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STEAM TURBINES
OUR MAINSTAY
BHEL has the capability to design, manufacture and commission steam turbines of up to 1000 MW rating for steam parameters ranging from 30 bars to 300 bars pressure and initial & reheat temperatures upto 600 oC.
Turbines are built on the building block system, consisting of modules suitable for a range of output and steam parameters.
For a desired output and steam parameters appropriate turbine blocks can be selected.
Turbines are classified based on method of steam generation.
APPLICATION RANGE OF STEAM TURBINE
SERIESTYPE OFSTEAM
GENERATOR
SPEEDRPM
POWER OUTPUT
MW
MAIN STEAM CONDITION REHEAT STEAM CONDITION
BACK PRESSURE
MBARBAR OC BAR OCTurbines for Fossil Fuel
Power PlantsFossil Fuel Steam
Generator3000 100-1000 130-250 500-540 30-70 500-600 20-300
Turbines for Nuclear Power Plants
Pressurised Light Water Reactor
3000 Upto 1000 40-70 250-300 8-15 200-250 20-300
Turbines for Combined Cycle Applications
Heat recovery Steam Generator
3000 Upto 300 30-140 500-540 30-50 500-540 20-300
STEAM TURBINES FOR FOSSIL FUEL POWER PLANTS
Three cylinder turbines (HMN Series), comprising of:
High pressure (HP) turbine Intermediate pressure (IP) turbine Low pressure (LP) turbines
i. Sliding pressure operation ii. Base load as well as two-shift operation
iii. Sub critical as well as super critical parameters
All the rotors are monoblock
HP & IP casings have double shell construction and LP has three-shell construction. IP turbines with single flow or with double flow. LP turbines are designed for normal as well as high back pressure conditions. Hollow guide blades with suction slits for moisture removal in last LP stage. Bearing pedestals isolated from turbine casings. Combined stop & control valves with individual servomotor. Sophisticated control and monitoring equipment such as Electro-hydraulic governing, automatic turbine run up system, turbine stress controller, automatic turbine tester etc.
High operational flexibility
i. Fast start up and shut down ii. Sharp load changes
Operation under wide frequency range (47.5 to 51.5 Hz)
Two cylinder turbines comprising of combined (HP&IP) and LP turbine (KN series) Two cylinder turbines comprising of HP and combined (IP&LP) turbines (HE series)
STEAM TURBINES FOR COMBINED CYCLES
Combined cycles offer substantial improvement in thermal cycle efficiency by lowering the heat rejection temperature.
Exhaust from gas turbine is used effectively for generating steam in fired or unfired heat recovery steam generator for running a suitable steam turbine.
Open cycle gas turbines can be profitably converted to a combined cycle plant even at a later stage depending upon the convenience of the utility.
BHEL Hardwar manufactures steam turbines for combined cycle power stations with gas turbines of 66 MW, 159 MW and 255 MW ISO ratings.
Steam cycle may be single, dual or triple pressure cycle.
With triple pressure cycle and suitable block combination of gas turbines, HRSG and steam turbines, cycle efficiency of about 58% can be achieved.
TURBINES WITH ADVANCED STEAM PARAMETERS
Application of higher parameters is the most direct way of increasing heat input to the cycle
Steam parameters of 300 bar pressure and 600 oC temperatureSix percent improvement in thermal cycle efficiencyNew materials for high temperature applicationsImpulse diagonal blading for the first stage HP and IP turbinesHeat shield at inlet of IP turbineIncreased wall sections for increased pressures
TURBINE BLADES
Cylindrical reaction blades for HP, IP and LP Turbines3-DS blades, in initial stages of HP and IP Turbine, to reduce secondary lossesTwisted blade with integral shroud, in last stages of HP, IP and initial stages of LP turbines, to reduce profile and Tip leakage lossesFree standing LP moving blades
Tip sections with supersonic designFir-tree rootFlame hardening of the leading edge
Banana type hollow guide bladeTapered and forward leaning for optimised mass flow distribution
ENGINEERING CAPABILITIES
Over the past two decades, BHEL has gained a vast experience in design, manufacture, erection and commissioning of various capacities of Turbine Generator sets ranging from 100 MW to 500 MW.
Many specific features to suit the customer requirements, layout & operation are taken care of. To name a few:
← HP/LP bypass Turbine Stress Evaluator, hand Barring Gear and Automatic Turbine Run-up System for 210 MW Russian Turbine.
