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DEPARTMENT OF MECHANICAL ENGINEERING
VOCATIONAL TRAINING REPORT ON ( WTM, TRACTION MOTOR ASSEMBLY,
HYDRO LAB, CNC MACHINES)
BHARAT HEAVY ELECTRICAL LIMITED BHOPAL UNIT
TENURE OF TRAINING – 12 JULY to 1 AUGUST
SUBMITTED BY : ROHIT SEN
BE (ME) 7th SEMESTER
0208ME151045
MAHARATNA COMPANY
BHARAT HEAVY ELECTRICAL LIMITED
 TYPE - State – owned enterprise
 Traded as - BSE:500103
 NSE:BHEL
 INDUSTRY – Electrical equipments
 Founded - 1964
 Founder - Government of india
 Headquarters – NEW DELHI
 Area served - World wide
 Key people - Atul sobti ( chairman&
MD)
 Revenue - ₹29,474.9crore
(2017)
 Operating income - ₹627.83crore
 Net income - ₹495.86 crore.
 Number of employees 39,821 (2017)
22km square of exploring bhel town
WATER TURBINE MANUFACTURING
BLOCK NO. 1
• MANUFACTURING OF FRANCIS TURBINE
• UNDER BALIMELLA PROJECT
• Water Turbine Manufacturing Block NO.1 are The Biggest Block In
BHEL Complex
• Hydro turbine and associated components are machined and
manufactured here
• The Francis turbine is a type of water turbine that
was developed by James B. Francis in Lowell,
Massachus It is an inward-flow reaction turbine
that combines radial and axial flow concepts.
• Francis turbines are the most common water
turbine in use today. They operate in a water head
from 40 to 600 m (130 to 2,000 ft) and are
primarily used for electrical power production. The
electric generators that most often use this type of
turbine have a power output that generally ranges
from just a few kilowatts up to 800 MW, Penstock
(input pipes) diameters are between 3 and 33 ft
(0.91 and 10 m). The speed range of the turbine is
from 75 to 1000 rpm.
MAJOR COMPONENTS OF FRANCIS
TURBINE
The Scroll casing.
 Runner, and Runner Cone
Shaft.
Draft tube cone., Hydrogenerator shaft.
Stay vanes.
Guide vanes.
Sealing box., pivot ring
Regulating ring ,Servomotor.
Upper case and Lower case
Link and Liver
Guide bearing .
THE SCROLL CASING
RUNNER & RUNNER CONE
HYDRO GENERATOR SHAFT DRAFT TUBE CONE
GUIDE VANES STAY VANES
REGULATING RING SEALING BOX
SERVOMOTOR
GUIDE BEARING
PARAMETERS GOVERNING
SELECTION OF FRANCIS TURBINE
SPECIFIC SPEED
AVAILABLE HEAD
ROTATIONAL SPEED
CAVITATION
EFFICIENCY
WATER QUALITY
1. SPECIFIC SPEED
The specific speed of turbine is the speed of a geometrically similar turbine which would
produce unit power ( one kilowatt) under unit head ( one meter) . The specific speed of a
turbine is given by manufacturer ( along with rating ) and will always refer to the point of
maximum efficiency..
Sr.no. Types of turbine Specific speed
1. Pelton wheel with single jet 80-30
2. Pelton wheel with multiple jet 30-50
3 Francis turbine 50-250
4 Kaplan turbine 250-850
AVAILABLE HEAD
CAVITATION
Cavitation is formation of the
liquid bubbles in the liquid
flowing through any hydraulic
turbine. Cavitation occurs when
the static pressure of the liquid
falls below its vapour pressure .
Cavitation is most likely to occur
near the fast moving blades of
the turbine and in the exit
region of the turbine
DIFFERENT EFFICIENCY
PARTS MANUFACTURED FOR CURRENT PROJECT
 part manufactured - forged runner
Project - AD hydro power ltd.
