a view to reduce the quantity of steam entrapped between the stop valve
and the control valves. In the event of sudden load throw off the more quantity
of entrapped steam may tend to over speed the turbine. It will be in the closed
position when the turbine is at standstill.
The emergency stop valve is equipped with a testing device which
permits checking of the valve spindle and piston rod for free movement at any
time without interfering with normal turbine operation.

SPEED MONITORING DEVICE

Convenience of operation or local site conditions of a turbine plant sometimes

warrant the accurate measuring or remote reading of the turbine speed. To this
effect, the speed will be measured by an electromagnetic pick-up which does
not require mechanical contact with rotating parts. This signal may also be used
as input for supplementary governor and control equipment.

OVER SPEED GOVERNOR AND ITS TESTING DEVICE

The over speed governor mounted on the rotor. During the normal operation
when the turbine speed exceeds the rated speed approximately by 10%, the
turbine trips automatically. The tester of over speed governor used to test the
freeness of the OSG pin during normal operation. The oil pressure at which the
pin comes out shall be compared with the test protocol.

TRIPPING DEVICE

In the event of a disturbance, the emergency tripping device serves for

admitting emergency trip oil. This causes closing of the valves and separation
of the turbine from the steam supply.

CASING EXPANSION MEASUREMENT

The device is used for measuring absolute displacement of the bearing pedestal
as a result of thermal expansion of the casing.

MEASUREMENT OF AXIAL DISPLACEMENT OF ROTOR

The thrust bearing forms the fixed point of the turbine rotor. An axial
displacements of the turbine beyond the given limits ( bearing clearances ) can
have serious consequences. The measuring unit operate on the eddy-current
principle.

LUBE OIL PRESSURE PROTECTION

VIBRATION MONITORING / VIBRATION PROBES

Vibration of a turbine while it is running originates from the rotor and is

transmitted to the external bearing housing through the bearing oil film which
has both spring and damping effects. Steam turbines have sensors installed to
measure the movement of the shafts in their bearings. This condition
monitoring can identify many potential problems and allows the repair of the
turbine to be planned before the problems become serious
 GAS TURBINES
TURBO MACHINES :

Turbines, compressors and fans are all members of the same family of
machines called turbo machines. Turbo machine is a power generating machine,
which employs the dynamic action of a rotating element, the rotor. The action
of the rotor changes, the energy level continuously, of the fluid flowing through
the turbo machine.

The majority of turbo machines run at comparatively higher speeds.

These machines are adiabatic machines with high fluid velocities

The power generating turbo machines decrease the energy level of the
working fluids passing through them. The principle element in a turbo machine
is the rotor, which performs the basic function of transfer of energy. The
example of these type machines are Gas turbines, Steam Turbines, etc

GAS TURBINE:

A gas turbine is an engine designed to convert the energy of a fuel into

some form of useful power such as mechanical power or high - speed thrust of a
jet. A Gas turbine basically consists of a gas generator section and a power
conversion section.
GAS TURBINE THEORY

A simple gas turbine is comprised of three main sections a compressor, a

combustor, and a turbine. The Gas Turbine operates on the principle of the
Brayton cycle, where compressed air mixed with fuel, and burned under
constant pressure conditions. The resulting hot gas is allowed to expand through
a turbine to perform work. In a 33% efficient gas turbine approximately two /
thirds of the work is spent compressing the air, the rest is available for other
work i.e.( mechanical drive, electrical generation ).

SECTION OF GAS TURBINE

GAS TURBINE DESCRIPTION :

The main sections of Gas turbine are

1. Compressor section
2. Combustion section
3. Turbine section

1. COMPRESSOR SECTION

The axial-flow seventeen stage compressor section consists of the

compressor rotor and casing, variable inlet guide vanes, and two exit guide
vanes.
In the compressor, air is confined to the space between the rotor and
stator blading where it is compressed in stages by an alternate series of rotating
( rotor ) and stationary ( stator ) air foil-shaped blades. Rotor blade supply the
force needed to compress the air in each stage and the stator blades guide the air
so that it enters the following rotor stage at the proper angle. The compressed
air exits through the compressor discharge casing to the combustion chamber.
Air is also extracted from the compressor for turbine cooling and for bearing oil
sealing.
Rotor :

The axial - flow compressor rotor assembly consists of 16 blade and

wheel assemblies and one blade and stub shaft assembly. The blade and stub
shaft assembly and the blade wheel assemblies are rabbeted and bolted together
concentrically around the rotor axis. The bolt holes are countersunk in the stub
shaft. This machining keeps the bolt heads and nuts flush with the wheel face
and reduces windage loss.

The stub shaft is machined to provide the forward and aft thrust faces and
the journal for the No1 bearing assembly, and the sealing surfaces for the No1
bearing oil seals and the compressor low pressure air seal.
 The compressor rotor assembly is dynamically balanced before it is
assembled to the prebalanced turbine rotor assembly. This completed assembly
is then dynamically balanced. The balance corrections are carefully and
properly distributed so as to compensate for internal bending moments in the
complete assembly.

