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    BHARAT HEAVY ELECTRICALS LIMITED is the largest engineeringand manufacturing enterprise in India in energy-related and

    infrastructure sector which includes Power, Railways, Telecom,

    Transmission and Distribution, Oil and Gas Sectors and many

    more. BHEL was established more than 50 years ago, ushering in

    the indigenous Heavy Electrical Equipment industry in India. The

    company has been earning profits since 1971-72 and paying

    dividends since 1976-77.

    BHEL is one of Indias nine largest Public Sector Undertakings or

    PSUs, known as the NAVRATNASor the nine jewels.

    BHEL manufactures over 180 products under 30 major product

    groups and caters to core sectors of the Indian economy viz.,

    Power Generation and Transmission, Industry, Transportation,

    Telecommunication, Renewable Energy, etc. The wide network of

    BHELs 14 manufacturing divisions, four Power Sector regional

    centers, over 100 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.

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

    supplied equipments.

    Overall it has installed power equipment for over 90000MW .It

    also among Indias fastest growing Industries.

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    MANUFACTURING UNITS AND PRODUCT PROFILE:

    NAME OF PLANT PLACE

    PRODUCT

    Steam less plant. Tiruchirappali

    (Tiruchy).

    Steam less steel tubes,

    Sriral fin welded tubes.

    Boiler auxiliaries.Ranipet. Electrostatic precipitation ,

    Air pre-heater ,

    Fans ,

    Wind electric generators ,

    Desalination plants.

    Industrial valves plant . Govindwal. Industrial valves and

    Fabrication.

    Heavy electrical

    equipment plant.

    Hardwar. Steam turbines ,

    Hydro turbines ,

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    Gas turbine ,

    Turbo generators ,

    Control panels,

    Light aircrafts ,

    Electrical machines.

    Central foundry forge

    plant.

    Hardwar. Heavy casting and forging.

    Heavy electrical plant. Bhopal. Steam turbines ,

    Turbo generators ,

    Hydro sets ,

    Switch gear controllers,

    Transformer plant. Jhansi. Transformers ,

    Diesel shunt less ,

    AC locos ,

    AC EMU.

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    Heavy power equipment

    plant.

    Hyderabad. Power generating set ,

    Industrial turbo sets,

    Compressors ,

    Pumps and heaters ,

    Bow mills ,

    Heat exchangers oil rings ,

    Gas turbines ,

    Switch gears.

    Electronic division. Bangalore . Energy meters ,

    Water meters ,

    Control equipment ,

    Capacitors ,

    Photovoltaic panels and

    Electronic private automatic branch

    exchange.

    Insulator plant. Jagdishpur. Insulators and bushing.

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    Electronic system

    division, electronic city.

    Bangalore. Simulator,

    Telecommunication system ,

    Other advanced microprocessor

    based control system.

    Electro porcelain

    division.

    Bangalore. Insulator and bushing ,

    Ceramic liners.

    Component fabrication

    plant .

    Rudrapur. Windmill ,

    Solar water heating system .

    Amerphass silicon solar

    cell plant.

    Guragaon. Solar cells ,

    Solar lanterns chargers ,

    Solar clocks.

    Heavy electrical

    equipment repair plant.

    Varanasi. Repair shop for power generating

    equipment.

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    Electrical machine repair

    shop .

    Mumbai. Repair of electrical machines.

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    HARIDWAR PLANT

    BHARAT HEAVY ELECTRICALS LTD.

    HEEP (HEAVYEL ECTRICAL

    EQUIPMENT PLANT)

    CFFP (CENTRAL FOUNDARY

    FORGED PLANT)

    BLOCK-2: HEAVY FABRICATION SHOP

    BLOCK-3: TURBINE MANUFACTURING BLOCK

    BLOCK-4: CIM (COILS & INSULATION MANU-

    BLOCK-5: CONDENCER FABRICATION & FORGR BLOCK

    BLOCK-6: FABRICATION SHOP, DIE SHOP

    BLOCK-7: CARPANTARY SHOP & HEAT TREATMENT SHOP

    BLOCK-8: HEAT EXCHANGER SHOP

    BLOCK-1: ELECTRICAL MACHINE SHOP

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    HEEP PRODUCT PROFILE

    1. THERMAL SETS :

    Steam turbines and generators up to 500 MW capacity for utility and

    combined cycle applications; capability to manufacture up to 1000 MW unit cycle.

