Bhelproject Report Me

RANIPUR, HARIDWAR (UTTARAKHAND)

A Project Report On:-

TURBINE UNIT MANUFACTURING TECHNOLOGY

Submitted By:- Submitted To:

BHARAT BHUSHAN MR. AMAR RAJ SURI

MECHANICAL 7TH SEMESTER SR. LECTURER

3064020(22244) MECHANICAL DEPTT.

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ACKNOWLEDGEMENT

It has been a very enriching experience being in “BHARAT HEAVY ELECTRICALS LIMITED,HARIDWAR”.i am extremely thankful to everyone who has helped me to give this training report its present form.

I am very thankful to MR. SANJAY SAXENA AGM(Block 3) for providing

me the opportunity to undergo my six weeks training at BHEL,

HARIDWAR.They guided me from time to time and gave me dynamic

Ideas and suggestion by which I am able to complete my training

successfuly.

I thank all visible and non visible hands,which helped me to complete

the practical training with great success.

SUMEET BEHL

GREEN HILLS ENGG. COLLEGE

ME 4TH YEAR

A. BHEL – AN OVERVIEW

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 since

1971-72 and achieved a sales turnover of Rs. 6347 crore with a pre-tax profit of Rs.

294 crore in 2000-01.

BHEL caters to core sectors of the Indian Economy viz., Power Generation's &

Transmission, Industry, Transportation, Telecommunication, Renewable Energy,

Defense, etc. The wide network of BHEL's 14 manufacturing division, four power

Sector regional centres, over 150 project sites, eight service centres and 18 regional

offices, enables the Company to promptly serve its customers and provide them with

suitable products, systems and services – efficiently and at competitive prices. BHEL

has already attained ISO 9000 certification for quality management, and ISO 14001

certification for environment management.

POWER GENERATION

Power generation sector comprises thermal, gas, hydro and nuclear power

plant business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or

65% of the total installed capacity of 99,146 MW in the country, as against nil till 1969-

70.

BHEL has proven turnkey capabilities for executing power projects from

concept to commissioning, it possesses the technology and capability to produce

thermal sets with super critical parameters up to 1000 MW unit rating and gas turbine

generator sets of up to 240 MW unit rating. Co-generation and combined-cycle plants

have been introduced to achieve higher plant efficiencies. to make efficient use of the

high-ash-content coal available in India, BHEL supplies circulating fluidized bed

combustion boilers to both thermal and combined cycle power plants.

The company manufactures 235 MW nuclear turbine generator sets and has

commenced production of 500 MW nuclear turbine generator sets.

Custom made hydro sets of Francis, Pelton and Kapian types for different head

discharge combination are also engineering and manufactured by BHEL.

In all, orders for more than 700 utility sets of thermal, hydro, gas and nuclear have

been placed on the Company as on date. The power plant equipment manufactured by

BHEL is based on contemporary technology comparable to the best in the world and is

also internationally competitive.

The Company has proven expertise in Plant Performance Improvement through

renovation modernisation and uprating of a variety of power plant equipment besides

specialised know how of residual life assessment, health diagnostics and life extension

of plants.

POWER TRANSMISSION & DISTRIBUTION (T & D)

BHEL offer wide-ranging products and systems for T & D applications. Products

manufactured include power transformers, instrument transformers, dry type

transformers, series – and stunt reactor, capacitor tanks, vacuum – and SF circuit

breakers gas insulated switch gears and insulators.

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

electric substances up to 400 kV level series compensation systems (for increasing

power transfer capacity of transmission lines and improving system stability and

voltage regulation), shunt compensation systems (for power factor and voltage

improvement) and HVDC systems (for economic transfer of bulk power).

BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for

reactive power management on long transmission lines). Presently a 400 kV Facts

(Flexible AC Transmission System) project under execution.

INDUSTRIES

BHEL is a major contributor of equipment and systems to industries, cement, sugar,

fertilizer, refinances, petrochemicals, paper, oil and gas, metallurgical and other

process industries. The range of system & equipment supplied includes: captive power

plants, co-generation plants DG power plants, industrial steam turbines, industrial

boilers and auxiliaries. Wate heat recovery boilers, gas turbines, heat exchangers and

pressure vessels, centrifugal compressors, electrical machines, pumps, valves,

seamless steel tubes, electrostatic precipitators, fabric filters, reactors, fluidized bed

combustion boilers, chemical recovery boilers and process controls.

The Company is a major producer of large-size thruster devices. It also supplies digital

distributed control systems for process industries, and control & instrumentation

systems for power plant and industrial applications. BHEL is the only company in India

with the capability to make simulators for power plants, defense and other applications.

The Company has commenced manufacture of large desalination plants to help

augment the supply of drinking water to people.

TRANSPORTATION

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

maintenance and after-sales service of Rolling Stock and traction propulsion systems. In the

area of rolling stock, BHEL manufactures electric locomotives up to 5000 HP, diesel-electric

locomotives from 350 HP to 3100 HP, both for mainline and shunting duly applications. BHEL

is also producing rolling stock for special applications viz., overhead equipment cars, Special

well wagons, Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use,

BHEL manufactures traction propulsion systems for other rolling stock producers of electric

locomotives, diesel-electric locomotives, electrical multiple units and metro cars. The electric

and diesel traction equipment on India Railways are largely powered by electrical propulsion

systems produced by BHEL. The company also undertakes retooling and overhauling of rolling

stock in the area of urban transportation systems. BHEL is geared up to turnkey execution of

electric trolley bus systems, light rail systems etc. BHEL is also diversifying in the area of port

handing equipment and pipelines transportation system.

TELECOMMUNICATION

BHEL also caters to Telecommunication sector by way of small, medium and large

switching systems.

RENEWABLE ENERGY

Technologies that can be offered by BHEL for exploiting non-conventional and

renewable sources of energy include wind electric generators, solar photovoltaic

systems, solar lanterns and battery-powered road vehicles. The Company has taken

up R&D efforts for development of multi-junction amorphous silicon solar cells and fuel

based systems.

INTERNATIONAL OPERATIONS

BHEL has, over the years, established its references in around 60 countries of the

world, ranging for the United States in the West to New Zealand in the Far East. These

references encompass almost the entire product range of BHEL, covering turnkey

power projects of thermal, hydro and gas-based types, substation projects,

rehabilitation projects, besides a wide variety of products, like transformers, insulators,

switchgears, heat exchangers, castings and forgings, valves, well-head equipment,

centrifugal compressors, photo-voltaic equipment etc. Apart from over 1110MW of

boiler capacity contributed in Malaysia, and execution of four prestigious power

projects in Oman, Some of the other major successes achieved by the Company have

been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh,

Azerbaijan, Sri Lanka, Iraq etc.

The Company has been successful in meeting demanding customer's requirements in

terms of complexity of the works as well as technological, quality and other

requirements viz extended warrantees, associated O&M, financing packages etc.

BHEL has proved its capability to undertake projects on fast-track basis. The company

has been successful in meeting varying needs of the industry, be it captive power

plants, utility power generation or for the oil sector requirements. Executing of

Overseas projects has also provided BHEL the experience of working with world-

renowned Consulting Organisations and inspection Agencies.

In addition to demonstrated capability to undertake turnkey projects on its own, BHEL

possesses the requisite flexibility to interface and complement with International

companies for large projects by supplying complementary equipment and meeting their

production needs for intermediate as well as finished products.

The success in the area of rehabilitation and life extension of power projects has

established BHEL as a comparable alternative to the original equipment manufactures

(OEMs) for such plants.

TECHNOLOGY UPGRADATION AND 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, spread over a 140 acre complex, leads

BHEL's research efforts in a number of areas of importance to BHEL's product range.

Research and product development centers at each of the manufacturing divisions play

a complementary role.

BHEL's Investment in R&D is amongst the largest in the corporate sector in India.

Products developed in-house during the last five years contributed about 8.6% to the

revenues in 2000-2001.

BHEL has introduced, in the recent past, several state-of-the-art products developed

in-house: low-NQx oil / gas burners, circulating fluidized bed combustion boilers, high-

efficiency Pelton hydro turbines, petroleum depot automation systems, 36 kV gas-

insulated sub-stations, etc. The Company has also transferred a few technologies

developed in-house to other Indian companies for commercialisation.

Some of the on-going development & demonstration projects include: Smant wall

blowing system for cleaning boiler soot deposits, and micro-controller based governor

for diesel-electric locomotives. The company is also engaged in research in futuristic

areas, such as application of super conducting materials in power generations and

industry, and fuel cells for distributed, environment-friendly power generation.

HUMAN RESOURCE DEVELOPMENT INSTITUTE

The most prized asset of BHEL is its employees. The Human Resource Development

Institute and other HRD centers of the Company help in not only keeping their skills

updated and finely honed but also in adding new skills, whenever required. Continuous

training and retraining, positive, a positive work culture and participative style of

management, have engendered development of a committed and motivated work force

leading to enhanced productivity and higher levels of quality.

HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT

BHEL, as an integral part of business performance and in its endeavour of becoming a

world-class organization and sharing the growing global concern on issues related to

Environment. Occupational Health and Safety, is committed to protecting Environment

in and around its own establishment, and to providing safe and healthy working

environment to all its employees.

For fulfilling these obligations, Corporate Policies have been formulated as:

ENVIRONMENTAL POLICY

Compliance with applicable Environmental Legislation/Regulation;

Continual Improvement in Environment Management Systems to protect our

natural environment and Control Pollution;

Promotion of activities for conservation of resources by Environmental

Management;

Enhancement of Environmental awareness amongst employees, customers and

suppliers. BHEL will also assist and co-operate with the concerned Government

Agencies and Regulatory Bodies engaged in environmental activities, offering the

Company's capabilities are this field.

OCCUPATIONAL HEALTH AND SAFETY POLICY

Compliance with applicable Legislation and Regulations;

Setting objectives and targets to eliminate/control/minimize risks due to

Occupational and Safety Hazards;

Appropriate structured training of employees on Occupational Health and Safety

(OH&S) aspects;

Formulation and maintenance of OH&S Management programmes for continual

improvement;

Periodic review of OH&S Management System to ensure its continuing suitability,

adequacy and effectiveness;

Communication of OH&S Policy to all employees and interested parties.

The major units of BHEL have already acquired ISO 14001 Environmental

Management System Certification, and other units are in advanced stages of acquiring

the same. Action plan has been prepared to acquire OHSAS 18001 Occupational

Health and Safety Management System certification for all BHEL units.

In pursuit of these Policy requirements, BHEL will continuously strive to improve work

particles in the light of advances made in technology and new understandings in

Occupational Health, Safety and Environmental Science.

PARTICIPATION IN THE "GLOBAL COMPACT" OF THE UNITED NATIONS

The "Global Compact" is a partnership between the United Nations, the business

community, international labour and NGOs. It provides a forum for them to work

together and improve corporate practices through co-operation rather than

confrontation.

BHEL has joined the "Global Compact" of United Nations and has committed to

support it and the set of core values enshrined in its nine principles

PRINCIPLES OF THE "GLOBAL COMPACT"

HUMAN RIGHTS

1. Business should support and respect the protection of internationally proclaimed

human rights; and

2. Make sure they are not complicit in human rights abuses.

Labour Standards

3. Business should uphold the freedom of association and the effective recognition

of the right to collective bargaining;

4. The elimination of all form of forces and compulsory labour.

5. The effective abolition of child labour, and

6. Eliminate discrimination.

Environment

7. Businesses should support a precautionary approach to environmental

challenges;

8. Undertake initiatives to promote greater environmental responsibility and

9. Encourage the development and diffusion of environmentally friendly

technologies.

By joining the "Global Compact", BHEL would get a unique opportunity of networking

with corporate and sharing experience relating to social responsibility on global basis.

ACTIVITY PROFILE

PRODUCTS - Industrial Fans

Power Generation & Transmission - Seamless steel Tubes

- Steam Turbine-Generator Sets &

Auxiliaries

- Fabric Filters

- Boiler and Boiler Auxiliaries - AC DC Motors, Variable

speed

- Once-through Boilers - AC Drive

- Nuclear Power Generation Equipment - Electronic Control Gear &

Automation

- Hydro Turbine-Generator Sets &

Auxiliaries

- Equipment

- Mini/Micro Hydro Generator Sets - DDC for Process Industry

- Gas Turbine-Generator Sets - Thruster Equipment

- Waste Heat Recovery Boilers - Power Devices

- Heat Exchangers - Energy Meters

- Condensers - Transformer

- Bowi Mills and Tube Mills - Switch gear

- Gravimetric Feeders - Insulator

- Regenerative Air Pre-Heaters - Capacitors

- Electrostatic Precipitators - Broad Gauge AC, AC/DC

Loco

motives

- Bag Filters - Diesel-Electric Shunting

Locomotives

- Valves - Traction Motors & Control

Equipment

- Pumps - Electric Trolley Buses

- Electrical Machines - AC/DC Electric Multiple

Units

- Piping Systems - Drives and Controls for

Metro

Systems

- Power, Distribution & Instrument - Battery-Operated

Passengers

Transformers Vans

- Reactors - X-Mas Trees and Well

Heads

- Synchronous Condensers - Cathodic Protection

Equipment

- Switchgear - Digital Switching Systems

- Control gear - Rural Automatic Exchange

- Distributed Digital Control for Power

Stations

- Simulators

- Bus Ducts - Wind Electric Generators

- Rectifiers - Solar Powered Water

Pumps

- Porcelain Insulators - Solar Water Heating

Systems

- Ceralin - Photo Votaic Systems

- Defense Equipment

INDUSTRIES/TRANSPORTATION/OIL

& GAS/

- Reverse Osmoses

Desalination

Plants

TELECOMMUNICATION/RENEWABLE

ENERGY

SYSTEMS & SERVICES

- Steam Turbine-Generator Sets - Turkey Utility Power

Stations/

EPC

- Gas Turbine-Generator Sets - Contracts

- Diesel Engine-Based Generators - Captive Power Plants

- Industrial Steam Generators - Co-generation Systems

- Heat Recovery Steam Generators - Combined Cycle Power

Plants

- Fluidised Bed Combustion Boilers - Modernisation &

Renovation of

Power

- Drive Turbine Stations and FLA Studies

- Manne Turbines - Switch yards and

Substations

- Industrial Heat Exchangers - HVDC Transmission

Systems

- Centrifugal Compressor - Shorts sines condensation

Systems

- Industrial Valves - Power system analysis

- Reactors - Electron comissionly and

operation

- Columns - Consultancy services

- Pressure Vessels - Consultancy Services

- Pumps

SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS CORE SECTORS

POWER TRANSMISSION & DISTRIBUTION

In the T&D sector, BHEL is both a leading equipment-manufacturer and a system-

integrator. BHEL-manufactured T&D products have a proven track record in India and

abroad.

In the area of T&D systems, BHEL provides turnkey solutions to utilities. Substations

and shunt compensation installations set up by BHEL are in operation all over the

country. EHV level series compensation schemes have been installed in KSEB, MSEB,

SMPSEB and POWERGRID networks. Complete HVDC systems can be delivered by

BHEL. The technology for state-of-the-art Flexible AC Transmission Systems (FACTS)

is being developed.

INDUSTRIES

Since inception in 1982, the Industry Sector business has grown at an impressive rate

and, today, contributes significantly of BHEL's turnover.

BHEL, today, supplies all major equipment for the industries: AC/DC machines,

alternators, centrifugal compressors, special reactor column, heat exchangers,

pressure vessels, gas turbine based captive co-generation and combined-cycle power

plants, DG power plants, steam turbines and turbo-generators, complete range of

steam generators for process industries, diesel engine-based power plants, solar water

heating systems, photovoltaic systems, electrostatic precipitators, fabric filters, etc.

The industries which BHEL serves include: Steel, Aluminium, Fertiliser, Refinery,

Petrochemicals, Chemicals, Automobiles, Cement, Sugar, Paper, Mining, Textile etc.

BLOCK III-TURBINE MANUFACTURING

L

1.1 Block-III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and

Turbines Blades. Special Toolings for all products are also manufactured in the

Tool Room located in the same block. Equipment layout plan is a per Drawing

appended in Section III. Details of facilities are given in Section II.

1.2 The Block consists of four Bays, namely, Bay-I and II of size 36x378 metres and

36x400 metres respectively and Bay-III and IV of size 24x402 metres and

24x381 metres respectively. The Block is equipped with the facilities of EOT

Cranes, compressed air, Steam, Overspeed Balancing Tunnel, indicating stands

for steam turbine, rotors, one Test stand for testing 210 MW steam turbines

Russian Design, one Test Stand for Hydro Turbine Guide Apparatus and two

separate Test Stands for the testing of Governing Assemblies of Steam and

Hydro Turbines.

1.3 All the parts are conserved, painted and packed before dispatch.

2.0 MANUFACTURING FACILITIES

2.1 HYDRO TURBINES

For manufacturing of Hydro Turbines, Bay-I has the following sections:

(a) Circular Components Machining Section – This section is equipped with a

number of large/ heavy size Horizontal and Vertical Boring Machines, Drilling

Machines, Centre Lathes, Marking Table and Assembly Bed. The major

components machined in this section are Spiral Casing with Stay Ring, Spherical

and Disc Valve bodies and Rotors.

(b) Runner and Servo Motor Housing Machining Section – This section is

equipped with NC/CNC and conventional machines comprising Heavy and

Medium size vertical and Horizontal Boring Machines, Centre Lathes, Grinding

machines and Drilling Machines, Marking Table, Assembly Bed, Assembly

Stands for Steam Turbine and Gas Turbine assemblies and Wooden Platform for

overturning heavy components. Hydro Turbine Runners, Servomotors, cylinders,

Labyrinth Ring, Regulating Ring, Stay Ring, Turbine Cover, Lower Ring, Kaplan

Turbine Runner Body and Blades are machined here.

