VOCATIONAL TRAINING REPORT

BHARAT HEAVY ELECTRICALS LIMITED

BHOPAL

Under The Guidance Of :

Shri. Nitesh Melgandi

Sr. Design Engineer, TRE Division

From: 2nd July to 14th July 2018

Submitted By:

Akash Jaggi
Mechanical Engineering
Token No: VT/2018/2287

Technocrats Institute of Technology & Science

Bhopal
 ACKNOWLEDGEMENT

It gives me immense pleasure to present my Training Report before you. I thankfully

acknowledge the staff of BHEL, Bhopal 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.

A special thanks to Mr.Nitesh Melgandi (Sr. Design Engineer TRE Division) to support
me during my Industrial Training. I pay my sincere regards to Mr. S.P. Shukla (HRDC
Department). I also thanks to Mr. Nitesh Melgandi for providing me theoretical material about
bhel . I also pay my sincere regards to my director sir Dr. S.K. Jain(Tit & Science).

Akash Jaggi

MECHANICAL (4th YEAR)

TiT & Science Bhopal
 CONTENT

 BHEL OVERVIEW
 BHEL’S CAPABILITIES
 ROLE OF BHEL
 HUMAN RESOURSE DEVELOPMENT
 MANUFACTURING UNIT IF BHEL
 BUSSINESS AREA OF BHEL
 INDUSTRY SECTOR
 TRANSPORTATION
 RESEARCH AND DEVELOPMENT
 PRODUCTS
 TECHNICAL COLLABORATION
 TURBINES
 HYDRO TURBINE
 TYPES OF WATER TURBINE
 SPECIFICATION OF WATER TURBINE
 WATER TURBINE MANUFACTURING PROCESSES
BHEL OVERVIEW

BHEL was established more than 50 years ago when its first plant was setup in Bhopal
ushering in the indigenous Heavy Electrical Equipment Industry in India.

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

related/infrastructure sector. BHEL was established more than four decades ago ushering in
the indigenous Heavy Electrical Equipment industry in India. BHEL has built over the years,
a robust domestic market position by becoming the largest supplier of power plant equipment
in India, and by developing strong market presence in select segment of the industry sector and
the Railway. Currently, 80% of the Nuclear power generation in the country is through BHEL
sets.

A dream which has been more than realized with a well recognized track record of
performance it has been earning profits continuously since 1971-72 and achieved a turnover of
Rs 2,658 crore for the year 2007-08, showing a growth of 17 per cent . Bharat Heavy Electricals
Limited is country’s ‘Navratna’ company and has earned its place among very prestigious
national and international companies. It finds place among the top class companies of the world
for manufacture of electrical equipments.

BHEL caters to core sectors of the Indian Economy viz., Power Generation's &
Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense, etc.
BHEL has already attained ISO 9000 certification for quality management, and ISO 14001
certification for environment management and OHSAS – 18001 certification for Occupational
Health and Safety Management Systems. The Company today enjoys national and international
presence featuring in the “Fortune International -500” and is ranked among the top 10
companies in the world, manufacturing power generation equipment. BHEL is the only PSU
among the 12 Indian companies to figure in “Forbes Asia Fabulous 50” list.

Probably the most significant aspect of BHEL’s growth has been its diversification
.The constant reorientation of the organization to meet the varied needs in time with a
philosophy that has led to total development of a total capability from concepts to
commissioning not only in the field of energy but also in industry and transportation.

In the world power scene BHEL ranks among the top ten manufacturers of power plant
equipments not only in spectrum of products and services offered, it is right on top. BHEL‘s
technological excellence and turnkey capabilities have won it worldwide recognition. Over 40
countries in world over have placed orders with BHEL covering individual equipment to
complete power stations on turnkey basis

BHEL has
 Installed equipment for over 90000MW of power generation-for utilities, captive
and industrial users.
 Supplied over 225000MW a transformer capacity and other equipment operating
in transmission and distribution network up to 400Kv (AC& DC).

 Supplied over 25000 motors with drive control system to power projects, petro
chemicals, refineries, steel, aluminum, fertilizers, cement plants etc.
 Supplied traction electrics and AC/DC locos to power over 12000kms railway
network.
 Supplied over one million valves to power plants and other industries.