    2. GAS TURBINES:

    Gas turbines for industry and utility application; range-3 to 200 MW (ISO). Gas turbines based co-generation and combined cycle system .

    3. HYDRO

    SETS :

    Custom built conventional hydro turbine of Kaplan, Francis and Pelton with

    matching generators up to 250 MW unit size.

    Pump turbines with matching motor-generators.

    Mini / micro hydro sets.

    Spherical butterfly and rotary valves and auxiliaries for hydro station .

    4. EQUIPMENT FOR NUCLEAR POWER PLANTS:

    Turbines and generators up to 500MW unit size.

    Steam generator up to 500MW unit size.

    Reheaters / separators.

    Heat exchangers and pressure vessels.

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    5. ELECTRICAL MACHINES :

    DC general purpose and rolling mill machines from 100 to 19000KW suitable for

    operation on voltage upto 1200V. These are provided with STDP, totally enclosed and

    duct ventilated enclosures .

    DC auxiliary mill motors .

    210 MW THRI-108/39 TYPE GENERATOR STATOR

    6. CONTROL PANEL:

    Control panel for voltage up to 400KW and control desks for generating stations and

    EMV substations.

    7. CASTING AND FORGINGS:

    Sophisticated heavy casting and forging of creep resistant alloy steels, stainless steel and other

    grades of alloy meeting stringent international specifications.

    8. DEFENCE PROCEDURE :

    Naval guns with collaboration of Italy.

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    CLASSIFICATION OF BLOCK 3

    Bay-1 is further divided into three parts

    1 HMS -In this shop heavy machine work is done with the help of different NC &CNC machines such as center lathes, vertical and horizontal boring & millingmachines. Asias largest vertical boring machine is installed here and CNChorizontal boring milling machines from Skoda of Czechoslovakia.

    2 Assembly Section (of hydro turbines) - In this section assembly of hydroturbines are done. Blades of turbine are Ist assemble on the rotor & after it thisrotor is transported to balancing tunnel where the balancing is done. Afterbalancing the rotor, rotor & casings both internal & external are transported to the

    customer. Total assembly of turbine is done in the company whish purchased itby B.H.E.L.

    3 OSBT (over speed balancing tunnel)-In this section, rotors of all type ofturbines like LP(low pressure) , HP(high pressure)& IP(Intermediate pressure)rotors of Steam turbine , rotors of Gas & Hydro turbine are balanced .In a largetunnel , Vacuum of 2 tor. is created with the help of pumps & after that rotor isplaced on pedestal and rotted with speed of 2500-4500 rpm .After it in a

    BLOCK-3

    BAY-1

    HMS (HeavyMachine shop)

    ASSEMBYSECTION

    OSBT

    BAY-2

    HMS

    ASSEMBLYSECTION

    BAY-3

    BEARINGSECTION

    TURNINGSECTION

    ASSEMBLYSECTION

    GOVERNINGSECTION

    BAY-4

    BLADE SHOP

    TURNINGSECTION

    HEAT

    TREATMEN-TSECTION

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    computer control room the axis of rotation of rotor is seen with help of computer& then balance the rotor by inserting the small balancing weight in the groovescut on rotor.

    `

    For balancing and over speed testing of rotors up to 320 tones in weight,1800 mm in length and 6900 mm diameter under vacuum conditions of 1Torr.

    Bay2 is divided in to 2 parts:

    1 HMS In this shop several components of steam turbine like LP, HP & IP rotors,Internal & external casing are manufactured with the help of different operationscarried out through different NC & CNC machines like grinding, drilling, vertical &horizontal milling and boring machines, center lathes, planer, Kopp millingmachine.

    2 Assembly section In this section assembly of steam turbines up to 1000 MWare assembled. Ist moving blades are inserted in the grooves cut oncircumferences of rotor, then rotor is balanced in balancing tunnel in bay-1. Afterit final assembly operation is done in whish guide blades are assembled insidethe internal casing & then rotor is fitted inside this casing. After it this internalcasing with rotor is inserted into the external.

