BHEL MECHANICAL ( 4TH YEAR ) INTERNSHIP -BLOCK-3(TURBINE SHOP)

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BHEL MECHANICAL ( 4TH YEAR ) INTERNSHIP -BLOCK-3(TURBINE SHOP)

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  • 1. INDUSTRIAL TRAINING REPORT(JUNE JULY 2014)Submitted in partial fulfilment of the requirementsOf the degree ofBachelor of TechnologyInMechanical EngineeringBy(ABHISHEK CHAUDHARY)(1101201085)(School of Civil and Mechanical Engineering)GALGOTIAS UNIVERSITYGREATER NOIDA2011-2015

2. ACKNOWLEDGEMENTAn engineer with only theoretical knowledge is not a completeEngineer. Practical knowledge is very important to develop andapply engineering skills.It gives me a great pleasure to have an opportunity toacknowledge and to express gratitude to those who wereassociated with me during my training at BHEL.I am very grateful to Mr. JAIKESH SINGH for providing me withan opportunity to undergo training under his able guidance.Furthermore, special thanks to Mr. Raj Singh for his help andsupport in Haridwar. Last, but not the least, I would also like toacknowledge the support of my college friends, who pursued theirtraining with me. We shared some unforgettable momentstogether.I express my sincere thanks and gratitude to BHEL authorities forallowing me to undergo the training in this prestigiousorganization.I will always remain indebted to them for their constant interestand excellent guidance in my training work, moreover forproviding me with an opportunity to work and gain experience.THANK YOU 3. ABSTRACTIn the era of Mechanical Engineering, Turbine, A Prime Mover ( Which uses the Raw Energy ofa substance and converts it to Mechanical Energy) is a well known Machine most useful in thethe field of Power Generation. This Mechanical energy is used in running an Electric Generatorwhich is directly coupled to the shaft of turbine. From this Electric Generator, we get electricPower which can be transmitted over long distances by means of transmission lines andtransmission towers.In my Industrial Training in B.H.E.L., Haridwar I go through all sections in TurbineManufacturing. First management team told me about the history of industry, Area, Capacity,Machines installed & Facilities in the Industry.After that they told about the Steam Turbine its types , parts like Blades, Casing, Rotor etc. Thenthey told full explanation of constructional features and procedure along with equipement used.Before telling about the machines used in Manufacturing of Blade, they told about the safetyprecautions, Step by Step arrangement of machines in the block with a well defined properformat. They also told the material of blade for a particular desire, types of Blades, Operationsperformed on Blades, their New Blade Shop less with Advance Technology like CNC ShapingMachine.I would like to express my deep sense of Gratitude and thanks to MR. JAIKESH SINGHin charge of training in Turbine Block in B.H.E.L., Haridwar. Without the wise counsel and ableguidance, it would have been impossible to complete the report in this manner. Finally, I amindebted to all who so ever have contributed in this report and friendly stay at Bharat HeavyElectricals Limited (BHEL). 4. INDEXACKNOWLEDGEMENTABSTRACTSR NO TOPIC PAGE NO.1. INTERODUCTION2. BHEL-ANOVERVEIW3. STEAM TURBINE4. TYPES OF STEAMTURBINE5. BHEL UNITS6. BHEL HARIDWAR7. TURBINE PARTS8. MANUFACTURINGPROCESS9. BLADE SHOP 5. 10. CONCLUSIONINTRODUCTIONBHEL is the largest engineering and manufacturing enterprise inIndia in the energy related infrastructure sector today. BHEL wasestablished more than 40 years ago when its first plant was setupin Bhopal ushering in the indigenous Heavy Electrical EquipmentIndustry in India a dream which has been more than realized witha well recognized track record of performance ithas been earning profits continuously since1971-72.BHEL caters to core sectors of the Indian Economy viz., PowerGeneration's & Transmission, Industry, Transportation,Telecommunication, Renewable Energy, Defense, etc. The widenetwork of BHEL's 14 manufacturing division, four power Sectorregional centers, over 150 project sites, eight service centers and18 regional offices, enables the Company to promptly serve itscustomers and provide them with suitable products, systems andservices efficiently and at competitive prices. BHEL has alreadyattained ISO 9000 certification for quality management, and ISO14001certification for environment management. The companys 6. inherent potential coupled with its strong performance make thisone of the NAVRATNAS, which is supported by the governmentin their endeavor to become future global players 7. B.H.E.L- An OverviewBHEL or the Bharat Heavy Engineering Limited is one of thelargest engineering and manufacturing organizations in thecountry and theBHEL, Haridwar is their gift to Uttaranchal. Withtwo large manufacturing plants, BHEL in Haridwar is among theleading industrial organizations in the state. It has established aHeavy Electrical Equipment Plant or HEEP and a Central FoundryForge Plant or CFFP in Haridwar.The Heavy