Project on bharat heavy electricals limited 4th sem

1. BABU BANARASI DAS INSTITUTE <br />OF TECHNOLOGY<br />A Report<br />on<br />BHARAT HEAVY ELECTRICALS LIMITED<br />HARIDWAR<br />Submitted to : Submitted by :<br />Mr. Yogesh Gupta Pankaj Singh Negi<br />Mr. B.P. BandhopadhyayaMechanical (4th Year)<br /> Roll No.: 0603540162<br />PREFACE<br />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.<br />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.<br />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<br />The project taken up was to study the Central foundry forge plant. <br />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. <br />HEEP <br />&<br />CFFP<br />bhel, haridwar<br />Acknowledgement <br />The preparation of this project would not have been possible without the guidance and blessings of several people. <br />I owe my thanks to Mr.S.K.Bajajfor this encouragement, expert guidance in bringing out this project. <br />PankajNegi<br />Contents<br />1.Prologe–A. BHEL–An Overview<br />B.HEEP–An Overview<br />2.Study on Turbines & Auxiliary Block<br />3.Study on Material Specification<br />4.Study On Blade Shop<br />5.Broad Specification of Major Machines Tools & Machines<br />(CNC & Non CNC)<br />6.Other Areas<br />A. bhel – an overview<br />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.<br /> 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.<br />POWER GENERATION<br />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.<br />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.<br />The company manufactures 235 MW nuclear turbine generator sets and has commenced production of 500 MW nuclear turbine generator sets.<br />Custom made hydro sets of Francis,Pelton and Kapian types for different head discharge combination are also engineering and manufactured by BHEL.<br />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.<br />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.<br />Industries<br />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.<br />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.<br />The Company has commenced manufacture of large desalination plants to help augment the supply of drinking water to people.<br />Transportation<br />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.<br />Telecommunication<br />BHEL also caters to Telecommunication sector by way of small, medium and large switching systems.<br />Renewable Energy<br />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.<br />Human Resource Development Institute<br />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.<br />ACTIVITY PROFILE<br />PRODUCTS- Industrial FansPower 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 EquipmentIndustries/Transportation/Oil & Gas/ - Reverse Osmoses Desalination PlantsTelecommunication/Renewable EnergySYSTEMS & 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<br />B. HEEP : AN OVER VIEW<br />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 quot;
Fortune International-500quot;
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.<br />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.<br />VISION<br />World-class, innovative, competitive and profitable engineering enterprise providing total business solutions.<br />MISSION<br />The leading Indian engineering enterprise providing quality products systems and services in the fields of energy, transportation, infrastructure and other potential areas.<br />VALUES<br />Meeting commitments made to external and internal customers.<br />Foster learning creativity and speed of response.<br />Respect for dignity and potential of individuals.<br />Loyality and pride in the company.<br />Team playing.<br />Zeal to excel.<br />Integrity and fairness in all matters.<br />HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)<br />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:-<br />1.ESTABLISHMENT AND DEVELOPMENT STAGES:<br />*Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the area of Scientific, Technical and Industrial Cooperation.<br />*DPR – prepared in 1963-64, construction started from October '63.<br />*Initial production of Electric started from January, 1967.<br />*Major construction / erection / commissioning completed by 1971-72 as per original DPR scope.<br />*Stamping Unit added later during 1968 to 1972.<br />*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.<br />*Motor manufacturing technology updated with Siemens collaboration during 1984-87.