Stator :

The compressor casing ( Stator ) encloses the compressor portion of the

rotor and is divided into four sections

-Inlet Casing
-Forward Casing
-Aft Casing
-Discharge Casing:

All of these sections are split horizontally to facilitate servicing.

Inlet Casing :

The inlet section directs the flow of outside air from the air inlet
equipment into the compressor blading. This section contains the variable inlet
guide vane assembly, No 1 bearing assembly, and the low pressure air seals.
Forward Casing :

The forward section of the compressor casing is downstream of the inlet

section. It contains the stator blading for stages 0 through 3. Bleed air from the
4th rotor stage ( Between the 3rd and 4th stator stages ) can be extracted through
four ports which are located about the aft section of the compressor casing.

Aft Casing :

The aft section, downstream of the forward section, contains the stator
blading for stages 4 through 9. Bleed air from the 10th rotor stage
( Between the 9th and 10th stator stages ) can be extracted through four ports
which are located in radial alignment with the ports used for 4 th stage air
extraction.

Discharge Casing :

The discharge section of the compressor casing, downstream of the aft

section, contains the stator blading for the stages 10 through 16, and exit guide
vane stages 1 and 2. A radially enlarged ( Bulkhead ) portion of this section
provides the mounting surface for the combustion chambers. Ten air foil shaped
support struts are secured equidistantly about the aft surface of the bulkhead
and angle inward to support the inner casing assembly ( inner barrel ). The
space between the forward portion of the inner barrel and the discharge section
outer shell, forms an annular air path that the high pressure air passes through to
enter the combustion section. This area is designed to decelerate the air flow
and increase static pressure of the combustion air supply.

Blading :

The stator blades have dovetail-shaped bases that fit into dovetail shaped
openings into the two-piece, semi circular ring. The ring fits into the groove of
the same shape machined in the compressor casing wall. Locking keys prevent
the rotating of the blade rings. The rotor blades also have dovetailed bases of a
wide angle design which fit into the matching dovetail openings in the wheels.
The rotor blades are peened in place.

Variable Inlet Guide Vanes:

The variable inlet guide vanes (in conjunction with 10 th stage air
extraction) permits fast, smooth acceleration of the turbine without compressor
surge (pulsation). A hydraulic cylinder, mounted on a base cross member,
actuates the inlet guide vanes through a large ring gear and multiple small
pinion gears.

2. COMBUSTION SECTION

The combustion section consists of combustion chambers, fuel nozzles,

flame detection equipment, spark plugs, and transition pieces.
The combustion chambers are arranged concentrically around the axial-
flow compressor and are bolted to the compressor discharge section bulk head.
Air for combustion is supplied directly from the axial flow compressor to the
combustion chambers. Fuel is fed into the chambers through fuel nozzles that
extend into each chambers liner cap.

Combustion chambers

The high pressure air flow from the compressor discharges into the
annular space created by the aft end of the discharge casing, frame assembly
and the forward section of the turbine shell. Up to this point, the air flow has
been in aft direction; now the air flow reverses. The air enters the combustion
chambers and flows forward, entering the liner through holes and louvers in the
liner wall. A portion of the air reaches the head of the combustion chamber and
enters the liner cap and the vortex generator nozzle.

The air flow through the combustion chambers has three functions

a) To oxidize the fuel

b) To cool the metal parts
c) And to adjust the extremely hot combustion products to the desired
turbine inlet temperature

Spark plugs

Combustion of fuel and air mixture is initiated by the spark plugs with
retracting electrodes. The spark plugs, installed in two of the combustion
chambers, receive power from the ignition transformers. The chambers without
the spark plugs are fired with flame from the fired chambers through
interconnecting cross fire tubes.

Ultra violet flame detector

 During the starting sequence, it is essential that an indication of the
presence or absence of flame be transmitted to the control system. For this
reason, a flame monitoring system is used consisting of two sensors which are
installed on two adjacent combustion chambers and an electronic amplifier
which is mounted in the turbine control panel.

Fuel nozzles

Each combustion chamber is equipped with a fuel nozzle that emits the
metered amount of fuel into the combustion liner. Gaseous fuel is admitted
directly into each chamber through metered holes located at the outer edge of
the swirl plate. When the liquid fuel is used it is atomized in the nozzle swirl
chamber by means of higher pressure air. The atomized fuel/air mixture is then
sprayed into the combustion zone. Action of swirl tip imparts a swirl to the
combustion air with the result of more complete combustion and essentially
smoke free operation of the unit.
Crossfire tubes

The 10 combustion chambers are interconnected by means of crossfire

tubes. These tubes enable flame from the fired chambers containing spark plugs
to propagate to the unfired chambers.

