SWITCHGEAR SIZING AND SELECTION

PROJECT REPORT

Guided By:
Mr. SRIKANTH KOLUKULA

Done By:
Mr.RAMANJANEYA

REDDY
Design Engineer

Mr.SHASHANK.B

GAS TURBINE ENGINEERING

Mr.GANESH.N

Hyderabad

DEPT. OF EEE
J.B.I.E.T

ACKNOWLEDGEMENT
I owe this profound acknowledgement to all those people who made this
project successful. I express my deep sense of gratitude to BHEL,
Ramachandrapuram, Hyderabad for permitting me work in their esteemed
organization.
I would like to thank Mr. B.Shyam Babu, Sr. Manager (Gas Turbine
Engineering ) and Mr. K.Srikanth, Design Engineer (Gas Turbine Engineering )
BHEL, R.C.Puram, Hyderabad for their kind co-operation without which the project
training would not have been completed.
I would like to extend my sincere thanks to Mr. K.Suresh, Dy. Manager (Gas
Turbine Engineering) and Mr. G. Nageshwer Rao, Design Engineer ( Gas Turbine
Engineering ) for their encouragement and constant support throughout the training.
I take the opportunity to thank our Head Of Department, Prof. Padmavathi
and also Prof.Sharma for their timely advice and guidance while pursuing this
project.

INTRODUCTION TO BHEL
BHEL is the largest engineering and manufacturing enterprise in India in the
energy-related/infrastructure sector, today. Established more than 40 years ago, BHEL
is ushering in the indigenous Heavy Electrical Equipment industry in India - a dream
that has been more than realized with a well-recognized track record of performance.
The company has been earning profits continuously since 1971-72 and paying
dividends since 1976-77.
BHEL, countrys premier engineering organization and one of the
NAVARATNA PSUs caters to core sectors of Indian economy viz Power Generation
and Transmission, Industry, Transportation, Oil & Gas, Renewable Energy. Having 14
Manufacturing Divisions, 08 Service Divisions, 15 Regional Offices, 04 Power Sector
Regional Centres and over 100 Project Sites spread all over the Country, BHEL
manufactures over 180 products under 30 major product groups. The financial
turnover during the year 2007-08 was Rs.21,401 Crores and Current Order Book is of
around Rs.1,20,000 Crores. BHEL plans to be a Rs.45,000 Crores Company by 201112 and a Rs.90,000 Crores Company by 2016-17. BHEL is the only PSU among the
12 Indian Companies to figure in Forbes Asian Fabulous 50 list. The Company to
promptly serve its customers and provide them with suitable products, systems and
services -- efficiently and at competitive prices. BHEL has a high level of quality &
reliability of its products 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 centre.
BHEL has

Installed equipment for over 90,000 MW of power generationfor

utilities, captive and industrial users.

Supplied over 2,25,000 MVA transformer capacity and other

equipment operating in transmission and distribution network up to
400 KV( AC& DC).

Supplied over 25,000 motors with drive control system to power

projects, petrochemicals, refineries, steel, aluminium, fertilizer, cement
plants, etc..

Supplied traction electrics and AC/DC locos to power over 12,000 kms
railway network.

Supplied over one million valves to power plants and other industries.

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 have engendered development of a committed
and motivated workforce setting new benchmarks in terms of productivity, quality and
responsiveness.

Power Generation
Power Generation Sector comprises thermal, gas, hydro and nuclear power
plant business. As of 31.3.2008, BHEL- supplied sets account for 85,811 MW or
nearly 64% of the total installed capacity of 1,34,722 MW in the country.
Significantly, these sets generated an all-time high 456.12 Billion Units of electricity,
contributing 73% of the total power generated in the country. The cumulative capacity
of projects installed worldwide have crossed 1,00,000 MW.
BHEL has proven turnkey capabilities for executing power projects from Concept-to
Commissioning. The Company has introduced new rating thermal sets of 270 MW,
525 MW & 600 MW in subcritical range and possesses the technology and capability
to produce large capacity thermal sets with super critical parameters and, advancedclass gas turbine-generator sets. Co-generation and combined cycle plants have been
introduced to achieve higher plant efficiencies. To make efficient use of the high-ashcontent coal available in India, BHEL also supplies circulating fluidized bed
combustion (CFBC) boilers for thermal plants. The Company manufactures

220/235/500/540 MW nuclear turbine-generator sets. Custom-made hydro sets of

Francis, Pelton and Kaplan types for different head-discharge combinations are also
engineered and manufactured by BHEL. The Company has proven expertise in Plant
Performance Improvement through renovation, modernization and up rating of a
variety of power plant equipment, besides specialized know-how of residual life
assessment, health diagnostics and life extension of plants. BHEL- built thermal sets
consistently exceed the national average efficiency parameters and have achieved the
highest-ever Plant Load Factor (PLF) of 80.5% during 2007-08, which is 1.9% higher
than the national average. Operating Availability (OA) was also the highest-ever at
86.7%. BHEL is one of the few companies worldwide, involved in the development
of Integrated Gasification Combined Cycle (IGCC) technology which would usher in
clean coal technology. BHEL has set up Asias first 6.2 MW IGCC power plants with
an indigenously designed pressurized fluidized bed gasifier. The Company has also
signed a MoU with APGENCO for setting up a 125 MW IGCC plant at Vijayawada.