Electrical Equipment Plant in Haridwar designs andmanufactures turbo generators, AC and DC motors, gas turbinesand huge steams. The Central Foundry Forge Plant in Haridwardeals withsteel castings and manufacturing of steel forgings.The BHEL plants in Haridwar have earned the ISO - 9001 and9002 certificates for its high quality and maintenance. These twounits have also earned the ISO - 14001 certificates. Situate inRanipur near Haridwar, the Bharat Heavy Engineering Limitedemploys over 8,000 people.BHEL is an integrated power plant equipment manufacturer andoneof the largest engineering and manufacturing companies inIndia in terms of turnover. BHEL was established in 1964,ushering in the indigenous Heavy Electrical Equipment industry inIndia - a dream that has been more than realized with a well-recognizedtrack record of performance. The company has beenearning profits continuously since 1971-72 and paying dividendssince 1976-77 .BHEL is engaged in the design, engineering,manufacture, construction, testing, commissioning and servicingof a wide range of products and services for the core sectors ofthe economy, viz. Power, Transmission, Industry, Transportation,Renewable Energy, Oil & Gas and Defence. BHEL has 15manufacturing divisions, two repair units, four regional offices,eight service centres, eight overseas offices and 8. 15 regional centres and currently operate at more than 150projectsites across India and abroad. BHEL places strong emphasis oninnovation and creative development of new technologies. Ourresearch and development (R&D) efforts are aimed not only atimproving the performance and efficiency of our existing products,but also at using state-of-the-art technologies and processes todevelop new products. This enables us to have a strong customerorientation, to be sensitive to their needs and respond quickly tothe changes in the market.The high level of quality & reliability of our products is due toadherence to international standards by acquiring and adaptingsome of the best technologies from leading companies in theworld including General Electric Company, Alstom SA, SiemensAG and Mitsubishi Heavy Industries Ltd., together withtechnologies developed in our own R&D centres. Most of ourmanufacturing units and other entities have been accredited toQuality Management Systems (ISO 9001:2008), EnvironmentalManagement Systems (ISO 14001:2004) and OccupationalHealth & Safety Management Systems (OHSAS 18001:2007).BHEL has a share of around 59% in India's total installedgenerating capacity contributing 69% (approx.) to the total powergenerated fromutility sets (excluding non-conventional capacity)as of March 31, 2012. We have been exporting our power andindustry segment products and services for approximately 40years. We have exported our products and services to more than70 countries. We had cumulatively installed capacity of over 8,500MW outside of India in 21 countries, including Malaysia, Iraq, theUAE, Egypt and New Zealand. Our physical exports range fromturnkey projects to after sales services.BHEL work with a vision of becoming a world-class engineeringenterprise, committed to enhancing stakeholder value. 9. Our greatest strength is our highly skilled and committedworkforce of over 49,000 employees. Every employee is given anequal opportunity to develop himself and grow in his career.Continuous training and retraining, career planning, a positivework culture and participative style of management - all thesehave engendered development of a committed and motivatedworkforce setting new benchmarks in terms of productivity, qualityand responsiveness.STEAM TURBINEA steam turbine is a mechanical device that extracts thermalenergy from pressurized steam, and converts it into rotarymotion.Its modern manifestation was invented by Sir CharlesParsons in 1884. It has almost completely replaced thereciprocating piston steam engine primarily because of its greaterthermal efficiency and higher power-to-weight ratio. Because theturbine generates rotary motion, it is particularly suited to be usedto drive an electrical generator about 10. 80% of all electricity generation in the world is by use of steamturbines. The steam turbine is a form of heat engine that derivesmuch of its improvement in thermodynamic efficiency through theuse of multiple stages in the expansion of the steam, whichresults in a closer approach to the ideal reversible process.ADVANTAGES:-ed.-free operation.DISADVANTAGES:-For slow speed application reduction gears are required. Thesteam turbine cannot be made reversible. The efficiency of smallsimple steam turbines is poor.STEAM TURBINES THE MAINSTAY OF BHEL:-commission steam turbines of up to 1000 MW rating for steamparameters ranging from 30 bars to 300 bars pressure and initial& reheat temperatures up to 600C.ting ofmodules suitable for a range of output and steam parameters. 11. ate turbineblocks can be selected.TypesThese arrangements include single casing, tandem compound and crosscompound turbines. Single casing units are the most basic style where asingle casing and shaft