(c) Guide Vanes and Shaft Machining Section – This section is equipped with

Heavy duty Lathe machines upto 16 metres bed, CNC turning machines,

Horizontal Boring Machine, Heavy planer, Deep Drilling Machine, Boring

Machines, marking Table, Marking Machines and Assembly Beds. Turbine

shafts, Guide Vanes, Journals and Rotors of Spherical and Disc Valves are

machined here. Rotors of Steam Turbines are also machined in this section.

(d) Assembly Section – In this section, assembly and testing of Guide Apparatus,

Disc Valve, Spherical Valves, Servo motor shaft and combined Boring of

coupling holes are done.

(e) Preservation and Packing Section – Final preservation and packing of all the

Hydro Turbine components / assemblies is done here.

(f) Small components Machining Section – This is equipped with Planetary

Grinding Machine, Cylindrical Grinding Machines, small size Lathes, Planers,

Vertical and Horizontal Boring Machines. Small components like Bushes, Levers,

Flanges etc. and governing assemblies and machines here.

(g) Governing Elements Assembly and Test Stand Section – This section is

equipped with facilities like oil Pumping Unit, Pressure Receiver, Servomotors

etc. for assembly and Testing of Governing Elements.

2.2 STEAM TURBINES

The facilities and parts manufactured in the various sections of Steam Turbine

manufacture are as follows:

(a) Turbine casing Machining Section – It is equipped with large size Planer,

Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring

machines etc. Fabrication works like casings, Pedestals etc. are received from

Fabrication Block-II.

(b) Rotor Machining Section – It is equipped with large size machining tools like

Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree

Groove Milling Machine etc. Some rotor forgings are imported from Russia and

Germany and some are indigenously manufactured at CFFP, BHEL, Hardwar.

(c) Rotor Assembly Section – This is equipped with Indicating Stand, Small size

Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors

and Discs. Machined Rotor, Discs and Blades are assembled here. Balancing

and over speeding of Rotor is done on the dynamic balancing machine.

(d) Turbine casing Assembly Section – Machined casings are assembled and

hydraulically tested by Reciprocating Pumps at two times the operating pressure.

(e) Test Station - Test station for testing of 210 MW USSR Steam Turbine at no

load is equipped with condensers, Ejector, Oil Pumps, Oil containers Steam

Connections etc, required for testing. Overspeed testing is done for emergency

Governor. Assembly Test Stands for different modules of Siemens design are

equipped with accessory devices.

(f) Painting Preservation and Packing Section – All the parts are painted,

preserved and packed here for final dispatch.

(g) Bearings and Miscellaneous Parts Machining Section – This section is

equipped with small and medium size basic machine tools, e.g., lathes, Milling

M/c, Horizontal Borer, Vertical Borer, drilling M/c etc. for manufacture of bearings

and other miscellaneous parts of turbine.

(h) Sealing and Diaphragm Machining Section – It is equipped with medium size

Vertical Boring, Horizontal Boring, Planning, Drilling Machines etc. wherein

castings of sealing Housings, Liner housings, Forgings of Rotor Discs, castings

and fabricated Diaphragms and components are machined. It is also equipped

with CNC machining center.

Precision Horizontal Boring, Plano-Milling machines etc, are for manufacture of

Governing Casting, Servo Casings and other medium parts of governing and

Main Turbine assemblies.

(i) Governing Machining Section – This section is equipped with medium size and

small size lathes, medium CNC lathe, Milling, Grinding, Drilling, Slotting and

Honing Machines. Governing assembly parts are machined here.

(j) Diaphragm and Governing Assembly Section – It is equipped with deflection

testing equipment for Diaphragms, Dynamic Balancing Machine for balancing

Impeller of Centrifugal Oil Pumps and small fittings and assembly equipment.

Governing test stand is equipped with the facilities like Oil Pumping Unit,

Pressure Receiver, Servomotor, overspeed testing of Emergency Governor etc.

(k) Light machine shop – In addition to normal conventional machine tools it is

equipped with CNC Lathes, CNC Milling, CNC Vertical Boring, Precision Milling,

planetary grinding machines etc. for manufacture of small and medium precision

components of governing and other turbine parts.

2.3 GAS TURBINE

All the components of Gas Turbine are machined and assembled using the

facilities available for manufacturing of steam and hydro turbines except the

following facilities which are procured exclusively for the manufacturing of Gas

Turbine and are installed in the areas specified for gas turbine manufacturing.

a) Hydraulic Lifting Platform

This facility is used for assembly and disassembly of G.T. Rotor. This is a

hydraulically operated platform which travels upto 10 M height to facilitate access

to different stages of Rotor. This is installed in Bay-I assembly area.

b) CNC Creep Feed Grinding M/c.

This is installed in Gas Turbine machining area Bay-II Extn. This M/c grinds the

hearth serration on rotor disc faces. Hirth serrations are radial grooves teeth on

both the faces of rotor discs. Torque is transmitted trough these serrations, which

are very accurately ground.

c) External Broaching Machine

This machine is installed in GT machining area and is used to make groove on

the outer dia of rotor discs for the fitting of moving blades on the discs.

d) CNC Facing Lathe

This machine is installed in GT machining area and is used basically for facing

rotor disc but can turn other components also.

e) CNC Turning Lathe

This machine is installed in Bay-I Heavy Machine Shop and is used to turn Tie

Rods of Gas Turbine, which have very high length / diameter ratio. Tie-Rod is a

very long bolt (length approx. 10 meter & dia 350-mm) which is used to assembly

and holds the gas turbine rotor discs to form a composite turbine rotor.

f) Wax Melting Equipment

This is low temp. electric furnace installed in Gas Turbine blading area in Bay-II.

It is used to mix and melt Wax and Colaphonium, which is required to arrest the

blade movement during the blade tip machining of stator blade rings.

g) Gas Turbine Test Bed

This test bed is installed near the Gas Turbine Machining area in Bay-II. This

facility is used to finally assemble the gas turbine. Combustion chambers are not

assembled here, which are assembled with main assembly at the site.

h) Combustion Chamber Assembly Platform

This facility is a 3 Tier Platform installed in Bay-I assembly area and is used for

assembly of Combustion Chambers of Gas Turbine.

3.0 MANUFACTURING PROCESS

3.1 HYDRO TURBINES

The major processes involved in various Hydro Turbine Sections are as follows:

- Marking and checking of blanks – manual as well as with special marking M/c.

- Machining on Horizontal Boring, Vertical Boring, Lathes etc. as the case may

be on CNC /Conventional Machines.

- Intermediate assembly operation is carried out on the respective assembly

beds provided.

- Then the assembly is machined as per requirement.

- The sub-assemblies are further assembled for hydraulic/functional testing.

Hydraulic testing is done using a power driven triple piston horizontal hydraulic

pump, which can generate a pressure of 200 Kg/Cm2. It can also be carried

out using a power pack.

- On Governing elements / assembly and test stand, the components / sub-

assemblies / assemblies are tested up to a hydraulic pressure of 200 Kg / c m2

using the piston pump. Oil testing upto 40 Kg / c m2 is carried out with oil

pumping unit, which is permanently installed on this bed.

3.2 STEAM TURBINE

Processes carried out in various sections of steam turbine manufacture are

based on the following main phases.

(a) Machine section – Castings, Forgings, welded structures and other blanks are

delivered to this section. The manufacturing process is based on the use of high

efficiency carbide tipped tools, high speed and high feed machining techniques

with maximum utilization of machine – tool capacity and quick acting jigs and

fixtures.

(b) Assembly Section – Casings and governing assemblies are hydraulically tested

for leakage on special test Bed. Assembled unit of governing and steam

distribution systems is tested on Governing Test Bed. General Assembly and

testing of Steam Turbine is carried out on the main Test Bed in Bay-II.

(c) Painting, Preservation and Packing – After testing the turbine, it is

disassembled and inspected. Then the parts are painted, conserved and packed

for final dispatch.

3.3 GAS TURBINE

The major processes involved in manufacturing Gas Turbine in various sections

of Bk-III are as follows:

a) Machining

Castings, Forgings, welded structures and other blanks are received from

concerned agencies in the respective sections. These are machined keeping in

view optimum utilization of machine tools and toolings. Special jigs and fixtures

are made available to facilitate accurate and faster machining. Proper regime

and tool grades have been established to machine the materials like inconel,

which have poor machinablity.

b) Main Assembly

Final assembly is done on test bed. Parts are assembled to make sub-

assemblies. These sub-assemblies are again machined as per technological and

design requirements and are made ready for final assembly. After assembly and

insulation assembled Gas Turbine is sent to site.

c) Rotor Assembly

The rotor is assembled on Hydraulic Lifting Platform and sent to main assembly,

where after checking clearances, it is sent for machining. After balancing, turbine

side of rotor is disassembled, inner casing is fitted and rotor reassembled. This

work is also carried out on Hydraulic Lifting Platform. Finally rotor is sent for

assembly on test bed.

d) Combustion Chamber Assembly

This assembly is carried out on 3 tier platform installed for this purpose in Bay-I

assembly. After machining of all components, ceramic tiles are fitted in flame

tube. Burner and piping etc. is fitted in dome and combustion chamber is finally

assembled. It is directly sent to site after insulation.