Industries
BHEL manufactures and supplies major capital equipment and systems like
captive power plants, centrifugal compressors, drive turbines, industrial boilers and
auxiliaries, waste heat recovery boilers, gas turbines, pumps, heat exchangers,
electrical machines, valves, heavy castings and forgings, electrostatic precipitators,
ID/FD fans, seamless pipes etc. to a number of industries like, metallurgical, mining,
cement, paper, fertilizers, refineries & petro-chemicals, etc., other than power utilities.
BHEL has also emerged as a major supplier of controls and instrumentation systems,
especially distributed digital control systems for various power plants and industries.

Transportation
Most of the trains in Indian Railways, whether electric or diesel powered, are
equipped with BHELs traction propulsion system and controls. The systems supplied
are both with conventional DC drives and state of the art AC drives. Indias first
underground metro at Kolkata runs on drives and controls supplied by BHEL. The
Company also manufactures complete rolling stock i.e., Mainline 25 kV AC
locomotives up to 5000 HP, EMU coaches and Diesel Electric Shunting Locomotives
from 350 HP to 2600 HP. BHEL also undertakes retrofitting and overhauling of
rolling stock. In the area of Urban transportation, BHEL is geared up for turnkey
execution of electric trolley bus systems, light rail systems and metro systems. BHEL

is contributing to the supply of electrics for EMUs for 15000V DC & 25 kV AC to

Indian Railways. Almost all the EMUs in service are with electrics manufactured and
supplied by BHEL. BHEL has also diversified into the area of track maintenance
machines for Indian Railways.

Renewable Energy
BHEL has been manufacturing and supplying a range of Renewable Energy
products and systems. It includes Photo Voltaic modules and systems. BHEL has
supplied stand alone Power Plants of ratings up to 150 KW peak, usually used as
Distributed Power generation plants. The Company has capability to design and
execute grid connected MW sized PV plants. BHEL is actively associated with the
development and adoption of Wind Power and Concentrated Solar Power (CSP)
projects in India and abroad.

Oil and Gas

BHEL is supplying onshore drilling rig equipment viz., draw-works, rotarytable, travelling block, swivel, mast and sub structure, mud systems and rig electrics
to ONGC and Oil India Ltd. Well heads & Xmas Tree valves up to 10,000 Psi rating
for onshore as well as offshore application are being supplied to ONGC, Oil India
Ltd. and Private Drilling Companies. BHEL has also supplied Casing Support
System, Mudline Suspension System and Block Valves to ONGC for offshore
application. It also has the capability to supply complete onshore drilling rigs, superdeep drilling rigs, desert rigs, mobile rigs, work over rigs and sub-sea well heads.
Currently, BHEL is executing orders for refurbishment and up-gradation of onshore
Oil Rigs from ONGC & Oil India Ltd. BHEL has supplied GT driven centrifugal
compressor packages to GAIL India Ltd. for their gas compressor stations for Dahej Vijaipur gas pipeline project.

Transmission
BHEL supplies a wide range of products and systems for transmission and
distribution applications. The products manufactured by BHEL include power
transformers, instrument transformers, dry type transformers, shunt reactors,
capacitors, vacuum and SF6 switchgear, gas insulated switchgears, ceramic insulators,
etc. BHEL has developed and commercialized the countrys first indigenous 36 kV

Gas Insulated Substation (GIS) and has also developed 145 kV GIS which has
undergone successful field trials at Hyderabad. For enhancing the power transfer
capability and reducing transmission losses in 400 kV lines, BHEL has indigenously
developed and executed a number of fixed series compensation schemes. BHEL has
indigenously developed and commercialized state-of-the-art 400 kV Controlled Shunt
Reactor (CSR) for reactive power management of long transmission lines. With a
strong

engineering

base,

the

Company

undertakes

turnkey

execution

of

substations/switchyards up to 400 kV and has the capability to execute 765 kV

projects. High Voltage Direct Current (HVDC) systems have been
Executed for economic transmission of bulk power over long distances.

International Business
BHEL has, over the years, established its references in more than 70 countries
across all inhabited continents of the world. These references encompass almost the
entire range of BHEL products and services, covering Thermal, Hydro and Gas-based
turnkey power projects, Substation projects and Rehabilitation projects, besides a
wide variety of products like: Transformers, Compressors, Valves and Oil Field
Equipment, Electrostatic Precipitators, Photovoltaic Equipment, Insulators, Heat
Exchangers, Switchgears, Castings and Forgings etc. Some of the major successes
achieved by BHEL have been in Gas-based power projects in Oman, Libya, Malaysia,
UAE, Saudi Arabia, Iraq, Bangladesh, Sri Lanka, China, Kazakhstan; Thermal power
projects in Cyprus, Malta, Libya, Egypt, Indonesia, Thailand, Malaysia, Sudan, Syria,
Ethiopia, Senegal, New Caledonia; Hydro power plants in New Zealand, Malaysia,
Azerbaijan, Bhutan, Nepal, Taiwan, Tajikistan, Vietnam, Rwanda, Thailand,
Afghanistan; and substation projects & equipment in various countries. Execution of
these overseas projects has also provided BHEL the experience of working with
world-renowned Consulting Organizations and Inspection Agencies. The Company
has been successful in meeting demanding requirements of International markets, in
terms of complexity of the works as well as technological, quality and other
requirements viz., HSE requirements, financing packages and associated O&M
services, to name a few. BHEL has proved its capability to undertake projects on fasttrack basis. BHEL has also established its versatility to successfully meet the other
varying needs of various sectors, be it captive power, utility power generation or for
the oil sector. Besides undertaking turnkey projects on its own, BHEL also possesses

