Introduction :

BHEL is the largest engineering and manufacturing

enterprise in India in the energy related infrastructure
sector today. BHEL was established more than 40 years
ago when its first plant was setup in Bhopal ushering in
the indigenous Heavy Electrical Equipment Industry in
India a dream which has been more than realized with
a well recognized track record of performance it has
been earning profits continuously since1971-72.BHEL
caters to core sectors of the Indian Economy viz., Power
Generation's & Transmission, Industry, Transportation,
Telecommunication, Renewable Energy Defence etc.
The wide network of BHEL's 14 manufacturing division,
four power Heavy Electricals Limited (B.H.E.L.) is the
largest engineering and manufacturing enterprise in
India.

PRODUCTS:
• Thermal power Plants
• Nuclear power Plants
• Gas based power Plants
• Hydro power Plants
• Boilers (steam generator)
• Boiler Auxiliaries
• Hydro generator
• Steam turbine
• Gas turbine
• Hydro turbine
o Solar Photo voltaics
 STEAM_TURBINE
MANUFACTURING & MANAGEMENT

MANAGEMENT:
One of your company’s main tasks is the production
of high-quality and technically complex turbines,
which you manufacture on behalf of power plant
construction companies, and so on. You purchase
some of the turbine components from suppliers, the
rest you manufacture yourself. Each process, from
component assembly, to plant acceptance and
delivery to the customer, is extremely time-
consuming. Delays may lead to severe contractual
penalties, and therefore, should be avoided at all
costs, or possible delays should be recognized as
such long before they arise.
You manage the manufacture of turbines as project
business. This allows you to plan and monitor
dates, costs, and revenue on a project-basis.
Because of your long years of experience in this
area, you already have standard project structures,
such as project plans, and networks, as well as
standard production data, such as task lists, prices,
duration, and so on. You can use these templates at
the start of a new project, and tailor them to the
individual needs of each project.
 DEPARTMENTs of steam turbine
management

STS : Steam turbine selling

STE : Steam turbine engg.
STM:Steam turbine manufacturing
MTX :Raw material management

1) STS:
On acceptance you create a sales order and release the project.
You plan revenue using a billing plan in the sales order. You
control the different billing dates using project milestones. In
accordance with the contractual negotiations with the
customer, a down payment is made on conclusion of the
contract.
2) STE:
On the basis of an inquiry, you create an operational project.
Because you are experienced in designing and manufacturing
turbines, you can make reference to an existing standard work
breakdown structure (WBS) and standard networks in the
system. First, you check the feasibility of the project dates. So
that you can quote a sales price, you perform sales pricing on
the basis of the project planning data.
3) STM:
 You manufacture one of the components yourself. As soon as
all components are available, you assemble the turbine.The
decision on which components are to be externally procured,
and which are to be manufactured in-house has already been
made. You deliver the finished product to your customer. Using
confirmation, you create the customer acceptance and
generate the final invoice.
During project processing, you constantly control project
earned value using confirmations and the cost/revenue
situation, so that you can take any corrective action that may be
required. You run several period-end closings, however only
one is run as an example. On completion of the project you
create the final invoice and close the project technically
4) MTX :
You procure one of the turbine components externally from a
supplier, and run through purchase order handling for that
part.You place orders for long-lead items early to avoid delays
to project progress. Your project controls the requirement for
particular components in the manufacture of the turbine
 PROCESS FLOW
1)Inquiry and Quotation Processing :
PURPOSE :
The aim of inquiry and quotation processing is to quickly hand
over a binding quotation that is attractive for the customer and
justifiable from a business point of view. An initial specification
of the product is created in line with the customer’s
requirements in the process.
On receipt, the inquiry is checked for completeness, and any
queries are raised to the customer. The inquiry is then checked
for its commercial and technical feasibility, and the importance
of the customer for the company is evaluated. Taking order
probability into consideration and on the basis of the
information gained from the checks and evaluations, the
company decides whether to create a quotation.
The next step is to process a technical solution. If required, the
product can be configured with the help of existing variants
and/or projects that have already been implemented. The
technical solution is used in costing any manufacturer costs that
might arise. Production and replenishment times are used to
determine the delivery date. The quotation is completed by
fixing the quotation price, which is determined on the basis of
the price the company expects the customer will accept, or on
estimated competitor prices. Legal terms and conditions are
also part of the completed quotation. On completion of the
quotation phase the quotation itself is created and sent to the
customer. Quotation processing ends with either order
placement or rejection of the quotation by the customer.
The scenario used here begins with a planning quotation. The
quoted technical solution is based on estimated activity and
function values, approximate measurements and weights,
drawings, and brief descriptions of the main assemblies. The
commercial contractual agreements indicate approximate
delivery dates and general delivery terms. The quotation is
created using a suggested retail price for the overall object, as
well as assembly costs, and any services that might arise.
PROCESS :
1. The process begins when you receive an inquiry for a
turbine. Customer documents specifying the
customer’s requirements in more detail may
accompany this inquiry. You manage all of these
documents together.
2. You expect costs to arise prior to quotation creation
because of the complexity of the product and the
special customer requirements. Therefore, you
create an inquiry project, so that you can account
assign the costs for inquiry processing.
3. You perform initial planning of dates and costs on
project basis.
4. On the basis of the planned costs, you determine the
sales price and transfer it to the quotation. Finally,
you print the quotation and send it to the customer.