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    Bay 3 is divided into 3 parts:

    1 Bearing section In this section Journal bearings are manufactured whish areused in turbines to overcome the vibration & rolling friction by providing the properlubrication.

    2 Turning section In this section small lathe machines, milling & boringmachines, grinding machines & drilling machines are installed. In this sectionsmall jobs are manufactured like rings, studs, disks etc.

    3 Governing section In this section governors are manufactured. Thesegovernors are used in turbines for controlling the speed of rotor within the certainlimits. Ist all components of governor are made by different operations then theseall parts are treated in heat treatment shop for providing the hardness. Then theseall components are assembled into casing. There are more than 1000 componentsof Governor.

    Bay-4 is divided into 3 parts:

    1 TBM (turbine blade manufacturing) shop- In this shop solid blade of both steam& gas turbine are manufactured. Several CNC & NC machines are installed heresuch as Copying machine, Grinding machine, Rhomboid milling machine, Duplexmilling machine, T- root machine center, Horizontal tooling center, Vertical &Horizontal boring machine etc.

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    2 Turning section- Same as the turning section in Bay-3, there are several small

    machines like lathes machines, milling, boring, grinding machines etc.

    3 Heat treatment shop- In this section there are several tests performed forchecking the hardness of different components. Tests performed are Sterelliting ,Nitriding ,DP test

    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 BLADES

    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.

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    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

    MACHINING OF BLADES

    Machining of blades is done with the help of Lathe & CNC machines. Some of the

    machines are:-

    Centre lathe machine

    Vertical Boring machine*

    Vertical Milling machine*

    CNC lathe machine

    *- Digital read output type

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    NEW BLADE SHOP

    A new blade shop is being in operation. Mostly 500MW turbine blades are

    manufactured in this shop. This is a highly hi tech shop where complete manufacturing

    of blades is done using single advanced CNC machines.

    Complete blades are finished using modernized CNC machines. Some of the machines

    are:-

    Pama CNC Ram Boring machine

    Wotum Horizontal m/c- with- 6 axis CNC c2ontrol

    CNC shaping machine

    CNC SHAPING MACHINE

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    STEAM TURBINES

    INTRODUCTION

    Of all heat engines and prime movers the steam turbine is nearest to the ideal and it is widely

    used in power plants and in all industries where power and/or heat are needed for processes.

    These include: pulp mills, refineries, petrochemical plants, food processing plants, desalination

    plants and district heating plants.

    Advantages include

    1. Ability to utilize high pressure and high temperature steam.

    2. High efficiency.3. High rotational speed.4. High capacity/weight ratio.5. Smooth, nearly vibration-free operation.6. No internal lubrication.7. Oil free exhausts steam.8.

    Disadvantages are

    For slow speed application reduction gears are required. The steam turbine cannot be made

    reversible. The efficiency of small simple steam turbines is poor.

    STEAM TURBINES THE MAINSTAY OF BHEL BHEL has the capability to design, manufacture and commission steam turbines of up to

    1000 MW rating for steam parameters ranging from 30 bars to 300 bars pressure andinitial & reheat temperatures up to 600 oC.

    Turbines are built on the building block system, consisting of modules suitable for arange of output and steam parameters.

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    For a desired output and steam parameters appropriate turbine blocks can be selected.

    TYPES OF TURBINES

    CONDENSING TURBINESWith the condensing turbine, the steam exhausts to the condenser and the latent heats

    of the steam is transferred to the cooling water. The condensed steam is returned to theboiler as feed water.

    CONDENSING BLEEDER TURBINESThe condensing bleeder turbine reduces the condenser losses as steam is bled off at

    several points of the turbine. The bleed-steam is used for feed water heating up to 20%

    of the total steam flow may be bled off.

    BACK-PRESSURE TURBINESBack-pressure turbines are often used in industrial plants; they act as a reducing station

    between boiler and process steam header. The process steam pressure is kept constant

    and the generator output depends on the demand for process steam. The backpressureturbine may also have bleed points and is then called a back-pressure-bleeder-turbine.

    TOPPING TURBINESTopping turbines have been used when old boilers are replaced with new high pressure

    boilers. The turbine is a backpressure turbine exhausting to the old boiler header still

    supplying steam to the old lower pressure turbines.