B.

BLADE SHOP

1. Introduction:

Major part of Turbine Blade Machining Shop is located in Bay-IV of Block-III. In

this shop various types of Steam Turbine and Gas Turbine Compressor blades

are machined from bar stock, drawn profile, precision and envelope forgings. It is

a batch production shop comprising of various kinds of CNC Machines and

Machining Centers, besides various special purpose and general purpose

machines. The layout of equipments is as per technological sequence of the

manufacturing process. Blade shop implements various On Line Quality Control

Techniques through Run Charts and Control charts. This shop is divided into four

distinct areas. Details of facilities are given in various schedules of Section-II.

2. Manufacturing Facilities:

i) Plain Milling Section

It prepares accurate reference surfaces on the blade blanks by milling and

grinding operation. It also manufactures the brazed type blades by

induction brazing of drawn profile and suitably machined spacers. This

section carries out banking by Band Saws, rhomboid grinding on Duplex

grinding machines and thickness grinding on Surface grinders.

ii) Copy Milling Section

The Semi blanks prepared from plain milling section are further machined

by copy Milling Machines / CNC machines (CNC Heller and BSK – Bed

type Klopp, BFH / BEK Knee type Machines) for concave and convex aero-

dynamic profile forms, (HTC-600, BFK Machines) for expansion angles,

Compound taper grinding of radial plane is carried out by Surface grinders.

It comprises of T-root machining centers for machining of T-root.

iii) LP Section

This area deals with all types of free standing and forged blades for steam

Turbine Compressor. The freestanding blades are cerrobend casted in

boxes to hold the blade with respect to the profile. These blades roots are

subsequently machined on NTH, MPA-80A and T30 Machining Centers.

There is a five station 360o circular copy milling machine for machining the

profile of envelope forged blades / stocks for Steam Turbine and Gas

Turbine Blades. It also has 3D copy Milling and CNC Machines with

digitizing features for Tip-thinning, Fitted milling. The inlet edge of the last

stage of Low pressure Turbine Moving blades are hardened on a Special

Purpose Flame Hardening equipment.

iv) Polishing Section

Blade Contours are ground and polished to achieve the desired surface

finish and other aerofoil requirements.

There are also other small sections e.g. Fitting Section, Tool and Cutter

Grinding, Toolings Repair Section in Blade Shop.

v) Inspection Device

- 3 D Coordinate Measuring Machines for taper and rhomboid checking.

- Moment weighing Equipment

- Real time Frequency analyzer for checking frequency of free standing

blades.

- Contour plotter for plotting of blade profile with various magnifications.

- Fir- tree root inspection device.

- Magna spray crack detection equipment.

vi) Miscellaneous

There are other important facilities e.g. High rack storage system for

fixtures. Compactor system storage for finish blades. Jib cranes and EOT

cranes for material handling. The semi finished batch of blades are kept in

special boxes for inter-operation movements. An AGV (Automated Guided

Vehicle) is also located in LP Section of Blade Shop for better material

movement.

3.0 MANUFACTURING PROCESS

The manufacturing process of turbine blades primarily depends on the type of

blade e.g. Bar type, Brazed type, Free standing (Forged type), Gas Turbine

Compressor blades. The bar type and brazed type blades are also known as

drum stage glades. The manufacturing technology of each of these blades along

with recommended machine tools / equipment is furnished below.

3.1 BAR TYPE BLADES

PROCESS / OPERATION MACHINE TOOL/EQUIPMENT

USED

i. Blanking of area material Circular saw/band saw

ii. Sizing to rectangular shape Hor. Milling Machine

iii. Thickness grinding Surface grinder

iv. Rhomboid milling Duplex milling machine

v. Rhomboid grinding Duplex grinding machine

vi. Milling perpendicularity on both

ends

Hor. Milling machine

vii. Milling radius on surround Hor. Copy milling m/c

viii. Finish milling of convex and

concave profile

Hor. Copy milling / CNC


ix. Milling expansion faces of

convex

And concave sides at root and

shroud

Hor. Copy milling m/c/

CNC milling m/c

x. Root slot/root chamfer and

Radit at root and shround

Milling

2 spindle T-root roughing, m/c

and

root radius copy milling m/c, T-

root

machining center

xi. Taper grinding Surface grinder

xii. Grinding and polishing of profile

And expansion faces

Abrasive belt polishing m/c

xiii. Final Rounding, chamfering etc. Manual fitting.

3.2 BRAZED TYPE BLADES


USED

i. Cutting of drawn profile &

spacer blank


ii. Sizing to rectangular shape Hor. Milling machine

iii. Thickness grinding Surface grinder

iv. Rough and finish milling of

internal profile of spacer


v. Cutting-off spacer Abrasive cutting

vi. Brazing of drawn profile and

spacer

Right frequency inducting brazing

installation

vii. Milling of width Duplex milling machine

viii. Pin rough and Root slot Vert. Milling m/c

ix. External profile rough and finish

machining


x. Pin turning Pin turning lathe

xi. Grinding and polishing Abrasive belt polishing m/c

xii. Debarring and rounding Manual fitting

3.3 FREE STANDING BLADES


USED

i. Grinding of ref. Belts Abrasive belt polishing

ii. Milling of inlet & outlet edge 3D Vert. Copy milling m/c

iii. Center hole drilling CNC machining Centre

iv. Encapsulating with cerrobend

alloy

Cerrobend casting equip.

v. Remelting of cerrobend alloy Fir-tree root machining center

vi. Remelting of cerrobend alloy Cerrobend casting equip.

vii. Machining of fillets Vertical 3D copy milling machine

viii. Grinding and polishing Abrasive belt polishing

ix. Cutting-off blade tip Abrasive cutting machine

x. Inlet edge hardening Frame hardening equipments. (if

required)

xi. Blade tip rounding Vert. 3-D dcopy milling m/c

xii. Tip thinning (if reqd.) -do-

3.3 GAS TURBINE BLADES


USED

i. Cerrobend casting Cerrobend casting equip.

ii. Root machining Hor. Machining center

iii. Remelting of cerrobend alloy Cerrobend casting equip.

iv. Profile checking Vert. Stand

v. Length cutting Circular saw/hor. Milling m/c

vi. Tenon Hor. Milling m/c

vii. Grinding and polishing of fillet Abrasive belt polishing m/c

A.

QUALITY CONTROL FACILITIES

As in BHEL Customer Focus is of prime significance, Quality Control Function

assumes vital role. Quality Control facilities get priority in investment planning. The

Group is equipped with the state-of-the-art testing, measuring and analytic facilities.

This chapter covers Facilities existing in various sections under Quality Management

Deptt.

1.0 FACILITIES IN QUALITY CONTROL – TURBINE BLOCK

Each Quality Control Station is equipped with conventional measuring

instruments as well as sophisticated testing machine to suit the inspection

requirements of the related area. Some of the important facilities are:-

i) CNC 3D Coordinate Measuring Machine – a fully computer controlled

modern machine for automatic inspection of complex or precision

components of size upto 2000x1200x1000 mm. The important features of

this machine are high-speed computer, versatile software, universal probe

head for scanning, digitization and plotting of known and unknown curves

etc.

ii) 2-D Coordinate Measuring Microscope – Used for highly accurate and

precise measurements of small and intricate components of the turbine.

The machine is equipped with multiple feature digital readouts of resolution

0.0001 mm, a separate light generator connected through fiber cables for

better accuracy, optical templates for various inspection purposes etc.

iii) Vibration Measuring Equipments – Three no. of vibration measuring

equipments are available for checking of blade frequency at various stages.

iv) Portable hardness testers it is being used for checking of hardness of

plane hardened- Nitrided and stellited components. It can measure upto a

range of HV 999.

v) MPI Machine – This is used for carrying out magnetic particle test for crack

detection on finished blades.

vi) Surface Finish Measuring Equipment – This is used for checking the

surface finish of machined components. Can measure in R, Rz and Ra.

Hardness Testers of different configurations

* SAROJ (VICKER CUM BRINELL) HV to BH 5 to 250 KG

* SAROJ B-3000 (BRINELL) BH 250 to 3000 Kg

* USSR (ROCKWELL) HRC 150 Kg

* USSR (BRINELL) BH 250 to 3000 Kg

* SAROJ (ROCKWELL CUM BRINELL) HRC/HB 60 to 250 Kg

* SAROJ (ROCKWELL) HRC 60 to 150 Kg

B.

