bhel turbine shop block 3 vocational training report

8/12/2019 Bhel Turbine Shop Block 3 Vocational Training Report

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Vocational Training Report

Turbine Blade Shop-Block 3

Bharat Heavy Electricals Limited

RanipurHarid!ar "#ttrakhand$

Submitted By Submitted To

Satyendra %umar

B-Tech 3rdyear

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JP Institute Of Engineering & Technology,Meerut (U.P)

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Declaration

I Satyendra Kumar student of b-tech 3rdyear of JP institute of engineering and

technology hereby declare that the training report entitled Turbine blade

shopis an original !or" and the same has not been submitted to any other

institute#

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&ckno!ledgement

It gi$es me immense pleasure to present my Pro%ect &eport before

you# I than"fully ac"no!ledge the staff of '()*+ (arid!ar

for gi$ing me so much co-operation and taught lots of ne! thingsto me+ !hich I am sure !ill help me in my !ar future#

, special than"s to r S#(aldar for his support during my Industrial

Training# I pay my sincere regards to him# .ithout his support I !as

not able to accomplish my training# I also than"s to all the !or"ingstaff of fabrication bloc" for their helpful guidance and support

during the period#I e/tend my than"s to my college for gi$ing me

such an opportunity under the super$ision of r 0arman ,"htar

Training and Placement fficer!ho is also an e/perienced person#

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manufacturing di$isions+ t!o repair units+ four regional offices+ eight

ser$ice centres+ eight o$erseas offices and 1A regional centres and

currently operate at more than 1A; pro%ect sites across India and

abroad# '()* places strong emphasis on inno$ation and creati$ede$elopment of ne! technologies# ur research and de$elopment

&?9 efforts are aimed not only at impro$ing the performance and

efficiency of our e/isting products+ but also at using state-of-the-art

technologies and processes to de$elop ne! products# This enables us

to ha$e a strong customer orientation+ to be sensiti$e to their needs

and respond 7uic"ly to the changes in the mar"et#

The high le$el of 7uality ? reliability of our products is due to adherence tointernational standards by ac7uiring and adapting some of the best

technologies from leading companies in the !orld including @eneral )lectric

8ompany+ ,lstom S,+ Siemens ,@ and itsubishi (ea$y Industries *td#+

together !ith technologies de$eloped in our o!n &?9 centres# ost of our

manufacturing units and other entities ha$e been accredited to Buality

anagement Systems IS :;;1C2;;


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himself and gro! in his career# 8ontinuous training and retraining+ career

planning+ a positi$e !or" culture and participati$e style of management - all

these ha$e engendered de$elopment of a committed and moti$ated !or"force

setting ne! benchmar"s in terms of producti$ity+ 7uality and responsi$eness#

ST), T6&'IF)

,

steam turbineis a mechanical de$ice that e/tracts thermal energy

from pressuri5ed steam+ and con$erts it into rotary motion# Its modern

manifestation !as in$ented by Sir 8harles Parsons in 1


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multiple stages in the e/pansion of the steam+ !hich results in a closer

approach to the ideal re$ersible process#

Types

These arrangements include single casing+ tandem compound and cross

compound turbines# Single casing units are the most basic style !here a single

casing and shaft are coupled to a generator# Tandem compound are used !heret!o or more casings are directly coupled together to dri$e a single generator# ,

cross compound Steam turbines are made in a $ariety of si5es ranging from

small 1 hp ;#>A ". units rare used as mechanical dri$es for pumps+

compressors and other shaft dri$en e7uipment+ to 2+;;;+;;; hp 1+A;;+;;; ".

turbines used to generate electricity# There are se$eral classifications for

modern steam turbines#

Steam Supply and Exhaust Conditions

These types include condensing+ non-condensing+ reheat+ e/traction and

induction#

Fon-condensing or bac"pressure turbines are most !idely used for process

steam applications# The e/haust pressure is controlled by a regulating $al$e 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 !here large amounts of lo! pressure process steam are a$ailable#

8ondensing turbines are most commonly found in electrical po!er plants#These turbines e/haust steam in a partially condensed state+ typically of a

