PROJECT REPORT

ON
STUDY OF MANUFACTURING OF STEAM TURBINE BLADES
A mini project
report submitted for partial fulfillment of the requirement
for the award of the degree of

“BACHELOR OF TECHNOLOGY IN
MECHANICAL ENGINEERING”
2018 - 2019
Under the Esteemed Guidance of

A.KRISHNA REDDY (Addl. Engineer)/HRDC W/S

At

SUBMITTED BY
S. DHANUSH KUMAR (15D41A03B1)
V. SAI VENKATESH (15D41A03C2)
Y. SAI ARAVIND REDDY (15D41A03C8)
D. SAI VARDHAN (16D45A0309)
 ACKNOWLEDGEMENT

First of all we are extremely thankful to Shri V. MURALI GOPAL sir, GENERAL MANAGER,
BHEL, Ramachandrapuram for giving us this opportunity to carry out project work at Bharath
Heavy Electronics Limited (BHEL),

We would like to express our sincere thanks to Shri A. KRISHNA REDDY sir for accepting to
be our guide and helping us throughout our project work.

We would also like to express our gratitude towards Shri GATINDRA MALIK Sir for accepting
our Internship application and for permitting us to do our industrial training at BHEL.

Additionally we want to thank all the Divisional managers, Engineers at BHEL, section in charges
and workers for their guidance and immense support in completing this Training. We also want to
thank our fellow trainees and apprentices for sharing their information and helping us in the plant.

Our special thanks to our HOD Sri M. SRINIVAS RAO sir of DEPARTMENT OF
MECHANICAL ENGINEERING, and Principal Dr. P.MALLESHAM sir, SRI INDU
COLLEGE OF ENGINEERING AND TECHNOLOGY who have given us their permission and
this opportunity to learn from our training.

We are grateful to our parents who have given us constant encouragement and inspiration in
pursuing our graduation.

Finally we would like to thank everyone who had directly or indirectly helped us in the successful
completion of this Project.
ABSTRACT:

In the era of Mechanical Engineering, Turbine, a Prime Mover (which uses the Raw
Energy of a substance and converts it to Mechanical Energy) is a well known machine and is most
useful in the field of Power Generation. This Mechanical energy is used in running an Electric
Generator which is directly coupled to the shaft of turbine. From this Electric Generator, we get
electric Power which can be transmitted over long distances by means of transmission lines and
transmission towers. In this Industrial Training in B.H.E.L, Ramachandrapuram; we have gone
through all sections in Turbine Manufacturing. This paper discusses about the history of industry,
Area, Capacity, Machines installed & Facilities in the Industry along with an overview, the Steam
Turbine its types, parts like Blades, Casing and Rotor etc. The full explanation of constructional
features and procedure along with equipment used are detailed below. The material of blade for a
particular desire, types of Blades, Operations performed on Blades, their New Blade Shop are also
mentioned with a well defined proper format.
INDEX:
SL. NO. TOPIC PAGE NO.
1 INTRODUCTION 1 to 4
1.1 BHEL Outlook and Over view 2
1.2 Products from BHEL 3
1.3 Services of BHEL, Hyderabad 4

2 STEAM TURBINES 5 to 7
2.1 Introduction to Steam Turbines 5
2.2 Types of Steam Turbines 7

3 STEAM TURBINE BLADES 8 to 9

3.1 Introduction 8
3.2 Turbine Casing 8
3.3 Turbine Rotors 8
3.4 Disc Rotors 9
3.5 Drum Rotors 9

4 CONSTRUCTIONAL FEATURES OF BLADE 9 to 18

4.1 Blade Profiles 9
4.2 Classification of Profiles 11
4.3 Types of Blade Roots 12
4.4 Dynamics of Blades 14
4.5 Blading Materials 17

5 MANUFACTURING PROCESS 18 to 26
5.1 Introduction 18
5.2 Classification of Manufacturing Process 19
5.2.1 Primary Shaping Process 19
5.2.2 Secondary Shaping 21

6 BLADE SHOP 26 to 30
 6.1 Operations performed on Blade Shop 26

7 BLADE SHOP FLOOR 30 to 31

7.1 Turbine Blade Manufacturing Shop 30
7.2 Turning Section 30
7.3 Heat Treatment Shop 31

8 PRODUCT AND PROCESS LAYOUT 31 to 34

8.1 Types of Blades 31
8.2 Operations performed on Blades 33
8.3 Machining of Blades 33
8.4 New Blade Shop 34

9 CONCLUSION 35

FIGURE INDEX:

1.1 BHEL

2.1 Sectional view of Steam Turbine

2.2 Installed Steam Turbine Shaft

4.1.1 H.P. Blade Airfoil Profile

4.1.2 H.P. Blade Profile
4.3 Types of Blade Roots
4.3.1 Fir Tree Root of H.P. Blades
4.3.2 I.P. T-Root
4.3.3 L.P. T-Root
4.4.1 Setting Angle Variation Error
4.4.2 Stages of S.T. Blades and Shroud
4.5 List of different S.T. Blade Materials
5.2.1 Casting
5.2.2 Gas Cutting
5.2.3 Forging
5.2.4 Horizontal Lathe Machine
5.2.5 Vertical Lathe
5.2.6 Milling Machine
5.2.7 Drilling Machine
5.2.8 Boring Machine
5.2.9 Shaper Machine
5.2.10 Planer Machine
5.2.11 Slotting Machine

6.1.1 Slab Milling

6.1.2 Fly Cutting
6.1.3 Slitting
6.1.4 Vertical Milling
6.1.5 Angle Cutter Milling

7.1 Blade Manufacturing Shop

7.2 Rotor turning lathe machine

8.1.1 Types of Blades

8.1.2 Complete Block Layout
8.1.3 Types of Turbine Blade Profiles
8.3.1 Product Layout, Cellular Layout, Functional Layout