Transition pieces

The transition pieces are the hot gases path link between the combustion
chambers and the first stage nozzle. They are clamped to the forward side of the
nozzle assembly. The nozzle assembly is sealed at both its outer and inner
periphery to prevent the leakage of hot gases. Before the compressor discharge
air flows into the combustion chamber, it must first pass around the transition
pieces. This encounter affords an exchange of heat ie cooling the transition
pieces and preheating the combustion air.

3. TURBINE SECTION

In the turbine section, high temperature gases from the combustion

section are converted to the shaft horsepower. The power required to drive the
load package and the compressor is provided by the two stage turbine rotor in
case of Fr5 design and by three stage turbine in case of Fr6 design. In case of
Fr5 design the first and second stage wheels are bolted together to make up a
single unit through which first and second stage nozzles direct the flow of
combustion gases.
Turbine rotor assembly

The turbine rotor assembly consists of the distance piece and the first
and second stage turbine wheels and buckets in case of Fr5 design.
The turbine wheels are forged of high temperature alloy steel. The second
stage wheel is forged with a stub shaft on which the journal and sealing surfaces
is machined for the No 2 bearing and its oil seal. At the stub shaft end is a
flange to couple the shaft to the driven device. The buckets have pine tree
slots.
The individual components of the rotor assembly are pre-balanced and
assembled so that the complete rotor assembly will required a minimum of
correction. The rotor assembly is dynamically balanced with any required
corrections carefully distributed to compensate for internal bending moments.
The turbine rotor assembly is bolted to the pre-balanced compressor rotor
assembly This complete rotor assembly is again dynamically balanced with any
required corrections carefully distributed to compensate for internal bending
moments.

Other important parts of Gas turbine:

BEARINGS
 The gas turbine unit has two main bearings, one located in the inlet
casing and the other located in the exhaust frame. Both bearings support the
compressor / turbine rotor, together called unit rotor. The No 1 bearing consists
of three major components: loaded thrust bearing, unloaded thrust bearing, and
journal bearing.
In addition, this bearing assembly contains an oil seal ring to ensure even
distribution of the lubricating oil on the rotor shaft.
The No 2 bearing assembly contains a journal bearing only.
The bearing assembly include oil seal assemblies, lube oil feed and drain
connections and the housing which encloses the assemblies: with the assemblies
keyed to the housing to prevent their movement with shaft rotation.

Lubrication System :

The main turbine bearings are pressure lubricated by lube oil supplied
from the lube oil header. The lube oil from the header flows through branch
lines to an inlet in each bearing housing.
The high pressure oil feed piping, when practical is run within the low
pressure tank drain line, or drain channels, as a protective measure. This type of
construction is referred to as double piping. In the event of high pressure pipe
leak, oil will not be sprayed on associated equipment and create a hazardous
condition.
When the lubrication oil enters the housing inlet, it flows into an annulus
around the bearing liner. From the annulus the oil flows through machined holes
in the liner to the journal bearing. Lubricating oil is prevented from escaping
along the turbine shaft by oil seals.
The drain oil, returns through passages in the bearing housing, then into
the drain line to the oil tank.
All the lube oil to the bearing is filtered and supplied at a controlled
temperature and pressure. Flow sights and thermocouples are installed in the
drain piping from each bearing. Flow sights provide a visual check of the oil
flow through the bearings and thermocouples provide indication of oil
temperature on the temperature indicator in the turbine control panel.
COUPLINGS

The couplings used on the turbine to connect the accessory drive gear
with the turbine shaft and to connect the turbine rotor with the load equipment.

Flexible gear-type couplings are installed on the gas turbine to do the

following
a) Connect two rotating shafts in order to transmit torque from one to the
other
b) Compensate for different types of misalignment ( Parallel, angular and
combination of both )
c) Compensate for axial movements of the shafts

APPLICATIONS OF GAS TURBINES

Gas Turbines are used in various fields for various applications such as:

1) POWER GENERATION

Higher capacity gas turbines are widely used in power generation and stand by
The grid system :Power is produced and distributed continuously
to large distances through a grid systems
Stand by generation : Power is produced for emergency uses in
hospitals, public building only for local purpose.

2) MECHANICAL DRIVE APPLICATION

To pump gas and oil through pipeline.

Instead of engines where power ranger is of range above 6 MW
where the scope of diesel engines is almost nil.

3) AUTOMOTIVE APPLICATION

For high speed engines.

For gas cars.
Hybrid electric vehicles. ( The gas turbines supply power to
recharge batteries of electric motors).
For racing cars.
In battle tanks.
 4) MARINE APPLICATION

Merchant containers.
Submarines.

5) AIR CRAFT APPLICATION

Unmanned vehicle systems.

Commercial aircrafts and military trainee.
Advanced military fighters.
Missiles.

6) CHEMICAL PROCESSING

Process drivers.
Petroleum production.
Natural gas manufacturing.
Plastics manufacturing.
Ethylene production

BHEL HYDERABAD GAS TURBINES

BHEL-Hyderabad has earned a name for successful diversification over

the years into a wide range of products and systems for Utility / Industry
Sectors.