OUTCOME:
On completion of inquiry and quotation processing, the
customer receives a quotation that may have been revised
several times over. In reality, the quotation process
(quotation – rejection – re-costing – new quotation) is repeated
several times over until both the customer and the tenderer
reach a satisfactory compromise. This cyclical process is not
illustrated in this example for reasons of simplicity.

3) Order Entry Processing

PURPOSE :
Incoming orders and order entry processing are
important for the value-added in the MTO process. On
receipt of an order, a significant amount of money may
already be due. At the same time a series of activities
are triggered in the enterprise, which unlike during
quotation creation are binding.
In the quotation phase, documents and data that are
created can be included in the order, or are the order
basis. On receipt of an order however, you have to
specify and define in detail the inexact and/or rough
details from the quotation. The main phases of
quotation processing are repeated here.
The incoming order phase finishes externally when the
order confirmation is sent to the customer. Internally,
this phase is complete when the requirements are finally
communicated to production and procurement or
assembly.

PROCESS :
The customer has accepted your offer for the turbine
project. Now you create a sales order in the system and
assign it to the project.
When you create the sales order you can use the
quotation as a reference. In this case, you receive
different order items reflecting the services to be
provided. If you create the order without reference, you
can create a single item that describes the overall
product.
1) During the contractual negotiations, you agreed on
terms of payment with the customer. You store a billing
plan in the sales order. You delete the billing plan for the
WBS element to enable the billing dates to be
transferred from the sales order to revenue planning for
the project.
2) When the customer accepts the offer, you release
your project and confirm the first activities. When you
confirm the activities, the customer's down payment
automatically becomes due through the milestone
linkage. A down payment request to the customer is
created.
3) You bill the down payment to the customer.
4) When the customer makes the down payment, you
post the incoming payment.
4) Project Processing
PURPOSE :
Once you have received your customer's down payment,
you begin processing the project. If the construction
department has released the bill of materials (BOM),
you assign the components on the BOM for the turbine
to the network activities of the project.
You explode the turbine assembly BOMs using material
requirements planning (MRP). You order some of the
turbine components from a vendor, and produce the
rest in-house.
You confirm each activity, and once a certain milestone
has been reached you bill a partial invoice.
PROCESS

5) Turbine Assembly :
PURPOSE
In this process it is presumed that the turbine is
assembled in the plant. Delivery to the customer takes
place as a whole and is not entered explicitly in the
system. After the turbine has been successfully
assembled and inspected, the last activities are
confirmed and the final invoice is created
PROCESS
1. You enter confirmation of the activities.
2. This confirmation causes the last billing
milestone to be triggered and you create the
final invoice
 6) Period-End Closing with the
Schedule Manager
PURPOSE :
Periodic processing, such as overhead application,
interest calculation, results analysis, incoming orders,
and settlement are executed on the basis of fiscal year
periods. This is generally at the start of a given period for
the preceding period.
Schedule Manager enables you to automatically
schedule and execute period-end closing tasks across
modules. Schedule Manager lets you analyze results,
correct any errors, and repeat period-end closing for all
incorrect data records.
PROCESS:
1. You first check the period settings in the
Schedule Manager and specify the objects for
which you wish to execute period-end closing.
2. As no settlement rule has been maintained for
your project, you schedule the task Generate
Settlement Rule.
3. You then schedule the flow definition Z_130.
This contains the following periodic tasks:
1. Overhead
2. Interest calculation
3. Cost forecasts
4. Results analysis
5. Incoming orders
6. Settlement

1. You monitor the results of the periodic task in

the Job Monitor.
 2. The person responsible receives a mail
containing all information relevant to the period-
end closing.