the requisite flexibility to interface and complement other International companies for
large projects, and has also exhibited adaptability by manufacturing and supplying
intermediate products. The Company is taking a number of strategic business
initiatives to fuel further growth in overseas business. This includes firmly
establishing itself in target export markets, positioning of BHEL as a regular EPC
contractor in the global market both in utility and IPP segments, and exploring various
opportunities for setting up overseas joint ventures etc.

Technology Upgradation, Research & Development

To remain competitive and meet customers expectations BHEL lays great
emphasis on the continuous upgradation 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
acquisition of new technologies from leading engineering organizations of the world.
The Corporate R&D Division at Hyderabad leads BHELs research efforts in number
of areas of importance to BHELs product range. Research and product development
centre at each of manufacturing divisions play a complementary role. Centre of
Excellence have been set up for Simulators, Computational Fluid Dynamics,
Permanent Magnetic Machines, Surface Engineering and Centre for Intelligent
Machines and Robotics (CIMAR). In addition to Corporate R&D Division, BHEL has
four specialized institutes viz., Welding Research Institute at Tiruchy, Ceramic
Technological Institute at Bangalore, Centre of Electric Traction and Hydro Lab at
Bhopal and Pollution Control Research Institute at Haridwar.
BHELs investment in R&D is among the highest in the corporate sector in India.
Products developed in-house during the last five years contributed 13.80% to the
revenues in 2007-08.
BHEL has introduced, in the recent past, several state-of-the-art products viz. 60 MW
Bubbling
Fluidized Bed Combustion Boiler for power generation against the maximum size of
40 MW being supplied so far, 260 MW steam turbine designed to suit combined cycle
power plants, Bypass Over Fire Air (BOFA) for reduction of NO x from coal-based
thermal power plant, high-efficiency Francis and Pelton hydro turbines, new LP
turbine variant which can be retrofitted in old Russian (LMW) 210 MW thermal sets,
automatic storage & retrieval system (ASRS) for storage and inventory management

system of the Indian Army, solar panels with 5500 watt output consisting of highefficiency multi-junction solar cells, satellite batteries for INSAT 4A, controlled shunt
reactor(CSR) for 400 kV transmission lines, Flexible AC transmission system
(FACTS) STATCOM, Phase Shifting Transformer (PST), 145kV gas insulated
Switchgear(GIS), micro-controller-based flame scanner, a more energy efficient
single cylinder non-reheat Steam turbine for 100-140 MW applications, IGBT-based
3-phase drive system for 700 HP Diesel Electric Locomotives, technology for
manufacture of 400kV long rod composite insulators with improved properties by
adding nano materials, performance analysis, diagnostic and optimization (PADO)
package for power plants, 91 Ton BHEL 280 Bowl Mill, etc. To meet its commitment
to clean environment, BHEL has developed design for an IGCC power plant and has
also signed an MOU for an IGCC plant at Vijayawada. The Company is also engaged
in research in futuristic areas like fuel cells for distributed environment friendly power
generation, clean coal technology applications, superconductivity applications in
transformers, generators/motors etc, thin film solar cells and nano technology for
various applications.

Human Resource Development Institute

The Human Resource Development Institute situated in Noida, a cornerstone
of BHELs learning Infrastructure, along with Human Resource Development Centers
at units and Advanced Technical Education Center (ATEC) in Hyderabad, through
various HRD efforts ensure that the prime resource of the organization the Human
Capital - is Always in a state of Readiness to meet the dynamic challenges posed by
a fast changing environment. It is their constant endeavour to take the HRD activities
to the strategic level of becoming active partner for achieving the organizational
goals. Guided by the HRD Mission Statement To promote and inculcate a valuebased culture utilizing the fullest potential of Human Resources for achieving the
BHEL Mission HRDI, through a step- by- step strategic long-term training process
and

several

short-term

need-based

programmes

based

on

comprehensive

organizational research, enable its human resources to unearth and polish their
potential. HRDI is spearheading the HRD initiatives in the Company and focusing on
competency, commitment and culture building. The various types of programme
being conducted at HRDI are:- _ Core Programmes _ Extension Programmes _
Change of House Programmes _ Strategic Need-based Programmes _ Competency-

based Programmes _ Functional Programmes. HRDI has streamlined induction

training for new entrants and has published Induction Training Modules at three levels
i.e. Dakshata, Nipun and Praveen for Engineers/Executive Trainees, Supervisory
Trainees and Artisan Trainees. HRDI is playing the pivotal role in institutionalizing
Mentoring throughout BHEL. In addition, HRDI provides professional support to
Corporate HR and HRD.
HRDI is also accepting consulting assignments from other organizations in a selective
manner.