HYDRO TURBINE LABORATORY

1. INTRODUCTION

Hydro Turbine Laboratory at HEEP, Hardwar was set up in late '60s. It comprises

of three Test Beds with electronic Instrumentation Laboratory for test bed

operation/maintenance and for carrying out Site Investigations. It has a modest

Workshop to manufacture hydro turbine models. Till December '95 about 160

number of tests have successfully been performed in the Laboratory which

include Contractual as well as Developmental tests on Hydro Turbine Models,

Calibration of Hydraulic Valves, Nozzles and Flow Measuring Devices for 210

MW Thermal Sets. Besides performing the main function of design/ development

of hydraulic passages of hydro turbines, design of models, their manufacture and

testing, the Laboratory has also been engaged in Field Test Studies at various

Hydro Power Sites for conducting Index Tests, Head Loss Measurement,

Uprating Studies and attending to various Site Problems.

2. DESIGN:

3. MANUFACTURING:

4. TESTING:

5. TESTING CAPABILITIES:

- Runaway speed tests of reaction and impulse turbine.

- Determination of MW output of prototype turbine under specified operating

conditions.

6.4 INSTRUMENTATION LABORATORY

The Instrumentation Laboratory is equipped with the most modern

instrumentation for carrying out accurate measurements during testing in the

Laboratory as well as during field testing. The major facilities are:

- Ultrasonic Flowmeter for field tests.

- Magnetic Tape Recorder with Waveform Analyzer.

- Microprocessor based Pressure Pulsation Measuring System.

- Microprocessor based Wicket Gate Torque Measuring System.

- Microprocessor based Hydraulic Thrust Measuring system.

7. RESEARCH AND DEVELOPMENT

The continuous inhouse research and development efforts of the Laboratory

have enabled it to establish new measurement methods for carrying out special

tests, to bridge know-how / know-why gaps, to resolve certain site problems and

to evolve and establish better and more efficient designs. The benefits of

research and development activities are passed on to the customers through

implementation of new concepts of existing sites and for future projects.

8. FIELD TESTING

The Laboratory is equipped to perform field efficiency and index tests on

prototype turbines at hydropower sites. Many site problems of hydraulic and

mechanical nature have been successfully solved as a result of extensive filed

tests and analysis carried out by the Laboratory. The Laboratory has successfully

carried out uprating studies at many hydro sites resulting in augmentation of

power generating capacity of the units at no extra or minimum cost. Extensive

work has been done by the Laboratory to tackle the problem of silt erosion of

runner blades at several hydro power stations situated in the Himalayan region.

9. CALIBRATION

The Laboratory is equipped with the required facilities for calibration of load cells,

pressure pulsation transducers, weights, volumetric tanks and torque wrenches.

Calibration of these terms is performed with respect to standards with history

traceable to N.P.L., Delhi.

10. FUTURE PLANS

Upgradation and modernization of Hydro Turbine Laboratory has been planned

in the following areas:

- Renovation of Test Beds to the cater for the requirements of IEC-995.

- Modernisation in the field of instrumentation.

- Addition of instantaneous in-siti calibration facility.

- Incorporation of Computerisation and Data Acquisition System

- Modernisation of Workshop facilities.

BROAD SPECIFICATION OF

MAJOR/IMPORTANT MACHINE TOOLS & MACHINES

A: CNC MACHINE TOOLS

CNC HORIZONTAL BORERS:

1. Item Description : CNC Horz. Borer

Model : RAPID 6C

Supplier : WOTN, GERMANY

CNC Control System : FANUC 12M

Spindle Dia. : 200mm

Table : 4000 x 4000 mm

Max. Load on Table : 100 T

Travers : X=20000, Y=5000, X=1400mm

Ram traverse : W = 1000 mm

Ram size : 400 x 400 mm

Power Rating : 90 KW

Weight of the m/c : 111 T

ATC Capacity : 60 Nos.

Plan No. : 1-227 (Block-I)

2. Item Description : CNC Stub BorerModel : DW 1800Supplier : HEYLIGENSTAEDT, GERMANYCNC Control System : SINUMERIK – 7TBoring Dai : 625 – 2500 mmTable : 4000 x 4000 mmHeadstock Travel : 4000 mmSpindle Speed : 0.5 –90 RPM (in 4 Steps)Power Rating : 63 KWMax. Load Capacity : 100 TWeight of the m/c : 72 TPlan No. : 27-420 (Block-III)

3. Item Description : CNC Horz. Borer (2 Nos.)Model : W200 HB –NCSupplier : SKODA, CZECH

CNC Control System : SINUMERIK 850 MSpindle Dia. : 200 mmTraverse : X=12500,

Y=5000,Z=2000mm

CNC LATHES

4. Items Description : CNC Centre LatheModel : D-1800 NYFSupplier : HOESCH MFD, GERMANYCNC Control System : SINUMERIK 3TCentre Distance : 8000 mmSwing Over Carriage : 1800 mmSwing Over Bed : 2400 mmSpindle Speed : 0 – 125 RPMPower Rating : 92 KWWeight of the Job : 110 TONWeight of the m/c : 124 TONPlan No. : 2-394 (Block-III)

5. Item Description : CNC Centre LatheMode : D-2300 NYFS-1Supplier : HOESCH MFC, GERMANYCNC Control System : SINUMERIK 7TCentre Distance : 18000 mmSwing Over Carriage : 2300 mmSwing Over Bed : 2900 mmSpindle Speed : 5 – 125 RPMPower Rating : 110 KWWeight of the job : 320 TONWeight of the m/c : 216 TONPlan No. : 2-360 (Block-III)

6. Item Description : CNC Centre Lathe

Model : KV2-1100 CNC

Supplier : RANVENSBURG, GERMANY

CNC Control System : SINUMERIK 820 T

Centre Distance : 12000 mm

Centre Height : 900 mm

Swing Over Carriage : 1100 mm

Swing Over Bed : 1400 mm

Max. Turning Length : 12000 mm

Spindle Speed : 2-600 RPM

Longitudinal Cutting Feed (Z-Axis) : 1-5000 mm / min.

Transfer Cutting Feed (X-Axis) : 1-5000 mm/min.

Main Spindle Drive Motor : 95.5 KW DC

Max. Feed Force – Z/X Axis : 45000 N

No. of Tool carriers : 3

Plan No. : 1-120 (Block-III)

CNC MILLING MACHINES

7. Item Description : CNC Horz. Milling M/c (6 Nos.)

Model : BFH-15

Supplier : BATLIBOI, INDIA

CNC Control System : SINUMERIK 810 M

Table : 1500 x 400 mm

Traverse : X=1170 mm

Y=420 mm

Z=420 mm

Spindle Speed : 45 to 2000 RPM


Max. Load Capacity : 630 Kg

Weight of the m/c : 4200 Kg

Plan No. : 2-449, 2-453, 2-454, 2-459, 2-460 (Block-

IIITBM)

8. Item Description : Universal Milling M/cs (2Nos.)

Model : BFK-15

Supplier : BATLIBOI, INDIA

CNC Control System : SINUMERIK 810 M

Table : 1500 x 400 mm

Traverse : X=1170 mm

Y=420 mm

Z=420 mm

Spindle Speed : 45-2000 RPM


Max. Load Capacity : 630 Kg

Weight of the m/c : 4200 Kg

Plan No. : 2-463, 2-466 (Block-III: TBM)

9. Item Description : CNC Bed Type Milling M/c

Model : FSQ 80 CNC

Supplier : TOSKURIM, CZECH

CNC Control System SINUMERIK 810 M

Table : 3000 x 800 mm

TEE SLOT 28H7

Traverse : X= 3000 mm

Y= 870 mm

Z= 850 mm

Spindle Speed Range : H – 2500 RPM

Spindle Drive Power : 18 KW continuous

22 KW intermittent

Spindle Head Size : 620 x 500 incldg ram

543 x 420 encldg ram

ATC Capacity : 24 Nos.

Table Load : 2500 Kg


CNC MACHINING CENTRES

10. Item Description : SPL. Purpose 6 Station T-Root Machining Centre

(2nos.)

Supplier : MIH, JAPAN

CNC Control System : FANUC 7M

Indexing Table : 1900 mm dia

Indexing Position : 6 Nos.

