Turbine Blade Shop-Block 3 Bhel.docKITE.doc

8/19/2019 Turbine Blade Shop-Block 3 Bhel.docKITE.doc

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AFIELD EXPOSURE

On

“General Awareness of Steam Turbine

Manufacturing (TUM,BL-3”

Submitted for the partial fulfillment of the Diploma of

Polytechnic Mechanical Engineering (Production)

KITE GROUP OF INSTITUTIONS, MEERUTSession- !"#-"$

Submitte% To- Submitte% B y –

Mr. Pradeep Ray PAWA !r. !"S#AWA#A

(#.$.D.% Me Deptt.) &inal 'ear

1


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&' LA)AT*+I PAWA !R. !"S#AWA#A of Polytechnic Final Year of ! E%

Meerut hereby declare that the training report entitled “ *eneral A+arene,,

of Steam urbine Manufacturing ( "M% - /01 is an original work and

the same has not been submitted to any other institute.

PAWA !r. !"S#AWA#A

&inal 'ear

ME (Production)

3


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Acknowledge en!

It gives me immense pleasure to present my Project Report before

you. I thankfully acknowledge the staff of !"#$ !aridwar for

giving me so much co%operation and taught lots of new things to

me$ which I am sure will help me in my war future.

& special thanks to Er. 2ai3e,h !umar for his support during my

Industrial 'raining. I pay my sincere regards to him. (ithout his

support I was not able to accomplish my training. I also thanks to all

the working staff of fabrication block for their helpful guidance and

support during the period .I e)tend my thanks to my college for giving

me such an opportunity.

+ T' TS"


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S o To.ics" +/er/iew to B0'L

1arious locations of B0'L3 om.anies /ision, mission an% /alues2 Business acti/ities# Manufacturing facilities$ lassi cation of .ro%uct4

&escri.tion of 5 bloc6s5 &escri.tion of bloc6 wit7 mac7ines8 General %escri.tion

"! Turbine bla%es"" )otors

#


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.!.".#% &n *verview!"# or the harat !eavy "ngineering #imited is one of the largest

engineering and manufacturing organi+ations in the country and the-#E % #arid+ar is their gift to ,ttaranchal. (ith two largemanufacturing plants$ !"# in !aridwar is among the leadingindustrial organi+ations in the state. It has established a !eavy"lectrical "-uipment Plant or !""P and a entral Foundry ForgePlant or FFP in !aridwar.

'he !eavy "lectrical "-uipment Plant in !aridwar designs andmanufactures turbo generators$ & and / motors$ gas turbines andhuge steams. 'he entral Foundry Forge Plant in !aridwar deals withsteel castings and manufacturing of steel forgings.

'he !"# plants in !aridwar have earned the I0* % 1223 and 1224certificates for its high -uality and maintenance. 'hese two units havealso earned the I0* % 35223 certificates. 0ituate in Ranipur near!aridwar$ the harat !eavy "ngineering #imited employs over 6$222

people.

$%EL &' (n &n!eg)(!ed *owe) *l(n! e+ &* en!(n -(c! )e) (nd one o- !.e l()ge'! eng&nee)&ng (nd(n -(c! )&ng co *(n&e' &n Ind&( &n !e) ' o- ! )no/e)0

$%EL w(' e'!( l&'.ed &n 1 ", '.e)&ng &n !.e &nd&geno '%e(/4 Elec!)&c(l E+ &* en! &nd '!)4 &n Ind&( 5 ( d)e( !.(!.(' een o)e !.(n )e(l&6ed w&!. ( well5)ecogn&6ed !)(ck

)eco)d o- *e)-o) (nce0 T.e co *(n4 .(' een e()n&ng*)o7!' con!&n o 'l4 '&nce 1 81582 (nd *(4&ng d&/&dend''&nce 1 8 588 0$%EL &' engaged in the design$ engineering$manufacture$ construction$ testing$ commissioning and servicing of awide range of products and services for the core sectors of theeconomy$ vi+. Power$ 'ransmission$ Industry$ 'ransportation$Renewable "nergy$ *il 7 8as and /efence. !"# has 39manufacturing divisions$ two repair units$ four regional offices$ eight