MANUFACTURING :
CONSISTS OF THE FOLLOWINF DEPARTMENTS:
1) MACHINE SHOP
2) ASSEMBLY SHOP
3) PLANNING SECTION
4) MAINTENANCE

1) A machine shop is a room, building, or company

where machining, a form of subtractive manufacturing, is done.
In a machine shop, machinists use machine tools and cutting
tools to make parts, usually of metal or plastic (but sometimes
of other materials such as glass or wood). A machine shop can
be a small business(such as a job shop) or a portion of a factory,
whether a toolroom or a production area for manufacturing.
The parts produced can be the end product of the factory, to be
sold to customers in the machine industry, the car industry,
the aircraft industry, or others. In other cases, companies in
those fields have their own machine shops.
The production can consist of cutting, shaping, drilling,
finishing, and other processes. The machine tools typically
include metal lathes, milling machines, machining centers,
multitasking machines, drill presses, or grinding machines,
many controlled with computer numerical control (CNC). Other
processes, such as heat treating, electroplating, or painting of
the parts before or after machining, are often done in a
separate facility. A machine shop can contain some raw
materials (such as bar stock for machining) and an inventory of
finished parts. These items are often stored in a warehouse.
A machine shop can be a capital intensive business, because
the purchase of equipment can require large investments. A
machine shop can also be labour-intensive, especially if it is
specialized in repairing machinery on a job production basis,
but production machining (both batch production and mass
production) is much more automated than it was before the
development of CNC, programmable logic
control(PLC), microcomputers, and robotics. It no longer
requires masses of workers, although the jobs that remain tend
to require high talentand skill. Training and experience in a
machine shop can both be scarce and valuable.

2) An assembly line is a manufacturing process (often called

a progressive assembly) in which parts (usually interchangeable
parts) are added as the semi-finished assembly moves from
workstation to workstation where the parts are added in
sequence until the final assembly is produced. By mechanically
moving the parts to the assembly work and moving the semi-
finished assembly from work station to work station, a finished
product can be assembled faster and with less labor than by
having workers carry parts to a stationary piece for assembly.
Assembly lines are designed for the sequential organization
of workers, tools or machines, and parts. The motion of workers
is minimized to the extent possible. All parts or assemblies are
handled either by conveyors or motorized vehicles such as fork
lifts, or gravity, with no manual trucking. Heavy lifting is done
by machines such as overhead cranes or fork lifts. Each worker
typically performs one simple operation.
According to Henry Ford:
The principles of assembly are these:
(1) Place the tools and the men in the sequence of the
operation so that each component part shall travel the least
possible distance while in the process of finishing.
(2) Use work slides or some other form of carrier so that when
a workman completes his operation, he drops the part always
in the same place—which place must always be the most
convenient place to his hand—and if possible have gravity carry
the part to the next workman for his own.
(3) Use sliding assembling lines by which the parts to be
assembled are delivered at convenient distances.

3) Planning:
 Work order copy from STS
  Decode engg information according to work
order
 Study of info
 Row material
 Purchased item
 Foundry / Casting
 Fabrication
Productionplanning is
the planning of production and manufacturing modules
in a company or industry. It utilizes the resource
allocation of activities of
employees, materials and production capacity, in order
to serve different customers.
Different types of production methods, such as single
item manufacturing, batch production, mass
production, continuous production etc. have their own
type of production planning. Production planning can be
combined with production control into production
planning and control, or it can be combined
with enterprise resource planning.
Production planning is used in companies in several
different industries, including agriculture industry,
amusement industry, etc.
4) MAINTENANCE :
Duties or Functions of Maintenance Department:
(A) Inspection:
(1) Inspection is concerned with the routine schedule checks of
the plant facilities to examine their condition and to check for
needed repairs.
(2) Inspections ensure the safe and efficient operation of
equipment and machinery.
(3) Frequency of inspections depends upon the intensity of the
use of the equipment. For example, belts in a machine may be
checked every week; furnace equipment every month; an over-
head bridge crane every four months and so on.
(4) Inspection section makes certain that every working
equipment receives proper attention.
(5) Items removed during maintenance and overhaul
operations are inspected to determine the feasibility of repairs.
(6) Maintenance items received from vendors are inspected
for their fitness.
(B) Engineering:
(1) Engineering involves alterations and improvements in
existing equipment and building to minimize breakdowns.
(2) Maintenance department also undertakes engineering and
supervision of constructional projects that will eventually
become part of the plant.
(3) Engineering and consulting services to production
supervision are also the responsibilities of maintenance
department.
(C) Maintenance (including Preventive Maintenance):
(1) Maintenance of existing plant equipment.
(2) Maintenance of existing plant buildings, and other service
facilities such as yards, central stores, roadways, sewers, etc.