BHEL manufactures over 180 products under 30 major product groups and caters to core
sectors of the Indian Economy viz., Power Generation & Transmission, Industry,
Transportation, Telecommunication, Renewable Energy, etc. The wide network of BHEL's 14
manufacturing divisions, four Power Sector regional centers, over 100 project sites, eight
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. The high level of quality & reliability of its products is due to the emphasis on design,
engineering and manufacturing to international standards by acquiring and adapting some of
the best technologies from leading companies in the world, together with technologies
developed in its own R&D centers.
  BHEL has acquired certifications to Quality Management Systems (ISO 9001),
Environmental Management Systems (ISO 14001) and Occupational Health &
Safety Management Systems (OHSAS 18001) and is also well on its journey
towards Total Quality Management.

 BHEL vision is to become a world class engineering enterprise, committed to

enhancing stakeholder value. The company is striving to give shape to its
aspiration and fulfill the expectations of the country to become a global presence:-

Vision:

“A world class engineering enterprise committed to enhance stakeholder values.”

Mission:

“To be an Indian multinational engineering providing total business solution through

quality product system and services in the field of energy, transportation, industry,
infrastructure and other potential area.

Values:

 Ensure speed of response.

 Foster learning, creativity and team work.

 Respect for dignity and potential of individuals

 Loyalty and pride in company

 Zeal for the change.

 Zeal to excel.
  Integrity and fairness in all matters.

 Strict adherence to commitments.

BUSINESS MISSION

To maintain a leading position as supplier of quality equipments, system and services

in the field of conversion, transmission, utilization, and conversation of energy for application
in the area of electric power, transportation oil and gas exploration and industries. To utilize
company’s capability and resources to expand busyness in to allied area an priority sector of
economy like defense, communication and electronics.

BHEL OBJECTIVES

A dynamic organization is one which keeps its aim high, adopts itself quickly to
changing environment, so we are in BHEL. The objectives of the company have been redefined
in the corporate plane for 90’s.

Growth

To ensure a steady growth by enhancing the competitive edge of BHEL in existing

busyness, new area and international market so as to fulfill national expectation from BHEL.

Profitability

To ensure a reasonable and adequate return on capital employed, primarily through

improvements in operation, efficiency, capacity utilization & productivity and to generate
adequate internal resources to finance the company’s growth.
Focus

To built a high degree of customer confidence by providing increased value of his money
through international standards of product quality performance and superior customer service.

People Orientation

To enable each employee to achieve his potential, improve his capabilities, understand
is role and responsibilities and participate and contribute to the growth and success of the
company.

Technology

To achieve technological excellence in operation of indigenous technologies and

efficient absorption and adoption of imparted technologies to suit business.

Image
To fulfill the expectations, which stack holders like government as owner employee,
customer and the country at large have from BHEL.
BHEL BHOPAL PROFILE

Heavy Electrical Plant , Bhopal is the mother plant of Bharat Heavy Electricals
Limited, the largest engineering and manufacturing enterprise inIndia in the energy-related and
infrastructure sector, today. It is located at about 7 kms. from Bhopal Railway station, about 5
kms. from Habibganj Railway station and about 18 kms. From Raja Bhoj Airport. With
technical assistance from Associated Electricals (India) Ltd., a UK based company, it came
into existence on 29th of August, 1956. Pt. Jawaharlal Nehru, first Prime minister of India
dedicated this plant to the nation on 6th of November, 1960.

BHEL, Bhopal with state-of-the-art facilities, manufactures wide range of electrical

equipments. It’s product range includes Hydro, Steam, Marine & Nuclear Turbines, Heat
Exchangers, Hydro & Turbo Generators, Transformers, Switchgears, Control gears,
Transportation Equipment, Capacitors, Bushings, Electrical Motors, Rectifiers, Oil Drilling
Rig Equipments and Diesel Generating sets.

BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving
towards excellence by adopting TQM as per EFQM / CII model of Business Excellence. Heat
Exchanger Division is accredited with ASME ‘U’ Stamp. With the slogan of “ Kadam kadam
milana hai, grahak safal banana hai”, it is committed to the customers.