Wt. of the parts - 9200kg
 part manufactured - main injector
Project - Tapovan Vishnugad hep
Wt of the part - 4900kg
Part manufactured - Runner hub
Projects - Pulichintala project
Wt of the part - 32000kg
Part manufactured -Runner blades
Project -parbati hep stage 3
Wt of the part - 3779kg
TRACTION MOTOR
MANUFACTURING BLOCK NO. 09
What is traction motor
A traction motor is an electric motor used for
propulsion of a vehicle, such as an electric
locomotive or electric roadway vehicle. Traction
motors are used in electrically powered rail vehicles
(electric multiple units) and other electric vehicles
including electric milk floats, elevators, conveyors,
and trolleybuses, as well as vehicles with electrical
transmission systems (diesel-electric, electric hybrid
vehicles), and battery electric vehicles.
TRACTION MOTOR PARTS
COMMUTATOR HUB COMMUTATOR CORE
STATOR FRAME ROTOR OF MOTOR
STATOR FIELD WINDING STATOR MAIN POLE & INTERPOLE
CARBON BRUSH HOLDER ARMATURE CORE & WINDING
TRACTION MOTORS BEING MANUFACTURED
S.NO. TYPE KW VOLTAGE CURRENT POLES RPM APPLICATI
ON
1 TM4501 172 324 610 4 490 DE LOCO
2 TM4605 82 155 625 4 220 DESHUNTER
3 TM4907AZ 280 325 1000 4 430 BGDE LOCO
4 TM5002AZ 282 350 925 4 444 3100 HP
BGDE LOCO
5 TM3701AZ 167 750 275 6 1100 1500V DC
EMU
6 TM4601BX 167 535 600 4 1260 25KV AC
LOCO
7 TM4303AZ 192 535 425 4 1240 BG AC EMU
HYDRO TEST LABORATORY BHEL
TESTING FACILITIES
Facilities for hydraulic testing of spiral casting, inlet valves, servomotors, oil pressure units
and other units.
Governor test stand – combined tesing of electrical mechanical cabinets.
Mechanical testing facilities.
Vibration and stress analysis.
Non destructive testing facilities
 Radiography
 Ultrasonic
 Magna flux
MACHINING FACILITIES
MACHINE TOOLS NO. LARGEST CAPACITY
LATHES 1 MAX Swing 4165mm, MAX, Bet centers 10668mm
CNC LATHES 2 MAX, Swing 3000mm, MAX, Bet centers 12000mm
CNC VERTICAL BORER 3 MAX Turning 10000mm, WT. of job 240T
PLANING MACHINE 4 SIZE OF JOB 9144*4038*12900mm
RADIAL DRILLING MACHINE 5 MAX, Size 2743mm
VERTICAL BORDERS 6 MAX Turning 12500mm, WT. of job 160T
INTRODUCTION TO CNC MACHINES
BLOCK DIAGRAM AND COMPONENTS OF CNC
MAJOR CNC MACHINES
MORANDO CNC LATHE MACHINE
A CNC lathe is typically designed to
utilize modern versions of carbide
tooling and processes. A part can be
designed for customization, and the
machine’s tool paths are often
programmed using the CAD or CAM
processes. The resulting coded
computer file is then uploaded to the
CNC machine, and the machine will
then automatically produce the
desired parts for which it was
programmed to design.