7uality near :;D+ at a pressure !ell belo! atmospheric to a condenser#

&eheat turbines are also used almost e/clusi$ely in electrical po!er plants# In a

reheat turbine+ steam flo! e/its from a high pressure section of the turbine and

is returned to the boiler !here additional superheat is added# The steam then

goes bac" into an intermediate pressure section of the turbine and continues its

e/pansion#

Casing or Shaft Arrangements


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Turbine arrangement features t!o or more shafts not in line dri$ing t!o or more

generators that often operate at different speeds# , cross compound turbine is

typically used for many large applications#

Priniple of !peration and "esign

,n ideal steam turbine is considered to be an isentropic process+ or constant

entropy process+ in !hich the entropy of the steam entering the turbine is e7ual

to the entropy of the steam lea$ing the turbine# Fo steam turbine is trulyisentropic+ ho!e$er+ !ith typical isentropic efficiencies ranging from 2;D-

:;D based on the application of the turbine# The interior of a turbine comprises

se$eral sets of blades+ or buc"ets as they are more commonly referred to# ne

set of stationary blades is connected to the casing and one set of rotating blades

is connected to the shaft# The sets intermesh !ith certain minimum clearances+

!ith the si5e and configuration of sets $arying to efficiently e/ploit the

e/pansion of steam at each stage#

Turbine Effiieny

To ma/imi5e turbine efficiency+ the steam is e/panded+ generating !or"+ in a

number of stages# These stages are characteri5ed by ho! the energy is e/tracted

from them and are "no!n as impulseor reactionturbines# ost modern steam

turbines are a combination of the reaction and impulse design# Typically+ higher

pressure sections are impulse type and lo!er pressure stages are reaction type#

#mpulse Turbines

,n impulse turbinehas fi/ed no55les that orient the steam flo! into high speed%ets# These %ets contain significant "inetic energy+ !hich the rotor blades+ shaped

li"e buc"ets+ con$ert into shaft rotation as the steam %et changes direction# ,

pressure drop occurs across only the stationary blades+ !ith a net increase in

steam $elocity across the stage#

$eation Turbines

In the reation turbine+ the rotor blades themsel$es are arranged to form

con$ergent no55les# This type of turbine ma"es use of the reaction force

produced as the steam accelerates through the no55les formed by the rotor#

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Steam is directed onto the rotor by the fi/ed $anes of the stator# It lea$es the

stator as a %et that fills the entire circumference of the rotor# The steam then

changes direction and increases its speed relati$e to the speed of the blades# ,

pressure drop occurs across both the stator and the rotor+ !ith steam

accelerating through the stator and decelerating through the rotor+ !ith no netchange in steam $elocity across the stage but !ith a decrease in both pressure

and temperature+ reflecting the !or" performed in the dri$ing of the rotor#

SPECIFICATIONS OF MACHINES AVAILABLE IN BLOCK-III:

%ertial Boring &ahine '

a/ diameter of !or" piece accommodated C1;;;;mm to

12A;;mm

a/ height of !or" piece CA;;;mm

9iameter of table CA;mm

a/ tra$el of $ertical tool head &, slides C32;;mm

a/ tra$el of $ertical tool heads from centre of

Table CA2A;mm

a/ !eight of !or" piece C2;; T

0or F=rpm1;;T for any speed

9iameter of boring spindle of combined head C1=;mm

Tra$el of boring spindle C12A;mm

Taper hole of boring spindle C1;;metric

Centre Lathe '(Biggest of all BHEL)

a/ diameter o$er bed C32;;mm

a/ diameter o$er saddle C2A;mm

*ength bet!een centers C1=m

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a/ !eight of !or" piece C1;; T

Spindle bore C:=mm

C*C Lathe '

anufacturerC Safop+ Italy

S!ing o$er carriage C3A;;mm

8entre distance C:;;;mm

.eight capacity C12; T

Spindle po!er C1:=K.

)/ternal chuc"ing range C2A;-2;;;mm

(ydrostat steady range C2;;-12A;mm

a/ spindle rpm C2;;

8F8 system CSIF6)&IK


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a/ turning diameter C;;;mm

Table Speed C;#2-A; rpm

Table load capacity C2;; T

illing spindle speed C3#4-3;;; rpm at4;K.