    APPLICATION RANGE OF STEAM TURBINE

    SERIES TYPE OFSTEAM

    GENERATOR

    SPEED

    RPM

    POWEROUTPUT

    MW

    MAIN STEAMCONDITION

    REHEATSTEAM

    CONDITION

    BACKPRESSUR

    MBARBAR OC BAR OC

    Turbines forFossil Fuel

    Power Plants

    Fossil FuelSteam

    Generator

    3000 100-1000 130-250

    500-540 30-70 500-600 20-300

    Turbines forNuclear

    Power Plants

    PressurizedLight Water

    Reactor

    3000 Upto 1000 40-70 250-300 8-15 200-250 20-300

    Turbines for

    CombinedCycleApplications

    Heat recovery

    SteamGenerator

    3000 Upto 300 30-

    140

    500-540 30-50 500-540 20-300

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    MIXED PRESSURE TURBINESMixed pressure turbines are used where excess steam from process is available for the

    low pressure part of the turbine, while steam at boiler pressure may be added to the high

    pressure part of the turbine when more loads is applied to the turbine.

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    OPERATING PRINCIPLE

    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.5. There is a conversion of heat energy to kinetic energy as the heat energy from the

    decrease in steam enthalpy is converted into kinetic energy by the increased steamvelocity.

    The nozzles may be convergent nozzles or they may be convergent-divergent nozzles.

    Convergent nozzles are used for smaller pressure drops where the minimum exit pressure is

    0.577 x the inlet pressure (the critical pressure for nozzles).

    If the exit pressure is less than 0.577 x inlet pressures, eddy-currents are developed and the

    exit velocity will be less than calculated.

    The convergent-divergent nozzles prevent eddy-currents and the calculated velocity will be

    obtained even at large pressure drops.

    The Impulse Principle

    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 appliedto the blade is developed by causing the steam to change direction of flow (Newtons 2 nd Law

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

    The fact that the pressure does not drop across the moving blades is the distinguishing feature

    of the impulse turbine. The pressure at the inlet to the moving blades is the same as the

    pressure at the outlet from the moving blades.

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    Reaction principle

    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 throughthe 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.

    Special Aspects of Reaction Turbines

    There is a difference in pressure across the moving blades. The steam will therefore tend to

    leak around the periphery of the blades instead of passing through them. Blade clearances

    therefore must be kept to a minimum. Also, due to be developed upon rotor and some

    arrangement must be made to balance this.

    Impulse Turbine Staging

    In order for the steam to give up all its kinetic energy to the moving blades in an impulse turbine,

    it should leave the blades at zero absolute velocity. This condition will exist if the blade velocity

    is equal to one half of the steam velocity. Therefore, for good efficiency the blade velocity

    should be about one half of steam velocity.

    In order to reduce steam velocity and blade velocity, the following methods may be used:

    1. Pressure compounding.

    2. Velocity compounding.

    3. Pressure-velocity compounding.

    4. Pressure Compounding

    TURBINE PARTS

    TURBINE BLADES

    Cylindrical reaction blades for HP, IP and LP Turbines

    3-DS blades, in initial stages of HP and IP Turbine, to reduce secondary losses

    Twisted blade with integral shroud, in last stages of HP, IP and initial stages of LPturbines, to reduce profile and Tip leakage losses

    Free standing LP moving blades

    o Tip sections with supersonic design

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    o Fir-tree root

    o Flame hardening of the leading edge

    Banana type hollow guide blade

    o Tapered and forward leaning for optimized mass flow distribution

    o Suction slits for moisture removal

    COMPUTATIONAL MESH FOR 3D ANALYSIS

    TURBINE CASING

    Casings or cylinders are of the horizontal split type. This is not ideal, as the heavy flanges of

    the joints are slow to follow the temperature changes of the cylinder walls. However, for

    assembling and inspection purposes there is no other solution.

    The casing is heavy in order to withstand the high pressures and temperatures. It is general

    practice to let the thickness of walls and flanges decrease from inlet- to exhaust-end.

    The casing joints are made steam tight, without the use of gaskets, by matching the flange

    faces very exactly and very smoothly. The bolt holes in the flanges are drilled for smoothly

    fitting bolts, but dowel pins are often added to secure exact alignment of the flange joint.

