Vocational Training Report

Turbine Blade Shop-Block 3

Bharat Heavy Electricals Limited
Ranipur,Haridwar (Uttrakhand)

Submitted By: Submitted To:

Yuganter Rawat Mr. Hitendra Bankoti

B-Tech 3 year

Amrapali Institute of technology and science.Haldwani

ACKNOWLEDGEMENT

"An engineer with only theoretical knowledge is not a complete

engineer. Practical knowledge is very important to develop and apply
engineering skills". It gives me a great pleasure to have an
opportunity to acknowledge and to express gratitude to those who
were associated with me during my training at BHEL.

Iam very great-full to Mr. R.M. Meena for providing me with an

opportunity to undergo training under his able guidance.
Furthermore, special thanks to Mr. Pradeep Pandey for his help and
support in haridwar. Last, but not the least, I would also like to
acknowledge the immense pleasure, brought about by my friends
Adhar,Ashis, Rohit as they pursued their training along with me. We
shared some unforgettable moments together.
Iexpress my sincere thanks and gratitude to BHEL authorities for allowing
me to undergo the training in this prestigious organization. I will always
remain indebted to them for their constant interest and excellent guidance in
my training work, moreover for providing me with an opportunity to work
and gain experience.

THANK YOU

3
B.H.E.L- An Overview

BHEL or the Bharat Heavy Engineering Limited is one of the largest

engineering and manufacturing organizations in the country and the
BHEL, Haridwar is their gift to Uttaranchal. With two large
manufacturing plants, BHEL in Haridwar is among the leading
industrial organizations in the state. It has established a Heavy
Electrical Equipment Plant or HEEP and a Central Foundry Forge
Plant or CFFP in Haridwar.

The Heavy Electrical Equipment Plant in Haridwar designs and

manufactures turbo generators, AC and DC motors, gas turbines and
huge steams. The Central Foundry Forge Plant in Haridwar deals with
steel castings and manufacturing of steel forgings.
The BHEL plants in Haridwar have earned the ISO - 900l and 9002
certificates for its high quality and maintenance. These two units have
also earned the ISO - 14001 certificates.Situate in Ranipur near
Haridwar, the Bharat Heavy Engineering Limited employs over 8,000
people.

BHEL is an integrated power plant equipment manufacturer and one of the

largest engincering and manufacturing companies in India in terms of
turnover. BHEL was established in 1964, ushering in the indigenous Heavy
Electrical Equipment industry in India -a dream that has been more than
realized with a well-recognized track record of performance. The company
has been carning profits continuously since 1971-72 and paying dividends
since 1976-77 .BHEL is engaged in the design, engincering,
manufacture, construction, testing, commissioning and servicing of a
wide range of products and services for the core sectors of the
economy, viz. Power, Transmission, Industry, Transportation,
4
Renewable Energy, Oil&Gas and Defence.BHEL has 15
manufacturing divisions, two repair units, four regional offices, eight
service centres, cight overseas offices and 15 regional centres and
currently operate at more than 150 project sites across India and
abroad. BHEL places strong emphasis on innovation and creative
development of new technologies. Our research and development
(R&D)efforts are aimed not only at improving the performance and
efficiency of our existing products, but also at using state-of-the-art
technologies and processes to develop new products. This enables us
to have a strong customer orientation, to be sensitive to their needs
and respond quickly to the changes in the market.
The high level of quality&reliability of our products is due to adherence to
international standards by acquiring and adapting some of the best
technologies from leading companies in the world including General Electric
Company, Alstom SA, Siemens AG and Mitsubishi Heavy Industries Ltd.,
together with technologies developed in our own R&D centres. Most of our
manufacturing units and other entities have been accredited to Quality
Management Systems (ISO 9001:2008), Environmental Management
Systems (1SO 14001:2004) and Occupational Health & Safety Management
Systems (OHSAS 18001:2007).

BHEL hasa share of around 59% in India's total installed generating capacity
contributing 69% (approx.) to the total power generated from utility sets
(excluding non-conventional capacity) as of March31, 2012. We have been
exporting our power and industry segment products and services for
approximately 40 years. We have exported our products and services to more
than 70 countries. We had cumulatively installed capacity of over 8,500 MW
outside of ndia in 21 countries, including Malaysia, Iraq, the UAE, Egypt
and New Zealand. Our physical exports range from turmkey projects to after
sales services.
BHEL Work with a vision ofbecoming a world-class engineering enterprise,
committed to enhancing stakeholder value.
Our greatest strength is our highly skilled and commited workforce of over
49,000 employees. Every employee is given an equal opportunity to develop
himself and grow in his career. Continuous training and retraining, career
planning, a positive work culture and participative style of management -all
these have cngendered development ofa commited and motivated workforce
setting new benchmarks in terms of productivity, quality and responsiveness.

