BHEL BLOCK 3 ppt

INDUSTRIAL TRAINING REPORTON

Turbine Blade Shop – Block 3Situated at

Bharat Heavy Electricals Limited

Department Of Mechanical Engineering, Quantum School Of Technology, Roorkee

Uttarakhand - INDIA

Presented By:

ADITYA AGGARWAL(10430104031)

Company Overview A NAVARATNA PUBLIC SECTOR ENTERPRISE ESTABLISHED IN 1964 ENERGY-RELATED/INFRASTRUCTURE SECTOR POWER, TRANSMISSION, INDUSTRY, TRANSPORTATION,

RENEWABLE ENERGY, OIL & GAS AND DEFENCE. QUALITY MANAGEMENT SYSTEMS (ISO9001:2008) ENVIRONMENTAL MANAGEMENT SYSTEMS (ISO

14001:2004) OCCUPATIONAL HEALTH & SAFETY MANAGEMENT

SYSTEMS (OHSAS 18001:2007) HIGHLY SKILLED AND COMMITTED WORKFORCE OF

46,748 EMPLOYEES ALL OVER INDIA

Manufacturing PlantBHEL Haridwar has two manufacturing plants:-

Heavy Electrical Equipment Plant (HEEP)

Central Foundry Forge Plant (CFFP).

HEEP includes design and manufacture of large steam and gas turbines, turbo generators, hydro turbines and generators, hydro turbines and generators, large AC/DC motors and so on.

CFFP is engaged in manufacture of Steel Castings: Upto 50 Tons Per Piece Wt & Steel Forgings: Upto 55 Tons Per Piece Wt.

Major Products of BHEL, HaridwarSteam turbineGas turbineSteam GeneratorsHRSG- Heat recovery steam generator TransformersLocomotivesCircuit BreakersPumps Motors- BOTH AC AND DC, LT AND HT

Generators

Product Profile - HEEP

Product Profile - CFFP

Turbine Shop – Block 3

General DetailsSteam Turbines, Gas Turbines and Turbines BladesSpecial Tooling for all products in the Tool Room

located in the same blockConsists of four Bays, namely, Bay-I and II of size

36x378 meters and 36x400 meters respectively and Bay-III and IV of size 24x402 meters and 24x381 metres respectively

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 .

Details of Bay ISize- 36x378 meters.Consists of following machines:-Hydraulic lifting platformCNC turning latheCombustion chamber assembly platform

Details of BAY II Size:- 36x400 meters CNC creep feed grinding machine

(Gas turbine machining area)External broaching machineCNC facing latheWax melting equipment Gas turbine test bed

Details of Bay IIISize :-24x402 metersCNC stub borerCNC milling machine Universal milling machineCNC bed type milling machineCNC surface broaching machine

Details of Bay IVSize:- 24x381 metres Turbine blade machining shopHeat treatment zone

Gas Turbine

Also called a combustion turbine, is a rotary engine that extracts energy from a flow of combustion gas.

Energy is extracted in the form of shaft power, compressed air and thrust, in any combination, and used to power aircraft, trains, ships, generators, and even tanks

Manufacturing Facilities - Gas Turbine

Hydraulic Lifting Platform: used for assembly and disassembly of G.T. Rotor.

CNC Creep Feed Grinding M/c: grinds the hearth serration on rotor disc faces.

External Broaching Machine: used to make groove on the outer dia of rotor discs for the fitting of moving blades on the discs.

CNC Facing Lathe: used for facing rotor disc. CNC Turning Lathe: used to turn Tie Rods of Gas Turbine. Wax Melting Equipment: used to mix and melt Wax to arrest

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

Gas Turbine Test Bed: used to finally assemble the gas turbine. Combustion Chamber Assembly Platform: used for assembly

of Combustion Chambers of Gas Turbine.

Manufacturing Process – Gas Turbine MACHINING: one of the most important material removal methods,

in which power driven machine tools, such as lathes, milling machine and drill presses are used with sharp cutting tools to achieve the desired geometry.

MAIN ASSEMBLY: Final assembly is done on test bed. Parts are assembled to make sub-assemblies.

ROTOR ASSEMBLY: The rotor is assembled on Hydraulic Lifting Platform and sent to main assembly, where after checking clearances, it is sent for machining.

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.

PAINTING, PRESERVATION AND PACKING: After testing, turbine is disassembled and inspected then the parts are painted and packed for final dispatch.

Steam Turbine

About Steam Turbine A steam turbine is a mech. device that extracts

thermal energy from pressurized steam, and converts it into rotary motion.