(3) Engineering and execution of planned maintenance, minor

installations of equipment, building and replacements.
(4) Preventive maintenance, i.e., preventing breakdown
(before it occurs) by well-conceived plans of inspection,
lubrication, adjustments, repair and overhaul.
(D) Repair:
(1) Maintenance department carries out corrective repairs to
alleviate unsatisfactory conditions found during preventive
maintenance inspection.
(2) Such a repair is an unscheduled work often of an
emergency nature, and is necessary to correct breakdowns and
it includes trouble calls.
(E) Overhaul:
(1) Overhaul is a planned, scheduled reconditioning of plant
facilities such as machinery, etc.
(2) Overhaul involves replacement, reconditioning,
reassembly, etc.
(F) Construction:
(1) In some organizations, maintenance department is
provided with equipment and personnel and it takes up
construction jobs also.
(2) Maintenance department handles construction of wood,
brick and steel structures, cement and asphalt paving,
electrical installations, etc.
(G) Salvage:
Maintenance department may also handle disposition of scrap
or surplus materials.
This function involves:
i. Segregation, reclamation and disposition of production
scrap, and
ii. The collection and disposition of surplus equipment,
materials and supplies.
(H) Clerical Jobs:
Maintenance department keeps records:
i. Of costs,
ii. Of time progress on jobs,
iii. Pertaining to important features of buildings and
production equipment; electrical installations; water, steam,
air and oil lines ; transportation facilities (such as elevators,
conveyors, powered trucks, cranes, etc.), etc.
(I) Generation and distribution of power and other utilities.
(J) Administration and supervision of labour force (of
maintenance department).
(K) Providing plant protection, including fire protection.
(L) Insurance administration.
(M) Establishing and maintaining a suitable store of
maintenance materials.
(N) Janitorial service.
(O) Housekeeping.
Good housekeeping involves upkeep and cleaning of
equipment, building, toilets, wash-rooms, etc.
(P) Pollution and noise abatement.
Organisation of Maintenance Department:
(1) The buildings, plant and services are called by the
accountant fixed assets and in many companies they form at
least 50% of the money invested.
In any company, small or big, it is therefore essential that
some part of the main organization should be responsible for
maintaining these important assets.
(2) The section or department which preserves and looks after
the upkeep of equipment, building etc., is called maintenance
department.
(3) To work satisfactorily, the maintenance department has an
organization structure.
(4) A few basic concepts of good organisations that
should be kept in mind in developing an organisation
are:
(a) A reasonably clear division of authority with little or no
overlap.
(b) Vertical lines of authority and responsibility should be kept
as short as possible. In other words, a level which simply
transmits information up and instructions down should be
eliminated.
(c) Keep optimum number of persons (3 to 6 is the average
value) reporting to an individual.
(d) Fit the organisation to the personalities involved. This
means that the organisation structure should be flexible and it
may be revised periodically to fit changing personnel and
conditions.
(5) The basic organisation structure of maintenance
department depends upon:
(a) Types of maintenance activities to be looked after:
The wider the maintenance field to be covered, the bigger is
the organisation.
(b) Continuity of operations:
The size of the maintenance force and therefore the
structure of maintenance organisation depend upon:
i. Whether it is a four, five or six working days week, and
ii. Whether the plant runs in one, two or three shifts.
(c) Size of the plant:
The organisation structure of the maintenance department
varies with the size of plant. The larger the plant the more the
number of persons in the maintenance force.
(d) Compact or dispersed plant:
A plant spread in a wider area (like ECIL Hyderabad) needs
decentralization and may require several parallel maintenance
organisations. A compact plant may need only one such
Organisation.
(e) Nature of industry, i.e., whether it is primarily an electrical,
electronics, chemical or a mechanical industry.
(f) State of training and reliability of work force.
(6) In establishing a maintenance organisation, it is
essential to recognize that:
(a) The plant is to be maintained at a level consistent with low
cost and high productivity;
(b) Supervisors should be appointed according to the duties
and responsibilities involved; and
(c) Modern age indicates greater need of newer engineering
techniques and skills.
 STEAM TURBINE
OPERATION
PRINCIPLE AND DESIGN :

An ideal steam turbine is considered to be an isentropic

process, or constant entropy process, in which the entropy of
the steam entering the turbine is equal to the entropy of the
steam leaving the turbine. No steam turbine is truly isentropic,
however, with typical isentropic efficiencies ranging from 20–
90% based on the application of the turbine. The interior of a
turbine comprises several sets of blades or buckets. One set of
stationary blades is connected to the casing and one set of
rotating blades is connected to the shaft. The sets intermesh
with certain minimum clearances, with the size and
configuration of sets varying to efficiently exploit the expansion
of steam at each stage.
Practical thermal efficiency of a steam turbine varies with
turbine size, load condition, gap losses and friction losses. They
reach top values up to about 50% in a 1,200 MW (1,600,000 hp)
turbine; smaller ones have a lower efficiency.[citation
needed] To maximize turbine efficiency the steam is expanded,
doing work, in a number of stages. These stages are
characterized by how the energy is extracted from them and
are known as either impulse or reaction turbines. Most steam
turbines use a mixture of the reaction and impulse designs:
each stage behaves as either one or the other, but the overall
turbine uses both. Typically, lower pressure sections are
reaction type and higher pressure stages are impulse type.
WORKING ON THE BASIS OF TYPES