BHEL Bhopal has its own Laboratories for material testing and instrument calibration
which are accredited with ISO 17025 by NABL. The Hydro Laboratory, Ultra High Voltage
laboratory and Centre for Electric Transportation are the only laboratories of its in this part of
theworld.
 BHEL Bhopal's strength is it's employees. The company continuously invests in
Human Resources and pays utmost attention to their needs. The plant's Township, well known
for its greenery is spread over an area of around 20 sq kms. and provides all facilities to the
residents like, parks, community halls, library, shopping centers, banks, post offices etc.
Besides, free health services is extended to all the employees through 350 bedded (inclusive of
50 floating beds) Kasturba Hospital and chain of dispensaries.

BHEL – BUSINESS AREAS

BHEL today is the largest Engineering Enterprise of its kind in India with excellent
track record of performance, making profits continuously since 1971-72.
BHEL's operations are organised around three business sectors, namely Power, Industry
- including Transmission, Transportation, Telecommunication & Renewable Energy - and
Overseas Business. This enables BHEL to have a strong customer orientation, to be sensitive
to his needs and respond quickly to the changes in the market.

 Power

 Industry

 Transportation

 Transmission

 Defenses etc.

The greatest strength of BHEL is its highly skilled and committed 42,600 employees.
Every employee is given an equal opportunity to develop himself and grow in his career.
Continuous training and retraining, career planning, a positive work culture and participative
style of management all these have engendered development of a committed and motivated
workforce setting new benchmarks in terms of productivity, quality and responsiveness.

POWER SECTOR

Power is the core sector of BHEL and comprises of thermal, nuclear gas, diesel and
hydro business. Today BHEL supplied sets, accounts for nearly 66 % of the total installed
capacity in the country as against nil till 1969-70.

BHEL manufactures boilers auxiliaries, TG sets and associate controls, piping and
station C & I up to 500 MW rating with technology and capability to go up to 1000 MW range.
The auxiliary products high value capital equipment like bowl and tube mills, pumps and
heaters, electrostatic precipitators, gravimetric feeders, fans, valves etc.

BHEL has contracted so far around 240 thermal sets of various ratings, which includes
14 power plants set up on turnkey basis. Nearly 85 % of World Bank tenders for thermal sets
floated in India have been won by the company against international competition.
BHEL has adopted the technology to the needs of the country and local conditions. This has
led to the development of several technologies in house. The fluidized bed boiler that uses low
graded high-ash abrasive Indian coal is an outcome of such an effort. With large-scale
availability of natural gas and the sudden increase in demand, BHEL began to manufacture gas
turbines and now possesses two streams of gas turbine technology.

It has the capability to manufacture gas turbines up to 200 MW rating and custom built
combined cycle power plants. Nuclear steams generators, turbine generators, sets and related
equipment of 235 MW rating have been supplied to most of the nuclear power plants in India.
Production of 500 MW nuclear sets, for which orders have been received.

BHEL has developed expertise in renovation and maintenance of power plant

equipment besides specialized know how of residual life assessment, health diagnostic and life
extensions of plants. The four power sectors regional centers at New Delhi, Chennai, Kolkata
and Nagpur will play a major role in giving a thrust to this business and focus BHEL's efforts
in this area.

As part of India’s largest Solar Power-based Island Electrification Project in India,

Bharat Heavy Electricals Limited (BHEL) has successfully commissioned two Grid-Interactive
Solar Power Plants of 100 KW each in Lakshadweep.
With this, the company has commissioned a total of eleven Solar Power Plants in the
Lakshadweep islands, adding over 1 MW of Solar Power to the power generating capacity of
the coral islands in the Arabian Sea.
 BHEL has proven turnkey capabilities for executing power projects from concept to
commissioning and manufactures boilers, thermal turbine generator sets and
auxiliaries up to 500MW.
 It possesses the technology and capability to procure thermal power generation up
to 1000MW.
 Co- generation and combined cycle plants have also been introduced.
 For the efficient use of high ash content coal BHEL supplies circulating fluidized
boiler.
 BHEL manufacturers 235MW nuclear sets and has also commenced production of
500MW nuclear turbine generator sets.