<br />*Facilities being modernized continually through Replacements / Reconditioning-Retrofitting, Technological / operational balancing.<br />2.INVESTMENTS:<br />*Gross Block as on 31.3.95 is Rs. 355.63 Crores (Plant and Machinery – Rs. 285.32 Crores).<br />*Net Block as on 31.3.95 is Rs. 113.81 Crores (Plant & Machinery – Rs. 76.21 Crores).<br />3.TOWNSHIP AND PERIPHERAL INFRASTRUCTURES:<br />*A large modern township for employees and allied personnel with social and welfare amenities.<br />*Medical:-MainHospital (200 beds)1<br />-Dispensaries in various9<br />townships sectors<br />-Occupational health center1<br />*Educational:No. of Schools (including19<br />Intermediate levels)<br />ScienceDegreeCollege1<br />*Residential: Around 6780 quarters.<br />*Other amenities:<br />Good Road network<br />Shopping Centres<br />Central Stadium<br />Community Centres<br />A Club<br />Police Stations<br />CISF – Complex for over 500 CISF personnel.<br />Convention Hall (a Most modern Air Conditioned Auditorium with 1500 seating capacity).<br />Parks.<br />4.HEEP PRODUCT PROFILE:<br />*THERMAL AND NUCLEAR SETS<br />(Turbines, Generators, Condensers and Auxiliaries of unit capacity upto 1000 MW)<br />*HYDRO SETS INCLUDING SPHERICAL AND DISC VALVES<br />(Kaplan, Francis, Pelton and reversible Turbines of all sizes and matching generators and auxiliaries maximum runner dia – 6600 mm)<br />*ELECTRICAL MACHINES:<br />(For various industrial applications, pump drives & power station auxiliaries, Unit capacity upto 20000 KW AC / DC)<br />*CONTROL PANELS<br />(For Thermal / Hydro sets and Industrial Drives)<br />*LARGE SIZE GAS TURBINES<br />(Unit Rating : 60-200 MW)<br />*LIGHT AIRCRAFT<br />*DEFENSE PRODUCTS<br />5. HEEP: FACILITIES AND INFRASTRUCTURE<br />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.<br />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.<br />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.<br />TURBINE AND AUXILIARY BLOCK-III<br />1.0GENERAL<br />1.1Block-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.<br />1.2The 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.<br />All the parts are conserved, painted and packed before dispatch.<br />MANUFACTURING FACILITIES<br />2.1HYDRO TURBINES<br />For manufacturing of Hydro Turbines, Bay-I has the following sections:<br />(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.<br />(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.<br />(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.<br />(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.<br />(e)Preservation and Packing Section – Final preservation and packing of all the Hydro Turbine components / assemblies is done here.<br />(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.<br />(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.<br />2.2STEAM TURBINES<br />The facilities and parts manufactured in the various sections of Steam Turbine manufacture are as follows:<br />(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.<br />(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.<br />(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.<br />(d)Turbine casing Assembly Section – Machined casings are assembled and hydraulically tested by Reciprocating Pumps at two times the operating pressure.<br />(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.<br />(f)Painting Preservation and Packing Section – All the parts are painted, preserved and packed here for final dispatch.<br />(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.<br />(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.<br />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.<br />(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.<br />(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.<br />(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.<br />2.3GAS TURBINE<br />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.<br />a)Hydraulic Lifting Platform<br />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.<br />b)CNC Creep Feed Grinding M/c.<br />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.<br />c)External Broaching Machine<br />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.<br />d)CNC Facing Lathe<br />This machine is installed in GT machining area and is used basically for facing rotor disc but can turn other components also.<br />e)CNC Turning Lathe<br />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.