IMPULSE TURBINES:
An impulse turbine has fixed nozzles that orient the
steam flow into high speed jets. These jets contain
significant kinetic energy, which is converted into shaft
rotation by the bucket-like shaped rotor blades, as the
steam jet changes direction. A pressure drop occurs
across only the stationary blades, with a net increase in
steam velocity across the stage. As the steam flows
through the nozzle its pressure falls from inlet pressure
to the exit pressure (atmospheric pressure, or more
usually, the condenser vacuum). Due to this high ratio of
expansion of steam, the steam leaves the nozzle with a
very high velocity. The steam leaving the moving blades
has a large portion of the maximum velocity of the
steam when leaving the nozzle. The loss of energy due
to this higher exit velocity is commonly called the carry
over velocity or leaving loss.
The law of moment of momentum states that the sum
of the moments of external forces acting on a fluid
which is temporarily occupying the control volume is
equal to the net time change of angular momentum flux
through the control volume.
The swirling fluid enters the control volume at radius
REACTION TURBINE :
In the reaction turbine, the rotor blades themselves are
arranged to form convergent nozzles. This type of
turbine makes use of the reaction force produced as the
steam accelerates through the nozzles formed by the
rotor. Steam is directed onto the rotor by the fixed vanes
of the stator. It leaves the stator as a jet that fills the
entire circumference of the rotor. The steam then
changes direction and increases its speed relative to the
speed of the blades. A pressure drop occurs across both
the stator and the rotor, with steam accelerating
through the stator and decelerating through the rotor,
with no net change in steam velocity across the stage
but with a decrease in both pressure and temperature,
reflecting the work performed in the driving of the rotor.
Operation and maintenance

A modern steam turbine generator installation

Because of the high pressures used in the steam circuits
and the materials used, steam turbines and their casings
have high thermal inertia. When warming up a steam
turbine for use, the main steam stop valves (after the
boiler) have a bypass line to allow superheated steam to
slowly bypass the valve and proceed to heat up the lines
in the system along with the steam turbine. Also,
a turning gear is engaged when there is no steam to
slowly rotate the turbine to ensure even heating to
prevent uneven expansion. After first rotating the
turbine by the turning gear, allowing time for the rotor
to assume a straight plane (no bowing), then the turning
gear is disengaged and steam is admitted to the turbine,
first to the astern blades then to the ahead blades slowly
rotating the turbine at 10–15 RPM (0.17–0.25 Hz) to
slowly warm the turbine. The warm-up procedure for
large steam turbines may exceed ten hours.[25]
During normal operation, rotor imbalance can lead to
vibration, which, because of the high rotation velocities,
could lead to a blade breaking away from the rotor and
through the casing. To reduce this risk, considerable
efforts are spent to balance the turbine. Also, turbines
are run with high-quality steam: either superheated
(dry) steam, or saturated steam with a high dryness
fraction. This prevents the rapid impingement and
erosion of the blades which occurs when condensed
water is blasted onto the blades (moisture carry over).
Also, liquid water entering the blades may damage the
thrust bearings for the turbine shaft. To prevent this,
along with controls and baffles in the boilers to ensure
high-quality steam, condensate drains are installed in
the steam piping leading to the turbine.
Maintenance requirements of modern steam turbines
are simple and incur low costs (typically around $0.005
per kWh);[25] their operational life often exceeds 50
years.[25]
Speed regulation