Health, Safety and Environment Management

BHEL is an environment friendly company in all its activities, products and
services besides providing safe and healthy working environment to all its
stakeholders. BHELs commitment towards conservation of environment, continued
and various Environment Improvement Projects (ElPs) successfully completed during
the year (2007-08). Major ElPs completed during the year in and around units/regions
and sites include cumulative tree plantation (over 1 lakh), Rainwater Harvesting
Plants, Energy & Conservation Projects utilizing efficient technologies, Chemical
storage & disposal plants, Resource conservation plants. These projects helped in
creating pollution free environment, conservation of precious resources like energy,
water, fuel oil, coolant besides installation of proper system for storage/handling of
chemical waste. All manufacturing units/regions of the Company are accredited to
international standards viz. ISO-14001 certification for environmental management
and OHSAS-18001 certification for occupational health and safety management
systems. The Company reiterates its commitment to United Nations Global Compact
Programme and the set of core values enshrined in its ten principles on human rights,
labour standards, environment and anticorruption
And intend to advance G.C. principles within the Companys sphere of influence and
has made it a part of its strategy, culture and day-to-day operations. BHEL continued
its commitment to the United Nations Global Compact Programme through regular
pooling of communication of progress (COP) at the United Nations Global Compact
website and organizing workshop to disseminate the concept of Global Compact.
Company publicly advocates with its employees and other stakeholders and regularly
incorporates its commitments towards G.C. programme through BHELs Annual
Report, press conferences and other public documents. Clean Development

Mechanism (CDM) has come as an additional catalyst. Functioning under Director/

E,R&D, the Clean Coal Power System Group in Corporate Office, organized a CDM
Awareness Program for the Nodal Officers of the units. In each unit, a CDM projects
committee has been formed, consisting of members from Engineering, Finance,
Marketing, Commercial, HSE and Training Functions, to identify projects, oversee the
registration, implementation; generate carbon credit and selling them. Consultants
suitable for the types of CDM projects of BHEL have been short-listed & guidelines
for engaging consultants had been issued. A broad reference list of CDM activity
projects both of in-house implementation and joint claim projects with customers has
been generated.

BHEL- HYDERABAD (RAMACHANDRAPURAM) UNIT:

As a member of the prestigious 'BHEL family', BHEL-Hyderabad has earned a
reputation as one of its most important manufacturing units, contributing its lion's
share in BHEL Corporation's overall business operations. The Hyderabad unit was set
up in 1963 and started its operations with manufacture of Turbo-generator sets and
auxiliaries for 60 and 110 MW thermal utility sets. Over the years it has increased its
capacity range and diversified its operations to many other areas. To day, a wide range
of products are manufactured in this unit, catering to the needs of variety of industries
like Fertilizers & Chemicals, Petrochemicals & Refineries , Paper, sugar, steel , etc.
BHEL-Hyderabad unit has collaborations with world renowned MNCs like M/S
General Electric, USA, M/S Siemens, Germany, M/S Nuovo Pignone, etc.
VISION: A World-class Engineering Enterprise Committed to enhancing Stakeholder
Value.
MISSION: To be an Indian Multinational Engineering Enterprise providing Total
Business Solutions through Quality Products, Systems and Services in the fields of
Energy, Industry, Transportation, Infrastructure and other potential areas.

PRODUCTS MANUFACTURED AT BHEL, HYDERABAD:

Major products of our units manufacture include the following.

Gas turbines

BHEL - the largest Gas Turbine manufacturer in India, with the state-of-art facilities
in all areas of Gas Turbine manufacture provide complete engineering in-house for
meeting specific customer requirement. With over 100 machines and cumulative fired
hours of over four million hours, BHEL has supplied gas turbines for variety of
applications in India and abroad. BHEL also has the world's largest experience of
firing highly volatile naphtha fuel on heavy duty gas turbines. BHEL is one of the few
business associates of M/s. GE, USA and under its comprehensive Technical
Collaboration Agreement from 1986, (license to manufacture rotors and hot gas path
components) offers complete power plant engineering solutions. BHEL also
manufactures Gas Turbine under its ongoing Technical Collaboration Agreement with
M/s Siemens, Germany. Some specific features:
1. Capability to fire a wide range of gaseous and liquid fuels and a mix of such fuels
ranging from clean fuels like Natural Gas, Distillate Oil, Naphtha, LNG to heavy fuels
like LSHS, crudes, blends, etc. Fuel economy over a wide range of ambient
temperatures and loads.
2. Facilities like Black start, fast start and emergency start.

3. Suitable for power generation and mechanical drive application. Models below 100
MW suitable for 50 Hz and 60 Hz.
4. All matching equipment like generators, compressors, etc. manufactured in-house.
Design of combustion systems as per international emission norms. Machines
designed as per major international codes like API, etc.
5. Suitable for IGCC applications.
6. Suitable for indoor or outdoor locations.
7. Use of water or steam injection for abatement of NOX emissions and power
augmentation.
BHEL equipped with precision and sophisticated machine - tools like CNC
Broaching Machine, 5-Axis Milling Machine and over speed Vacuum Balancing
Tunnel offers Conversion, Modification and Up-gradation services - through joint
venture with GE for all existing Gas turbines. Services are also offered for all Field
support, Retrofits and repairs, inspections and Technical Consultancy on "Operation
& Maintenance of Gas Turbine Based Power Plants".