<br />f)Wax Melting Equipment<br />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.<br />g)Gas Turbine Test Bed<br />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.<br />h)Combustion Chamber Assembly Platform<br />This facility is a 3 Tier Platform installed in Bay-I assembly area and is used for assembly of Combustion Chambers of Gas Turbine.<br />MANUFACTURING PROCESS<br />3.1HYDRO TURBINES<br />The major processes involved in various Hydro Turbine Sections are as follows:<br />Marking and checking of blanks – manual as well as with special marking M/c.<br />Machining on Horizontal Boring, Vertical Boring, Lathes etc. as the case may be on CNC /Conventional Machines.<br />Intermediate assembly operation is carried out on the respective assembly beds provided.<br />Then the assembly is machined as per requirement.<br />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.<br />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.<br />STEAM TURBINE<br />Processes carried out in various sections of steam turbine manufacture are based on the following main phases.<br />(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.<br />(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.<br />(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.<br />3.3GAS TURBINE<br />The major processes involved in manufacturing Gas Turbine in various sections of Bk-III are as follows:<br />a)Machining<br />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.<br />b)Main Assembly<br />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.<br />c)Rotor Assembly<br />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.<br />d)Combustion Chamber Assembly<br />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.<br />B.<br />BLADE SHOP<br />1.Introduction:<br />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.<br />2.Manufacturing Facilities: <br />i)Plain Milling Section<br />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.<br />ii)Copy Milling Section<br />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.<br />iii)LP Section<br />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.<br />iv)Polishing Section<br />Blade Contours are ground and polished to achieve the desired surface finish and other aerofoil requirements.<br />There are also other small sections e.g. Fitting Section, Tool and Cutter Grinding, Toolings Repair Section in Blade Shop.<br />v)Inspection Device<br />-3 D Coordinate Measuring Machines for taper and rhomboid checking.<br />Moment weighing Equipment<br />-Real time Frequency analyzer for checking frequency of free standing blades.<br />-Contour plotter for plotting of blade profile with various magnifications.<br />-Fir tree root inspection device.<br />-Magna spray crack detection equipment.<br />vi)Miscellaneous<br />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.<br />3.0MANUFACTURING PROCESS<br />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.<br />3.1BAR TYPE BLADES<br />PROCESS / OPERATIONMACHINE TOOL/EQUIPMENT USEDi.Blanking of area materialCircular saw/band sawii.Sizing to rectangular shapeHor. Milling Machineiii.Thickness grindingSurface grinderiv.Rhomboid millingDuplex milling machinev.Rhomboid grindingDuplex grinding machinevi.Milling perpendicularity on both endsHor. Milling machinevii.Milling radius on surroundHor. Copy milling m/cviii.Finish milling of convex and concave profileHor. Copy milling / CNCHor. Milling machineix.Milling expansion faces of convexAnd concave sides at root and shroudHor. Copy milling m/c/CNC milling m/cx.Root slot/root chamfer andRadit at root and shroundMilling2 spindle T-root roughing, m/c androot radius copy milling m/c, T-rootmachining centerxi.Taper grindingSurface grinderxii.Grinding and polishing of profileAnd expansion facesAbrasive belt polishing m/cxiii.Final Rounding, chamfering etc.Manual fitting.<br />3.2BRAZED TYPE BLADES<br />PROCESS / OPERATIONMACHINE TOOL/EQUIPMENT USEDi.Cutting of drawn profile & spacer blankHor. Milling machineii.Sizing to rectangular shapeHor. Milling machineiii.Thickness grindingSurface grinderiv.Rough and finish milling of internal profile of spacerHor. Milling machinev.Cutting-off spacerAbrasive cuttingvi.Brazing of drawn profile and spacerRight frequency inducting brazing installationvii.Milling of widthDuplex milling machineviii.Pin rough and Root slotVert. Milling m/cix.External profile rough and finish machiningHor. Milling machinex.Pin turningPin turning lathexi.Grinding and polishingAbrasive belt polishing m/cxii.Debarring and roundingManual fitting<br />3.3GAS TURBINE BLADES<br />PROCESS / OPERATIONMACHINE TOOL/EQUIPMENT USEDi.Cerrobend castingCerrobend casting equip.ii.Root machiningHor. Machining centeriii.Remelting of cerrobend alloyCerrobend casting equip.iv.Profile checking Vert. Standv.Length cuttingCircular saw/hor. Milling m/cvi.TenonHor. Milling m/cvii.Grinding and polishing of filletAbrasive belt polishing m/c<br />A.