STEAM TURBINE

A steam turbine is a mechanical device that extracts thermal energy

from pressurized steam, and converts it into rotary motion. Its modern
manifestation was invented by Sir Charles Parsons in 1884. It has
almost conmpletely replaced the reciprocating piston steam engine
(invented by Thomas Newcomen and greatly improved by James
Watt) primarily because of its greater thermal efficiency and higher
power-to-weight ratio. Because the turbine generates rotary motion, it
is particularly suited to be used to drive an electrical generator - about
80% of allelectricity generation in the world is by use of steam
turbines. The steam turbine is a form ofheat engine that derives much
of its improvement in thermodynamicefficiency through the use of
multiple stages in the expansion of the steam, which results in a closer
approach to the ideal reversible process.

Types
These arrangements include single casing, tandem compound and cross
compound turbines. Single casing units are the most basic style where a single
casing and shaft are coupled to a generator. Tandem compound are used where
two or more casings are directly coupled together to drive a single generator. A
cross compound Steam turbines are made in a variety of sizes ranging from
small 1hp (0.75 kW) units (rare) used as mechanical drives for pumps,
compressors and other shaft driven equipment, to 2,000,000 hp (1,500,000 kW)
turbines used to generate electricity. There are several classifications for
modern steam turbines.

Steam Supply and Exhaust Conditions

These types include condensing, non-condensing, reheat, extraction and

induction.

Non-condensing or backpressure turbines are most widely used for process

steam applications. The exhaust pressure is controlled by a regulating valve to
suit the needs of the process steam pressure. These are commonly found at
refineries, district heating units, pulp and paper plants, and desalination
facilities where large amounts of low pressure process steam are available.
Condensing turbines are most commonly found in electrical power plants.
These turbines exhaust steam in a partially condensed state, typically of a
quality near 90%, at a pressure well below atmospheric to a condenser.
Reheat turbines are also used almost exclusively in electrical power plants. In a
reheat turbine, steam flow exits from a high pressure section of the turbine and
is returned to the boiler where additional superheat is added. The steam then
goes back into an intermediate pressure section of the turbine and continues its
expansion.

Casing or Shaft Arrangements

Turbine arrangement features two or more shafts not in line driving two or more
generators that often operate at different speeds. A cross compound turbine is
typically used for many large applications.

Principle of Operation and Design

An ideal steam turbine is considered to be an isentropic process, or constant
entropy process, in which the entropy of the steam entering the turbine is equal
to the entropy of the steam leaving the turbine. No steam turbine is truly
"isentropic", however, with typical isentropic efficiencies ranging from 20%
90% based on the application of the turbine. The interior of a turbine comprises
several sets of blades, or "buckets" as they are more commonly referred to.One
set of stationary blades is connected to the casing and one set of rotating blades
is connected to the shaft. The sets intermesh with certain minimum clearances,
with the size and configuration of sets varying to efficiently exploit the
expansion of steam at each stage.
Turbine Efficiency

To maximize turbine efficiency, the steam is expanded, generating work, in a

number of stages. These stages are characterized by how the energy is extracted
from them and are known as impulse or reaction turbines. Most modern steam
turbines are a combination of the reaction and impulse design. Typically, higher
pressure sections are impulse type and lower pressure stages are reaction type.
Impulse Turbines
An impulse turbine has fixed nozzles that orient the steam flow into high speed
jets. These jets contain significant kinetic energy, which the rotor blades, shaped
like buckets, convert into shaft rotation as the steam jet changes direction. A
8
pressure drop occurs across only the stationary blades, with a net increase in
steam velocity across the stage.

Reaction Turbines

In the reaction turbine, the rotor blades themselves are arranged to form
convergent nozzles. This type of turbine makes use of the reaction force
produced as the steam accelerates through the nozzles formed by the rotor.
Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the
stator as a jet that fills the entire circumference of the rotor. The steam then
changes direction and increases its speed relative to the speed of the blades. A
pressure drop occurs across both the stator and the rotor, with steam
accelerating through the stator and decelerating through the rotor, with no net
change in steam velocity across the stage but with a decrease in both pressure
and temperature, reflecting the work performed in the driving of the rotor.

