Training presentation of bhel block 3 - abc

RAJ KUMAR GOEL INSTITUTE OF TECHNOLOGY

GHAZIABAD

INDUSTRIAL TRAINING PRESENTATION

ON

Bharat Heavy Electricals Limited

Ranipur, Haridwar ( Uttrakhand )

DEPARTMENT OF MECHANICAL ENGINEERING

Submitted To :

Mr. XYZ

Submitted By :

ABC

Roll No.

ME 4th Year

ACKNOWLEDGEMENT

I acknowledge all those whose guidance andencouragement has made successful in winding up thisopus. I take this opportunity to express my deep andsincere gratitude to our department staff that have beenkind enough to spare their valuable time, on which I hadno claims. Their guidance and motivation conceived adirection in me and made the report a success.

I would like to thanks all faculty & staff members &Dept. Head Mr. Ravi Shankar Prasad of MechanicalEngineering department of Raj Kumar Goel InstituteOf Technology , Ghaziabad. Who give me lot ofinspiration and skills to complete this Report successfully.

TABLE OF CONTENTS

• INTRODUCTION OF B.H.E.L

• OVERVIEW OF THE ENTERPRISE

• OCCUPATIONAL HEALTH AND SAFETY POLICY

• STEAM TURBINES USED

• TYPES OF STEAM TURBINE

• MANUFACTURING PROCESS

• BLOCK-3 LAYOUT

• BLADE SHOP

• TYPES OF BLADE

• OPERATIONS PERFORMED ON BLADES

• ACHIEVED DURING THE TRAINING

• REFERENCES

INTRODUCTION OF BHEL

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

and manufacturing enterprise in India.

• Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960

in the area of Scientific, Technical and Industrial Cooperation.

• BHEL has its setup spread all over India namely New Delhi, Gurgaon,

Haridwar, Rudrapur, Jhansi, Bhopal, Hyderabad, Jagdishpur ,

Tiruchirapalli, Bangalore and many more.

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

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

• BHEL has already attained ISO 9000 certification for quality

management, and ISO14001 certification for environment management.

• It is one of India's nine largest Public Sector Undertakings or PSUs,

known as the “NAVRATNAS” or “The Nine Jewels”.

OVERVIEW OF THE ENTERPRISE

BHEL is the largest engineering and manufacturing enterprise in India in the energy

& infrastructure sector today. BHEL was established more than 40 years ago when

its first plant was setup in Bhopal in the indigenous Heavy Electrical Equipment

Industry in India a dream which has been more than realized with a well recognized

track record of performance it has been earning profits continuously since1971-72.

BHEL caters to core sectors of the Indian Economy viz., Power Generation's &

Transmission, Industry, Transportation, Telecommunication, Renewable Energy,

Defense, etc. The wide network of BHEL's 14 manufacturing division, 4 power

Sector regional centers, over 150 project sites, 8 service centers and 18 regional

offices, enables the Company to promptly serve its customers and provide them with

suitable products, systems and services – efficiently and at competitive prices. BHEL

has already attained ISO-9000 Certification for quality management, and ISO-14001

Certification for environment management.

The company’s inherent potential coupled with its strong performance

make this one of the “NAVRATNAS”, which is supported by the government in

their endeavor to become future global players.

OCCUPATIONAL HEALTH AND SAFETY POLICY

• Compliance with applicable Legislation and Regulations.

• Setting objectives and targets to eliminate/control/minimize risks

due to Occupational and Safety Hazards.

• Appropriate structured training of employees on Occupational

Health and Safety (OH&S) aspects.

• Formulation and maintenance of OH&S Management programs

for continual improvement.

• Periodic review of OH&S Management System to ensure its

continuing suitability, adequacy and effectiveness.

• Communication of OH&S Policy to all employees and interested

parties.

• The major units of BHEL have already acquired ISO-14001

Environmental Management System Certification, and other units

are in advanced stages of acquiring the same.

STEAM TURBINESA turbine is a device that converts chemical energy into mechanical

energy, specifically when a rotor of multiple blades or vanes is driven

by the movement of a fluid or gas. In the case of a steam turbine, the

pressure and flow of newly condensed steam rapidly turns the rotor.

This movement is possible because the water to steam conversion

results in a rapidly expanding gas. As the turbine’s rotor turns, the

rotating shaft can work to accomplish numerous applications, often

electricity generation.