<br />HYDRO TURBINE LABORATORY<br />1.INTRODUCTION<br />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.<br />2.DESIGN:<br />3.MANUFACTURING:<br />4.TESTING:<br />5.TESTING CAPABILITIES:<br />Runaway speed tests of reaction and impulse turbine.<br />Determination of MW output of prototype turbine under specified operating conditions.<br />6.INSTRUMENTATION LABORATORY<br />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:<br />-Ultrasonic Flowmeter for field tests.<br />-Magnetic Tape Recorder with Waveform Analyzer.<br />-Microprocessor based Pressure Pulsation Measuring System.<br />-Microprocessor based Wicket Gate Torque Measuring System.<br />-Microprocessor based Hydraulic Thrust Measuring system.<br />7.CALIBRATION<br />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.<br />D.<br />CENTRAL PLANT STORES<br />General<br />Materials from suppliers, sub-contractors, other unitsand ancillaries enters the factory premises from eastern gate.<br />Material Receipt<br />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.<br />Material Issue<br />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.<br />Stores Custodies<br />The locations, where various types of material are stored by Central Plant Stores, have been classified as custody-I, II, III, IV & V.<br />Custodies & Materials Stores<br />Custodies and the main categories of materials stored are as below:<br />BROAD SPECIFICATION OF<br />MAJOR/IMPORTANT MACHINE TOOLS & MACHINES<br />A : CNC MACHINE TOOLS<br />CNC HORIZONTAL BORERS:<br />1.Item Description:CNC Horz. Borer<br />Model:RAPID 6C<br />Supplier:WOTN, GERMANY<br />CNC Control System:FANUC 12M<br />Spindle Dia.:200mm<br />Table:4000 x 4000 mm<br />Max. Load on Table:100 T<br />Travers:X=20000, Y=5000, X=1400mm<br />Ram traverse:W = 1000 mm<br />Ram size:400 x 400 mm<br />Power Rating:90 KW<br />Weight of the m/c:111 T<br />ATC Capacity:60 Nos.<br />Plan No.:1-227 (Block-I)<br />2.Item Description:CNC Stub Borer<br />Model:DW 1800<br />Supplier:HEYLIGENSTAEDT, GERMANY<br />CNC Control System:SINUMERIK – 7T<br />Boring Dai:625 – 2500 mm<br />Table:4000 x 4000 mm<br />Headstock Travel:4000 mm<br />Spindle Speed:0.5 –90 RPM (in 4 Steps)<br />Power Rating:63 KW<br />Max. Load Capacity:100 T<br />Weight of the m/c:72 T<br />Plan No.:27-420 (Block-III)<br />3.Item Description:CNC Horz. Borer (2 Nos.)<br />Model:W200 HB –NC<br />Supplier:SKODA, CZECH<br />CNC Control System:SINUMERIK 850 M<br />Spindle Dia.:200 mm<br />Traverse:X=12500,<br />Y=5000,<br />Z=2000mm<br />CNC LATHES<br />4.Items Description:CNC Centre Lathe<br />Model:D-1800 NYF<br />Supplier:HOESCH MFD, GERMANY<br />CNC Control System:SINUMERIK 3T<br />Centre Distance:8000 mm<br />Swing Over Carriage:1800 mm<br />Swing Over Bed:2400 mm<br />Spindle Speed:0 – 125 RPM<br />Power Rating:92 KW<br />Weight of the Job:110 TON<br />Weight of the m/c:124 TON<br />Plan No.:2-394 (Block-III)<br />5.Item Description:CNC Centre Lathe<br />Mode:D-2300 NYFS-1<br />Supplier:HOESCH MFC, GERMANY<br />CNC Control System:SINUMERIK 7T<br />Centre Distance:18000 mm<br />Swing Over Carriage:2300 mm<br />Swing Over Bed:2900 mm<br />Spindle Speed:5 – 125 RPM<br />Power Rating:110 KW<br />Weight of the job:320 TON<br />Weight of the m/c:216 TON<br />Plan No.:2-360 (Block-III)<br />6.Item Description:CNC Centre Lathe<br />Model:KV2-1100 CNC<br />Supplier:RANVENSBURG, GERMANY<br />CNC Control System:SINUMERIK 820 T<br />Centre Distance:12000 mm<br />Centre Height :900 mm<br />Swing Over Carriage:1100 mm<br />Swing Over Bed:1400 mm<br />Max. Turning Length:12000 mm<br />Spindle Speed:2-600 RPM<br />Longitudinal Cutting Feed (Z-Axis):1-5000 mm / min.<br />Transfer Cutting Feed (X-Axis):1-5000 mm/min.