SPECIFICATIONS OF MACHINE SAVAILABLE IN BLOCK-| |I:

Vertical Boring Machine :

" Max diameter of work piece accommodated :10000mm to
12500mm
Max height of work piece :5000mm
Diameter of table :8750mm
Max travel of vertical tool head RAM slides :3200mm
Max travel of vertical tool heads from centre of

Table :525Omm

" Max weight of work piece :200 T

For N<=6rpm; 100T for any speed

Diameter of boring spindle of combined head :160mm
Travel of boring spindle :1250mm
 Taper hole of boring spindle :100metric

Centre Lathe :(Biggest of all BHEL)

" Max diameter over bed :3200mm
Max diameter over saddle :250mm
" Length between centers :16m
:100 T
" Max weight of work piece
Spindle bore :96mm

CNC Lathe :

Manufacturer: Safop, Italy

Swing over carriage :3500mm
Centre distance :9000mm
:120 T
Weight capacity
Spindle power :196KW
" External chucking range :250-2000mm
Hydrostat steady range :200-1250mm
Max spindle rpm :200
" CNC system :SINUMERIK
840D

CNC Indicating stand :

Manufacturer : Heinrich Georg, Germany
Turning diameter :5.3m
Turning length :15m

Weight capacity :160 T

CNCVertical Borer :
Manufacturer : M/S Pietro Carnaghi, Italy
" Machine model :AP 80TM
6500
Table diameter :6500mm
Max turning diameter :8000mm
10
 Min boring diameter :660mm
Max height for turning and milling :7000mm
Table Speed :0.2-50 rpm
Table load capacity :200 T

Milling spindle speed :3.4-3000 rpm

Spindle taper :BT 50
CNC system :SINUMERIK 840D

CNC Facing Lathe: KH-200-CNC

Swing over bed :2300mm
Swing over carriage :1800mm
" Max distance between faced plate and carriage :2000mm
" Max weight of job held in chuck :6000kg
" Face plate diameter :1800mm
Spindle speed :14-400rpm
Main spindle drive :95.5KW
Step boring Machine :
" Max boring diameter :2500mm
" Min boring diameter :625mm
Table :4000mmx4000mm
Max weight of job :100 T
Headstock travel :4000mm

Double Column Vertical Borer :

" Table diameter :4000mm
Max travese of cross rail :4250mm
Max weight of work piece :4200mm
Max weight of job :50 T
CNC Skoda Horizontal Borer :
Spindle diameter :200mm
Taper spindle :BT 50
RAM size :450x450mm
RAM length :1600mm
Spindle length :2000mm
" Headstock 5000mnm
11
 Table :4000x3500mm
" CNC system :SIMENS 850mm
" Job :LP. Outer

Horizontal Borer : LSTG 8006

Spindle diameter :250mm
Height of machining bed :600mm
" Max boring depth with spindle :2000mm
" Max extension of RAM :1600mm
Width of bed guide ways :2500mm
Actual length of headstock with vertical lift :2150mm
Actual length of column horizontal feed :15000mm
" Lowest position of spindle axis upon bed guideways :1475mm
" Machine weight with clectrical cquipments :140 T
" Height of machine :10.3m
CNC Lathe : 1-120
Manufacturer : Ravensburg
" Main spindle bore :150mm
" Distance between centers :12m
" Turning diameter over bed cover :1400mm
Turning diameter over carriage :1100mm
Workpiece weight unsupported :4000kg
Workpiece weight between centers :20 T

Centre Lathe : 1-23

Manufacturer: K3TC, USSR
" Max diameter over bed :1250mm
Max diameter over saddle :900mm
Length between centers :6300mm
" Max weight of work piece :25 T
" Spindle bore :80mm
Machine wattage :55KW

Horizontal Boring Machine : 1-28

12
 Diameter of spindle :150mm
Working surface of table :2250x 1250mm
" Max travel of table :1200mm
Max vertical travel of headstock :2000mm
Horizontal Boring Machine :
" Boring spindle taper :BT50
" Boring spindle diameter :160mmn
" Headstock vertical travel :3000mm
Longitudinal RAM travel :700mm
Longitudinal spindle travel :1000mm
" Column cross travel :10m
" Rotary table travel :3000mm
" Table load :40 T

Horizontal Boring Machine:1-11

" Boring spindle internal taper material :200
" Boring spindle diameter :320mm
" Max spindle travel :2500mm
. Vertical head travel :6000mm
Transverse column travel :6000mm
Max longitudinal column travel :800mm
" Machine wattage :90KW
Double Column Rotary Table Vertical Borer:
" Max diameter of work piece accommodated :10m
Max height of work piece accommodated :5m
Diameter of table :8.75m
. Max travel of vertical tool head RAM slides :3.2m
" Max travel of vertical tool head from centre of table :5.25m
Max weight of work piece :200T for N<=8rpm; 100T for any speed
Diameter of boring spindle of combined head :160mm
" Travel of boring spindle :1250mm
" Taper hole of boring spindle :100mm