1. IMPULSE TURBINE

2. REACTION TURBINE

IMPULSE TURBINE :

The principle of the impulse steam turbine consists of a casing containing

stationary steam nozzles and a rotor with moving or rotating buckets. The

steam passes through the stationary nozzles and is directed at high velocity

against rotor buckets causing the rotor to rotate at high speed.

The following events take place in the nozzles :

1. The steam pressure decreases.

2. The enthalpy of the steam decreases.

3. The steam velocity increases.

4. The volume of the steam increases.

TYPES OF STEAM TURBINES

PRINCIPLE OF IMPULSE TURBINE :

If steam at high pressure is allowed to expand through stationary nozzles,

the result will be a drop in the steam pressure and an increase in steam

velocity. In fact, the steam will issue from the nozzle in the form of a high-

speed jet. If this high steam is applied to a properly shaped turbine blade, it

will change in direction due to the shape of the blade. The effect of this

change in direction of the steam flow will be to produce an impulse force,

on the blade causing it to move. If the blade is attached to the rotor of a

turbine, then the rotor will revolve. Force applied to the blade is developed

by causing the steam to change direction of flow (Newton’s 2nd Law –

change of momentum). The change of momentum produces the impulse

force, which rotates the turbine blades.

REACTION TURBINE :

A reaction turbine has rows of fixed blades alternating with rows of

moving blades. The steam expands first in the stationary or fixed

blades where it gains some velocity as it drops in pressure. It then

enters the moving blades where its direction of flow is changed thus

producing an impulse force on the moving blades. In addition,

however, the steam upon passing through the moving blades again

expands and further drops in pressure giving a reaction force to the

blades. This sequence is repeated as the steam passes through

additional rows of fixed and moving blades.

MANUFACTURING PROCESS

1. PRIMARY SHAPING PROCESS

2. SECONDARY MACHINING PROCESS

PRIMARY SHAPING PROCESS

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

• Casting

• Powder metallurgy

• Plastic technology

• Gas cutting

• Bending and

• Forging

SECONDARY MACHINING PROCESSAs large number of components require further processing after the primaryprocesses. These components are subjected to one or more number of machiningoperations in machine shops, to obtain the desired shape and dimensional accuracyon flat and cylindrical jobs. The process of removing the undesired or unwantedmaterial from the work-piece or job or component to produce a required shapeusing a cutting tool is known as machining. This can be done by a manual processor by using a machine called machine tool (traditional machines namely lathe,milling machine, drilling, shaper, planner, slotter).

Some of the common secondary or machining processes are:

• Turning

• Threading

• Knurling

• Milling

• Drilling

• Boring

• Planning

• Shaping

BLOCK 3 LAY-OUT

BLADE SHOP

Blade shop is an important shop of Block 3. Blades of all the stages

of turbine are made in this shop only.

They have a variety of centre lathe and CNC machines to

perform the complete operation of blades. The designs of the blades

are sent to the shop and the Respective job is distributed to the

operators. Operators perform their job in a fixed interval of time.

TYPES OF BLADE

Basically the design of blades is classified according to the stages of

turbine. The size of LP TURBINE BLADES is generally greater than that

of HP TURBINE BLADES. At the first T1, T2, T3 & T4 kinds of blades

were used, these were 2nd generation blades. Then it was replaced by TX,

BDS (for HP TURBINE) & F shaped blades. The most modern blades are F

& Z shaped blades.

OPERATIONS PERFORMED ON BLADES

Some of the important operations performed on blade manufacturing

are:-

• Milling

• Blank Cutting

• Grinding of both the surfaces

• Cutting

• Root milling

ACHIEVED DURING THE TRAINING

Gone through rigorous 4 Weeks training under the guidance of capable

engineers and workers of BHEL Haridwar in Block-3 “TURBINE

MANUFACTURING” headed by Senior Engineer of department Mr.

ALOK SHUKLA situated in Ranipur, Haridwar,(Uttarakhand).

The training was specified under the Turbine Manufacturing

Department. Working under the department I came to know about the basic

grinding, scaling and machining processes which was shown on heavy to

medium machines. Duty lathes were planted in the same line where the

specified work was undertaken.

The training brought to my knowledge the various

machining and fabrication processes went not only in the manufacturing of

blades but other parts of the turbine.

REFERENCES:

• Wikipedia

• Figures from manufacturing data web page BHEL.com.

• Google

• Report maintained during training.

THANK YOU