Diagram of a steam turbine generator system

The control of a turbine with a governor is essential, as
turbines need to be run up slowly to prevent damage
and some applications (such as the generation of
alternating current electricity) require precise speed
control.[26] Uncontrolled acceleration of the turbine
rotor can lead to an overspeed trip, which causes the
governor and throttle valves that control the flow of
steam to the turbine to close. If these valves fail then
the turbine may continue accelerating until it breaks
apart, often catastrophically. Turbines are expensive to
make, requiring precision manufacture and special
quality materials.
During normal operation in synchronization with the
electricity network, power plants are governed with a
five percent droop speed control. This means the full
load speed is 100% and the no-load speed is 105%. This
is required for the stable operation of the network
without hunting and drop-outs of power plants.
Normally the changes in speed are minor. Adjustments
in power output are made by slowly raising the droop
curve by increasing the spring pressure on a centrifugal
governor. Generally this is a basic system requirement
for all power plants because the older and newer plants
have to be compatible in response to the instantaneous
changes in frequency without depending on outside
communication
THERMODYNAMICS OF STEAM
TURBINE
The steam turbine operates on basic principles
of thermodynamics using the part 3-4 of the Rankine
cycle shown in the adjoining
diagram. Superheated steam (or dry saturated steam,
depending on application) leaves the boiler at high
temperature and high pressure. At entry to the turbine,
the steam gains kinetic energy by passing through a
nozzle (a fixed nozzle in an impulse type turbine or the
fixed blades in a reaction type turbine). When the steam
leaves the nozzle it is moving at high velocity towards
the blades of the turbine rotor. A force is created on the
blades due to the pressure of the vapor on the blades
causing them to move. A generator or other such device
can be placed on the shaft, and the energy that was in
the steam can now be stored and used. The steam
leaves the turbine as a saturated vapor (or liquid-vapor
mix depending on application) at a lower temperature
and pressure than it entered with and is sent to the
condenser to be cooled.[28] The first law enables us to
find a formula for the rate at which work is developed
per unit mass. Assuming there is no heat transfer to the
surrounding environment and that the changes in kinetic
and potential energy are negligible compared to the
change in specific enthalpy we arrive at the following
equation
where
+ Ẇ is the rate at which work is developed per unit
time
+ ṁ is the rate of mass flow through the turbine

Isentropic efficiency
To measure how well a turbine is performing we can
look at its isentropic efficiency. This compares the actual
performance of the turbine with the performance that
would be achieved by an ideal, isentropic, turbine.
[29] When calculating this efficiency, heat lost to the
surroundings is assumed to be zero. Steam's starting
pressure and temperature is the same for both the
actual and the ideal turbines, but at turbine exit, steam's
energy content ('specific enthalpy') for the actual
turbine is greater than that for the ideal turbine because
of irreversibility in the actual turbine. The specific
enthalpy is evaluated at the same steam pressure for the
actual and ideal turbines in order to give a good
comparison between the two.
The isentropic efficiency is found by dividing the actual
work by the ideal work

where
h3 is the specific enthalpy at state three
h4 is the specific enthalpy at state 4 for the actual
turbine
 h4s is the specific enthalpy at state 4s for the isentropic
turbine
BASIC COMPONENTS OF STEAM TURBINE :

BLADE AND STAGE DESIGN:

Turbine blades are of two basic types, blades
and nozzles. Blades move entirely due to the impact of
steam on them and their profiles do not converge.
This results in a steam velocity drop and essentially
no pressure drop as steam moves through the blades.
A turbine composed of blades alternating with fixed
nozzles is called an impulse turbine, Curtis
turbine, Rateau turbine, or Brown-Curtis turbine.
Nozzles appear similar to blades, but their profiles
converge near the exit. This results in a steam
pressure drop and velocity increase as steam moves
through the nozzles. Nozzles move due to both the
impact of steam on them and the reaction due to the
high-velocity steam at the exit. A turbine composed of
moving nozzles alternating with fixed nozzles is called
a reaction turbine or Parsons turbine.
Except for low-power applications, turbine blades are
arranged in multiple stages in series,
called compounding, which greatly
improves efficiency at low speeds.[18] A reaction
stage is a row of fixed nozzles followed by a row of
moving nozzles. Multiple reaction stages divide the
pressure drop between the steam inlet and exhaust
into numerous small drops, resulting in a pressure-
compounded turbine. Impulse stages may be either
pressure-compounded, velocity-compounded, or
pressure-velocity compounded. A pressure-
compounded impulse stage is a row of fixed nozzles
followed by a row of moving blades, with multiple
stages for compounding. This is also known as a
Rateau turbine, after its inventor. A velocity-
compounded impulse stage (invented by Curtis and
also called a "Curtis wheel") is a row of fixed nozzles
followed by two or more rows of moving blades
alternating with rows of fixed blades. This divides the
velocity drop across the stage into several smaller
drops.[19] A series of velocity-compounded impulse
stages is called a pressure-velocity
compounded turbine.

BLADE DESIGN CHALLENGES:

A major challenge facing turbine design was reducing
the creep experienced by the blades. Because of the
high temperatures and high stresses of operation,
steam turbine materials become damaged through
these mechanisms. As temperatures are increased in
an effort to improve turbine efficiency, creep becomes
significant. To limit creep, thermal coatings
and superalloys with solid-solution strengthening
and grain boundary strengthening are used in blade
designs.
Protective coatings are used to reduce the thermal
damage and to limit oxidation. These coatings are
often stabilized zirconium dioxide-based ceramics.
Using a thermal protective coating limits the
temperature exposure of the nickel superalloy. This
reduces the creep mechanisms experienced in the
blade. Oxidation coatings limit efficiency losses
caused by a buildup on the outside of the blades,
which is especially important in the high-temperature
environment.
The nickel-based blades are alloyed with aluminum
and titanium to improve strength and creep
resistance. The microstructure of these alloys is
composed of different regions of composition. A
uniform dispersion of the gamma-prime phase – a
combination of nickel, aluminum, and titanium –
promotes the strength and creep resistance of the
blade due to the micro-structure.