BHEL_ started manufacturing of Heavy Duty Gas Turbines in technical

collaboration with General Electric,USA in 1986. M/s General Electric with
more than 50 years of experience in Power industry is the market leader in gas
Turbines business with over 6000 installations and 200 million fired hours
experience.

BHEL has already installed over 90 machines including exports to

Malaysia, Saudi Arabia, Oman with fired hours experience of over 2 million.
This includes operation of scores of machines firing Naphtha.

BHEL GAS TURBINES AN IDEAL CHOICE

 BHEL Gas Turbines ( of GE technology ) have been developed over the
years based on wide ranging requirements of customers and have following
advantages.

Capability to fire a wide range of gaseous fuels ( Natural Gas, Refinery

Gas, LPG, Low Btu gases), Liquid fuels ( Distillate, Naphtha, Kerosene
etc ), Residual heavy fuels ( Furnace oil, LSHS etc.) and a mix of
gaseous and liquid fuels etc.
Capability to ensure fuel economy over a wide range of ambient
temperatures and loads.
Black start, Quick start and Emergency start facility
Options are available for choosing type of starting device as per need.
Models below 100 MW are suitable for both 50 HZ and 60 Hz
applications.
State -of -the-art micro-processor based control system with redundant
protection to ensure maximum reliability and fast response.
Package concept to limit site work to the minimum.
Low exhaust emission levels:

Reduced smoke levels because of air atomization. Nox emission can

be controlled with water/steam injection and through the use of
advanced multi nozzle Quit Combustors/Dry Low Nox combustors.

Available as a building block for integration to Combined cycle,

Cogeneration plants.
Controlled noise level:
Noise level can be controlled with special acoustic arrangements
Suitable for power generation and mechanical drive applications.
Ideally suited for Integrated Gasification Combined Cycle (IGCC )
plants.
BHEL is one of the few GE licensees to manufacture Rotor and Hot
Gas components.
GAS TURBINE MODELS FROM BHEL HYDERABAD

MODEL ISO RATING WEIGHT

OUTPUT HEAT RATE TONS
( KW ) ( Kcal / kwhr )

MS3002J 10450 3357 69

MS5001PA 26300 3022 84

MS6001B 39620 2699 91

MS6001FA 70140 2515 110

MS9001E 123400 2545 220

Technical details of Four frames of Turbines

Description Fr1 Fr3 Fr5 Fr6

MW Rating 4.77 10.88 25.25 38.49

Speed 102.9 6500 5105 5105
Efficiency % 26 26.4 27.7 36.3
Turbine inlet 943.3 943.3 943.3 1104
Temp Deg C
Turbine Exhaust 535 526.7 493 543
Temp Deg C
No of shafts 2 2 1 1
No of Combustors 1 6 10 10
No of Comp Stages 15 15 17 17
No of Turbine Stages 1+1 1+1 2 3
No of journal bearings 4 4 2 2
Wt of pkd Unit( Tonnes ) 30.4 51.26 83.2 89.9
Wt Flange to flange 12.1 21.64 29.5 31.8

MODEL MS3002J ( FR 3 )

MS3002J is a two shaft machine along with simple cycle operation or

regenerative cycle variants. This gas turbine is ideally suited as a prime mover
for mechanical drives or for captive power generation. Suitable gear box if
required is provided between gas turbine and driven equipment. These gas
turbines are compact and hence suitable for transportation to inaccessible areas.
BHELs experience includes supplies to industries and utility for mechanical
drive application as well as captive power generation.

The main features of the gas turbine are :

15 Stage axial compressor

Reverse flow type, laterally mounted 6 nos combustion chambers
Single stage LP & HP turbines
Variety of starting means like motor, diesel engine
All major accessories are shaft driven with redundant systems on base
Second stage variable angle nozzles
Widely used as mechanical drive for gas/oil transportation/other
applications

MODEL MS5001PA ( FR 5 )

This single shaft Heavy Duty Gas turbine, has earned the name as
Industrys workhorse and is ideal for base/peak load power generation and
cogeneration /combined cycle operations. It is also used as prime mover for
mechanical drive applications.

The main features of the Gas turbines are :

17 Stage Axial compressor and 2 Stage turbine
Combustion system consisting of 10 nos reverse flow combustion
chambers.
Provision of modulating inlet guide vanes for decreasing the air flow,
independent of unit speed to provide for higher efficiency over a wide
load range.
Long shank buckets designed to isolate turbine wheel rim from Hot gas
path. Fist stage buckets with Vacuum plasma spray ( VPS ) coating
Long diffuser, turning vanes and generous casing /plenum dimensions to
maximize recovery of last stage residual kinetic energy.