Custom made hydro sets of Francis, pelton and kepian types for different head
discharge combination are also engineering and manufactured by BHEL.
In, all 700 utility sets of thermal, hydro, gas and nuclear have been placed on the
company as on date. The power plant equipment manufactured by BHEL is based on
contemporary technology comparable to the best in the world and is also internationally
competitive.
The Company has proven expertise in Plant Performance Improvement through
renovation modernization and up rating of variety of power plant equipment besides
specialized know how of residual life assessment, health diagnostics and life extension of
plants.
POWER TRANSMISSION AND DISTRIBUTION (T&D)

BHEL offer wide-ranging products and systems for T & D applications Products.
manufactured include power transformers, instrument transformers, dry type
transformers, series – and shunt reactor, capacitor tanks, vacuum – and SF circuit breakers gas
insulated switch gears and insulators.

A strong engineering base enables the Company to undertake turnkey delivery of

electric substances up to 400 kV level series compensation systems (for increasing power
transfer capacity of transmission lines and improving system stability and voltage regulation),
shunt compensation systems (for power factor and voltage improvement) and HVDC systems
(for economic transfer of bulk power). BHEL has indigenously developed the state-of-the-art
controlled shunt reactor (for reactive power management on long transmission lines). Presently
a 400 kV Facts (Flexible AC Transmission System) project under execution.

A wide range of transmission products and systems are produced by BHEL to meet the
needs of power transmission and distribution sector. These include:

 Dry Type Transformers

 SF6 Switch Gears
 400 KW Transmission Equipment
 High Voltage Direct Current System
 Series and Shunt Compensation Systems

In anticipation of the need for improved substations, a 33 KV gas insulated sub station
with micro processors base control and protection system has been done.
INDUSTRY SECTOR

BHEL is a major contributor of equipment and system to important industries like

 Cement
 Petrochemicals
 Fertilizers
 Steel papers
 Refineries
 Mining and telecommunication

BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for
reactive power management on long transmission lines). Presently a 400 kV FACTS (Flexible
AC Transmission System) projects is under execution.

The range of system and equipment supplied includes:-

 Captive power plants

 High speed industrial drive turbines
 Industrial boilers and auxiliaries
 Waste heat recovery boilers
 Gas turbine pump, valves, seamless steel tubes
 Heat exchangers
 Process control etc.

The Company is a major producer of large-size thruster devices. It also supplies digital
distributed control systems for process industries, and control & instrumentation systems for
power plant and industrial applications. BHEL is the only company in India with the capability
to make simulators for power plants, defense and other applications.
 The Company has commenced manufacture of large desalination plants to help
augment the supply of drinking water to people.

TRANSPORTATION

BHEL is involved in the development design, engineering, marketing, production,

installation, and maintenance and after-sales service of Rolling Stock and traction propulsion
systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000 HP,
diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting duly
applications. BHEL is also producing rolling stock for special applications viz., overhead
equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides traction propulsion
systems for in-house use, BHEL manufactures traction propulsion systems for other rolling
stock producers of electric locomotives, diesel-electric locomotives, electrical multiple units
and metro cars. The electric and diesel traction equipment on India Railways are largely
powered by electrical propulsion systems produced by BHEL. The company also undertakes
retooling and overhauling of rolling stock in the area of urban transportation systems. BHEL
is geared up to turnkey execution of electric trolley bus systems, light rail systems etc. BHEL
is also diversifying in the area of port handing equipment and pipelines transportation systems.

 65 % of trains in Indian Railways are equipped with BHEL's traction and traction
control equipment. These include:
 Broad Gauge 3900 HP AC / DC locomotives
 Diesel Shunting Locomotives up to 2600 HP
 5000 HP AC Loco with thyristor control
 Battery Powered Road Vehicles and Locomotives
TELECOMMUNICATION

BHEL also caters to telecommunication sector by way of small, medium and large
switching system.

Renewable energy
Technologies that can be offered by BHEL for exploiting non-conventional and
renewable resources of energy includes: wind electric generators, solar power based water
pumps, lighting and heating systems.

The company manufactures wind electric generators of unit size up to 250 KW for wind farms,
to meet the growing demand for harnessing wind energy.