    Double casings are used for very high steam pressures. The high pressure is applied to the

    inner casing, which is open at the exhaust end, letting the turbine exhaust to the outer

    casings.

    TURBINE ROTORSThe design of a turbine rotor depends on the operating principle of the turbine. The impulse

    turbine with pressure drop across the stationary blades must have seals between stationaryblades and the rotor. The smaller the sealing area, the smaller the leakage; therefore the

    stationary blades are mounted in diaphragms with labyrinth seals around the shaft. This

    construction requires a disc rotor. Basically there are two types of rotor:

    Disc RotorsAll larger disc rotors are now machined out of a solid forging of nickel steel; this should

    give the strongest rotor and a fully balanced rotor. It is rather expensive, as the weight of

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    the final rotor is approximately 50% of the initial forging. Older or smaller disc rotors

    have shaft and discs made in separate pieces with the discs shrunk on the shaft. The

    bore of the discs is made 0.1% smaller in diameter than the shaft. The discs are then

    heated until they easily are slid along the shaft and located in the correct position on the

    shaft and shaft key. A small clearance between the discs prevents thermal stress in the

    shaft.

    Drum RotorsThe first reaction turbines had solid forged drum rotors. They were strong, generally well

    balanced as they were machined over the total surface. With the increasing size of

    turbines the solid rotors got too heavy pieces. For good balance the drum must be

    machined both outside and inside and the drum must be open at one end. The second

    part of the rotor is the drum end cover with shaft. The end cover is made with a shrink fit

    and welded of 600-700 *10^6 Pascal.

    TUEBINE SEALS

    Blade sealsThe efficiency of reaction turbines depends to a large extent on the blade seals; radial as

    well as axial seals are often part of the shroud with the seal clearances kept as small as

    possible. As protection for the axial seals some manufacturers apply an adjustable thrust

    bearing. The whole thrust block is able to be axially adjusted. During startup the thrust

    block is pushed against a stop in the direction of exhaust of exhaust for maximum seal

    clearances. When turbine is heated up and has been on load for a short time the thrust

    block is pulled forward against a forward stop for minimum seal clearance and maximum

    blade efficiency.

    Shaft SealsShaft seals must be provided in order to prevent or at least reduce steam leakage where

    the shafts extend through the casings. Also when low pressure turbines are under

    vacuum the seals must prevent air from leaking into the casing.

    Ordinary soft packing may be used for shaft sealing in small turbines. Carbon rings are

    also very common for small turbines. The carbon ring is made up of three segments

    butting together tightly under the pressure of a garter spring. The ring has a few

    hundreds of millimeter clearance around the shaft and is prevented from turning by a

    locking pin. The ring has a slight side clearance in the housing allowing it to move freely

    in radial directions. Carbon rings are self-lubricating but have a tendency to corrode the

    shaft when the turbine is shut down.

    Water SealThe water seal cannot operate properly at low speed and gland steam must be applied

    for sealing during start-up until the turbine speed is approximately 2000rev/mm. Water

    seals are supplied with clean cool condensate from the extraction pump. It may be

    supplied directly or via a head tank with automatic level-control.

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    TURBINE COUPLINGS

    The purpose of couplings is to transmit power from the prime mover to the driven piece

    of machinery. For heavy loads the solid flange coupling is used. The flanges are

    generally integral parts of the shafts, but they may be separate parts for smaller turbines.

    In this case each coupling part has a tapered bore and keyway to fit the tapered end o fthe shaft. Following the taper the shaft has a large thread allowing the coupling to be

    secured tightly with a large nut.

    The friction between the coupling halves and the shear force of the bolts transmits the

    power. For maximum shear stress the bolts must be fitted. The coupling bolts should be

    undercut, that is machined off to a diameter slightly less than the bottom diameter of the

    thread to avoid any strain on the thread.

    In some cases the couplings must compensate for axial expansion and contraction of

    the rotors and in this case a flexible coupling is applied. The outer half has internal

    gears, while the inner part has matching external gears. The coupling works like thespline on a driveshaft for a car.

    The couplings for very large shafts will need a large diameter if the bolts are used to

    transmit the power. The bolts can be much smaller if they are not allowed to transmit

    power. In the coupling shear pins carry the load. The area exposed to shear is the shear

    pins to be located at a large radius from the shaft centre. The coupling bolts are not fitted

    as they are exposed to tensile stress only.