BHEL can provide suitable two shaft machines for mechanical drive
applications.
MODEL MS6001B ( FR 6 )

This is one of the most popular 30-40 MW range single shaft gas turbine
with traditional features of fuel flexibility, efficiency, compactness and ease of
operation & maintenance. Ideally suited for captive generation, cogeneration
and combined cycle applications.

Some of the features of the Gas Turbine are:

17 Stage axial compressor and 3 Stage turbine.

Combustion system consisting of 10 nos reverse flow combustion
chambers ( Slot cooled ).
First stage VPS coated buckets
Air cooled first and second stage nozzle segments, precision cast from
corrosion resistant super alloys.
Three stage disc type turbine with first two stages cooled with
compressor discharge and extraction air.
Modulating inlet guide vanes for higher efficiency over a wide load range
in combined cycle/ cogeneration applications.
Rugged two bearing construction.

BHEL can provide single base as well as split base designs.

MODEL MS6001FA ( FR 6 FA )

This model combines the features of Aircraft engines with the heavy duty
models without compromising on the reliability / availability aspects. The
development of this model takes into consideration the long term IGCC
requirement and hence is capable of supplying 20% compressor discharge air
for gasification.

Major new generation features (F technology ) in this model are :

Directionally solidified first stage buckets with serpentine cooling ( to

support higher firing temperature )
Axial exhaust diffuser for optimum performance in heat recovery
applications
Honey comb shroud/diaphragm seals
 Two bearing design

Salient constructional features of the 6FA machine are :

18 Stage Axial compressor and 3 stage turbine

Modulating IGVs for compressor inlet flow variation
Inlet stage air extraction for cooling, sealing and surge control during
startup
Six combustion liners ( inner walls with thermal barrier coating )
Impingement cooling through a perforated shelf for transition pieces
Accessory systems like lube oil/ gas fuel module, liquid fuel and
atomizing air compressor models are independent with their own drives.
There is no accessory gear box
Off-base turbine enclosure to facilitate more space for maintenance
( with a host facility inside )
Axial Exhaust and front end drive for generator
Starting through motor or static frequency converter

MODEL MS9001E ( FR 9 )

Designed specially for 50 Hz operation, the MS9001E has provided to be

a workhorse in the global power industry. The design characterizes all well
proven and rugged features of across the line BHEL-GE Gas Turbines including
excellent fuel flexibility. Like other BHEL-GE GTs, this model is versatile. Its
compact design lends itself to flexibility in plant layout and easy addition of
increments of power in phased manner. The 3- bearing design of the rotor
system provides a dynamically stable and rugged rotor. Whether in simple cycle
or combined cycle application, base load or peaking duty, 9E packages are
comprehensively engineered with integrated systems that include controls,
auxiliaries, ducts and silencing. They are designed for reliable operation and
minimum maintenance.

The major constructional features are :

17 Stage axial compressor

Variable inlet guide vanes for optimum efficiency
Pressure lubricated three bearing system
Combustion system consisting of 14 nos reverse flow combustors
3 Stage turbine, air cooled First stage and Second stage nozzles and
buckets
 Factory packed and tested accessory

ROTOR
 MACHINING AND ASSEMBLY OF STEAM TURBINE
ROTOR
1. Inspection of the forging and verification of test certificates