Plan No. : 2-356, 2-41 (Block-III: TBM)

11. Item Description : SPL Purpose FIR Tree Root M/cing Cenre

Model : NTH 200

Supplier : RIGID, SWITZERLAND

CNC Control System : SINUMERIK 7M

Table : 1400 x 1400 mm

Traverse : X= 1950 mm

Y= 900 mm

Z= 600 mm

Spindle Speed : 30600 RPM

No of Spindle : 4


Plan No. 2-354 (Block-III TBM)

CNC VERTICAL BORERS

12. Item Description : CNC Vertical Borer

Model : TMD – 40 / 50

Supplier : OSAKA MACHINES, JAPAN

CNC Control System : FANUC 6TB, 3TC

Table dia : 4000 mm

Turning dia : 5000 mm

Turning Height : 4200 mm

Spindle Speed : 0.23-30 RPM

No. of Ram : 2


Max. Load Capacity : 70T

Machine Weight : 100 T

Max. Ram Travel (Vertical) : 2200 mm


13. Item Description : CNC Vertical Borer (2 Nos.)

Model : 40 DZ

Supplier : SCHIESS, GERMANY

CNC Control System : SINUMERIK 850 TTable : 4000 mmMax. Turning dia : 5000 mmMax. Turning Height : 4200 mm

Ram size : 300 x 250 mmTable Speed : 0.63 – 63 RPMMax. Vertical Travel of Ram : 2200 mmPower Rating : 71 KWTable Load Carrying Capacity: 80 TATC Capacity : 12 Nos.Plan No. : 1-235 (Block-I), 2-472 (Block-III)

14. Item Description : CNC Vertical BorerModel : 32 DS 250Supplier : SCHIESS, GERMANYCNC Control System : SINUMERIK 850TTable : 2500 mmTable Load Carrying Capacity: 25TMax. Turning Dia : 3200 mmMax. Turning Height : 2200 mmRam Size : 210 x 250 mmMax. Travel of Ram : 1400 mmTable Speed : 0.8 – 160 RPMPower Rating : 56 KWATC Capacity : 12 Nos.Plan No. : 2-483 (Block-III)

OTHER SPECIAL PURPOSE CNC MACHINES

15. CNC SURFACE BROACHING M/C

Make : Marbaix Lapointe, UK

Model : Champion 32 /10, 300

CNC System : SINUMERIC 850 M

Broaching capacity (pulling force): 320 KN

Broaching slide stroke : 10.3 mm

Broaching slide width : 1500 mm

Max tool length (continuous /row): 9650 mm

Broaching Speed (cutting stroke) : 1-25 M/min

Broaching Speed (return stroke) : 60 M/min

Drive power rating : 135 KW

Broaching slide movement : Electro-mechanical

Maximum noise level : < 80 Dbs

Max. dia of the disc (mountable) : 2300 mm

Max. weight of the job : 3000 Kgs

Indexing & rotating tables : 1500 mm, 1000 mm

Indexing accuracy : +/- 3 Arc sec.

Plan No. : 2-485

16. CREEP FEED GRINDING M/C

Make : ELB CHLIFE, GERMANY

Model : ELTAC SFR 200 CNC

CNC System : SINUMERIC 3 GG

Work-piece diameter : 200 – 2000 mm

Work height : 2400 mm

Rotary & indexing table dia. : 2050 mm

Indexing accuracy : +/- 1 ARC SEC

Max. load capacity : 20000 KG

Y-axis (grinding head movement)

Vert. Traverse : 750 mm

Z- axis (grinding head support)

Movement on cross rail)

Horizontal traverse : 2400 mm

Traverse feed rate : 02 – 1200 mm /min

Grinding head main support

Drive motor : 34 KW

Grinding wheel max. Dia. : 500 mm

Max. Width : 100 mm

Bore : 203.2 mm

Surface speed : 16-35 M/Sec.

Plan No. : 2-491

17. BROACH SHARPENING M/C

Make : LANDRIANI, ITALY

CNC System : SELCA

Work-piece diameter : Upto 250 mm

Work Length : 200 mm

Plan No. : 2-487

BROAD SPECIFICATIONS OF

MAJOR / IMPORTANT MACHINE TOOLS & MACHINES

B: NON-CNC MACHINE TOOLS

(1) PRECISION HEAVY DUTY LATHE

Manufacturer: Karamatorsk Heavy Machine Tool Works (USSR); Model KS-1614

Specifications

1. Maximum Swing 2000mm

2. Maximum Diameter of work piece over the Saddle 1500 mm

3. Maximum Distance between Centres 8000mm

4. Diameter of Spindle bore 80 mm

5. Maximum Taper when machining by the method of

Combined Feeds

0.15 mm

6. Maximum Length between Centres when machining

by the method of Combined Freeds

1200 mm

7. Maximum Weight of work piece 20000 kg

8. Maximum Length of Machine over the Saddle 8000 kg

9. Maximum Summary Effort of Cutting 10,000 kg

10

.

Limit Dimension of Thread Cut:

Thread Pitch Max Length of Thread,

Min Max mm

Metric Threade Pitch (in mm) 1 96 6300

British Trhread Pitch (Per inch) 20 3/8 6300

Name of Part Pow

er

Displacement in mm

Manual Per Rev.

of Dial

One

Division

Of Dial

Represent

Rapid

Traver

se

M/min

Carriage 2.02

Transverse

Slide

1130 1130 8 0.1 mm 1.03

Longitudinal

Slide

600 600 6 0.1 mm 0.48

Tool Slide 150 6 0.1 mm -

Rotary Part 90o 5 o 0.5 -

Maximum Displacement of the Tailstock Spindle 260 mm

Maximum Transverse Displacement of the Tailstock 17 mm

Rotating Built –in Centre Available

Power Extraction of the Tailstock Spindle Available

Rapid Traverse of the Tailstock 3.44 M/min

12. Overall Dimension:

Length 13900 mm Width 3845 mm Height 2865 mm

13. Plant No. 2-182 (Block-III)

UNIVERSAL VERTICAL TURNING & BORING MACHINE

Manufacturer : Kolomna Machine Tool Works (USSR)

Model – KY 152

Specifications

1. Maximum Dia. of workpiece accommodated 10000/12500

mm

2. Dia. of central table 8750 mm

3. Maximum travel of vertical Tool Heads from center of table 5250 mm

4. Maximum weight of workpiece accommodated on central table

(a) With table speed limited to n (n 6) r.pm. 200 T

(b) At any speed 100 T

5. Maximum cutting force with different length of tool over-hang (L) from head face

R.H. Head

16000 Kg with L 1500 mm

7500 Kg with L 2000 mm



L.H. Head

12500 Kg with L 1500 mm




6. Rated cutting dia on central table 6300 mm

7. Maximum cutting torque on central table 80000 Kg.M

8. Speed range of central table rotation Minimum = 0.112 r p.m.

Maximum – 11.2 r.p.m.

9. Travel rate of column assembly 190 mm /minute

10. Plan No. 1-13 (Block-I)

1-24 (Block-III)

BALANCING MACHINE

Manufacturer: SCHENK (West Germany)

Model: Dj 90

Specifications

1. Weight of rotor 10,000 to

80,000 kg

2. Minimum weight without considerable loss of 5000 kg

measuring sensitivity, provided the berings can

accommodate such small rotors.

3. Maximum weight for one bearing pedestal 45,000 kg

4. Height of rotor axis above machine bed 1600 mm

5. Rotor diameter (free swing over machine bed) not

considering the funnel

4000 mm

6. Diameter of journal Max. 540 mm

7. Diameter of journal, with special sleeve bearing cups

made from high grade material.

Max. 600 mm

8. Minimum distance between bearings for less than 10

tons rotor

1500 mm

9. Minimum distance between bearings for more than

10 tons rotor

1900 mm

10

.

Maximum distance between coupling plague and

center of the scond bearing pedestals

13500 mm

11

.

Rotational Speeds Min. 800 rpm

(a) For rotors from 5 to 10 tons Max. 4000

rpm

Min. 700 rpm

(b) For rotors from 10 to 20 tons Max. 3600

rpm

Min. 600 rpm

(c) For rotors from 20 to 80 tons Max. 3600

rpm

12

.

Maximum test speed and overspeeds

(a) For rotors upto 50 tons

(b) For rotors upto 50 to 80 tons

4500 rpm

3600 rpm

13

.

Maximum centrifugal force admissible on each

bearing pedestals for short period of time

50,000 Kg

14

.

Balancing accuracy to be obtained depending on

Selling Weight

0.3 to 3

micron

15

.

Sensitivity of indication depending on rotor weight,

speed and selling weight

0.1-8

div/micron

16

.

Accuracy of the angle indication 1 o – 2o

17

.

Stiffness of bearing pedestals, when mounted on

machine bed

(a) With unclamped bearings 1.2 Kg/micron

(0.85

micron/Kg)

(b) With clamped bearing 100

Kg/micron

(0.01

micron /Kg).

SPECIAL DRILLING & BORING MACHINE

Manufacturer: Machine Tool Works, Ryazan (USSR)

Model: PT 182 H5

SPECIFICATIONS:

1. Swing over bed 800 mm

2. Drilling dia 40-80 mm

3. Boring dia 80-250 mm

4. Swing of job in rest Max

Min

300 mm

110 mm

5. Swing of job in

Headstock chuck

Max.

Min.

300

110 mm

6. Maximum length of job 3000 mm

7. Maximum weight of job 2000 Kg

8. Number of spindles Headstock

Stemstock

1

1

9. Spindle location Horizontal

10

.

Distance to spindle axis: From bed wasy

From floor

400 mm

1100 mm

11

.

Head stock Spindle speed Max

Min.

750 r.p.m.

71. r.p.m.

Number of steps of spindle

speed

Spindle braking

24

Available

12

.

Stemstock Spindle speeds Max.

Min.

730 r.p.m.

123 r.p.m.

Number of steps of spindle

speed

Stemstock feed

Max.

Min.