STREAM SUPPLY AND EXHAUST

CONDITION :
These types include condensing, non-
condensing, reheat, extraction and induction.
Condensing turbines are most commonly found in
electrical power plants. These turbines
receive steam from a boiler and exhaust it to
a condenser. The exhausted steam is at a
pressure well below atmospheric, and is in a
partially condensed state, typically of
a quality near 90%.
Non-condensing or back pressure turbines are
most widely used for process steam
applications, in which the steam will be used
for additional purposes after being exhausted
from the turbine. The exhaust pressure is
controlled by a regulating valve 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 where large
amounts of low pressure process steam are
needed.
Reheat turbines are also used almost
exclusively in electrical power plants. In a
reheat turbine, steam flow exits from a high-
pressure section of the turbine and is
returned to the boiler where additional
superheat is added. The steam then goes back
into an intermediate pressure section of the
turbine and continues its expansion. Using
reheat in a cycle increases the work output
from the turbine and also the expansion
reaches conclusion before the steam condenses,
thereby minimizing the erosion of the blades
in last rows. In most of the cases, maximum
number of reheats employed in a cycle is 2 as
the cost of super-heating the steam negates
the increase in the work output from turbine.
Extracting type turbines are common in all
applications. In an extracting type turbine,
steam is released from various stages of the
turbine, and used for industrial process needs
or sent to boiler feedwater heaters to improve
overall cycle efficiency. Extraction flows may
be controlled with a valve, or left
uncontrolled. Extracted steam results in
a loss of power in the downstream stages of
the turbine.
Induction turbines introduce low pressure
steam at an intermediate stage to produce
additional power.
CASING:
These arrangements include single casing,
tandem compound and cross compound turbines.
Single casing units are the most basic style
where a single casing and shaft are coupled to
a generator. Tandem compound are used where
two or more casings are directly coupled
together to drive a single generator. A cross
compound turbine arrangement features two or
more shafts not in line driving two or more
generators that often operate at different
speeds. A cross compound turbine is typically
used for many large applications. A typical
1930s-1960s naval installation is illustrated
below; this shows high- and low-pressure
turbines driving a common reduction gear, with
a geared cruising turbine on one high-pressure
turbine.
TWO FLOW ROTORS:
The moving steam imparts both a tangential and
axial thrust on the turbine shaft, but the
axial thrust in a simple turbine is unopposed.
To maintain the correct rotor position and
balancing, this force must be counteracted by
an opposing force. Thrust bearings can be used
for the shaft bearings, the rotor can use
dummy pistons, it can be double flow- the
steam enters in the middle of the shaft and
exits at both ends, or a combination of any of
these. In a double flow rotor, the blades in
each half face opposite ways, so that the
axial forces negate each other but the
tangential forces act together. This design of
rotor is also called two-flow, double-axial-
flow, or double-exhaust. This arrangement is
common in low-pressure casings of a compound
turbine

TYPES OF STEAM TURBINE :

1.High pressure turbine (H.P. Turbine)
2.Intermediate pressure turbine (I.P. Turbine)
3.Low pressure turbine (L.P. Turbine)
High pressure turbine (H.P. Turbine) High pressure
and temperature fluid at the inlet of the turbine
exit as lower pressure and temperature fluid. The
difference is energy converted by the turbine to
mechanical rotational energy, less any
aerodynamic and mechanical in efficiencies
incurred in the process. Since the fluid is at a lower
pressure at the exit of the turbine than at the inlet,
it is common to say the fluid has been “expanded”
across the turbine.
H. P turbine blades • Aturbine blade is the
individual component which makes up the turbine
section of a gas turbine. The blades are responsible
for extracting energy from the high temperature,
high pressure gas produced by the combustor.
ADVANTAGES OF H.P TURBINE BLADE
• Ability to utilize high pressure and high
temperature steam.
• High efficiency.
• High rotational speed.
• High capacity/weight ratio.
• Smooth, nearly vibration-free operation.
• No internal lubrication.
• Oil free exhausts steam.

Low Pressure Turbine

• LP turbine is designed to be a dual flow turbine.
Steam enters the center of the turbine from the
crossover pipe and flows across the reaction
blading in two opposite directions. This
configuration reduces axial thrust on the turbine
and allows for a smaller turbine installation. On
ships where space is not a concern, a single flow
turbine is used.