 Steam turbines

BHEL, Ramachandrapuram has been

playing an active role for almost four
decades in its promise of "bringing
power to the people". BHEL has
responded to requirements of the
nation with a comprehensive range of
products. This has been achieved by
superior

technology

Which

is

supported by an integrated workforce

of skilled professionals and an accent on quality, excellence and efficiency. At
BHEL Hyderabad, the art of Steam Turbine Building has been perfected over a
quarter of a century by the absorption of leading technologies and building up
of experience for catering to every possible application in the product range.

Turbo generators:

BHEL presently has manufactured Turbo-Generators of ratings upto 560 MW

and is in the process of going upto 660 MW. It has also the capability to take up the
manufacture of ratings upto 1000 MW suitable for thermal power generation, gas
based and combined cycle power generation as-well-as for diverse industrial
applications like Paper, Sugar, Cement, Petrochemical, Fertilizers, Rayon Industries,
etc. Based on proven designs and know-how backed by over three decades of
experience and accreditation of ISO 9001, the Turbo-generator is a product of highclass workmanship and quality. Adherence to stringent quality-checks at each stage
has helped BHEL to secure prestigious global orders in the recent past from Malaysia,
Malta, Cyprus, Oman, Iraq, Bangladesh, Sri Lanka and Saudi Arabia. The successful
completion of the various export projects in a record time is a testimony of BHEL's
performance.

Heat Exchangers:

BHEL Hyderabad has supplied a variety of Heat Exchangers in large numbers

for diversified applications. Among them are Steam Surface Condensers, Air
Evacuation System, Feed Water Heaters, Deaerators Inter-Stage Gas Coolers, Process
Heat Exchangers, Air cooled Heat Exchangers, L.P.G Bullets. These are rendering
good service in a number of Power Plants, Fertilizer, petroleum, Petrochemical, Steel
and other Industrial Plants.

Pumps:

BHEL started manufacture of Pumps during the mid-sixties under technical

collaboration with M/s Sigma Lutin, Czechoslovakia, to meet the requirements of 60
MW, 110 MW and 210 MW thermal power stations, the scope of which was widened
to meet the requirements of power plants upto 500 MW, with the help of another
collaboration with M/s Weir Pumps, U.K. BHEL has also made some in-house
product development to gain spin off benefits from the above collaboration as well as
to develop new pumps to meet the requirements of Combined Cycle Power plants.
BHEL has undertaken a design up-gradation and retrofit of the existing 200 KHI
Boiler Feed pumps Inside Stators with energy efficient hydraulics and cartridge
design internals under technical tie-up with M/s Sulzer Pumps, Germany; and
recommended the upgraded 200 KHI-S Boiler Feed pump to all customers of 110
MW & 210 MW Power Stations operating with the earlier Czech design for increase
of pump availability and reliability and also considerable reduction in operational
costs.

Pulverizers:

BHEL manufactures mills for pulverized coal fired Thermal and Industrial
boilers. BHEL till date has manufactured over 1200 bowl mills and over 100 tube
mills, operating in different coal fired Thermal power stations in India. BHEL has
absorbed technology from world leader M/s. Combustion Engineering USA for bowl

mills. The specific range - 583 XRP/XRS to 1043 XRP covers the-state-of-the-art
mills required for the Indian market and are supplied as Industrial boilers as-well-as
Utility boilers of 60 MW, 110 MW, 120 MW, 210 MW, 250 MW & 500 MW capacity.
To meet the requirement of very high ash content coal with high moisture, BHEL in
collaboration with M/s Stein Industries, France of the ALSTHOM group,
manufactures Ball Tube Mills for Tower-type Boiler as-well-as conventional Boiler.
These are horizontal mills that grind coal by impact and attrition. They do not lose
any of their grinding characteristics with time, and provide constant fineness
throughout the service life of their wear parts. They are the only mills truly adapted to
both, very abrasive high -ash coals and very low volatile coals which require very fine
grinding.

Oil rigs:

BHEL started manufacturing oil field equipment in collaboration with M/s US

Steel Engineers and Consultants USA (National Oil Well), M/s Skytop Brewster USA,
M/s Branham Industries USA, M/s IRI International, USA. After successful
absorption of technology, BHEL now has the capability to manufacture conventional
deep drilling rigs up to a depth of 9000 meters, mobile rigs to a depth of 3000 meters

and well servicing rigs to a well depth of 6100 meters. BHEL is authorized by the
American Petroleum Institute (API) for manufacturing products under specification
API 4F, API 7K and API 8A. BHEL also undertakes refurbishment, upgradation and
renovation of the existing rigs with the customers to provide better flexibility of
operation for faster drilling, and higher availability of rigs. BHEL, since the first order
for oil rigs in 1977, has manufactured and supplied 84 nos. drilling and well servicing
rigs to both M/s ONGC Ltd. and M/s Oil India Ltd. that are deployed for drilling and
well servicing operations. In addition BHEL has upgraded 3 nos. rigs by installing
Independent Rotary Drive system. BHEL offers services for refurbishment and
modernization of the rigs and rig equipment of both BHEL make and also others. This
includes:
-Total inspection of rig equipment
-Major overhauling of rig equipment
-Supply of spares (for BHEL make rigs)
-Refurbishment of rig equipment
-Repairs on mast and substructures and reassessment of the structure
-Upgradation of rigs
-Supply & installation of Independent Rotary Drive system on the
conventional drilling rigs.