6

1680 mm /

min

168 mm /

min

Number of feed steps Stepless

13

.

Overall dimensions

Length 13500 mm

Width 2300 mm

Height 1700 mm

Weight 23844 Kg.

14

.

Plan No 1-105

(Block-III)

SPECIAL INTERNAL GRINDING MACHINE

Manufacturer: Saratov Machine Binding Works (USSR)

Model : MB 6020 T

SPECIFICATIONS

1. Diameter of ground holes

(a) Maximum

(b) Minimum

320 mm

90 mm

2. Maximum length of grinding (with maximum hole

diameter)

560 mm

3. Maximum weight of work 600 Kg

4. Distance from spindle axis to floor level 1100 mm

5. Distance from spindle axis to table

(a) Maximum 300 mm

(b) Minimum 100 mm

6. Cantilever vertical travel

(a) Per one revolution of handwheel 0.133 mm

(b) Speed of rapid vertical traverse (from motor) 190 mm /

min.

(c) Per dial graduation 0.01 mm

7. Table working surface dimensions 500 x 1200

mm

8. Table cross-traverse

(a) To operator from intermediate (zero) position 200 mm

(b) From operator from intermediate (zero) position 200 mm

(c) Total 400 mm

(d) For one revolution of hand wheel 0.2 mm

(e) For one dial graduation 0.01 mm

(f) Speed of rapid traverse (from motor) 280 mm /

min

UNIVERSAL THREAD GRINDING MACHINE

Manufacturer: Moscow Jig Boring Machine Plant (USSR)

Model: 5822B3

SPECIFICATIONS

1. Maximum diameter of work

admitter

160 mm

2. Nominal diameter of thread being

ground

Min

Max

25 mm

125 mm

3. Thread pitch Min

Max

0.5 mm

6 mm

4. Maximum length of thread being

ground,

(a) By single-ribbed wheel 75 mm

(b) By multiple ribbed wheel 55 mm

5. Maximum taper of thread: 1o 47' 24"

or 1:16

6. Table

Maximum longitudinal table

traverse,

(a) By hand 425 mm

(b) By power 415 mm

Table rapid withdrawal speed (variable:

maximum

about 1.2

m/min)

7. Taper

(a) Headstock spindle MT 4

(b) Tailstock spindle MT 5

8. Grinding Wheelhead

Maximum cross feed

(a) By hand 125 mm

(b) By power 50 mm

Movement per dial division 0.005 mm

Movement per dial revolution 1 mm

PLANER

Manufacturer: The Yefemov Plant TIAZHSTANKOGIDRO-PRESS (USSR)

Model: 7A288-T

SPECIFICATIONS

1. Max. width of planning 4000 mm

2. Max. height under cross rail 4000 mm

3. Distance between housings 4250 mm

4. Max. travel of slides below cross rail and inside

housing

(a) for vertical tool heads 700 mm

(b) for side tool heads 700 mm

5. Max. allowable weight of workpiece 100 T

6. Max. cutting force

Arrangement for mechanizing and automating the

machine operation is available

40000 Kg.

7. Table

Dimension of working surface of table,

(a) Width 3600 mm

(b) Length 12000 mm

Table Stroke, Max. 12000 mm

Min. 3000 mm

Safety devices to stop table after

worm disengaging.

Available.

8. Tool Heads

Number of tool heads (a) Vert. 2

(b) Side 2

Travel of tool heads, mm. V.Tool Side Tool Heads

Heads R.H. L.H.

(i) Max. vertical travel 700 3750 3750

(ii) Max. horizontal travel 5000 700 700

(iii) Travel per turn of hand-wheel

lever, (in mm)

Vertical travel 1.14 4.25 4.25

Horizontal travel 0.52 1.14 1.14

(iv) Dial division value

Vertical 0.1 0.2 0.2

Horizontal 0.2 0.1 0.1

(v) Rapid travel

Speed mm

Vertical 1.25 2.5 2.5

Horizontal 2.5 1.25 1.25

9. Cutter Head:

(i) Max. dimension of tool holder Vertical Side

Tool head Tool head

(a) Width 120 mm 120 mm

(b) Height 120 mm 120 mm

(ii) Max. angle of slide Swiveling

(a) To the right 60 o 45o

(b) To the left 60 o 45o

(iii) Dial division value 10 10

(iv) Swiveling of cutter head plate 10 o 10 o

(v) Cutter head automatic lifting during

return stroke of table

Available Available

10. Cross Rail:

Maximum travel 4000 mm

Rapid travel speed Not less than 0.3 M/min

Time of cross rail automatic fixing 20 to 30 sec.

Main drive motor 2 x 130 KW

11. Plan No. 2-189 (Block-III)

MATERIALS SPECIFICATION

X20 – Cr – 13

A. 13% Cr. Stainless Steel Bars (Hardened & Tempered)

1. General : This specification governs the quality of stainless steel

bars of grade X20 – Cr. –13

2. Application : For machining of moving and guide blades of steam

Turbine.

3. Condition of Delivery : Hot rolled / Forged & hardened and tempered. The

bars shall be straight and free from waviness.

4. Complete with standards: There is no Indian standard covering this material.

5. DIMENSIONS & TOLERANCES :

Dimension : Bars shall be supplied to the dimensions specified in the

purchase order unless otherwise specified in the order.

The bars shall be supplied in random length of 3 to 6

meters with a maximum of 10% shorts down to meter.

Forged bars shall be supplied in length of 1.5 to 3 meters.

Tolerance : The tolerance on cross sectional dimensions shall be as

per table.

5.1. Hot Rolled Bars : Tolerance on hot rolled flat bars shall be as

specified below :

"b" width across flates

mm

Allowable deviation

on "b" mm

"s" thickness

mm

Allowable devi.

on 'S' mm

Up to 35 + 1.5 Up to 20 +1

b s

Over 35 and Upto 75 + 2 Over – 20

and Upto –

40

+ 2

Over 75 + 3 Over 40 + 3

Note : Other tolerances shall be as per DIN 1017. Twisting and bending off the bars

shall not exceed 0.001X length of the bar. Bulging on the sides shall not be more

than 0.01 x b and 0.01 x s respectively.

5.2 Forged Bar : Tolerances on size for forged bars

shall be +8% of the size.

6. MANUFACTURE:

6.1 The steel shall be manufactured in basic electric furnace process and

subsequently vacuum degassed or electric slag refined (ESR). Any other

process of meeting shall be subjected to mutual agreement between supplier

& BHEL.

6.2 For manufacture of flat bars, if initial material is other than ignot (e.g.

continuous casting), supplier shall mention it in his quotation for prior

approval from BHEL.

7. HEAT TREATMENT :

7.1 The bars shall be heat treated to get the desired mechanical properties

specified in this specification. The hardening temperature shall be in the

range of 980 – 10300C and the tempering temperature shall not be below

6500C As per DIN-19440.

7.2. Minimum possible residual stress shall be aimed with slow cooling and longer

duration of tempering treatment.

7.3. If the bars require straightening after heat treatment, the bars shall be stress

relieved after straightening operation at 300C below the actual tempering

temperature.

8. FREEDOM FROM DEFECTS:

8.1 The bar shall be free from lamination cracks, scabs, seams, shrinkage

porosity, inclusions and other harmful defects.

8.2 Decarburisation and other material defects shall not exceed the dimensional

tolerances and machining allowances.

9. FINISH:

9.1 The bar surface be smooth, free from laps, rolled in scale etc. Dents roll

marks. Scratches are permitted provided their depth does not exceed half the

tolerance limits specified in table.

9.2 Repair of surface flaws by welding in not permitted

9.3 The edges of bars shall be cut square by swaing or shearing.

10. CHEMICAL COMPOSITION: The chemical composition of material shall be

as follows (table analysis in %)

Element Min. Max.

Carbon 0.17 0.22

Silicon 0.10 0.50

Manganese 0.30 0.80

Chromium 12.50 14.00

Nickel 0.30 0.80

Sulphur -- 0.020

Phosphorus -- 0.030

11. SELECTION OF TEST SAMPLES :

11.1 Chemical analysis shall be reported on each heat basis..

11.2 For Mechanical Test

11.2.1 One tensile & 3 impact test samples shall be selected for mechanical

testing per melt per heat treatment batch basis from lot of size.

11.2.2 The uniform strength of a delivery shall be certified through hardness test.

In case of bars with sectional dimensions more than 120mm, all the bar

shall be tested for hardness. In case of bars with sectional dimension less

than or equal to 120mm hardness shall be checked on 10% of the bars or

10 numbers of bars which ever is higher.

11.2.3 The mechanical and notch impact test is to be done in longitudinal

direction on the hardest and softest bars. Test sample shall be to Km. at

1/3rd below the surface of the bars.

12. Mechanical Properties:

12.1 The material shall comply with the following mechanical properties at

room temperature.

0.2% : 600 N/MM2 Min

Tensile strength : 800 – 950 N/mm2

% Elongation on 5.65 : 15 min.