    GOVERNING OF STEAM TURBINE

    Governing of steam turbine is done through electro-hydraulic systems.

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    TURBINES WITH ADVANCED STEAM PARAMETERS

    Application of higher parameters is the most direct way of increasing heat input

    to the cycle

    Operation under wide frequency range (47.5 to 51.5 Hz)

    Steam parameters of 300 bar pressure and 600 oC temperature

    Six percent improvement in thermal cycle efficiency

    New materials for high temperature applications

    Impulse diagonal blading for the first stage HP and IP turbines

    Heat shield at inlet of IP turbine

    Increased wall sections for increased pressures.

    SALIENT FEATURES

    Turbines for both nozzle control as well as throttle control mode.

    Turbines can operate with any boiler and are suitable for

    i. Constant pressure as well as sliding pressure operation

    ii. Base load as well as two-shift operation

    iii. Sub critical as well as super critical parameters

    All the rotors are monoblock

    HP & IP casings have double shell construction and LP has three-shell construction.

    IP turbines with single flow or with double flow.

    LP turbines are designed for normal as well as high back pressure conditions.

    Hollow guide blades with suction slits for moisture removal in last LP stage.

    Bearing pedestals isolated from turbine casings.

    Combined stop & control valves with individual servomotor.

    Sophisticated control and monitoring equipment such as Electro-hydraulic governing,automatic turbine run up system, turbine stress controller, automatic turbine tester etc.

    High operational flexibility

    i. Fast start up and shut down

    ii. Sharp load changes

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    TURBINE CONSTRUCTION

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    MANUFACTURING FACILITIES

    The plant is fully equipped with the modern and sophisticated manufacturing and

    testing facilities to produce sets upto1000MW rating. These include:-

    1. Blade shop for manufacture of both moving and stationary blades.

    2. Special purpose CNC tools.

    3. Over speed & Vacuum-Balancing Tunnel.

    Some of special purpose CNC lathe machines are:-

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    MILLING OF BLADE ROOTS OF LP ROTOR ON KOPP MACHINE

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    ENGINEERING CAPABILITIS:

    BHEL carries out life extension programs on steam turbines of various ratings, whichforewarn the impending failure and help in reducing costly plant breakdowns byrecommending replacement and up gradation of defective components.

    Over the past two decades, BHEL has gained a vast experience in design, manufacture,

    erection and commissioning of various capacities of Turbine Generator sets ranging from 100

    MW to 500 MW.

    Many specific features to suit the customer requirements, layout & operation are takencare of. To name a few:

    HP/LP bypass Turbine Stress Evaluator, hand Barring Gear and Automatic Turbine Run-up System for 210 MW Russian Turbine.

    Base load/cycle /Two-shift operations

    Throttle /Nozzle governing

    Constant/Sliding pressure operation

    RENOVATION & MODERNISATION (R&M)

    Depending on the actual operating conditions, material properties of the componentsdegrade as function of service life due to one or more time dependent material damagemechanisms such as creep, fatigue, corrosion, erosion, wear embattlement etc.

    Life extension programme (LEP) is a special package comprising systems and

    methodologies, which evaluates the residual life of components through sophisticatedNDT, FEM stress analysis and metallurgical technique.

    Many improvements in material and design of critical components with state-of-artdesign is a part of the life extension process. Thus the performance, availability andefficiency of the plant may be improved by R&M Programs.

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    Technology / Collaborations

    The technological base of BHEL in the area of Steam turbines and Turbo Generatorshas been created by acquiring technological information from the collaborators. InitiallyBHEL had collaboration with M/s LMW USSR for 100 and 210 MW sets. In 1976, BHEL

    entered into technical collaboration agreement with M/s Siemens-KWU, Germany toacquire the know-how and know-why for turbine generator sets upto 1000 MW. Thiscollaboration still continues. This helps BHEL to keep pace with the worldwidetechnological progress and offer state of the art equipment to its customer. Under thiscollaboration agreement, BHEL has established strong design, manufacturing andservicing base for unit up to 500 MW ratings.

    BHEL PROGRESS REPORT CHART OF 2008-2009

  • 7/28/2019 boiler report on bhel

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