Spindle taper C'T A;



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a/ !eight of !or" piece C42;;mm

a/ !eight of %ob CA; T

C*C S0oda Hori1ontal Borer '

Spindle diameter C2;;mm Taper spindle C'T A;

&, si5e C4A;/4A;mm

&, length C1=;;mm

Spindle length C2;;;mm

(eadstoc" CA;;;mm

Table C4;;;/3A;;mm

8F8 system CSI)FS


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Centre Lathe ' 5-.6

anufacturer C K3T8+ 6SS&

a/ diameter o$er bed C12A;mm

a/ diameter o$er saddle C:;;mm *ength bet!een centers C=3;;mm

a/ !eight of !or" piece C2A T

Spindle bore C


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"ouble Column $otary Table %ertial Borer '

a/ diameter of !or" piece accommodated C1;mL12#Am

a/ height of !or" piece accommodated CAm

9iameter of table CAm a/ tra$el of $ertical tool head &, slides C3#2m

a/ tra$el of $ertical tool head from centre of table CA#2Am

a/ !eight of !or" piece C2;;T for F


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Table diameter C2;A;mm

S!ing diameter C2A;;mm

8F8 control CSI))FS-3@@

Broahing &ahine ' 'roaching capacity C32 T

'roaching stro"e C1;#3m

'roaching slide !idth 1A;;mm

'roaching specific cutting stro"e C1#2AmLmin

'roaching specific return stro"e C=;mLmin

a/ diameter of disc C23;;mm

a/ mo$e of table C=;;mm (eli/ angleLs"e! angle setting CN4AL-4A

8one angle C;-2;

C*C Lathe '

anufacturer C Innse 'erardi+ Italy

S!ing o$er carriage C1A;;mm

S!ing o$er bed C2;;;mm

8apacity C3; T

8ost C1= crore



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Tunnel diameter C=:;;mm

a/ thic"ness of tunnel C2A;;mm

Steel plate thic"ness C32mm

8ost of balancing e7uipment0) C444 la"hs

Total cost of balancing tunnel C>>; la"hs

&ain +eatures of "ri8e '

9ri$e motors 2 no# C:A;M 98+ A;;rpm+3#A

. each

Total dri$e po!er C> .2/3#A

&2 set of "ri8e '

Synchronous motors C11 KM+:.+A;(5+A;;rpm

98 @enerator 2 no# C:A;M+A;;rpm+3#


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1


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1:


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*P rotor !ith mo$ing blades $arious blade profiles

2;


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STEA& +L!9 TH$!:2H STEA& T:$B#*E

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2A


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&oderni1ation of +ailities'

8F8 *athe for *P &otor from S,0P+ IT,*

8F8 (ori5ontal 'oring machine for machining of casing fromP,,+ IT,*

8F8 Indicating Stand for *P &otor 'lade machining from @)&@+

@)&,F

8F8 0ir Tree &oot illing machine

8F8 @antry illing machine

&a;or +ailities for *ew Turbine Shop'

8F8 M 'orer-Table diameter->A;;mm

8F8 M 'orer-Table diameter-4;;;mm

8F8 ( 'orer Spindle 9iameter-2;;mm+1=;mm

2=


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8F8 *athe capacity-12; T+3

Tool Brands'

Wiia

!an"ic#

!eco

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Isear

$isson

%uhring

Inian tools

Mitutoyo

Tool #nstruments'

Die ring sanner

'ac# sa" frae

urr cutter

!oli ta (car*ie)

'an ta

2rinding Cutters'

+o*ination cutter-/0/

1illet cutter-2/034

'an ill cutter

En ill cutter

Internal rofile cutter

!hell en ill cutter2305/

all nose

!la* ill

500 MW Steam Turbie:

HP Turbine:

Moule 6'3/-//4

!tea Pressure 6-7/8g9s:.c

!tea teerature 6;37 eg.cel

2


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7) Dou*le e:ual angle illing cutter

