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ACKNOWLEDGEMENT
Before we get into detail of the report, I feel the heartfelt responsibility to my
acknowledgement to several people to whom I own the success of my venture of training and
writing this report.
I am grateful to Mr. ALOK SHUKLA Sr.MANAGER (TURBINE GOVERNING SECTION)
who allowed me to undergo vocational summer training and guided me during training period
at BHARAT HEAVYELECTRICAL LIMITED,HARIDWAR which holds the rank
amongst the top Public Sectors in India , exhibiting excellent performance with safest and
most friendly environment, fulfilling all kinds of standards respective to its name, reputation
and fame.
I would like to give special thank to all the staff of BHEL TURBINE SECTION for their
great and remarkable contribution, support and guidance during training period. Their
constant effort made this training really a learning experience. The well planned schedule and
structure helped me in understanding the systems and equipments easily and effectively.
PRACHETASH SRIVASTAVA
Mechanical Engineering
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TABLE OF CONTENT
1. BHEL
AN OVERVIEW.5
2. HEEPAN OVERVIEW..6
3. TURBINES & AUXILLIARY BLOCK.7
4. HYDRO TURBINE....8
5. STEAM TURBINE9-10
6. GAS TURBINE11-14
7. MANUFACTURING PROCESS15-17
8. BLADE SHOP.18-21
9.BROAD SPECIFICATION OF MAJOR MACHINES TOOLS
& MACHINES - CNC MACHINE TOOLS..22-25
10. NON CNC MACHINE TOOLS.26-27
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1.BHELAN OVERVIEW
BHEL is the largest engineering and manufacturing enterprise in Indiain 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 Indiaa 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., PowerGeneration'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 nuclearpower plant business as of
31.03.2001, BHEL supplied sets account fornearly 64737 MW or 65% of the total installed
capacity of 99,146 MW inthe country, as against nil till 1969-70.
BHEL has proven turnkey capabilities for executing power projectsfrom 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. Cogeneration 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.
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2.HEEP: AN OVERVIEW
Over the years, Bharat Heavy Electricals Limited has emerged as world class Engineering
and Industrial giant, the best of its kind in entire South East Asia. Its business profile cutsacross various sectors of Engineering/Power utilities and Industry. The Company today
enjoys national and international presence featuring in the "Fortune International- 500" and is
ranked among the top 12 companies in the world, manufacturing power generation
equipment. BHEL has now 14 Manufacturing Divisions, 8 Service Centres and 4 Power
Sectors Regional Centres besides a large number of project sites spread over India and
abroad.
HEEP: FACILITIES AND INFRASTRUCTURE
Modernization and regular up gradation / up gradation of facilities andcother infrastructure is
a continuous endeavor at HEEP, BHEL. After initial setting up of the plant during the year
1964-72, in collaboration with the Soviet Union, the plant facilities and infrastructures have
since been continuously upgraded under various investment projects viz, Stamping Unit
Project, LSTG Project, Motor Project, Governing Components Project, TG Facilities
Modernization, TG Facilities Augmentation, Quality Facilities Augmentation, EDP projects,
Gas Turbine Project, Facilities have also been added and establishments have been created
for new projects in Defense and Aviation Project. Additionally, R &D facilities have also
been created under Generators Research Institute, Pollution Control Research Institute, HTL
modernization and other such scheme.
Today the Plant has unique manufacturing and testing facilities,computerized numerically
controlled machine-tools, Blade shop, heavy duty lathes, milling machines, boring machines,
machining centers and many more. The Over Speed Vacuum Balancing Tunnel created for
rotors up to 1300 MW (32T, 6.9 M dia bladed rotor, 6 rpm up to 4500 rpm) is one of the 8
of its kind in the entire world.
The total spectrum of sophisticated, unique and other facilities at HEEP,Hardwar are the
state-of-the-art in manufacturing processes and can beutilized for a variety of products'manufacture.
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3.TURBINE AND AUXILIARY BLOCK-III
GENERAL
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 as per Drawing appended in Section III. Details of facilities
are given in Section II.
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.
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4.HYDRO TURBINES
For manufacturing of Hydro Turbines, Bay-I has the following sections:
Circular Components Machining SectionThis 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.
Runner and Servo Motor Housing Machining SectionThis section is
equipped with NC/CNC and conventional machines comprising Heavy and Medium
size vertical and Horizontal Boring Machines, Centre Lathes, Grinding machines andDrilling 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.
Guide Vanes and Shaft Machining SectionThis section is equipped with
Heavy duty Lathe machines up to 16 metres bed, CNC turning machines, Horizontal
Boring Machine, Heavy planer, Deep Drilling Machine, Boring Machines, markingTable, 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.
Assembly SectionIn this section, assembly and testing of GuideApparatus, Disc Valve, Spherical Valves, Servo motor shaft and combined Boring of
coupling holes are done.