Horizontal borer:1-2
Spindle diameter :220mm
13
 Working surface :8100 x 5000mm
" Max vertical travel :3mm
" Max transverse travel of column :6m
Max longitudinal travel of column :6m
" Max longitudinal travel of spindle :1.8m
CNC Lathe : 2-360
Manufacturer : Hoesch
" Max load :320 T
" Max length between centers :18m
Swing over bed :3.2m
Horizontal Borer:2-198
Spindle diameter :220mm
" Max vertical travel :3m
" Max transverse travel of column :6m
Max longitudinal travel of column :6m
Max longitudinal travel of spindle :1.8m
Working surface :1800x500mm
Creep Feed Grinding Machine :
Diameter of job :2m
Job height :2.4m
Table rpm :10rpm(max)
Table diameter :2050mm
" Swing diameter :2500mm
" CNCcontrol :SIEMENS-3GG
Broaching Machine :
Broaching capacity :32 T
Broaching stroke :10.3m
" Broaching slide width 1500mm
" Broaching specificcutting stroke :1.25m/min
" Broaching specific return stroke :60m/min
Max diameter of disc :2300mm
Max move of table :600mm
" Helix angle/skew angle setting :+45/-45
" Cone angle :0-20
CNC Lathe:
14
 Manufacturer : Innse Berardi, Italy
" Swing over carriage :1500mm
Swing over bed :2000mm
Capacity :30 T
Cost :16 crore
" CNC system :SINUMERIK 840D

Over Speed Balancing of Turbines :

Main features :
Type of pedestials :DH 90/DH 12
Rotor weight :Min 4 MT, Max 320 MT
" Rotor diameter :Max 6900mm
" Rotorjournal diameter :Min 250mm,Max 950mm
" Bearing centre distance :Min 3000mm,Max 15700mm
Balancing speed :180-3600rpm
Min vibration limit :1micron
" Max vacuum :1 torr
Tunnel Features:
" Tunnel length :19000mm
Tunnel diameter :6900mm
Max thickness of tunnel :2500mm
" Steelplate thickness :32mm
" Cost of balancing cquipment(FE) :444 lakhs
" Total cost of balancing tunnel :770 lakhs
Main Features of Drive :
Drive motors (2 no.) :950V DC, 500rpm,3.5
MW each
Total drive power :7 MW(2x3.5)
MG set of Drive :
" Synchronous motors :11KV,9MW,5OHz,500rpm
" DCGenerator (2 no.) :950V,500rpm,3.8MW each

3d coordinate measuring machine in new blade shop:

Model refrence: 22129 LIETZ Germany
15
Plan no 3-068
Measuring range:
X axis 2200mm
Y axis 1200mm
Z axis 900 mm
Volumetric error: (max) 1.5 micron
Resolution: 0.05 micron
Max weight of job: 2250 kg
Accuracy: 1.5+L/350 micron
Application: dimensional and profile
management of turbine moving and guide blades

16
HOW IT WORKS

HEAT ENERGY

DYNAMIC ACTION OF THE STEAM

Pressure 1Velocity
DIRECTION OF MOTION
ICHANGE OF MOMENTUM
DRIVING FORCE
KINETIC ENERGY

17
 Main Components of Steam Turbine
1 2 45 6

1. Fixed/Guide Blades 5. Gland seals 9. Governing System

2. Moving Blades 6. Bearing & bearing Pedestal 10. Control & Instr.
3. Cylinder 7. Coupling
4. Rotor 8. Stop &Control Valves

Principal equipments in ThermalPower

Plant Turbine Generator produce
produce electricity
power GENERATOR

TURBINE

B
Condenses
the steam to
L water

R DEAERATOR cONDENSER

BFP Increases the

Increases the pressure of
HP L
pressure of CE PUMP water
HEATERS HEATERS
water
Heat the water
Heat the water

18
 WORKING PRINCIPLE OF STEAM TURBINE

ROTATING -Steam at high pressure &temperature is made

BLADE
ROW to pass through a row of fixed blade mounted on
stationary body in Casing.
-There will be drop in pressure of the steam
across the fixed blade resulting to very high
steam velocity at the exit of fixed blade
FIXED
BLADE
"The high velocity steam then impinges on
ROW another row of rotating blades mounted on the
rotor shaft
DRIVING
STATIONARY FORCE "The impingement of high velocity steam
BOÐYLASTNG
generates drivingforce on these rotating blades
which rotate the rotor.
A set of fixed blades blades and rotating blades
mounted on rotor is called stage of turbine.
Depending on steam condition and power
output, number of stages in steam turbine is
decided