5) 8ey"ay illing cutter

?) Milling cutter for chain "heels

-/) !ingle corner rouning illing cutter

--) +on@e0 illing cutter

-4) +onca@e illing cutter

-3) T slot illing cutter "ith lane arallel shan#

-) T slot illing cutter "ith Morse taer shan# ha@ing taere en

-;) +ylinrical illing cutter

-2) !lot illing cutter "ith arallel shan#

-7) En ill "ith arallel shan#

-5) all nose en ill "ith arallel shan#

-?) 1lat en taere ie sin#ing cutter "ith lane arallel shan#

4/) all nose taer ie sin#ing cutter "ith lane arallel shan#

4-) !lot illing cutter "ith orse taere shan# ha@ing tange en

44) En ill "ith orse taere shan# ha@ing tange en

43) all nose en ill "ith orse taere shan# ha@ing tange en

4) 1lat en taere ie sin#ing cutter "ith orse taere shan# ha@ing tae

en

4;) all nose taere ie sin#ing cutter "ith orse taere shan# ha@ing

tae en

42) !lot illing cutter "ith orse taere shan# ha@ing tae en

47) En ill orse taere shan# ha@ing tae en

45) all nose ill orse taere shan# ha@ing tae en

4?)


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33) all nose en ill "ith 794 taer shan#

3) Wooruff #ey slot illing cutter "ith arallel shan#

3;) !cre"e shan# slot rill

Ma!"r C"m#"et$ "% Steam Turbie:

=P


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'P


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-;) Pin Taer (4;0-/)

-2) Journal earing !hell

-7) +asing

-5) %uie *ush

-?) Piston (;//MW)

4/) Aal@e +one

4-) Bo#e

44) Manrel

43) !uort


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First Generation Blades :

T4 Profile laes

+ylinrical Profile laes (-?7/)

Second Generation Blades :

T Profile laes

+ylinrical Profile laes ( late -?5/)

-G %ain in !tage Efficiency o@er T4 Profile laes

TX Profile Blades

+ylinrical Profile laes ( late -??/)

2ains '


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F- Blades

2ains '

+ rho*oi achinecell

3) + hea@y9light uty achine or+>+ rofile an fillet achiningcenter

2) !hrou coying +>+ hea@y9light uty achine

7) Taer grining +>+ cree fee griningachine

5) %rining an olishing Polishing achine?) 1inal fitting of *laes

-/)Ai*ro finishing of *laes Ai*ro finishing e:uient

--)1inal insection

Se


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4) Prearation of technological ens for "or#iece holing

+>+ achining center

3) +olete *lae achining("ith noralshrou9F shrou)

+>+ ; a0is achining centre

) Insection 3D +MM

;) illing off technological ens at root anshrou raius achining

+>+ achining centre

2) 1itting

7) @i*ro finishing for surface finishingiro@eent

Ai*ro finishing e:uient

5) Insection

"u#ber of ad$ance desi%n blades:

Blades &'() '(()T Profile *lae -/3?/ 254/

1 an 3D! *lae 3-// 45;4

1ree staning *lae 44 4;4

"O"- D*ST+,TI.* T*STI"G /Li0uid penetration 1#a%netic

fla2radio%rap!45

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 etc., and based on its success, the same techniue was used

for other plants to sort out inherent problems. !rid-induced "utages !rid disturbance induced outages

were o#ercome by house load schemes and in one-month #i$., %ay &''(, as many as &5) house load

operations too* place and units operated withstanding these transients. Healthiness of the control

system and other euipment to withstand e+ternal grid transients was remar*able. he sharp corner in

the root section of the blade causes the blade to crac*. 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

3=


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etc., and based on its success, the same techniue was used for other plants to sort out inherent

problems. he material used was &r-%o martensitic steel,which is a #ery high temperature resistant

material. he microstructure was obser#ed was tempered martensitic structure. hese turbine blades

were collected from %adras /tomic Power 0tation 1%/P02 for analysis. hese blades were found to be

failed. hese blades were used for thepresent in#estigation of defects using ultrasonic phased array and

3-ray radiography techniues. urbine blades are *nown to fail due to tempered martensite

embrittlement, fatigue, fretting, high temperature creep age hardening, firtree design, high residual

stresses etc.

8hemical compositions of the turbine bladeC

Element Weight %

Sulphur ;#;1: to ;#;3Phosphorus ;#;1: to ;#;2

bhel turbine shop block 3 vocational training report

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