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service centres$ eight overseas offices and 39 regional centres andcurrently operate at more than 392 project sites across India andabroad. !"# places strong emphasis on innovation and creative

development of new technologies. *ur research and development:R7/; efforts are aimed not only at improving the performance andefficiency of our e)isting products$ but also at using state%of%the%arttechnologies and processes to develop new products. 'his enables usto have a strong customer orientation$ to be sensitive to their needsand respond -uickly to the changes in the market.

T.e .&g. le/el o- + (l&!4 9 )el&( &l&!4 o- o ) *)od c!' &' d e !o

(d.e)ence !o &n!e)n(!&on(l '!(nd()d' 4 (c+ &)&ng (nd(d(*!&ng 'o e o- !.e e'! !ec.nolog&e' -)o le(d&ngco *(n&e' &n !.e wo)ld &ncl d&ng Gene)(l Elec!)&c :o *(n4,Al'!o SA, S&e en' AG (nd M&!' &'.& %e(/4 Ind '!)&e'L!d0, !oge!.e) w&!. !ec.nolog&e' de/elo*ed &n o ) own R9Dcen!)e'0 Mo'! o- o ) (n -(c! )&ng n&!' (nd o!.e) en!&!&e'.(/e een (cc)ed&!ed !o ; (l&!4 M(n(ge en! S4'!e ' 2==?@, En/&)on en!(l M(n(ge en! S4'!e '


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0'"&< ',R I="

&

,team turbine is a mechanical device that e)tracts thermal energy

from pressuri+ed steam$ and converts it into rotary motion. Its modernmanifestation was invented by 0ir harles Parsons in 3665. It hasalmost completely replaced the reciprocating piston steam engine:invented by 'homas =ewcomen and greatly improved by >ames(att; primarily because of its greater thermal efficiency and higher

power%to%weight ratio. ecause the turbine generates rotary motion$ itis particularly suited to be used to drive an electrical generator ? about62@ of all electricity generation in the world is by use of steam

turbines. 'he steam turbine is a form of heat engine that derives muchof its improvement in thermodynamic efficiency through the use of


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multiple stages in the e)pansion of the steam$ which results in a closer approach to the ideal reversible process.

ype,

'hese arrangements include single casing$ tandem compound and crosscompound turbines. 0ingle casing units are the most basic style where a singlecasing and shaft are coupled to a generator. 'andem compound are used wheretwo or more casings are directly coupled together to drive a single generator. &cross compound 0team turbines are made in a variety of si+es ranging fromsmall 3 hp :2.A9 k(; units :rare; used as mechanical drives for pumps$compressors and other shaft driven e-uipment$ to 4$222$222 hp :3$922$222 k(;turbines used to generate electricity. 'here are several classifications for modernsteam turbines.

Steam Supply and E4hau,t 5ondition,

'hese types include condensing$ non%condensing$ reheat$ e)traction andinduction.

=on%condensing or backpressure turbines are most widely used for processsteam applications. 'he e)haust pressure is controlled by a regulating valve tosuit the needs of the process steam pressure. 'hese are commonly found atrefineries$ district heating units$ pulp and paper plants$ and desalinationfacilities where large amounts of low pressure process steam are available.

ondensing turbines are most commonly found in electrical power plants. 'heseturbines e)haust steam in a partially condensed state$ typically of a -uality near12@$ at a pressure well below atmospheric to a condenser.

Reheat turbines are also used almost e)clusively in electrical power plants. In areheat turbine$ steam flow e)its from a high pressure section of the turbine andis returned to the boiler where additional superheat is added. 'he steam thengoes back into an intermediate pressure section of the turbine and continues itse)pansion.