Low Pressure Turbine blade Titanium alloys offer

high strength to intermediate temperatures at a
density almost half that of steel and nickel-based
superalloys. As a result, they have been adopted
widely in the fan and compressor stages of the gas
turbine for both disc and blade applications..
• LP blade is larger than HP & IP.

INTERMEDIATE PRESSURE TURBINE

• Intermediate pressure turbine having more
pressure then L.P turbine and lass than the high
pressure turbine(H.P) .
Its blade is larger than high pressure turbine.
 Blade of intermediate pressure turbine
• The size of blades of I.P steam turbine is larger
than H.P steam turbine , but smaller than L.P
steam turbine.

Control Valves
• Steam inlet valves perform one of two functions,
protection or control.
• Steam inlet control valves regulate the flow
and/or the pressure of steam through the turbine.
Their position, from closed to fully open, is
determined by the turbine electronic controlled.

Cutting method
• Plasma cutting:- Inert gas is blown at high speed
out of a nozzle; at the same time an electrical arc is
formed through that gas from the nozzle to the
surface being cut, turning some of that gas to
plasma.
• CNC cutting machine:-Based on CNC programs.
• Flame cutting:-A common propane/air flame
burns at about 2,000 °C (3,630 °F), a
propane/oxygen flame burns at about 2,500 °C
(4,530 °F), and an acetylene/oxygen flame burns at
about 3,500 °C (6,330 °F).

BLADE DESIGN
Based on the information provided in the previous sections,
an efficient and reliable blade design will satisfy the
following requirements:
1. The blade material must have a sufficient yield
strength to resist plastic deformation, and must be
able to retain such yield strength, or at least most of
it, at elevated temperatures.
2. The blade material must be able to be processed
and worked with easily (this is one of thedownsides of Titanium
alloys as they are not easily
welded and they are expensive to produce).
3. Blade materials must exhibit a moderate elastic
modulus so that the blade neither deforms
exceedingly nor breaks suddenly under normal
operating stresses.
4. Preferably, blade materials should be low-density in
order to decrease the centrifugal forces, and
therefore centrifugal stresses, on the blades.
5. The blades must be corrosion-resistant, even in the
presence of aggressive ionic solutions formed by
impurities in the steam.
6. Blades must be manufactured in such a way as to
minimize initiation of cracks during the
manufacturing process.
Kiyoshi Segawa, et al, have developed a new rotor blade
for steam turbine plants [15]. The new blade design
optimized blade aerodynamics near the root section of the
blade, thus decreasing both profile and endwall losses.
Based on the results of 3-D stage and air turbine tests, the
new rotor blade was found to increase stage efficiency by
about 0.3%. In addition, the new blade design was found to
improve internal efficiency and reduce manufacturing costs
by reducing the blade number by 15% [15].
Walker and Hesketh have determined that improvements
in efficiency can be realized by the optimization of
aerodynamic parameters including stage heat-drop, blade
velocity distribution, surface finish, and three-dimensional
design [9]. However, in order to optimize these parameters
the constraints imposed by manufacturing costs and
mechanical limitations must be considered. For example,
reduction of blade stress can be realized with the
implementation of lighter-weight materials, such as
Titanium alloys. However, such alloys are not suitable for
use in regions of elevated temperatures and they are neither
easily nor cheaply manufactured. Thus, in order to improve
turbine efficiency, a happy medium between cost and
performance must be established.
Overall, an improved blade design consisting of strong,
erosion and corrosion-resistant materials with optimized
aerodynamic parameters will result in a more efficient
turbine.

STEAM TURBINE (-3 series)

This range Oi Impulse Reaction Turbines are With unidirectional
axial steam flow and are built based on modular concept using
building block principle. With this concept, it is possible to
optimize the flow path for any specific appl icationfparameters
and yet use standard and proven components for casings, guide
blade carriers, bearing pedestals, nozzles, stop & governing
valves. servo motors, exhaust sections, tast stage blading, etc.
Robust drum type rotor with integral shrouds, labyrinth glands
for sealing of Otor ends interstage, ensure greater reliability
and efficiency. These Turbines usually employ a gear box
between Turbine end Generator to achieve optimum
efficiencies.

1) Front Bearing Housing

2) Rear Bearing Housing
3) Front Journal gearing
4) Thrust Bearing
5) Rear Bearing
6) Outer Casing
7) Guide blade Carrier
8) Balance Piston Gland
9) Front GIand
10) Rear Gland
11) Exhaust Hood
12) HP Control Valve Assy
13) Servo Motor Assy
14) Rotor
15) Extraction Branch
16) LP control valves