The steam turbine rotor comes as a forging with the allowances on

diameters and lengths. The documents are verified for its work order and
drawing numbers. The material marks like forging number and heat number are
verified and attested by the quality control inspector.
2. Centering both the ends with 60 or 90 degrees
The forging is moved for machining the centres on horizontal boring
machine suitable to the CNC machine on which it is planned.
3. Rough and finish machining of blading plan including the front and rear
glands
After centres the rotor is loading on the CNC machine such a way that
the rotor portion from front oil gland to rear gland can be machined. A skim
cut will be taken on the tail stock side for steady rest support and the centre
angles are corrected which was made earlier on horizontal boring machine.
The blading plan machining is carried out in a sequence front gland to rear
gland.
4. Marking for lock ways ( Blade grooves ) openings and radial balancing
plane holes and angle holes on front and rear gland area
The marking operation is carried out for blade groove openings, radial
balancing plane holes and LP blades position. The blade groove openings
follow the sine curve with 360 degrees rotation ie all the openings are not
made in the same plane.
5. Lock way opening and holes drilling and tapping on balancing plane
The lock way opening operation is carried out on horizontal boring machine
with the help of end mills suitably with small radius. The shape of the opening
follow the moving blade blade root.
6. Sealing fins caulking on blading plan and glands
The sealing fins in between the moving blade rows arrest the steam leakage
from high pressure stage to the low pressure stage. The projecting fins keeps a
small gap for stationary blades shrouds which are mounted in the casing. The
sealing fins are made out of spring steel and rolled to the required diameter of
the rotor on special purpose rolling machine and the bottom side of the fin is
bent to the L shape for holding it in the fin groove when caulked along with a
wire of square cross section. The fins along with the wire is caulked with the
help of chisel operated with pneumatic gun.
7. Sealing fins turning
The excess diameter of the sealing fins are turned on the lathe and required log
sheets are maintained after measuring by the quality control inspectors. The
operation is to be carried out before blading as it is difficult to measure the
diameters after blading.
8. Lock way regulation
The lock way openings made on horizontal boring machine allows a small
radius in the corners due to the cutter radius. The corner material is chipped off
with the help of chisels and the groove is made suitable for blade entry.
9. Blades assembly
After completion of lock way regulation, the moving blades of that particular
row are identified and inserted through the opening. Each blade is inserted into
the opening in position and a brass packing piece having the radius is inserted
below the blade and hammered such that the blade lifted above and touches the
top suspension surface. While mounting the blades, the gap between the two
blades are maintained to the requisite value.
10. Lock way drilling and tapping
After assembling all the blades the lock way closing is done with a blade which
does not have any root details like other blades. The final gap between the two
blades near the opening is measured accurately and the lock blade is machined
accordingly. After mounting all the blades of different rows in the similar
method ,the lock blades of all the rows are drilled and tapped and screws are
fixed into the tapped holes such that the blades should not come out of the rotor
due to the centrifugal force which is acting on the blade while rotation.
11. Screws fixing with ball and impression
After drilling the holes they are tapped and screws are fitted with a steel ball
under the screw and impression is taken on the screw bottom to ensure the drill
depth and positive locking of the screw with the tapped hole. The ball is
working as a locking arrangement for the screw. The additional length of the
screw above the blade is chipped of with chisel manually.
12. A-Wheel drilling
All the high pressure Impulse blades are with fork type root. The impulse wheel
diameter is always bigger than the first stage reaction row. The fork root blades
are placed in position with the help of fixture on the rotor drilling and taper
reaming operations are carried out on special purpose drilling machine. The gap
between the blades is controlled carefully. After drilling and reaming the blades
are fixed in position with the taper pins and hammered with pneumatic
machines. The uneven surface is turned while finish machining.
13. LP- blades drilling
In some industrial turbines the last row LP blades are with fork type root. The
fork root blades are placed in position with the help of fixture on the
rotor.Drilling and taper reaming operations are carried out on special purpose
drilling machine similar to A-Wheel drilling. After drilling and reaming the
blade is removed and numbered including the rotor location so that the
numbered blade with the same location is to be used while assembly.
14. Fir-tree root machining
The big capacity rotors above 30 MW, the last stage LP rows are designed some
times with Fir-tree root as a requirement instead of inverted double T-root and
Fork root. The root machining is carried out on horizontal boring machine. The
rotor is mounted on hydrostatic steadies at both ends on journal area. The rear
end is held in the indexing mechanism for accurate rotation for each position of
the blade root. The rotor is indexed for the groove position and locked with the
steady rests hydraulically. The fir-tree machining is carried out in two different
ways. In the first method the groove machining is carried out with the help of
fir-tree attachment. The attachment is capable of making the rotation in an arc
set to the required radius while cutting. In the second method no attachment is
being used and the cutter moves in an arc with a CNC program.
15. Flange hole drilling and reaming

The output end of the steam turbine rotor is connected with the generator with a
coupling. The coupling are of two types First one is called the rigid coupling
and the second one is called the flexible coupling.The rigid coupling in the form
of a flange. The flange is the either integral with the rotor or separate flange
mounted by shrink fitting and keyways. The coupling holes are machined on
horizontal boring machine including the reaming operation with the help of a
jig or with a CNC program.The reaming operation itself is having some
allowance to carry out the final reaming operation along with the generator
rotor flange at site.
16. Shrouds, journals and ends including the coupling area

The shrouds machining is carried out after the mounting the moving blades
having shrouds. Along with both the journals and end details with CNC
programs. So much of care will be taken to avoid deviations while machining
the shrouds journals and ends. The flexible coupling is mounted on the taper
portion which is on the rear end of the rotor. The taper surface is blue matched
with the coupling while machining.
Journal machining : Both the Journals machining is carried out with lot of
care. The blading plan diameters set within 20 microns on both the ends and
journal machining is carried out in three steps with single point tool. After
machining and polishing with fine abrasive paper, the cylindricity and run outs
are measured in three areas along the length of the journal in both the planes
within 10 microns and recorded. The surface is rolled with hardened rollers by
applying pressure on the roller and the lubrication oil. After that the surface is
once again polished with fine abrasive paper and a diamond tool is passed over
the surface under the spring tension. The surface gives mirror finish after this
operation.
17. Total length machining including the threading.

The total length machining and threading operations are carried out on
conventional lathe some times after carrying out the remaining pending
operations like key phasor etc on horizontal machines.
18. Machining Over Speed Governor (OSG )details in the front end
The over speed governor mounted in the front portion of the turbine rotor.
During the operation when the turbine speed exceeds the rated speed
approximately by 10%, the spring loaded pin which is mounted in the OSG
body projects out of the body due to the centrifugal force and turbine trips
automatically.The OSG details are part of the rotor which are made in the
integral rotor as per the customer requirement. Most of the OSG bodies are
machined separately and mounted on the rotor.