5a,ing or Shaft Arrangement,

1=


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'urbine arrangement features two or more shafts not in line driving two or moregenerators that often operate at different speeds. & cross compound turbine istypically used for many large applications.

Principle of $peration and De,ign

&n ideal steam turbine is considered to be an isentropic process$ or constantentropy process$ in which the entropy of the steam entering the turbine is e-ual

to the entropy of the steam leaving the turbine. =o steam turbine is truly“isentropicB$ however$ with typical isentropic efficiencies ranging from 42@%12@ based on the application of the turbine. 'he interior of a turbine comprisesseveral sets of blades$ or “bucketsB as they are more commonly referred to. *neset of stationary blades is connected to the casing and one set of rotating bladesis connected to the shaft. 'he sets intermesh with certain minimum clearances$with the si+e and configuration of sets varying to efficiently e)ploit thee)pansion of steam at each stage.

urbine Efficiency'o ma)imi+e turbine efficiency$ the steam is e)panded$ generating work$ in anumber of stages. 'hese stages are characteri+ed by how the energy is e)tractedfrom them and are known as impulse or reaction turbines.


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0team is directed onto the rotor by the fi)ed vanes of the stator. It leaves thestator as a jet that fills the entire circumference of the rotor. 'he steam thenchanges direction and increases its speed relative to the speed of the blades. &

pressure drop occurs across both the stator and the rotor$ with steam

accelerating through the stator and decelerating through the rotor$ with no netchange in steam velocity across the stage but with a decrease in both pressureand temperature$ reflecting the work performed in the driving of the rotor.

SPECIFICATIONS OF MACHINES AVAILABLE IN BLOCK-III:

6ertical -oring Machine 7

•


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•


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•


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•


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5entre athe 7 =/80


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Double 5olumn Rotary able 6ertical -orer 7•


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• 'able diameter C4292mm• 0wing diameter C4922mm• = control C0I"


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• 'unnel diameter CG122mm•


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2=


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21


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#P rotor with moving blades various blade profiles

22


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S EAM & $W #R$"*# S EAM "R- E

23


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2"


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2#


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2


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28


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Moderni:ation of &acilitie,7

• = #athe for #P Rotor from 0&F*P$ I'Y

•

= !ori+ontal oring machine for machining of casing from P&


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• = #athe capacity%342 '$62'

• = Fir 'ree Root


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• G .)&ng• Ind&(n !ool'• M&! !o4o

Tool *nstruments9

• D&e )&ng '*(nne)• %(ck '(w -)( e• $ )) c !!e)• Sol&d !(* #38 deg0cel• Re.e(!&ng !e *e)(! )e >#38 deg0cel• e&g.! >? "== Kg• Leng!. o- Ro!o) >"0 1• %e&g.! >201#

L: Turbine9• Mod le >N3=52C1='+0• e&g.! >30# T• Leng!. o- Ro!o) >?08• &d!. >1=08• %e&g.! >"0

*: Turbine9• Leng!. >"0"2#• &d!. >#• %e&g.! >"0?

3=


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• S!e( *)e'' )e >"1Kg '+0c• S!e( !e *e)(! )e >#38 deg0cel

Milling utters9

1@ S&de end -(ce &ll&ng c !!e)2@ In!e)lock&ng '&de (nd -(ce &ll&ng c !!e)3@ S.ell end &ll c !!e)"@ Me!(l 'l&!!&ng '(w#@ S&ngle (ngle &ll&ng c !!e)

@ Do le ne+ (l (ngle &ll&ng c !!e)8@ Do le e+ (l (ngle &ll&ng c !!e)?@ Ke4w(4 &ll&ng c !!e)

@ M&ll&ng c !!e) -o) c.(&n w.eel'1=@ S&ngle co)ne) )o nd&ng &ll&ng c !!e)