TURBINES:

Basically a turbine is rotary engine in which the kinetic energy of a moving

fluid is converted into mechanical energy by causing a bladed rotor to rotate. Claude
Burdin coined the term from the Latin turbinis( or vortex ) during an 1828
engineering competition. The simplest turbines have one moving part, a rotor
assembly, which is a shaft with blades attached. Moving fluid acts on the blades, or
the blades react to the flow, so that they rotate and impart energy to the rotor. Early
turbine examples are windmills and water wheels. Gas, steam, and water turbines
usually have a casing around the blades that focuses and controls the fluid. The casing
and blades may have variable geometry that allows efficient operation for a range of
fluid-flow conditions.

Theory of operation:
A working fluid contains potential energy (pressure head) and kinetic
energy (velocity head). The fluid may be compressible or incompressible.
Several physical principles are employed by turbines to collect this energy:

Impulse turbines

These turbines change the direction of flow of a high velocity fluid jet. The
resulting impulse spins the turbine and leaves the fluid flow with diminished kinetic
energy. There is no pressure change of the fluid in the turbine rotor blades. Before

reaching the turbine the fluid's pressure head is changed to velocity head by
accelerating the fluid with a nozzle. Pelton wheels and de Laval turbines use
this process exclusively. Impulse turbines do not require a pressure casement around
the runner since the fluid jet is prepared by a nozzle prior to reaching turbine.
Newton's second law describes the transfer of energy for impulse turbines.

Reaction turbines

These turbines develop torque by reacting to the fluid's pressure or weight.

The pressure of the fluid changes as it passes through the turbine rotor blades. A
pressure casement is needed to contain the working fluid as it acts on the turbine
stage(s) or the turbine must be fully immersed in the fluid flow (wind turbines). The
casing contains and directs the working fluid and, for water turbines, maintains the
suction imparted by the draft tube. Francis turbines and most steam turbines
use this concept. For compressible working fluids, multiple turbine stages may be
used to harness the expanding gas efficiently. Newton's third law describes the
transfer of energy for reaction turbines.
Turbine designs will use both these concepts to varying degrees whenever
possible. Wind turbines use an airfoil to generate lift from the moving fluid and
impart it to the rotor (this is a form of reaction). Wind turbines also gain some energy
from the impulse of the wind, by deflecting it at an angle. Crossflow turbines are
designed as an impulse machine, with a nozzle, but in low head applications maintain
some efficiency through reaction, like a traditional water wheel. Turbines with
multiple stages may utilize either reaction or impulse blading at high pressure. Steam
Turbines were traditionally more impulse but continue to move towards reaction
designs similar to those used in Gas Turbines. At low pressure the operating fluid
medium expands in volume for small reductions in pressure. Under these conditions
(termed Low Pressure Turbines) blading becomes strictly a reaction type design with
the base of the blade solely impulse. The reason is due to the effect of the rotation
speed for each blade. As the volume increases, the blade height increases, and the
base of the blade spins at a slower speed relative to the tip. This change in speed
forces a designer to change from impulse at the base, to a high reaction style tip.
Classical turbine design methods were developed in the mid 19th century.
Vector analysis related the fluid flow with turbine shape and rotation. Graphical

calculation methods were used at first. Formulae for the basic dimensions of turbine
parts are well documented and a highly efficient machine can be reliably designed for
any fluid flow condition. Some of the calculations are empirical or 'rule of thumb'
formulae, and others are based on classical mechanics. As with most engineering
calculations, simplifying assumptions were made.

Types of turbines:

Steam turbines are used for the generation of electricity in thermal

power plants, such as plants using coal or fuel oil or nuclear power.
They were once used to directly drive mechanical devices such as ship's
propellors (eg the Turbinia), but most such applications now use
reduction gears or an intermediate electrical step, where the turbine is used
to generate electricity, which then powers an electric motor connected
to the mechanical load.

Gas turbines are sometimes referred to as turbine engines. Such engines

usually feature an inlet, fan, compressor, combustor and nozzle (possibly
other assemblies) in addition to one or more turbines.

Transonic turbine The gasflow in most turbines employed in gas turbine

engines remains subsonic throughout the expansion process. In a transonic
turbine the gasflow becomes supersonic as it exits the nozzle guide vanes,
although the downstream velocities normally become subsonic. Transonic
turbines operate at a higher pressure ratio than normal but are usually less
efficient and uncommon. This turbine works well in creating power from
water.

Contra-rotating turbines Some efficiency advantage can be obtained if

a downstream turbine rotates in the opposite direction to an upstream unit.
However, the complication may be counter-productive.