19. Key ways, Balancing holes on oil gland etc in front and rear ends
The operations like keyways, balancing holes etc which are not carried out
earlier are completed on horizontal boring machine.

20. Blue matching and key way matching for coupling

The high capacity utility turbines which runs at 3000 RPM and connects the
generator is provided with rigid coupling ie flange type coupling. The high
speed turbines are designed with flexible coupling. The coupling is mounted
separately on the rear end of the rotor and locked with threaded nut. Before
mounting the coupling onto the rotor shaft the surface is blue matched with the
same coupling which is going to be mounted. In some design the keyways and
keys are existing for positive locking of the coupling. The keyways also
matched with the key and the coupling is mounted on the shaft.

21. Shrinking of pinion for hand barring device / Hydraulic barring wheel
The hand barring wheel is used to rotate the rotor after the turbine have been
shut down to prevent bowing. The arrangement is made to rotate the pinion by
manually or by some other mean. Sometimes the hydraulic barring wheel also
mounted on the rotor in addition to the pinion. The hydraulic barring wheel also
for the same purpose it works similar to a pelton wheel, where the hydraulic oil
at high-pressure and velocity impinges on the barring wheel blades.
22. Assembling of OSG parts / Body mounting on the rotor
The assembling of OSG parts in the body is done as per the assembly sequence.
The parts are drawn from stores including the spring which is calibrated. The
individual parts are also measured dimensionally before assembly. The
assembled body of OSG the mounted on the rotor and indicated with reference
to the rotor.

23. LP blades assembly / Frequency test

The LP blades used for drilling and reaming are collected and assembled as per
the numbering. The taper pins are driven from one side and hammered. After
assembly the individual blades are subjected to the frequency test by Quality
Control inspector. If the values are within the limits the assembly of the blade is
acceptable and the values are recorded in log-sheet.

24. Mounting of Lacing wire or Double end taper pins

The double end taper pins are mounted along with the blades. The lacing wire
mounting is carried out by passing the wire, steel rod, through a set of the
blades.
The ends of the wire is locked by brazing.

25. Tip grinding for LP blades

The tip grinding operation is carried out only for LP blades to achieve the
required diameter. The operation is carried out on lathe with pneumatic or
electric abrasive wheel hand grinder. The grinder is fixed on the tool post
similar to the cutting tool. The taper or plain diameters for the blades are
maintained with carriage movement.

26. Centrifuging, Balancing without coupling

The rotor is sent for centrifuging and balancing. The balancing operation is
carried out without flexible coupling. The balancing weights are added in the
balancing grooves made in the front and rear reference plane and in the
balancing holes made in the blading plan. The centrifuging is carried out at 120
% of the rated speed.

27. Projection turning

After first balancing and centrifuging the rotor is loaded on lathe and the
projections of the blades are removed by taking a small cut on the shroud
diameters. The projections are generally observed on lock blades.

28. Coupling assembly

The rigid couplings are heated separately to a particular temperature and
mounted on the shaft. The flexible couplings are fixed on to the shaft by
expanding the bore of the coupling by allowing the hydraulic oil with high
pressure through the shaft and pushing hydraulically. After the keeping in
position the oil pressure is released.Separately designed hydraulic fixture is
used for this purpose.
29.Final balancing
The final balancing operation is carried out after mounting the coupling. The
rotor is subjected to the rated speed and the balancing weights added in the
earlier balancing operation are corrected to achieve finer balancing.

30.Testing
The testing operation is carried out after balancing. The rotor is lowered in to
the casing. The require clearances are verified and recorded in the log sheets.
The rotor allowed to run in the turbine to the maximum tripping speed. The
function of the mechanical OSG governor also verified.

31.Final polishing after testing and dispatch

The rotor is removed from the turbine casing after testing. The physical checks
are made. The rotor is polished thoroughly, packed dispatched.

PARTS OF ROTOR
The whole steam turbine rotor construction is divided in three parts
1. BLADING PLAN

Blading plan, also called it as blading portion, is the portion of the rotor
which converts the heat energy of the steam into mechanical energy while it
flows from front portion to the rear portion. The blading plan is fitted with one
row of impulse type moving blades and no of reaction type moving blades. The
passage between two adjacent blades makes a nozzle for steam flow. The root
details of moving blades depends upon the strength required to keep the blades
in position. The various bladeroot and other details machined on the blading
plan are mentioned below.
a) Inverted single T-root :

All the high pressure reaction blades are with inverted T-root details. Except
the Impulse stage.
b) Inverted double T-root :