International operations
BHEL has, over the years established its references in over 50 countries of the world,
ranging from the united-states in the west to new-Zealand in the far-east. These references
encompass almost the entire product range of BHEL, covering turnkey power projects of
thermal, hydro and gas based type sub-station projects, rehabilitation projects, besides a wide
variety of products, like switch gear, transformer, heat exchangers, insulators, castings and
forgings. Apart from over 1100MW of boiler capacity contributed in Malaysia, some of the
other major successes achieved by the company have been in Oman, Saudi Arabia, Libya,
Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan, Sri lanka, Iraq etc. execution of
overseas projects has also provided BHEL the experience of working with world renowned
consulting organizations and inspection agencies.

RESEARCH AND DEVELOPMENT(R&D)

To remain competitive and meet customers’ expectations, BHEL lays great emphasis
on the continuous up gradation of products and related technologies, and development of new
products. The company has upgraded its products to contemporary levels through continuous
in house efforts as well as through acquisitions of new technologies from leading engineering
organizations of the world.
Research and product development centers at each of the manufacturing divisions play a
complementary role.

BHEL’s investment in R&D is amongst the largest in the corporate sector in India.
BHEL's vision is to become a world-class engineering enterprise, committed to
enhancing stakeholder value. The company is striving to give shape to its aspirations and fulfill
the expectations of the country to become a global player.

The greatest strength of BHEL is its highly skilled and committed 42,600 employees.
Every employee is given an equal opportunity to develop himself and grow in his career.
Continuous training and retraining, career planning, a positive work culture and participative
style of management – all these have engendered development of a committed and motivated
workforce setting new benchmarks in terms of productivity, quality and responsiveness.

BHEL has a corporate R & D center supported by R & D groups at each of the
manufacturing divisions. The dedicated effort of BHEL's R & D engineers have produced
several new products like automated storage retrieval system automated guide vehicles for
material transportation etc. Establishment of Asia's largest fuel evaluation test facility at
Tiruchi was high light of the year. This facility will enable evaluation of combustion, heat
transfer and pollution parameters in boilers.

Major R & D achievement include:

 Design manufacture and supply of countries first 17.2 MW industrial steam turbines.
 Development of 4700 HP AC / DC loco for Indian Railways.
 Development of largest capacitor voltage transformers of 8800 PF 400 KV rating.
 Development and application low cost ROBOTS for job loading/unloading.

According to ex- CMD Mr. R.K.D. Shah, "BHEL is spending Rs. 60 Crores on
Research and Development. Earning from product which has been commercialized has gone
up 26 % to Rs. 760 Crores."
PRODUCTS

Thermal Power Plants

 Steam turbines, boilers and generators of up to 800 MW capacity for utility and
combined-cycle applications ; Capacity to manufacture boilers and steam turbines with
supercritical system cycle parameter and matching generator up to 1000 MW unit size.

 Steam turbines, boilers and generators of CPP applications; capacity to manufacture

condensing, extraction, back pressure, injection or any combination of these types of
steam turbines.

Nuclear Power Plants

 Steam generator & Turbine generator up to 700 MW capacity.

Gas-Based Power Plants

 Gas turbines of up to 280 MW (ISO) advance class rating.
 Gas turbine-based co-generation and combined-cycle systems of industry and utility
applications.

There are other products given as follows

Hydro Power Plants, DG Power Plants, Industrial Sets, Boiler, Boiler Auxiliaries, Piping
System, Heat Exchangers and Pressure Vessels Pumps, Power Station Control Equipment,
Switchgear, Bus Ducts, Transformers, Insulators, Industrial and Special Ceramics, Capacitors,
Electrical Machines, Compressors, Control Gear, Silicon Rectifiers, Thyristor GTO/IGBT
Equipment , Power Devices, Transportation Equipment

Oil Field Equipment, Casting and Forgings, Seamless Steel Tubes, Distributed Power
Generation and Small Hydro Plants.
TECHNICAL COLLABORATIONS