<br />Main Spindle Drive Motor:95.5 KW DC<br />Max. Feed Force – Z/X Axis:45000 N<br />No. of Tool carriers:3<br />Plan No.:1-120 (Block-III)<br />UNIVERSAL VERTICAL TURNING & BORING MACHINE<br />Manufacturer :Kolomna Machine Tool Works (USSR)<br />Model – KY 152<br />Specifications<br />1.Maximum Dia. of workpiece accommodated10000/12500 mm<br />2.Dia. of central table8750 mm<br />3.Maximum travel of vertical Tool Heads from center of table5250 mm<br />4.Maximum weight of workpiece accommodated on central table<br />(a) With table speed limited to n (n 6) r.pm.200 T<br />(b) At any speed100 T<br />5.Maximum cutting force with different length of tool over-hang (L) from head face R.H. Head<br />16000 Kg with L 1500 mm<br />7500 Kg with L 2000 mm<br />2000 Kg with L 3000 mm<br />1200 Kg with L 3700 mm<br />L.H. Head<br />12500 Kg with L 1500 mm<br />7500 Kg with L 2000 mm<br />2000 Kg with L 3000 mm<br />1200 Kg with L 3700 mm<br />6.Rated cutting dia on central table6300 mm<br />7.Maximum cutting torque on central table80000 Kg.M<br />8.Speed range of central table rotationMinimum = 0.112 r p.m.<br />Maximum – 11.2 r.p.m.<br />9.Travel rate of column assembly190 mm /minute<br />10.Plan No.1-13 (Block-I)<br />1-24 (Block-III)<br />SPECIAL DRILLING & BORING MACHINE<br />Manufacturer: Machine Tool Works, Ryazan (USSR)<br />Model: PT 182 H5<br />SPECIFICATIONS:<br />1.Swing over bed800 mm2.Drilling dia40-80 mm3.Boring dia80-250 mm4.Swing of job in restMaxMin300 mm110 mm5.Swing of job inHeadstock chuckMax.Min.300110 mm6.Maximum length of job3000 mm7.Maximum weight of job2000 Kg8.Number of spindlesHeadstockStemstock119.Spindle locationHorizontal10.Distance to spindle axis:From bed wasyFrom floor400 mm1100 mm11.Head stock Spindle speedMaxMin.750 r.p.m.71. r.p.m.Number of steps of spindle speed Spindle braking 24Available12.Stemstock Spindle speedsMax.Min.730 r.p.m.123 r.p.m.Number of steps of spindle speedStemstock feedMax.Min.61680 mm / min168 mm / minNumber of feed stepsStepless13.Overall dimensionsLength13500 mmWidth2300 mmHeight 1700 mmWeight23844 Kg.14.Plan No1-105 (Block-III)<br />SPECIAL INTERNAL GRINDING MACHINE<br />Manufacturer: Saratov Machine Binding Works (USSR)<br />Model : MB 6020 T<br />SPECIFICATIONS<br />1.Diameter of ground holes(a) Maximum(b) Minimum320 mm90 mm2.Maximum length of grinding (with maximum hole diameter)560 mm3.Maximum weight of work600 Kg4.Distance from spindle axis to floor level1100 mm5.Distance from spindle axis to table(a) Maximum(b) Minimum300 mm100 mm6.Cantilever vertical travel(a) Per one revolution of handwheel0.133 mm(b) Speed of rapid vertical traverse (from motor)190 mm / min.(c) Per dial graduation0.01 mm7.Table working surface dimensions500 x 1200 mm8.Table cross-traverse(a) To operator from intermediate (zero) position200 mm(b) From operator from intermediate (zero) position 200 mm<br />A.<br />Classification of Blades<br />L.P. Moving Blade Forged Ist Stage.<br />L.P. Moving Blade 500 MW Last Stage.<br />100 MW 25th Stage Impulse Blade.<br />Compressor blade Sermental coated.<br />Compressor Blade 'O' stage.<br />Gas Turbine Compressor Blade.<br />T-2 Blade.<br />T-4 Blade.<br />3DS Blade.<br />Brazed Blade<br />Russian Design Blades.<br />Z – Shroud Blade.<br />Twisted Blade.<br />Present Range of Blades.<br />BOARD OF DIRECTORS<br />K.G. RamachandranChairman & Managing Director<br />Bharat Heavy Electricals Limited<br />BHEL House, Siri Fort, New Delhi – 110 049<br />A.V. SinghAdditional Secretary & Financial Advisor<br />Ministry of Industry.Deptt.of Heavy Industry<br />UdyogBhawan, New Delhi – 110 011<br />Pradeep KumarJoint Secretary<br />Ministry of Industry.Deptt of Heavy Industry<br />UdyogBhawan, New Delhi – 110 011<br />Dr. Jamshed J. IraniManaging Director<br />Tata Iron & Steel Company Limited<br />Jamshedpur – 831 001<br />ShekharDattaEx-Managing Director & President<br />Greaves Limited, E/8, SeaFacePark<br />Bhulabhai Desai Road, Mumbai – 400 001<br />Ms. TarjaniVakilEx-CMD, EXIM Bank of India<br />A-1, IshwarDasMansion, Nana Chowk<br />Mumbai – 400 007<br />J. JayaramanEx-CMD, Cochin Refineries Limited<br />39/4, AshwinApartment<br />C.P. Ramaswamy Road, Chennai – 600 018<br />K.C. LahiryDirector (Power)<br />Bharat Heavy Electricals Limited<br />BHEL House, Siri Fort, New Delhi – 110 049<br />K.S. RaoDirector (IS&P)<br />Bharat Heavy Electricals Limited<br />Integrated Office Complex<br />Lodhi Road, New Delhi – 110 003<br />Ishan ShankarDirector (Personnel)<br />Bharat Heavy Electricals Limited<br />BHEL House, Siri Fort, New Delhi – 110 049<br />M.K. MittalDirector (ER&D)<br /> Bharat Heavy Electricals Limited<br />BHEL House, Siri Fort, New Delhi – 110 049<br />