Some of the Low pressure blades are with inverted double T-root details.
C) Fork root :
All the high pressure Impulse blades and some of the last row LP blades are
with fork type root. The fork root blades are placed in position on the rotor and
taper drilling, reaming operations are carried out on special purpose drilling
machine. The gap between the two blades are maintained while drilling.
d )Firtree-root :
The big capacity rotors above 30 MW, the last stage LP rows are designed some
times with Firtree root as a requirement instead of inverted double T-root and
Fork root.
e) Sealing fin grooves:
The sealing fin grooves are machined along with the finish machining of
balding plan.
f) Balancing grooves:
Balancing grooves are made on either ends of the blading plan to carry the
unbalance weight while rotor is balanced after completion total machining and
assembly. For big capacity rotors the additional balancing plan is given in the
middle of the rotor. The balancing weights are in the form of segments and
locked in the position after fixing.
g) Tapped Balancing holes:
Tapped balancing holes are provided in the middle of the blading plan to
accommodate the balancing weights.The balancing weights are in the form of
screws. The weights are locked in the position with the help of steel balls in the
bottom.
2. FRONT END

The front end consisting of front steam gland, front oil gland, front journal,
thrust collar, OSG parts, toothed pinion for electronic governing control and
pinion for to drive the main oil pump.
3. REAR END

The rear end consisting of rear steam gland, rear oil gland.Rear journal, barring
wheel, hydraulic barring wheel and coupling which is connected to the load.

SEQUENCE OF OPERATIONS IN STEAM TURBINE ROTOR

MACHINING AND ASSEMBLY

OP NO DESCRIPTION
1. Inspection of the forging and verification of test certificates
2. Centering both the ends with 60 or 90 degrees
3. Rough and finish machining of blading plan including the front
and rear glands
4. Marking for lock ways ( Blade groove) openings and radial
balancing plane holes and angle holes in front and rear gland
area.
5. Lock way opening and holes drilling and tapping on balancing
plane
6. Sealing fins caulking on blading plan and glands.
7. Sealing fins turning
8. Lock way regulation
9. Blades assembly
10. Lock blade drilling and tapping
11. Screws fixing with ball and impression
12. A - Wheel drilling ( Fork root type )
13. LP drilling ( Fork root type )
14. Fir-tree root machining
15. Flange hole drilling and reaming (For utility turbine rotors)
16. Shrouds, journals and ends machining including coupling taper.
17. Total length finishing including threading
18. Machining Over Speed Governor (OSG )details in the front end
19. Key ways, Balancing holes on oil gland etc in front and rear
ends
20. Blue matching and key way matching for coupling
21. Shrinking of pinion for hand barring device / Hydraulic barring
wheel
22. Assembling of OSG parts / Body mounting on the rotor
23. LP blades assembly / Frequency test
24. Mounting of Lacing wire or double end taper pins
25. Tip grinding for LP blades
26. Centrifuging, balancing without coupling
27. Projection turning
28. Coupling assembly
29. Final balancing
30. Testing
31. Final polishing after testing and dispatch

TYPES OF BLADES
 Moving blades Guide blades

A-Wheel blades Nozzles

HP moving blades HP Guide
blades
LP moving blades LP Guide
blades

TYPES OF MOVING BLADE ROOTS

Single inverted T-root
Double inverted T-root
Fork root
Fir tree root

TYPES OF BLADE MATERIAL

X20Cr13 ( Suitable for working temp
up
to 400 deg c )
X22crMoV12.1 ( Suitable for working temp
from 400 to 500 deg c )
SEQUENCE OF OPERATIONS IN BLADING
PLAN MACHINING

1. MATERIAL ATTESTATION OF FORGING

2. CENTERING ON BOTH ENDS INCLUDED ANGLE 90DEG / 60

DEG

3. LOADING IN BETWEEN CENTRES ON LATHE

4. REFERENCE CUT FOR STEADY

5. SHIFT THE STUDY TO REFERENCE CUT AREA

6. CORRECT THE CENTRES AND GIVE TAILSTOCK SUPPORT

7. ROUGH MACHINE THE BLADING PLAN DIAS AND LENTHS

WITH SURFACE ALLOWANCE OF 1 MM

8. BLADE GROOVES ROUGHING

9. FINISH TURN ALL THE BLADING PLAN DIAS AND LENGTHS

10.FINISH TURN THE BLADE GROOVE DETAILS

11.MACHINING OF SEALING FIN GROOVES

12.ROUGHING AND FINISHING OF LP AND A-WHEEL

13.BALANCING GOOVES ETC

14.FRONT AND REAR GLAND ROUGHING AND FINISHING

15.MARKING 12 PARTS AND INDICATIONS

 TYPES OF COUPLING FOR POWER
TRANSMISSION

1. INTEGRAL FLANGE
2. MOUNTABLE RIGID FLANGE
3. FLEXIBLE COUPLING
MECHANICAL OVERSPEED GOVERNOR

1. INTEGRAL WITH THE ROTOR

2. MOUNTED SEPERATELY