LP rotor with moving blades various blade profiles

19
 Types of Steam Turbine
Steam Turbine consist of many stages which are classified into
High Pressure (HP), Intermediate Pressure (IP) & Low Pressure (LP)
stages according to steam Pressure
Single Cylinder Turbine

" Two Cylinder Turbine

" Three Cylinder Turbine

Smaller rating turbines are generally single/two cylinder

turbine& higher rating sets are three cylinder turbine.
(Individual Cylinder is called HP,IP & LP Cylinder or module respectively)
STEAM FLOW THROUGH STEAM TURBINE

HP Turbine IP Turbine LP Turbine

20
 Type of Steam Turbine
According ro Steam Pressure Drop
" Impulse Turbine- More Pressure Drop in Guide Blade
" Reaction Turbine-More Pressure Drop in Moving Blade
Accordingto Valve control arrangement
" Nozzle Controlled -- Sequencial Opening of Admission Valves
Throttle Controlled - Simultaneous opening of Admission Valves
According to constructional Arrangement
. Tandem Compound - Full train of HP,IP &LP Turbine & Generator
Cross Compound -- HP or lP connected to LP Turbine of other Train
Tandem
HPT IPT LPT Generator
Compound
Cross compound

HPT IPT LPT Generator

Type of Steam Turbine

According to Back Pressure
Condensing Turbine - Steam condenses in condenser
" Industrial Turbine -- Exhaust Steam used for Industrial Application
According to Main Steam Pressure
Constant Pressure Operation- Boiler Pressure Constant
Sliding Pressure Operation - Boiler Pressure Varies as per Load demand
Modified Sliding Pressure Operation--- Boiler Pressure Variation with
some throttle reserve

21
 Nozzle/Throttle Comparison
NOZZLE CONTROL MACHNE THROTTLE CONTROL
MACHINE
IMPULSE TURBINE WITH DLAPHRAGMS, REACTION TURBINE
LINEAR
NO NOZZLE SEGMENTS
NOZZLE SEGMENTS IN THE PERIPHERY
NO PRESSURE DROP
PRESSURE DROP IN THE NOZZLES
SIMULTANEOUS OPENING
SEQUENTIAL VALVE OPENING FULL ARC ADMISSION
PARTIALARC ADMISSION
HIGHER THROTTLINGLOSS AT
LOWERTHROTTLING LOSS AT PART LOADSPARTLOADS
PERFORMANCE NOT VERY POOR AT PART PERFORMANCE POOR AT PART
LOAD LOAD
TURBINES IDEAL FOR PEAK LOAD TURBINESIDEALFOR BASE
OPERATION LOADOPERATION

22
 BHEL Profile of Steam Turbine
30 MW Set
50 MW Set
60MW Set
100 MW Set
110 MW Set
120 MW Set
154 MW CCPP
160 MW Set
200/21O MW Set
235 MW Nuclear Set
250 MW Set
270 MW Set
500 MW
525 MW
600 MW
660 MW
800MW

Power breakup
" 210 MW Sets 26.5% +33.5% +40%
" 250 MW Sets 27%+32.2% +40.8%
" 500MW Sets 28% + 34.6% + 37.4%

Cylinder Efficiency (Siemens Design Tutine)

HP Turbine 86%-88%
IPTurbine 90-94%
LP Turbine 87%-90%

3
 Modernization of Facilities:

CNC Lathe for LP Rotor from SAFOP, ITALY

CNC Horizontal Boring machine for machining of casing from
PAMA, ITALY

CNC Indicating Stand for LP Rotor Blade machining from GEORG,

GERMANY

CNC Fir Tree Root Milling machine

CNC Gantry Milling nmachine

Major Facilities for New Turbine Shop:

CNCVBorer-Table diameter-7500mm
" CNC V Borer-Table diameter- 4000mm
CNC H Borer Spindle Diameter-200mm, 160mm
CNC Lathe capacity-120 T,80T
CNC Fir Tree Root Milling machine
" CNC Gantry Milling machine

Highlights:
> Imported Substitutions :
Hybrid burner for gas turbine
E ring for gas turbine

24
 Deep hole drilling in HP outer casing supplicd by Machine
Shop, CFFP
Process Improvement :
Slitting of casing, thrust rings, GT rings on Band Saw
milling machine, thus saving the time on critical machines
such as Ram Borers

Using KOMET drilling systems, the productivity in joint

plane dilling of casing and LP Rotors has increased
Seeing the congestion on KOOP milling machine, a new
work center machine called RAMBHOR machine(No. 2473