11@ :on/eC &ll&ng c !!e)12@ :onc(/e &ll&ng c !!e)13@ T 'lo! &ll&ng c !!e) w&!. *l(ne *()(llel '.(nk1"@ T 'lo! &ll&ng c !!e) w&!. Mo)'e !(*e) '.(nk .(/&ng !(*e)ed

end1#@ :4l&nd)&c(l &ll&ng c !!e)1 @ Slo! &ll&ng c !!e) w&!. *()(llel '.(nk18@ End &ll w&!. *()(llel '.(nk1?@ $(ll no'ed end &ll w&!. *()(llel '.(nk1 @ Fl(! end !(*e)ed d&e '&nk&ng c !!e) w&!. *l(ne *()(llel '.(nk2=@ $(ll no'ed !(*e) d&e '&nk&ng c !!e) w&!. *l(ne *()(llel '.(nk21@ Slo! &ll&ng c !!e) w&!. o)'e !(*e)ed '.(nk .(/&ng !(nged

end22@ End &ll w&!. o)'e !(*e)ed '.(nk .(/&ng !(nged end23@ $(ll no'ed end &ll w&!. o)'e !(*e)ed '.(nk .(/&ng !(nged

end2"@ Fl(! end !(*e)ed d&e '&nk&ng c !!e) w&!. o)'e !(*e)ed '.(nk

.(/&ng !(**ed end2#@ $(ll no'ed !(*e)ed d&e '&nk&ng c !!e) w&!. o)'e !(*e)ed

'.(nk .(/&ng !(**ed end2 @ Slo! &ll&ng c !!e) w&!. o)'e !(*e)ed '.(nk .(/&ng !(**ed

end28@ End &ll o)'e !(*e)ed '.(nk .(/&ng !(**ed end2?@ $(ll no'ed &ll o)'e !(*e)ed '.(nk .(/&ng !(**ed end2 @ Ro g.&ng end &ll w&!. *()(llel '.(nk 7n&'.&ng !4*e3=@ Ro g.&ng end &ll w&!. *()(llel '.(nk )o g.&ng !4*e31@ Slo! &ll&ng c !!e) w&!. 8 2" !(*e) '.(nk32@ End &ll w&!. 8 2" !(*e) '.(nk33@ $(ll no'ed end &ll w&!. 8 2" !(*e) '.(nk3"@ ood) H ke4 'lo! &ll&ng c !!e) w&!. *()(llel '.(nk3#@ Sc)ewed '.(nk 'lo! d)&ll

31


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Major Components of Steam Turbine:

• LP Ro!o)• LP Inne) :('&ng U**e) %(l- • LP Inne) :('&ng Lowe) %(l- • LP O !e) :('&ng U**e) %(l- • LP O !e) :('&ng Lowe) %(l- • IP Ro!o)• IP Inne) :('&ng U**e) %(l- • IP Inne) :('&ng Lowe) %(l- • IP O !e) :('&ng U**e) %(l- • IP O !e) :('&ng Lowe) %(l- • %P Ro!o)•

%P Inne) :('&ng U**e) %(l- • %P Inne) :('&ng Lowe) %(l- • %P O !e) :('&ng U**e) %(l- • %P O !e) :('&ng Lowe) %(l- • D&H 'e)• G$:


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11@ $e()&ng12@ $e()&ng S.ell13@ Angle R&ng1"@ Slee/e1#@ P&n T(*e) :ro le Bla%es

:4l&nd)&c(l P)o7le $l(de' < l(!e 1 =@

Gains 9

33


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Red ce' P)o7le Lo''e'=02 G(&n &n S!(ge E c&enc4 o/e) T" P)o7le $l(de'

A..lications 9

M&ddle S!(ge O- %0P0 (nd I0P T ) &neIn&!&(l S!(ge o- L0P0 T ) &ne

• 3&S Bla%es 9

Gains 9Red ce' Second()4 Flow Lo''e'=0# 10= G(&n &n S!(ge E c&enc4 o/e) TX P)o7le$l(de'