% Reduction in area : 50 min. *

Impact (mean of 3.1S0 – V sample) : 20 J min.

Hardness (HB-30) : 280

* The smallest value shall be at least 14 J.

12.2 Tensile test shall be carried out in accordance with IS : 1608 or equivalent

international standard.

12.3 Impact test shall be carried out on 3 ISO-V samples in accordance with IS

: 1757 or equivalent international standard only one test value out of

three, can be below the specified value ; but in no case it should be below

2/3rd of the minimum specified value; but in no case it should be below

2/3rd of the minimum specified impact value.

12.4 Hardness test (Brinell) shall be carried out according to IS : 1500 or

equivalent international standard.

13. NON DESTRUCTIVE TEST: Following NDT shall be carried out.

13.1 UT of the prematerial combined with 100% magnetic partial testing of all

bars in delivery condition.

13.2 Complete UT of all bars in delivery condition.

13.2.1 In case of testing as per 14(a) U.T. shall be carried out as per HW 0850

192 (SEP 1923) test class D3 and MPI of all bars except of face areas. In

case of testing as per 14(b) UT shall be carried out as per HW 0850 192

(SEP 1923) test class D2.

13.2.2 Mix up test (verification test) of all bars.

13.2.3 Visual inspection of all bars

13.2.4 Acceptance Criteria

a) Magnetic Particle Test : When MT is carried out as per clause 14.1.

Surface defects with expected depth > 1 mm are unacceptable.

Indication > 5 mm are unacceptable.

Defect indication observed during MT, can be removed by grinding

(dressing up) but with in 1mm depth.

b) Ultrasonic Test : Quality class 2b with following modification that

individual indication > 2mm EFB (KSR) and back wall losses > 3dB are

unacceptable.

X2 – CrMoV1 21

B. 600 N/MM2 minimum 0.2% Proof stress Heat resistant steel bars for steam

turbine blades

1. General : Hot rolled and forged bars of steel grades X22 CrMoV1

21.

2. Application : Bars are required for machining of guide and moving

blades for steam turbines.

3. Dimension & Tolerance :

"b" width across

flates mm

Allowable deviation

on "b" mm

"s" thickness

mm

Allowable

devi. on 'S'

mm

Up to 35 & Over 35 ± 1.5 Up to 20 &

Over 20

+1

Upto 75 + 2 Upto – 40 + 2

Over 75 + 3 Over 40 + 3

4. Chemical Composition:

Element % min. % max.

Carbon 0.18 0.24

Silicon 0.10 0.50

Manganese 0.30 0.80

sb


Malybeonum 0.80 1.20

Vanadium 0.25 0.35

Nickel 0.30 0.80

Sulphur -- 0.020

Phosphorous -- 0.030

5. MECHANICAL PROPERTIES:

0.2 % proof stress : 600 N/mm2 min.

Tensile Strength : 800-950 N/MM2

% Elongation : 14 Min.

% Reduction in area : 40% Min.

Notch Impact Value : 27 J * Min.

* Average of 3 IS0 – V Samples.

C. 600 N/MM2 0.2% PROOF STRESS FORGED BLADES

1. General : This specification governs the quality of guide and moving

blades forged from steel grade X 20 or 13.

2. Application : The blades are used for steam turbines.

3. Condition of Delivery: The forged blades shall be supplied in heat treated forged

blade shall be supplied with center holes made in

accordance with respective technical requirements or

ordering drawing.

4. Dimensions & Tolerance: The dimension and tolerances shall be as per

ordering drawing accompanying the order.

5. Manufacture : The steel shall be manufactured in the blade electrical

furnace and for subsequently refined to ensure turbine

blade quality. The forgings shall be made as envelope

forging or precision forging, subsequently machine /

grinder to achieve the ordering drawing dimensions and

surface finish.

6. Heat Treatment:

6.1. The forging shall be heat treated to get desired mechanical properties.

6.2. The tempering temperature shall not be below 6500 C. The minimum

residual are to be aimed through sufficient duration of the tempering

treatment and the slow cooling rate from the tempering temperature.

6.3. The blades are to be straightened after heat treatment, each straightening

operation is to be followed by a stress relieving temperature and in no case

below 6100C followed by slow cooling.

7. Freedom from Defects: Blades shall be free from folds due to forging; cracks,

tearing and other material defects, elonganed non-metallic

and jusions, seams etc. any blade blade containing such

defects shall be rejected.

8. Surface finish : The blade shall be supplied in a desoaled and deburred

condition. The surface finish shall comply with the

requirements specified on the drawing. In the surface is

ground prior to blasting the the surface finish must be

anouired in compliance with the finish specified on the

drawing. Grinding may be performed to a depth not more

than H/2 and ground areas shall be blended over a

length of LP/2. However H shall not be exceeded.

H : Allowable profile deviation on the pressure side.

LP : Profile length measured from leading edge to trailing edge.

9. Chemical Composition: The chemical analysis of the material shall

confirm to the following:

Element % min. % max.

Carbon 0.17 0.22

Silicon 0.10 0.50

Manganese 0.30 0.80


Nickel 0.30 0.80

Sulphur -- 0.020

Phosphorous -- 0.030

10. Selection of Test Sample: All tests and

examination shall be performed on specimens taken

in accordance with annexure 1 from at least one

blade of each drawing per melts and heat treatment

batch.

11. Mechanical properties:

11.1 The mechanical properties of the blade material shall conform to the following :

0.2 % proof stress : 600 N/mm2

Tensile Strength : 800-950 N/MM2

% Elongation : 15 Min.

% Reduction in area : 50 Min.

Impact Value (Average of

3, ISO – V Sample) : 20 J Min.

Brinell hardness HB 30 : 280 Max.

11.2 Tensile Test: The tensile test piece shall confirm to the gauge length.

11.3 Impact test shall be carried out on standard test piece as per ISO – V notch

according to IS: 1757.

11.4 Hardness Test: The brinell hardness test HB 30 shall be carried out according

to IS : 1500.

12. Non Destructive Test:

12.1 Blade shall only be manufactured from ultrasonically examined rare material.

12.2 In order to ensure freedom from defects. All blades shall be subjected to

magnetic particle examination prior to shipment.

13. Dimenional Checks for Acceptance:

13.1 The supplier shall check 100% of the forging w.r.t. to all parameters.

13.2 Dimensions parameters to be checked for acceptance.

Following dimensional parameters of each of the check sections as

specified in ordering drawing shall be inspected after fixing / clamping the

forging in vertical stand to check conformance of profile of individual section

as well as in relation to each other.

o From tolerance for pressure side = H

o From tolerance for suction side = R, max differenceR

o From tolerance for Inlet edge = H

o Twist Tolerance = (H, R) max.

Profile thickness of each section. = D Max. / D / D1

Max. profile length of each section.

Root dimensions.

Base dimensions.

Base plate contour.

Axial and tangential shift of profile with respect to root.

Overall length of forging.

Surface finish.

13.3 Procedure for dimensional checks :

Check of inlet edge : The profile of inlet edge shall be checked by using split

profile gauges.

Check of Profile: All the dimensional parameters mentioned at (13.2) shall

be checked using a vertical measuring stand.

Drilling of BHEL Centre holes

Checking of BHEL Centres.

CLASSIFICATION OF BLADES

L.P. Moving Blade Forged Ist Stage.

L.P. Moving Blade 500 MW Last Stage.

100 MW 25th Stage Impulse Blade.

Compressor blade Sermental coated.

Compressor Blade 'O' stage.

Gas Turbine Compressor Blade.

T-2 Blade.

T-4 Blade.

3DS Blade.

Brazed Blade

Russian Design Blades.

Z – Shroud Blade.

Twisted Blade.

Present Range of Blades.

Future Range of Blades.

MANUFACTURING DIVISIONS

Heavy Electricals Plant, Piplani, Bhopal

Electricals Machines Repair Plant (EMRP), Mumbai

Transformer Plant P.O. BHEL, Jhansi.

Bharat Heavy Electricals Limited :– Heavy Electricals Equipment Plant,

– Central Foundary Forge Plant., Ranipur, Hardwar

Heavy Equipment Repair Plant, Varanasi.

Insulator Plant, Jagdishpur, Distt. Sultanpur.

Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad

High Pressure Boiler Plant & Seamless Steel Tube Plant, Tiruchirappalli.

Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex, Ranipet.

Industrial Valves Plant, Goindwal.

Electronics Division :– Electronics Systems Division.

– Amorphous Silicon Solar Cell Plant (ASSCP).

– Electroporcelains Division.

– Industrial Systems Group.

BANGALORE.

Component Fabrication Plant, Rudrapur.

Piping Centre, Chennai.

Regional Operations Division, New Delhi

CONTENTS

1. Prologe – A. BHEL – An Overview

B. HEEP – An Overview

2. Study on Turbines & Auxiliary Block

3. Study on Material Specification

4. Study On Blade Shop

5. Broad Specification of Major Machines Tools & Machines

(CNC & Non CNC)

6. Other Areas

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