Tool Brands:

" Widia
Sandwick
Seco
Isear
Addisson
" Guhring
" Indian tools
Mitutoyo

Tool Instruments:

Die ring spanner

Hack saw frame
Burr cutter
Solid tap (carbide)
" Hand tap

Grinding Cutters:
Combination cutter-140x40mm
Fillet cutter-160x32mm
Hand mill cutter
 End mill cutter
Internal profile cutter
Shell end mill cutter-63x80mm
Ball nose
Slab mill

500 MWSteamTurbine
> HP Turbine:
Module :H30-100-2
Steam Pressure :170Kg/sq.cm
Steam temperature :537 deg.cel
Reheating temperature :537 deg.cel
Weight :86400 Kg
Length of Rotor :4.61m
Height :2.15m

> LP Turbine:
Module :N30-2x10sq.m
Weight :3.5 T
Length of Rotor :8.7m
Width :10.7m

Height :4.6m

IP Turbine:
Length :4.425m
Width :5m

Height :4.8m
Steam pressure :41Kg/sq.cm
Steam temperature :537 deg.cel

Milling Cutters:
1) Side end face milling cutter
2) Interlocking side and face milling cutter
3) Shell end mill cutter
4) Metal slitting saw
5) Single angle milling cutter
6) Double unequal angle milling cutter
7) Double equal angle milling cutter
26
8) Keyway milling cutter
9) Milling cutter for chain wheels
10) Single corner rounding milling cutter
11) Convex milling cutter
12) Concave milling cutter
13) T slot milling cutter with plane parallel shank
14) T slot milling cutter with Morse taper shank having tapered end
15) Cylindrical milling cutter
16) Slot milling cutter with parallel shank
17) End mill with parallel shank
18) Ball nosed end mill with parallel shank
19) Flat end tapered die sinking cutter with plane parallel shank
20) Ball nosed taper die sinking cutter with plane parallel shank
21) Slot milling cutter with morse tapered shank having tanged end
22) End mill with morse tapered shank having tanged end
23) Ball nosed end mill with morse tapered shank having tanged end
24) Flat end tapered die sinking cutter with morse tapered shank having tapped end
25) Ball nosed tapered die sinking cutter with morse tapered shank having tapped end
26) Slot milling cutter with morse tapered shank having tapped end
27) End mill morse tapered shank having tapped end
28) Ball nosed millmorse tapered shank having tapped end
29) Roughing end mill with parallel shank finishing type
30) Roughing end mill with parallel shank roughing type
31) Slot milling cutter with 7/24 taper shank
32) End mill with 7/24 taper shank
33) Ball nosed end mill with 7/24 taper shank
34) Woodruff key slot milling cutter with parallel shank
35) Screwed shank slot drill

27
 Majg Camnnts fStaam Tutine
LP Rotor

LP Inner Casing Upper Half

LP Inner Casing Lower Half
LP Outer Casing Upper Half
LP Outer Casing Lower Half
IP Rotor

IP Inner Casing Upper Half

IP Inner Casing Lower Half
IP Outer Casing Upper Half
IP Outer Casing Lower Half
HP Rotor

HP Inner Casing Upper Half

HP Inner Casing Lower Half
HP Outer Casing Upper Half
HP Outer Casing Lower Half
Diffuser
GBC (Guide Blade Carrier)
IVCV (Intercept Valve Control Valve)
ESVCV (Emergency Stop Valve Control Valve)

Auxiliary Parts of Steam Turbine:

1) Valve Seal
2) U-Ring
3) Piston Rod
4) Base Plate
5) Sealing Ring
6) Liner
7) Guide Ring
8) Valve Cover
9) Guide Blades :
Fixed BIlades

Moving Blades
10) Support
11) Bearing
12) Bearing Shell
13) Angle Ring
14) Sleeve
15) Pin Taper (25x140)
28
 16) Journal Bearing Shell
17) Casing
18) Guide bush
19) Piston (500MW)
20) Valve Cone
21) Yoke
22) Mandrel
23) Support Ring
24) Thrust Ring
25) Adjusting Ring
26) Shaft Sealing Cover

Typs ofBlacs:
T2 blades
T4 blades
TX blades
3DS blades
F- blades
GT-Compress blades
Brazed blades
Russian design blades
Z-Shroud blades
Compressor blades (Sermental coated)
LP Moving blade 500MW

NewBlactSha

First Generation Blades :