A..lication 9

In&!&(l S!(ge o- %0P0 (nd I0P T ) &ne

• =- Bla%es

Gains 9

Red ce' Ind&)ec! Flow Lo''e'=0# 10= G(&n &n S!(ge E c&enc4 o/e) TX P)o7le$l(de'

A..lications 9

Re() S!(ge o- %0P0 (nd I0P T ) &neM&ddle S!(ge o- L0P0 T ) &ne

Se?uential o.eration for mac7ining of T> bla%es9

+.eration Mac7ine

1@ $l(nk&ng2@ R.o o&d (c.&n&ng

$(nd '(w:N: ).o o&d

(c.&ne cell

3"


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3@ Re o/(l o- !ec. (llow(nce *()!&ngoH

(nd '(w

"@ Roo! (c.&n&ng :N: .&g. '*eed )oo!(c.&n&ng

#@ P)o7le (nd eC*(n'&on (ngle


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+ - &'ST)U T*1' T'ST* G (Li?ui% .enetration,magnetic aw ra%iogra.7


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"R- E MA ER A S

In the case of turbine$ the advancement in steam conditions mainlyaffects its high pressure :!P; and intermediate pressure :IP;sections.&s a result$ the associated rotations as well as stationary partsof these sections e)perience more severe service conditions than thatof conventional sets. 0ince they operate well within the creep range$

their design is based primarily on the long%term creep strength ofthematerial$ but the stress levels during steady and non%steady operatingconditions$ particularly during 91DO contemplate the use of 34 rsteel rotor with steam cooling to bring the rotor temperature downto 9GGO $ where its creep strength is ade-uate to meet the design

pressure. !owever$ presently several super 34 r steels with muchsuperior creep resistance are available and they should also beconsidered before a final decision is taken. &bove 91DO steam

temperature$ N34 r


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such as low sulfur silicon deo)idation :low 0;$ vacuum o)ygendecarburi+ation :K*/;$ vacuum carbon deo)idation :K /;$ central+one refining : MR;$ electro slag hot topping :"0!'; and electroslag remelting :"0R;. y employing these techni-ues$ eitherindividually or in combination$ production e)perience with low%alloyferritic D1Q$ 34 r as well as austenitic steels 5$ 52Q demonstrate thatthe rotors of the candidates materials can be made to the re-uired si+eand -uality without e)periencing much

problems.

-ladingonventional 34 r


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embrittlement 53Q. "fforts are$ therefore$ being made to improve thefracture toughness of the IP rotor steel by improved steel makingtechnology and closer control of chemical composition. 'heinteraction between


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E L E C T R I C A L

M A I N T A I N E N C E

M E C H A N I C A L

M A I N T A I N E N C E

S T O R E S

T O O L C R I B

T R O L L E ! T R A C "

S T O R E S

C N C

M A I N T A I N E N C E T

B M

B L A N " I N #

M A C H I N E

RAILWA! TROLLE! TRAC"

H E A $ ! M A C H I N E S H O %

B A ! &


B A ! '

T ( R N I N # A N ) M I L L I N #

S E C T I O N

B A ! *

T B M

B A ! +

TROLLE! TRAC"

"=


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RAILWA! TROLLE! TRAC"

# O $ E R N I N #

A N ) M E ) I ( M

M A C H I N E S H O %

T B M

L % B L A ) E S E C T I O N

B A ! +

# O $ E R N I N #

A S S E M B L !

T E S T I N #

, H ! ) R O - S T E A M .

T O O L R O O M

B A ! +

L I # H T M A C H I N E

S H O % B A ! *

S

O / / I C E O / # M , T ( M .

# T M A C H I N E S H O % B A !

'

A S S E M B L !

H E A $ !

B A ! &

M A C H I N E

S H O %

# T

A S S E M B L !

A S S E M B L ! A R E A B A ! '

B L A ) E A S S E M B L !


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Turbine Blade Shop-Block 3 Bhel.docKITE.doc