← Base load/cycle /Two-shift operations← Throttle /Nozzle governing← Constant/Sliding pressure operation← High back pressure for desert application.
BHEL Hardwar has a strong engineering base with qualified and experienced engineers supported by technicians, spanning the functions of proposal, performance and product engineering, project management, field engineering, research and development, computerisation etc.
MANUFACTURING FACILITIES
The plant is fully equipped with the most modern and sophisticated manufacturing and testing facilities to produce sets upto 1000 MW rating. These include:
Blade Shop for manufacture of both moving and stationary blades
Special purpose CNC machine tools
Overspeed & Vacuum Balancing Tunnel-a unique facility for balancing and overspeeding of rotors for turbines
QUALITY – A MATTER OF COMMITMENT
An ISO 9001 Company Quality, a watchword in incoming materials, in-process, machining, assembly and testing. Quality Assurance, Quality Plan, Field Quality being an integral part of the total process. Fully equipped Centre Plant Laboratory to support, sophisticated testing and measuring instruments viz. CNC 3 D Co-ordinate Measuring Machine. NDT facilities: X-ray, Gama ray, Ultrasonic Magnetic particle testing. Recognised by MIS TUV, Germany as a reputed manufacturer of pressure vessels ASME U stamp ASME R Stamp
Technology / Collaborations
The technological base of BHEL in the area of Steam turbines and Turbo Generators has been created by acquiring technological information from the collaborators.
Initially BHEL had collaboration with M/s LMW USSR for 100 and 210 MW sets. In 1976, BHEL entered into technical collaboration agrrement with M/s Siemens-KWU, Germany to acquire the know-how and know-why for turbine generator sets upto 1000 MW. This collaboration still continues.
This helps BHEL to keep pace with the worldwide technological progress and offer state of the art equipment to it's customer.
Under this collaboration agreement, BHEL has established strong design, manufacturing and servicing base for unit upto 500 MW ratings.
BHEL’S LARGE SIZE GAS TURBINES
FUEL FLEXIBILITY
Gas Turbine burners are designed to burn a wide variety of fuels ranging from clean fuels like Natural Gas, Distillate Oil, Naphtha, LPG to heavy fuels like LSHS. Gas Turbines can be operated in mix-mode also.
HIGH RELIABILITY
High reliability and long operating life are the prime basis of the design philosophy adopted for these Gas Turbines. The reliability of M/s SIEMENS/ BHEL designed Gas Turbine is unsurpassed with more than 2 million hours of successful operation for module V94.2 itself.
This measure of high reliability has been achieved through a combination of sound design engineering, established manufacturing processes with well defined quality management systems.
HIGH EFFICIENCY
These Gas Turbines have high efficiency in Open Cycle and in Combined Cycle Operation. The provision of inlet guide vanes improves the combined cycle efficiency at part loads.
LOW EMISSION
While on natural gas very low NOx and negligible CO emissions are achieved without steam/water spray in specially designed Hybrid Burners. Steam/water spray assists in reduction of NOx emissions when firing liquid fuels like Naphtha, Distillate No.2 etc.
HIGHLY EFFICIENT NEWLY DEVELOPED 'A' SERIES GAS TURBINES
NEW DESIGN BASED ON PROVEN FEATURES
Advanced series of gas turbine designed to meet higher efficiencies have been developed by Siemens and designated as Vxx.3A series of machines. The 3A
series machines are state-of-art machines with basic features adapted from previous gas turbine series. Important design features of the 3A gas turbine are:
1. New compressor blading 2. Fewer hot gas path components 3. Film cooled turbine blades 4. Hybrid burner ring (HBR) combustor with 24 burners 5. Lower cooling air requirement and thus more air available for clean
combustion
Advances made in the development of this series of gas turbines are particularly evident in the combustion chamber. The ring type combustion chamber is connected to the turbine outer casing. The hybrid burners form a continuos ring flame thus eliminating the localized hot and cold spots. The objective here is to reduce the pollutant emissions.
THE MAJOR BENEFITS FOR ADVANCE GAS TURBINE
1. Large saving in operating costs due to lowest fuel consumption 2. Low maintenance costs as a result of readily maintainable machine
construction and long intervals between inspections 3. Excellent operating availability and reliability 4. Lower life-cycle cost
MANUFACTURING FACILITIES
The plant is fully equipped with the modern and sophisticated machine-tools and testing equipment to produce steam turbine sets upto 1000MW ratings and Gas Turbine sets upto 300MW ratings.