Preservation and Packing SectionFinal preservation and packing of all the
Hydro Turbine components / assemblies is done here.
Small components Machining Section This is equipped with PlanetaryGrinding 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.
Governing Elements Assembly and Test Stand SectionThis section
equipped with facilities like oil Pumping Unit, Pressure Receiver.
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5.STEAM TURBINES
The facilities and parts manufactured in the various sections of Steam
Turbine manufacture are as follows:
Turbine casing Machining SectionIt 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.
Rotor Machining Section
It is equipped with large size machining tools likeTurning 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 indigenouslymanufactured at CFFP, BHEL, Hardwar.
Rotor Assembly SectionThis 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.
Turbine casing Assembly SectionMachined casings are assembled and
hydraulically tested by Reciprocating Pumps at two times the operating pressure.
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.
Painting Preservation and Packing Section All the parts are painted,
preserved and packed here for final dispatch.
Bearings and Miscellaneous Parts Machining Section This section isequipped with small and medium size basic machine tools, e.g., lathes, Milling M/c,
Horizontal Borer, Vertical Borer, drilling M/c etc. formanufacture of bearings and
other miscellaneous parts of turbine.
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ROTOR ASSEMBLY OF V94.3A STEAM TURBINE
Sealing and Diaphragm Machining SectionIt is equipped with medium
size Vertical Boring, Horizontal Boring, Planning, Drilling Machines etc. where in
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.
Governing Machining SectionThis section is equipped with medium size and
small size lathes, medium CNC lathe, Milling, Grinding, Drilling,Slotting and Honing
Machines. Governing assembly parts are machinedhere.
Diaphragm and Governing Assembly SectionIt 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, over speed testing of Emergency Governor etc.
Light machine shopIn addition to normal conventional machine tools it is
equipped with CNC Lathes, CNC Milling, CNC Vertical Boring,
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Precision Milling, planetary grinding machines etc. for manufacture of small and
medium precision components of governing and other turbine parts.
6.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.
Hydraulic Lifting PlatformThis facility is used for assembly and disassembly of G.T. Rotor. This is
ahydraulically operated platform which travels upto 10 M height to facilitateaccess to
different stages of Rotor. This is installed in Bay-I assembly area.
CNC Creep Feed Grinding M/c.This is installed in Gas Turbine machining area Bay-II Extn. This M/cgrinds the
hearth serration on rotor disc faces. Hirth serrations are radialgrooves teeth on both
the faces of rotor discs. Torque is transmitted troughthese serrations, which are very
accurately ground.
External Broaching MachineThis machine is installed in GT machining area and is used to make grooveon the
outer dia of rotor discs for the fitting of moving blades on the discs.
CNC Facing LatheThis machine is installed in GT machining area and is used basically forfacing rotor
disc but can turn other components also.
CNC Turning LatheThis machine is installed in Bay-I Heavy Machine Shop and is used to turnTie 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 isused to assembly and holds the
gas turbine rotor discs to form a compositeturbine rotor.
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GAS TURBINE
Wax Melting EquipmentThis is low temp. electric furnace installed in Gas Turbine blading area inBay-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.
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. Combustionchambers are not assembled
here, which are assembled with main assembly at the site.
Combustion Chamber Assembly PlatformThis facility is a 3 Tier Platform installed in Bay-I assembly area and is used for
assembly of Combustion Chambers of Gas Turbine.
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7.MANUFACTURING PROCESS
HYDRO TURBINES
The major processes involved in various Hydro Turbine Sections are asfollows: 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.
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 / subassemblies/
assemblies are tested up to a hydraulic pressure of 200 Kg / cm2 using the piston pump. Oil
testing upto 40 Kg / c m2 is carried out withoil pumping unit, which is permanently installed
on this bed.
STEAM TURBINEProcesses carried out in various sections of steam turbine manufacture arebased
on the following main phases.
Machine sectionCastings, Forgings, welded structures and other blanksare delivered to
this section. The manufacturing process is based on the useof high efficiency carbide tipped
tools, high speed and high feed machiningtechniques with maximum utilization of machine
tool capacity and quickacting jigs and fixtures.
Assembly Section Casings and governing assemblies are hydraulicallytested for leakage
on special test Bed. Assembled unit of governing andsteam distribution systems is tested on
Governing Test Bed. GeneralAssembly and testing of Steam Turbine is carried out on the
main Test Bedin Bay-II.
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OVERSPEED & BALANCING TUNNEL
Painting, Preservation and PackingAfter testing the turbine, it isdisassembled and
inspected. Then the parts are painted, conserved andpacked for final dispatch.
GAS TURBINEThe major processes involved in manufacturing Gas Turbine in various
sections of Block-III are as:-
MachiningCastings, 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 tooling. 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.
Main AssemblyFinal assembly is done on test bed. Parts are assembled to make subassemblies. 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.