PRODUCT COLLABORATIONS

# Thermal Sets, Hydro Sets, Motors & Prommashexport

Control Gears. RUSSIA

# Bypass & Pressure Reducing Systems Sulzer Brother Ltd.

SWITZERLAND

# Electronic Automation System for Siemens AG.

Steam Turbine & Generators GERMANY

# Francis Type Hydro Turbines General Electric

CANADA

# Moisture Separator Reheaters Baloke Duerr

GERMANY

# Christmas Trees & Conventional Well National Oil Well

Head Assemblies, USA

# Steam Turbines , Generators and Axial Siemens AG.

Condensers GERMANY

# Cam Shaft Controllers and Tractions Siemens AG.

Current Control Units GERMANY
MAJOR CUSTOMERS OF B.H.E.L

 Supplied to all major utilities in India :

NationalThermalPowerCorporation(NTPC)
PGCIL
NJPC
NHPC
NLC
NPCIL
NEEPCO
APTRANSCO
APGENCO
JPPCL
ALL State Electricity Boards (SEBs)

 Abroad:
TNB,Malaysia
PPC,Greece
MEW,Oman
OCC,Oman
GECOL,Libya
Trinidad&Tobago
NewZealand
Tanzania etc
MAJOR COMPETITORS OF BHEL

1. Ansaldo Italy
2. Asea Brown Boueri Switzerland
3. Beehtel USA
4. Block & Neatch USA
5. CNMI & EC China
6. Costain U.K.
7. Electrim Poland
8. Energostio Russia
9. Electro Consult Italy
10. Franco Tosi France
11. Fuji Japan
12. GEC Alsthom U.K.
13. General Electric USA
14. Hitachi Japan
15. LMZ Russia
16. Mitsubishi Japan
17. Mitsui Japan
18. NEI U.K.
19. Raytheon USA
20. Rolls Royce Germany
21. Sanghai Electric Co. China
DIVISIONS OF BHEL

There are 20 Divisions of BHEL, they are as follows:

 HEEP, Haridwar
 HPEP, Hyderabad
 HPBP, Tiruchi
 SSTP & MHD, Tiruchi
 CFFP, Haridwar
 BHEL, Jhansi
 BHEL, Bhopal
 EPD, Bangalore
 ISG, Bangalore
 ED, Bangalore
 BAP, Ranipet
 IP, Jagdishpur
 IOD, New Delhi
 COTT, Hyderabad
 IS, New Delhi
 CFP, Rudrapur
 HERP, Varanasi
 Regional Operations Division ARP, New Delhi
 TPG, Bhopal
 Power Group (Four Regions and PEM)
MANUFACTURING UNIT OF BHEL

First Generation Units

BHOPAL Heavy Electrical Plant

HARDWAR Heavy Electrical Equipment Plant

HYDERABAD Heavy Electrical Power Equipment Plant

TIRUCHY High Pressure Boiler Plant

Second Generation Units

JHANSI Transformer and Locomotive Plant

HARDWAR Central Foundry and Forge Plant

TIRUCHY Seamless Steel Tube Plant

Unit Through Acquisition and Merger

BANGALORE Electronic Division

Electro Porcelain Division

 New Manufacturing Units

RANIPAT Boiler Auxiliaries Plant

JAGDISHPUR Insulator Plant

RUDRAPUR Component and Fabrication Plant

BANGALORE Industrial System Group

HUMAN RESOURCE DEVELOPMENT

The greatest strength of BHEL is its highly skilled and committed manpower. Every employee
is given an equal opportunity to develop himself and improve his position. Continuous training
& retraining, career planning, a positive work culture and participative style of management
have engendered development of a committed and motivated work foam ready to take up the
challenge of making BHEL a competitive world-class organization. As a proccss of linking
HRM to market forces / stakeholder driven policies, an e-enabled Performance Management
System has been established for executives - a new benchmark in promoting performance-led
growth. To encourage individuals for capability building and for continuous improvement
through emotivity & innovation in every sphere of activity, an c-network based Improvement
Projects Rewards Scheme' (IMPRESS) has been introduced company wide.
TURBINE

Turbine is a rotary mechanical device that extracts energy from a fluid flow and converts it into
useful work. A turbine is a turbomachine with at least one moving part called a rotor assembly,
which is a shaft or drum with blade.attached. Moving fluid acts on the blades so that they move
and impart rotational energy to the rotor. Early turbine examples are windmills
andwaterwheels.
Gas, steam, and water turbines usually have a casing around the blades that contains and
controls the working fluid. Credit for invention of the steam turbine is given both to the British
engineer Sir Char. Parsons (1854-1931), for invention of the reaction turbine and to Swedish
engineer Gustaf de Laval (1845-1913), for invention of the impulse turbine. Modern steam
turbines frequently employ both reaction and impulse in the same unit, typically varying the
degree of reactional impulse from the blade root to its periphery.

