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Project on bharat heavy electricals limited 4th sem
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BABU BANARASI DAS INSTITUTE
OF TECHNOLOGY
A REPORT
ON
BHARAT HEAVY
ELECTRICALS LIMITED
HARIDWAR
Submitted to : Submitted by :
Mr. Yogesh Gupta Pankaj Singh Negi
Mr. B.P. BandhopadhyayaMechanical (4th
Year)
Roll No.: 0603540162
PREFACE
In the present competitive world market when customer satisfaction is the
prime objective. Quality, price and services are the major areas to conquer.
Initiative, foresight, talent and competency are imperative to manage the
business.
The B.Tech.course imparts the students the tinge of such virtues and
prepares to take the technical world in their stride. In the midst of the course.
Summer training in some technical organization is arranged for the students:
that is vitally essential. Such training gives practical experience and helps the
students to view the real technology closely, which in turn widely influences
their conceptions and perceptions.
The summer training assumed all the more significance when it is done
ina reputed, last growing and professionally managed world level organization
like BHARAT HAVEY ELECTRICALS LIMITED. I was really fortunate in
getting an opportunity to work with them
The project taken up was to study the Central foundry forge plant.
I feel proud of getting a chance to study the technical system of a world
level company and have learnt a lot about the complicity and legal aspects of
the system.
HEEP
&
CFFP
BHEL, HARIDWAR
ACKNOWLEDGEMENT
The preparation of this project would not have been possible
without the guidance and blessings of several people.
I owe my thanks to Mr.S.K.Bajajfor this encouragement,
expert guidance in bringing out this project.
PankajNegi
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
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.
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.
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.
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.
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
Transformers
- Battery-Operated Passengers
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
B. HEEP : AN OVER VIEW
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 cuts across 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.
The Company is embarking upon an ambitions growth path through clear vision,
mission and committed values to sustain and augment its image as a world class
enterprise.
VISION
World-class, innovative, competitive and profitable engineering enterprise
providing total business solutions.
MISSION
The leading Indian engineering enterprise providing quality products systems and
services in the fields of energy, transportation, infrastructure and other potential
areas.
VALUES
Meeting commitments made to external and internal customers.
Foster learning creativity and speed of response.
Respect for dignity and potential of individuals.
Loyality and pride in the company.
Team playing.
Zeal to excel.
Integrity and fairness in all matters.
HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)
At Hardwar, against the picturesque background of Shivalik Hills, 2 important
manufacturing units of BHEL are located viz. Heavy Electrical Equipment Plant
(HEEP) & Central Foundry Forge Plant (CFFP). The hum of the construction
machinery woke up Shivalik Hills during early 60s and sowed the seeds of one of
the greatest symbol of Indo Soviet Collaboration – Heavy Electrical Equipment
Plant of BHEL. Following is the brief profile of Heavy Electrical Equipment
Plant:-
1. ESTABLISHMENT AND DEVELOPMENT STAGES:
* Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in
the area of Scientific, Technical and Industrial Cooperation.
* DPR – prepared in 1963-64, construction started from October '63.
* Initial production of Electric started from January, 1967.
* Major construction / erection / commissioning completed by 1971-72 as per
original DPR scope.
* Stamping Unit added later during 1968 to 1972.
* Annual Manufacturing capacity for Thermal sets was expanded from 1500
MW to 3500 MW under LSTG. Project during 1979-85 (Sets upto 500 MW,
extensible to 1000/1300 MW unit sizes with marginal addition in facilities
with the collaboration of M/s KWU-Siemens, Germany.
* Motor manufacturing technology updated with Siemens collaboration during
1984-87.
* Facilities being modernized continually through Replacements /
Reconditioning-Retrofitting, Technological / operational balancing.
2. INVESTMENTS:
* Gross Block as on 31.3.95 is Rs. 355.63 Crores (Plant and Machinery – Rs.
285.32 Crores).
* Net Block as on 31.3.95 is Rs. 113.81 Crores (Plant & Machinery – Rs.
76.21 Crores).
3. TOWNSHIP AND PERIPHERAL INFRASTRUCTURES:
* A large modern township for employees and allied personnel with social and
welfare amenities.
* Medical: - MainHospital (200 beds) 1
- Dispensaries in various 9
townships sectors
- Occupational health center 1
* Educational: No. of Schools (including 19
Intermediate levels)
ScienceDegreeCollege 1
* Residential: Around 6780 quarters.
* Other amenities:
- Good Road network
- Shopping Centres
- Central Stadium
- Community Centres
- A Club
- Police Stations
- CISF – Complex for over 500 CISF personnel.
- Convention Hall (a Most modern Air Conditioned Auditorium with 1500
seating capacity).
- Parks.