Statorless turbine Multi-stage turbines have a set of static (meaning

stationary) inlet guide vanes that direct the gasflow onto the rotating rotor
blades. In a statorless turbine the gasflow exiting an upstream rotor

impinges onto a downstream rotor without an intermediate set of stator

vanes (that rearrange the pressure/velocity energy levels of the flow) being
encountered.

Ceramic turbine Conventional high-pressure turbine blades (and vanes)

are made from nickel-steel alloys and often utilise intricate internal aircooling passages to prevent the metal from melting. In recent years,
experimental ceramic blades have been manufactured and tested in gas
turbines, with a view to increasing Rotor Inlet Temperatures and/or,
possibly, eliminating aircooling. Ceramic blades are more brittle than their
metallic counterparts, and carry a greater risk of catastrophic blade failure.

Shrouded turbine Many turbine rotor blades have a shroud at the top,
which interlocks with that of adjacent blades, to increase damping and
thereby reduce blade flutter.

Shroudless turbine Modern practise is, where possible, to eliminate

the rotor shroud, thus reducing the centrifugal load on the blade and
the cooling requirements.

Bladeless turbine uses the boundary layer effect and not a fluid
impinging upon the blades as in a conventional turbine.

Water turbines
o Pelton turbine, a type of impulse water turbine.
o Francis turbine, a type of widely used water turbine.
o Kaplan turbine, a variation of the Francis Turbine.
o Voith, water turbine.

Wind turbine These normally operate as a single stage without nozzle

and interstage guide vanes. An exception is the olienne Bolle, which
has a stator and a rotor, thus being a true turbine.

Tide turbine

GAS TURBINES
A gas turbine is an internal combustion engine that extracts energy from a flow of gas.
Intake air is heated by burning after being mixed with some fuel source, and then
directed out an expanding nozzle, flowing past the turbine on the way. They are
continuous combustion engines that produce work by burning fuel. Gas turbines are a
versatile, cost effective source of electricity, mechanical power and propulsion.
The air is sucked from the surroundings and then squeezed to attain high pressures by
a series of compressor stages. The highly compressed air enters a combustion
chamber. It is here that fuel is mixed together with the air and burnt in a controlled
fashion.
Generally gas turbines can use both gas and liquid fuels or combination of both. The
burning of fuel causes rapid expansion of gases within the combustion chamber and
then passes through a series of turbine stages. This generates the power required to
drive the compressor stages and supply other needs. Once the past this stage, the
expanded gas then leaves the gas turbine at a high velocity.

COMPRESSOR SECTION

The axial flow seventeen-stage compressor section consists of the compressor

rotor and the enclosed casing, variable inlet guide vanes, and two exit guide vanes.
Air is confined to the space between the rotor and stator blade where it is
compressed in stages by an alternate series of rotor and stator blades. Rotor blades
supply the force needed to compress the air in each stage and the stator blades guide
the air in each stage and the stator blades guide the air so that it enters the following
rotor stage at the proper angle. The compressor air exits through the compressor
discharge casing to the combustion chambers. Air is also extracted from the
compressor for turbine cooling and for the bearing lubes oil sealing.
COMBUSTION SECTION
The combustion section consists of combustion chambers, fuel nozzles, flame
detection equipment, spark plugs, and transition pieces. High-pressure air from the
compressor discharge is directed around the annulus space and in to the combustion
chamber liners. Fuel is supplied to each combustion chamber through a nozzle that
extends into chambers liner cap.
COMBUSTION WRAPPER: It is a fabricated casing that encloses the combustion area
providing a surface for the combustion chamber assemblies.
COMBUSTION CHAMBER:

The high-pressure air from the compressor discharge flows

into the annular space created by the aft end of the discharge casing, frame assembly
and the forward section of the turbine shell. The air enters the combustion chambers
and flows forward, entering the liner through the holes and louvers in the liner wall. A
portion of the air reaches the head of the combustion chamber and enters the liner cap
and the vortex generator nozzle.
The airflow through the combustion chambers has three main functions; to
oxidize the fuel, to cool the metal parts, and to adjust the extremely hot combustion
products to the desired turbine inlet temperature. The hot combustion gases from the
reaction zone are passed through the thermal soaking zone and then into the dilution
zone where additional air is mixed with the combustion gases.
SPARK PLUGS:

Combustion of the fuel and air mixture is initiated by the spark plugs
with retracting electrodes. The spark plugs, installed in two of the combustion
chambers, receive power from ignition transformers. The chambers without spark
plugs are fired with flame from the fired chambers through interconnecting crossfire
tubes.
During the starting sequence it is essential that
an indication of the presence or absence of flame be transmitted to the control system.
For this reason the flame monitoring system is used consisting of sensors, which are
installed, in adjacent combustion chamber and an electronic amplifier mounted on the
turbine control panel.
ULTRAVIOLET FLAME DETECTORS:

Each combustion chamber is equipped with a fuel nozzle that emits a

metered amount fuel into the combustion liner. Gaseous fuel is admitted directly into
the chambers through the metering holes located in the outer wall of the gas fuel tip.
When liquid fuel is used, it is atomized in the nozzle swirl chamber by means of highpressure air.
FUEL NOZZLES:

All the combustion chambers are interconnected by means of

cross fire tubes; these allow flame from the fire chambers to propagate to the unfired
chamber.
CROSS FIRE TUBES:

TURBINE SECTION:
In the turbine section, high temperature gases from the combustion section are
converted to shaft horsepower. The two-stage turbine rotor provides the power
required to drive the load package and the compressor. The first-stage, or highpressure wheel and the second stage, or low-pressure wheel is bolted together to make
up a single unit through which the first and second stage nozzles direct the flow of
combustion gases. These components, with associated air seals and deflectors, are
contained within the turbine shell.
The forward section of the turbine shell forms the casing for the shaft end of
the compressor discharge and the combustion sections. The shaft section of the shell
forms the casing for the first and second stage nozzle and the shrouds for the first and
second stage turbine rotors.
EXHAUST FRAME

The exhaust frame is bolted to the turbine shell. Structurally the frame consist
of an outer and an inner cylinder inter connected by a radial struts. The bearing is
supported from the inner cylinder. The exhaust diffuser is located between the outer
and inner cylinder. Gases exhausted from the third turbine stage enter the diffuser
where the velocity is reduced by diffusion and pressure is recovered at the diffuser
exit vanes to assist in directing the gases radial outward into exhaust plenum.
ACCESSORY BASE:
Most of the mechanical and electrical auxiliary equipment necessary for
starting and operating a gas turbine is contained with in the accessory base. The
major components of an accessory base are:

Starting System.
Lubricating System.
Cooling Water System.
Gas Fuel System.
Liquid Fuel System.
Atomizing System
Trip Oil System.

Starting system
Before the gas turbine can be fired and brought to operating speed it must be rotated
and cranked by accessory equipment. This is accomplished by starting device which
can be induction motor, a diesel engine etc operating through a turbine to start up.
Also at shutdown, this same equipment continues to rotate the turbine at low speed
for cool down purpose.

Lubrication system
The lubricating system requirements for a gas turbine power plant are furnished by a
common forced feed lubrication system. This lubrication system completes with
tanks, pumps, coolers, filters and various controls and protection device furnishes
normal lubrication and absorption of heat rejection load of turbine. Lubricating fluid
is circulated to the main turbine bearing and to the turbine accessory gear.
The main components include lube reservoir, main lube pump (driven by accessory
gear), emergency and auxiliary lube pump, and pressure relief valve, lube fluid heat
exchanger, lube filters and bearing header pressure regulator.
Cooling water system
Cooling water system is pressurized closed system designed to accommodate the
heat dissipation requirements of the turbine and the generator, atomizing air precooler and the turbine supports. The cooling water system is comprised of both onbase and off-base mounted components. The on-base components include the heat
exchangers in the turbine support legs, flow regulating valves, orifices and hand
valves. The off base components are customer supplied.
Gas fuel system
Gas fuel system is used to control the flow of gas fuel to turbine combustion
chambers at the proper pressure and flow rates to meet all of the starting,
accelerating and loading requirements of gas turbine operation. The major
components include gas valve with necessary inlet piping and strainers, fuel vent
valve, control servo valves, pressures gauges and distribution piping to the
combustion fuel nozzles.
Liquid fuel system
This system pumps and distributes fuel as supplied from the off-base source to the
nozzles of the combustion system. After being filtered, the fuel flow is divided into
equal parts for the distribution to the combustion chambers of required pressure and
flow rate. Controlling the position of the fuel pump, bypass valve regulates the
amount of fuel input to the turbine combustion system by varying the amount of the
bypassed fuel. The major Components of this system include low pressure fuel
strainers, fuel oil stop valve, liquid fuel pump, fuel pump discharge relief valve, false
drain valve and dual fuel system.
Atomizing air system
The atomizing air system provides sufficient pressure in the air-atomizing chambers
of fuel nozzle body to maintain the proper ratio of atomizing air pressure to the
compressors discharged pressure. The ratio is approximately 1.2 or greater over the
full operating range of the turbine. Since the output of the main atomizing air
compressor, driven by the accessory gear is low at turbine firing speed, and starting
atomizing air compressors provides a similar ratio during the firing and warm up
period of the starting cycle, and a portion of the accelerating cycle. The major

components include main atomizing air compressors, the starting atomizing air
compressors and atomizing air heat exchanger.
Trip oil system
The hydraulic trip oil system is the primary protection interface between the turbine
control and protection system circuits (speedtronic control system) and the
components on the turbine, which admit, or shut off fuel to the turbines lube fluid
system, is used in the are trip oil system.
Fire fighting system
A fire fighting system is the key element among the fire protection features of a gas
turbine. The CO2 fire protection system is designed to extinguish fire by reducing
the percentage of oxygen level. The major components include CO2 cylinders,
discharge pipes and nozzles, solenoid pilot valves, fire detectors and pressures
switches.

GT Models and Ratings

Model
MS1002
MS3142(J)
PG5371(PA)
PG6561(B)
PG6101(FA)
PG9171(E)
PG9231(EC)
PG9351(FA)
PG9551(H)

ISO Rating (kw)

5070
10450
26300
39620
70140
123400
169200
255200
380000

ISO Efficiency (%)

24.5
25.6
28.5
31.9
34.2
33.8
34.9
36.5
-