Types of Turbine
1. Water Turbine
2.Gas Turbine
3.Steam Turbine

Water Turbine-
A water turbine is a rotary engine that takes energy from moving
water.
Water turbines were developed in the 19th century and were widely used for industrial power
prior to ckctrical grids. Now they are mostly used for electric power generation. Water turbines
arc mostly found in Embankment dams to generate electric power from water kinetic cncrgy.
Types of water Turbine

Reaction turbine:
 VLH
 Francis
 Kaplan, Propeller, Bulb, Tube, Stratlo
 Tyson
 Gorky

Impulse turbine:
 Waterwheel
 Pelton
 Turgo
 Crossflow (also known as the Michell-Ban. or Ossberger turbine)
 Jonval turbine
 Reverse overshot water-wheel
 Archimedes' screw turbine

Pelton Wheel

The Pelton wheel is a impulse type water turbine. It was invented by Lester Allan Pelton in the
1870s. The Pe1ton wheel extracts energy from the impulse of moving water, as opposed to
water’s dead weight like the tradition overshot water wheel. Many variations of impulse
turbines existed prior to Pelton's design, but they were less efficient than Pelton's design. Water
leaving those wheels typically still had high speed, carrying away much of the dynamic energy
brought to the wheels. Pelton's paddle geometry was designed so that when the rim ran at 1/2
the speed of the water jet, the water left the wheel with very little speed; thus his design
extracted almost al1 of the water impulse energy —which allowed for a very efficient turbine.
Schematic diagram of Pelton Wheel
Francis Turbine

The Francis turbine is a type of water turbine that was developed by James B. Francis in Lowell,
Massachusetts. It is an inward-flow reaction turbine that combines radial and axial flow
concepts. Francis turbines arc the most common water turbine in use today. They operate in a
water head from 33 to 123 feet (10 to 37 meters) and am primarily used for electrical power
production. The generators which most often use this type of turbine, have a power output
which generally ranges from 10 to 750 megawatts, though mini-hydro installations may be
lower. Penstock (input pipes) diameters are between 3 and 33 00(0.91 and 10.06 mores). The
speed range of the turbine is from 83 to 1000 rpm. Wicket gates around the outside of the
turbine’s rotating runner control the rate of water flow through the turbine for different power
production rates. Francis turbines are almost always mounted with the shaft vertical to keep
water away from the attached generator and to facilitate installation and maintenance access to
it and the turbine.
Kaplan Turbine-

The Kaplan turbine is a propeller-type water turbine which has adjustable blades. It was
developed in 1913 by the Austrian professor Viktor Kaplan, who combined automatically
adjusted propeller blades with automatically adjusted wicket gates to achieve efficiency over a
wide range of flow and water level.

The Kaplan turbine was an evolution of Francis turbine. Its invention allowed efficient power
production in low-head applications that was not possible with Francis turbines. The head
ranges from 10-70 meters and the output from 5 to 200 MW. Runner diameters are between 2
and 11 meters. The range of the turbine rotation is from 79 to 429 rpm. The Kaplan turbine
installation believed to generate the most power from its nominal head of 34.65m is as of 2013
the Tocoma Power Plant (Venezuela) Kaplan turbine generating 235MW with each of ten 4.8m
diameter runners.
Water Turbine Manufacturing Block BHEL

A leading engineering enterprise which supplies all types of equipment for hydro power
generation.

A leading turbine manufacturing offering a wide range of Hydro Turbine, Valves, Governors,
Turbine and Station Auxiliary systems, Balance of plants for Hydro Power Station and related
Services.

Installed manufacturing capacity: 2500 MW/annum.

Two units manufacturing hydro turbines.

In the market for more than three decades.

Dedicated shop area of over 100000 sq. meters.

Ultramodern model development and testing facilities.