4. HEEP PRODUCT PROFILE:
* THERMAL AND NUCLEAR SETS
(Turbines, Generators, Condensers and Auxiliaries of unit capacity upto
1000 MW)
* HYDRO SETS INCLUDING SPHERICAL AND DISC VALVES
(Kaplan, Francis, Pelton and reversible Turbines of all sizes and matching
generators and auxiliaries maximum runner dia – 6600 mm)
* ELECTRICAL MACHINES:
(For various industrial applications, pump drives & power station
auxiliaries, Unit capacity upto 20000 KW AC / DC)
* CONTROL PANELS
(For Thermal / Hydro sets and Industrial Drives)
* LARGE SIZE GAS TURBINES
(Unit Rating : 60-200 MW)
* LIGHT AIRCRAFT
* DEFENSE PRODUCTS
5. HEEP: FACILITIES AND INFRASTRUCTURE
Modernisation and regular upgradation / up gradation of facilities and other
infrastructure is a continuous endeavour 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 Modernisation, 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 schemes.
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 upto 1300 MW (32T, 6.9 M –
dia bladed rotor, 6 rpm upto 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 be utilized for
a variety of products' manufacture.
TURBINE AND AUXILIARY BLOCK-III
1.0 GENERAL
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 work 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 hold 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 are 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 MachiningCenters, 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 free standing 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 finishedbatch 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
Hor. Milling machine
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
PROCESS / OPERATION MACHINE TOOL/EQUIPMENT
USED
i. Cutting of drawn profile & spacer
blank
Hor. Milling machine
ii. Sizing to rectangular shape Hor. Milling machine
iii. Thickness grinding Surface grinder
iv. Rough and finish milling of internal
profile of spacer
Hor. Milling machine
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
Hor. Milling machine
x. Pin turning Pin turning lathe
xi. Grinding and polishing Abrasive belt polishing m/c
xii. Debarring and rounding Manual fitting
3.3 GAS TURBINE BLADES
PROCESS / OPERATION MACHINE TOOL/EQUIPMENT
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.
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. 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. 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.
D.
CENTRAL PLANT STORES
General
Materials from suppliers, sub-contractors, other unitsand ancillaries enters the
factory premises from eastern gate.
Material Receipt
The materials are unloaded at receipt area, identified in the Central Plant Stores
and subsequently shifted to respective custody areas after inspection. In case of
heavy materials, receipt areas are adjacent to custody areas.
Material Issue
All the materials are received by Central Plant Stores and issued to users /
manufacturing blocks. Manufacturing blocks have their own sub-stores to receive
material from Central Plant Stores and further issue it to the shop / sections
concerned.
Stores Custodies
The locations, where various types of material are stored by Central Plant Stores,
have been classified as custody-I, II, III, IV & V.
Custodies & Materials Stores
Custodies and the main categories of materials stored are as below:
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
CNC Control System : SINUMERIK – 7T
Boring Dai : 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)
3. Item Description : CNC Horz. Borer (2 Nos.)
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
Weight of the m/c : 124 TON
Plan No. : 2-394 (Block-III)
5. Item Description : CNC Centre Lathe
Mode : 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
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)
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
2000 Kg with L 3000 mm
1200 Kg with L 3700 mm
L.H. Head
12500 Kg with L 1500 mm
7500 Kg with L 2000 mm
2000 Kg with L 3000 mm
1200 Kg with L 3700 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)
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
(b) Minimum
300 mm
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
A.
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.
BOARD OF DIRECTORS
K.G. Ramachandran Chairman & Managing Director
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi – 110 049
A.V. Singh Additional Secretary & Financial Advisor
Ministry of Industry.Deptt.of Heavy Industry
UdyogBhawan, New Delhi – 110 011
Pradeep Kumar Joint Secretary
Ministry of Industry.Deptt of Heavy Industry
UdyogBhawan, New Delhi – 110 011
Dr. Jamshed J. Irani Managing Director
Tata Iron & Steel Company Limited
Jamshedpur – 831 001
ShekharDatta Ex-Managing Director & President
Greaves Limited, E/8, SeaFacePark
Bhulabhai Desai Road, Mumbai – 400 001
Ms. TarjaniVakil Ex-CMD, EXIM Bank of India
A-1, IshwarDasMansion, Nana Chowk
Mumbai – 400 007
J. Jayaraman Ex-CMD, Cochin Refineries Limited
39/4, AshwinApartment
C.P. Ramaswamy Road, Chennai – 600 018
K.C. Lahiry Director (Power)
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi – 110 049
K.S. Rao Director (IS&P)
Bharat Heavy Electricals Limited
Integrated Office Complex
Lodhi Road, New Delhi – 110 003
Ishan Shankar Director (Personnel)
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi – 110 049
M.K. Mittal Director (ER&D)
Bharat Heavy Electricals Limited
BHEL House, Siri Fort, New Delhi – 110 049