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Rotor Assembly
The rotor is assembled on Hydraulic Lifting Platform and sent to mainassembly, 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.
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.
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8.BLADE SHOP
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 TurbineCompressor blades are machined from barstock, 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.
Manufacturing Facilities:
Plain Milling SectionIt 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.
Copy Milling SectionThe Semi blanks prepared from plain milling section are further machined by copy Milling
Machines / CNC machines (CNC Heller and BSKBed type Klopp, BFH / BEK Knee type
Machines) for concave and convex aerodynamic 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.
LP SectionThis area deals with all types of free standing and forged blades for steam Turbine
Compressor. The freestanding blades are cerro bend 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 theprofile of
envelope forged blades / stocks for Steam Turbine and GasTurbine Blades. It also has 3D
copy Milling and CNC Machines withdigitizing features for Tip-thinning, Fitted milling. The
inlet edge of the laststage of Low pressure Turbine Moving blades are hardened on a
SpecialPurpose Flame Hardening equipment.
Polishing SectionBlade Contours are ground and polished to achieve the desired surface finishand other
aerofoil requirements.There are also other small sections e.g. Fitting Section, Tool and CutterGrinding, Toolings Repair Section in Blade Shop.
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Inspection Device
3 D Coordinate Measuring Machines for taper and rhomboid checking.
Moment weighing Equipment.
Real time Frequency analyzer for checking frequency of free standingblades.
Contour plotter for plotting of blade profile with various magnifications.
Fir- tree root inspection device.
Magna spray crack detection equipment.
MANUFACTURING PROCESS
The manufacturing process of turbine blades primarily depends on the typeof blade e.g. Bar
type, Brazed type, Free standing (Forged type), GasTurbine Compressor blades. The bar type
and brazed type blades are alsoknown as drum stage glades. The manufacturing technology
of each of theseblades along with recommended machine tools / equipment is
furnishedbelow.
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9. 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 Borer
Model : DW 1800
Supplier : HEYLIGENSTAEDT, GERMANY
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CNC Control System : SINUMERIK7T
Boring Dia : 625 2500 mm
Table : 4000 x 4000 mm
Headstock Travel : 4000 mm
Spindle Speed : 0.5 90 RPM (in 4 Steps)
Power Rating : 63 KW
Max. Load Capacity: 100 T
Weight of the m/c : 72 T
Plan No. : 27-420 (Block-III)
CNC LATHE FOR ROTOR MACHINING
3. Item Description : CNC Horz. Borer (2 Nos.)
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Model : W200 HB NC
Supplier : SKODA, CZECH
CNC Control System : SINUMERIK 850 M
Spindle Dia. : 200 mm
Traverse : X=12500,
Y=5000,
Z=2000mm
CNC LATHES
4. Items Description : CNC Centre Lathe
Model : D-1800 NYF
Supplier : HOESCH MFD, GERMANY
CNC Control System : SINUMERIK 3T
Centre Distance : 8000 mm
Swing Over Carriage : 1800 mm
Swing Over Bed : 2400 mm
Spindle Speed : 0 125 RPM
Power Rating : 92 KW
Weight of the Job : 110 TON
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Weight of the m/c : 124 TON
Plan No. : 2-394 (Block-III)
5. Item Description : CNC Centre Lathe
Model : D-2300 NYFS-1
Supplier : HOESCH MFC, GERMANY
CNC Control System : SINUMERIK 7T
Centre Distance : 18000 mm
Swing Over Carriage : 2300 mm
Swing Over Bed : 2900 mm
Spindle Speed : 5 125 RPM
Power Rating : 110 KW
Weight of the job : 320 TON
Weight of the m/c : 216 TON
Plan 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
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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
Power Rating : 11 KW
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-3)
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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
Power Rating : 11 KW
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
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22 KW intermittent
Spindle Head Size : 620 x 500 incldg ram
543 x 420 encldg ram
ATC Capacity : 24 Nos.
Table Load : 2500 Kg
Plan No. : 2-484 (Block-III)
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
Centre
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
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Spindle Speed : 30600 RPM
No of Spindle : 4
Power Rating : 22 KW
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
OTHER SPECIAL PURPOSE CNC MACHINES
13. 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
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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 f : 1500 mm, 1000 mm
Indexing accuracy : +/- 3 Arc sec.
Plan No. : 2-485
14. 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
CNC BROACHING MACHINE
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
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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. : 2-49
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10.NON-CNC MACHINE TOOLS
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
BALANCING MACHINE
Manufacturer: SCHENK (West Germany)
Model: Dj 90
Specifications
1. Weight of rotor - 10,000 to 80,000kg
2. Minimum weight without considerable loss of measuring sensitivity,
provided the berings can accommodate such small rotors- 5000 kg
3. Maximum weight for one bearing pedestal l- 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
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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