V T2 Profile Blades
Cylindrical Profile Blades (1970)
Second Generation Blades :
T4 Profile Blades
V Cylindrical Profile Blades ( late 1980)
1% Gain in Stage Efficiency over T2 Profile Blades
" TX Profile Blades
Cylindrical Profile Blades (late 1990)
Gains :
29
 Reduces Profile Losses
0.2% Gain in Stage Efficiency over T4 Profile Blades

Applications :

Middle Stage Of H.P. and I.P Turbine

Initial Stage of L.P. Turbine

3DS Blades :

Gains :

* Reduces Secondary Flow Losses

0.5-1.0% Gain in Stage Efficiency over TX Profile Blades

Application:
Initial Stage of H.P. and I.P Turbine

" F- Blades

Gains :

Reduces Indirect Flow Losses

0.5-1.0% Gain in Stage Efficiency over TX Profile Blades

Applications :
Rear Stage of H.P. and I.P Turbine
Middle Stage of L.P. Turbine

Sequential operation for machining of TX blades:

Operation Machine

1) Blanking Band saw

2) Rhomboid machining CNC rhomboid machine cellI
30
 3) Removal of tech allowance/parting off band saw
4) Root machining CNC high speed root machining
5) Profile and expansion angle(internal and CNC heavy/light duty machine or
external) CNC profile and fillet machining
center
6) Shroud copying CNC heavy/light duty machine
7) Taper grinding CNC creep feed grinding machine
8) Grinding and polishing Polishing machine
9) Final fitting of blades
10) Vibro finishing of blades Vibro finishing equipment
11) Final inspection

Sequential operation for machining of 3DS and F blades:

Operation Machine

1) Blanking Band saw

2) Preparation of technological ends for work CNC machining center

piece holding
3) Complete blade machining(with normal CNC 5 axis machining centre
shroud/Z shroud)
4) Inspection 3D CMM
5) milling off technological ends at root and CNC machining centre
shroud radius machining
6) Fitting
7) vibro finishing for surface finishing Vibro finishing equipment
improvement
8) Inspection

Number of advance design blades:

Blades 250MW 500MW
TX Profile blade 10390 6820
F and 3DS blade 3100 2852
Free standing blade 224 252

31
NON- DESTRUCTIVE TESTING (Liquid penetration ,magnetic flaw&radiography)

Failure of the turbine blades was one of the challenges addressed with the help of BHEL by modifications
of LP stage-5 blade, shroud modifications et., and based on its success, the same technique was used for
other plants to sort out inherent problems. Grid-induced Outages Grid disturbance induced outages were
overcome by house load schemes and in one-month viz., May 1998, as many as 150 house load operations

took place and units operated withstanding these transients. Healthiness of the control system and other
equipment to withstand external grid transients was remarkable. The sharp corner in the root section of
the blade causes the blade to crack. Failure of the turbine blades was one of the challenges addressed with
the help of BHEL by modifications of HP stage-5 blade, shroud modifications etc., and based on its success,
the same technique was used for other plants to sort out inherent problems. The material used was 12Cr
Mo martensitic steel, which is a very high temperature resistant material. The microstructure was observed
was tempered martensitic structure. These turbine blades were collected from Madras Atomic Power
Station (MAPS) for analysis. These blades were found to be failed. These blades were used for the present
investigation of defects using ultrasonic phased array and X-ray radiography techniques. Turbine blades
are known to fail due to tempered martensite embrittlement, fatigue, fretting, high temperature creep

age hardening, firtree design, high residual stresses etc.

Chemical compositions of the turbine blade:

Element Weight %
Sulphur 0.019 to 0.03
Phosphorus 0.019 to 0.028
Carbon 0.20 to 0.24
Chromium 12.8 + 1.2
Manganese 0.45 to 0.54
Silicane 0.30 to O.43
Nickel 0.40 to 0.52
Vanadium 0.05
Molybdenum 0.1 to 0.13
Iron Balance