It has almost completely replaced the reciprocating piston steam engine (invented by Thomas Newcomen and greatly improved by James Watt) primarily because of its greater thermal efficiency and higher power-to-weight ratio.

Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator – about 80% of all electricity generation in the world is by use of steam turbines.

Steam Flow Diagram

Manufacturing Process – Steam TurbineThe facilities and parts manufacturing of Steam Turbine are

as follows: TURBINE CASING MACHINING SECTION: equipped with

large size Planer, Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines .

ROTOR MACHINING SECTION : Equipped with large size machining tools like Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree Groove Milling Machine etc.

ROTOR ASSEMBLY SECTION : Equipped with Indicating Stand, Small size Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and Discs.

TURBINE CASING ASSEMBLY SECTION : Machined casings are assembled and hydraulically tested by Reciprocating Pumps at two times the operating pressure.

TEST STATION : Equipped with condensers, Ejector, Oil Pumps, Oil containers Steam Connections etc, required for testing.

OVER SPEED VACUUM BALANCING TUNNEL: Vibration and frequency of rotor shaft is tested at very high speed of 4500rpm.

Blade ShopTurbine Blade

Machining Shop is located in Bay-IV of Block-III.

A batch production shop comprising of various kinds of CNC Machines and Machining Centres.

Manufacturing Facilities – Blade Shop Blade shop is divided into four distinct areas:-PLAIN MILLING SECTION: it prepares accurate

reference surfaces on the blade blanks by milling and grinding operation.

COPY MILLING SECTION: the semi blanks prepared from plain milling section are further machined by copy milling machines for concave and convex aero-dynamic profile forms.

LP SECTION: this area deals with all types of free standing and forged blades for steam turbine compressor.

POLISHING SECTION: blade contours are ground and polished to achieve the desired surface finish and other aerofoil requirements.

Inspection of Blade3 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 magnification.Magna spray crack detection equipment.

Manufacturing Process - BladeThe manufacturing

process of turbine blades primarily depends on the type of blade e.g. Bar type, Brazed type, Gas Turbine blade

1. Bar Type Blade

PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED

Blanking of area material

Circular saw/band saw

Sizing to rectangular shape

Hor. Milling Machine

Thickness grinding Surface grinder

Rhomboid milling Duplex milling machine

Taper grinding Surface grinder

Grinding and polishing of profile

Abrasive belt polishing m/c

2. Brazed Type Blade

PROCESS / OPERATION

MACHINE TOOL/EQUIPMENT USED

Cutting of drawn profile & spacer blank

Hor. Milling machine

Thickness grinding Surface grinder

Cutting-off spacer Abrasive cutting

Milling of width Duplex milling machine

Grinding and polishing Abrasive belt polishing m/c

3. Gas Turbine Blade

PROCESS / OPERATION

MACHINE TOOL/EQUIPMENT USED

Cerrobend casting Cerrobend casting equip.

Root machining Hor. Machining center

Length cutting Circular saw/hor. Milling m/c

Tenon Hor. Milling m/c

Grinding and polishing of fillet

Abrasive belt polishing m/c

SPECIFICATIONS OF MACHINES AVAILABLE IN

BLOCK-III

Vertical Boring Machine Max diameter of work piece

accommodated :10000mm Max height of work piece :5000mm Diameter of table :8750mm Max travel of vertical tool head RAM slides

:3200mm Max travel of vertical tool heads

from centre of table :5250mm Max weight of work piece

:200 T For N<=6rpm;100T for any speed

Diameter of boring spindle of combined head:160mm

Centre Lathe

Max diameter over bed :3200mmMax diameter over saddle :250mmLength between centers :16mMax weight of work piece :100 TSpindle bore :96mm

CNC Lathe

Manufacturer : Safop, Italy Swing over carriage

:3500mm Centre distance :9000mm Weight capacity :120 T Spindle power :196KW External chucking range :250-

2000mm Hydrostat steady range :200-1250mm Max spindle rpm :200 CNC system :SINUMERIK 840D

CNC Vertical Borer

Manufacturer :Pietro Carnaghi, Italy Machine model :AP 80TM-6500 Table diameter :6500mm Max turning diameter

:8000mm Min boring diameter :660mm Max height for turning and milling :7000mm Table Speed :0.2-50 rpm Table load capacity :200 T Milling spindle speed :3000

rpm at40KW Spindle taper :BT 50 CNC system :SINUMERIK 840D

CNC Skoda Horizontal Borer Spindle diameter :200mmTaper spindle :BT 50RAM

Size :450x450mmRAM length :1600mmSpindle length :2000mmHeadstock :5000mmTable :4000x3500mmCNC system :SIMENS850mmJob : I.P. Outer

Thank You

+ QUERIES