Sophisticated CADCAM facilities.

ISO 9001 Certification.

ASME "Q" stamp for fabrication tacit...

WTM Block is Sub divided into 5 division

1. Bay -1
2. Bay- 2
3. Bay- 3/4
4. Assembly
5. Gov. Assembly

Product Manufacter in Bhel Booal

 Pelton, Francis, Kaplan, Propeller, Bulb, Tubular Turbines from 2 MW to 300 MW,
Butterfly and Spherical type shutoff Valves, Pressure Relief Valves, Discharge
Regulators, Associated auxiliaries and station equipment. Matching Hydro
Generators for the above turbines

 Reversible Pump Turbines, Generators, Motors with associated Control, Excitation

Equipment, Auxiliaries and Station Equipments.

 Digital (Micro processor based), Compact /Analog, Electro Hydraulic Governors

for Power Stations. Oil pressure system of 20 to 100 bar for the above.
  Standardized Micro Hydro sets of Tubular and Bulb type with output ranging from
100 kw to 2 MW sets along with matching generator, compact Governor for small
Hydro-sets, speed increasing gear unit Excitation Equipment, Associated
Auxiliaries and Station Equipment.

 Renovation, uprating and modernization of Hydro equipment, execution of EPC/

turnkey contracts including civil works.

Specifications of Turbines

Francis Turbine

Unit Rating(MW)
5-300

Head(m) 30-600

Runner Diameter(mm) 1000 - 7500

No. of Units Orders 190 12241MW

Commissioned 190 8115 MW

Large Franci Turbines

Project Rating Head Speed Runner Dia. Spiral

(No.xmw) (m) (rpm) (mm) Inlet
(mm)

DEHAR 6 X 165 320 300 3730 4500

RANJIT SAGAR 4 X 150 100 166.7 4550 5000

RANGANADI 3 X 135 304 300 3850 2400

INDIRA SAGAR 8 X 125 60 115.4 5650 7000

KALINADI 6 X 135 350 375 3072 2060

Pe1ton Turbine

Unit Rating(MW) 1.5-300

Head(m) 200-1500

Runner Diameter(mm) 1000-5000

No. of Units Orders 46 1501 MW

Commissioned 30 788 MW

Large PeIto Turbine

Project Rating Head Speed Runner Dia.

(No.xmw) (m) (rpm) (mm)

VARAHI 2 X 115 460 250 4500

SHARAVATHY 2 X 89 440 300 3680

CHUKHA 4 X 84 435 300 3680

TILARI 1 X 60 625 500 2640

BHABHA 3 X 40 887 500 2960

MALANA 2 X 43 480 500 2300

PYKARA* 3 X 50 1026 600 2665

Machine Shop in WTM
Operations Perform

1. Turning

2. Drilling

3. Boring

4. Faceing

5. Milling

TURNING

Turning is a machining process in which a cutting tool, typically a non-rotary tool bit,
describes a helical toolpath by moving more or less linearly while the work piece rotates.

DRILLING

The operation of making round holes in metal in metal pieces is known as drilling as drilling.
It is done with the help of drilling machine.
BORING

Enlarging or smoothing an existing hole created by drilling, moulding etc. i.e. the machining
of internal cylindrical. forms (generating) a) by mounting workplace to the spindle via a chuck
or faceplate b) by mounting workplace onto the cross slide and placing cutting tool into the
chuck. This work is suitable for castings that are to awkward to mount in the face plate. On
long bed lathes large workplace can be bolted to a fixture on the bed and a shaft passed between
two lugs on the workpiece and these lugs can be bored out to size. A limited application but
one that is available to the skilled turner/machinist.
FACING

It is part of the turning process. It involves moving the cutting tool at right angles to the axis
of rotation of the rotating work piece. This can be performed by the operation of the cross-
slide, if one is fitted, as distinct from the longitudinal feed (turning). It is frequently first
operation performed in the production of the workpiece, and often the last- hence the phrase
“ending up”.

MILLING

Milling (grinding), the process of grinding grain or other materials in a mill. Milling machine,
a cutting and shaping equipment removing asphalt pavement with a milling machine
Photochemical milling (disambiguation) a part of the leather crusting process.