32
TURBINE MATERIALS
In the case of turbine, the advancement in steam conditions mainly
affects its high pressure (HP) and intermediate pressure (IP)
sections.As a result, the associated rotations as well as stationary parts
of these sections experience moresevere service conditions than that
of conventional sets. Since they operate well within the creep range,
their design is based primarily on the long-term creep strength ofthe
material, but the stress levels during steady and non-steady operating
conditions, particularly during 593°C contemplate the use of 12Cr
steel rotor with steam cooling to bring the rotor temperature down
to 566°C, where its creep strength is adequate to meet the design
pressure. However, presently several super 12Cr steels with much
superior creep resistance are available and they should also be
considered before a final decision is taken. Above 593°C steam
temperature, X12CrMoWVNbN 10 11and austenitic stainless steel
must be considered. Amongst the austenitic steels, A286 and
X8CrNiMoBNb 16 16 offer better creep strength for an HP rotor of
advanced sets operating at 649°C. One of the rotor-related problems is
the maximum size that can be produced from the 12Cr and austenitic
steels. Due to severe segregation in conventional ingots, the size of
the austenitic steel rotors used in carlier supercritical units was limited
to small size, as a result of which, it became necessary to divide the
HPturbine into two stages. It is estimated that a large advanced plant
would require a one-piece super-alloy HP rotor forging
weighing 11,300 kg with a barrel diameter of 890mm. Similarly, a
double-flow reheat rotor made of 12Cr steel is expected to be about
1150mm in diameter and 31,750 kg in weight, which would
require to start with an ingot size of 63,500 kg. Significant progress
has been made, in recent years, in increasing the size as well as the
quality of the forging by employing modern steel making techniques
such as low sulfur silicon deoxidation (low S), vacuum oxygen
decarburization (VOD), vacuum carbon deoxidation (VCD), central
zone refining (CZR), electro slag hot topping (ESHT) and electro
slag remelting (ESR). By employing these techniques, either
individually or in combination, production experience with low-alloy
ferritic [39], 12Cr as well as austenitic steels [4, 40] demonstrate that
33
the rotors of the candidates materials can be made to the required size
and quality without experiencing much
problems.
Blading
Conventional 12CrMoV steel blades are adequate to meet the steam
temperature at 566°C. But a wide variety of high-temperature blade
materials with proven service performance in large gas turbines are
available, and they should be considered for more advanced steam
conditions. These include super 12Cr steels, austenitic steels, Nimonic
80A, 90, 105, 115, In718 and precision casting alloys such asUdimet
500 and IN 738LC.
LP Rotor
The principal requirements of material for lowpressure (LP) rotor are
high yield strength to withstand the high stress imposed on it by long
blades and high fracture toughness to minimize subcritical flaw
growth so as to avoid the possibility of fast fracture. 3.5NiCrMoV
steel is widely used for LP rotor throughout the power industry. To
avoid temper embrittlement, the maximum operating temperature of
the LP rotor made of this steel is generally limited to about 350°C [9].
The inlet steam temperature to LP turbine of the supercritical
units,on the other hand, is dictated by the exhaust steam from the
second IP section. The IP-LP crossover temperature from advanced
supercritical units at steam temperatures of 593°C and above
would be 400-455°C [9]. To maintain the inlet steam temperature of
LP turbine at its present maximum allowable limit, it would be
necessary to cool the steam either through cooling of the rotor
or by adding an additional stage of expansion to the IP turbine. The
latter approach would be a difficult design task, as it requires usage of
long blades at high temperature, whereas the former approach has to
sacrifice a part of the thermal efficiency. Another approach to the
problem would be to render LP rotor material more resistant to temper
embrittlement [41]. Efforts are, therefore, being made to improve the
fracture toughness of the IP rotor steel by improved steel making
technology and closer control of chemical composition. The
interaction between Mn, Si, P and Sn was shown to have promoted

34
the degree of temper embrittlement. Resistance to temper
embrittlement of 3.5NiCrMoVrotor steel with low Mn and low Si
contents was found to have greatly improved as compared to
conventional steel [9]. By utilising the modern steel making
technologies, it is now possible to decrease both Mn and Si contents
to levels of- 0.002%.

35
 LAYOUT OF BLOCK-3 WAYFROMBLOCK-2

MAINTAINENCEMAINTAINENCE TBM
BLANKING
MECHANICAL TOOL-CRIB TROLLEY
TRACK MAINTAINENCE
ELECTRICAL
STORES STORES
CNC MACHINE

RAILWAY TROLLEY TRACK

SHOP
MACHINE
HEAVY SHOP
MACHINE
HEAVY
TURNING
MILLING
AND
BAY-4
TBM

BAY-I BAY-2 SECTION

BAY3

TROLLEY TRACK

MACHINE MEDIUM
AND
GOVERNING
HEAVY ASSEMBLYAREAHEAVYMACHINE
ASSEMBLY
BAY2 SHOP
MACHINE SECTION
LPBLADE
ASSEMBLY
BLADE
SHOP
SHOP TBM

ASSEMBLY BAY-4
BAY-I -T GOVERNING
ASSEMBLY
G HYDRO/
TESTING STEAM)

OF MACHINE
SHOP
BAY-2
(TUM)
GM LIGHTMACHINE TOOL-ROOM
OFFICE BAY4
G-T SHOP
BAY-3

RAILWAY TROLLEY TRACK