A CNC lathe is controlled by a menu-
type interface on a computer. The
operator who manages the process
can actually see a visual simulation of
SPECIFICATION OF MORANDO CNC LATHE
speed 1.5 to 200 rpm
Feed 0.5to 200 mm/min
Distance between center 6000mm
Height from center 770mm
Maximum load between center 35 ton
Swing over bed 1520mm
CNC ELGA MILLING MACHINE
• BUTLER ELGA MILLING CS10 BED
TYPE MILLING MACHINE
• TABLE : 3300mm*1030mm
• TRAVELS : X AXIS 2500mm,
VERTICAL 1000mm, CROSS TRAVEL
1000MM
• ISO 50 SPINDLE
• MACHINE COMES WITH 3 AXIS
DIGITAL READOUT
HOMMA GRINDING CNC MACHINE
FEED 0.64 TO 1700 MM
SPEED OF VERTICAL
TRAVERSE OF SPINDLE
 MAIN BORING AND
MILLING SPINDLE
 HIGH SPEED SPINDLE
3.5 TO 500 RPM
63 TO 2000 RPM
BORING SPINDLE TRAVERSE 3000 mm
HORIZONTAL TRAVERSE OF
COLUMN ON BED
27600mm
FULL BED LENGTH 40800mm
VERTICAL BORING MACHINE RUNNER BLADE TURNING
MACHINE
 MAXIMUM CAPACITY 90 TONS
 MAXIMUM JOB DIAMETER - 7696MM
 TABLE DIAMETER - 6705MM
 LENGTH OF THE JOB THAT CAN BE DONE
-7200MM
 MAXIMUM DIAMETER - 8000MM
 MAXIMUM LENGTH - 8000MM
PLASMA CUTTING CNC
MACHINE
Plasma cutting is a process that cuts through
electrically conductive materials by means of an
accelerated jet of plasma typical materials cut
with a plasma torch include steel, stainless steel,
aluminum, brass and copper etc. plasma cutting
process is accomplished by a compressed gas (
oxygen, inert gases ) which is blown through a
nozzle at high speed towards the work piece. An
electric arc is formed between electrode near the
nozzle and work piece itself then it delivers
sufficient heat to melt through the work piece
 Cutting temperature - 32000*Celsius
 Max thickness of the plate – 300mm
 Max bed length- 7000mm
ELECTRO SLAG WELDING
MACHINE
 Job completed in one pass only.
 For job of thickness 40-110mm single
nose is used
 For job of thickness greater than
110mm double nose is used
 Lesser defect as compared to manual
arc welding machine
 It can lay metal at a rate between 15
and 20 kg per hour
 This process is very efficient material
handling is minimized since filler
material utilization is high
THANKS any queries

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PROJECT REPORT ON BHEL BHOPAL FOR MECHANICAL

  • 1. DEPARTMENT OF MECHANICAL ENGINEERING VOCATIONAL TRAINING REPORT ON ( WTM, TRACTION MOTOR ASSEMBLY, HYDRO LAB, CNC MACHINES) BHARAT HEAVY ELECTRICAL LIMITED BHOPAL UNIT TENURE OF TRAINING – 12 JULY to 1 AUGUST SUBMITTED BY : ROHIT SEN BE (ME) 7th SEMESTER 0208ME151045
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  • 5. BHARAT HEAVY ELECTRICAL LIMITED  TYPE - State – owned enterprise  Traded as - BSE:500103  NSE:BHEL  INDUSTRY – Electrical equipments  Founded - 1964  Founder - Government of india  Headquarters – NEW DELHI  Area served - World wide  Key people - Atul sobti ( chairman& MD)  Revenue - ₹29,474.9crore (2017)  Operating income - ₹627.83crore  Net income - ₹495.86 crore.  Number of employees 39,821 (2017)
  • 6.
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  • 11.
  • 12. 22km square of exploring bhel town
  • 13. WATER TURBINE MANUFACTURING BLOCK NO. 1 • MANUFACTURING OF FRANCIS TURBINE • UNDER BALIMELLA PROJECT • Water Turbine Manufacturing Block NO.1 are The Biggest Block In BHEL Complex • Hydro turbine and associated components are machined and manufactured here
  • 14. • The Francis turbine is a type of water turbine that was developed by James B. Francis in Lowell, Massachus It is an inward-flow reaction turbine that combines radial and axial flow concepts. • Francis turbines are the most common water turbine in use today. They operate in a water head from 40 to 600 m (130 to 2,000 ft) and are primarily used for electrical power production. The electric generators that most often use this type of turbine have a power output that generally ranges from just a few kilowatts up to 800 MW, Penstock (input pipes) diameters are between 3 and 33 ft (0.91 and 10 m). The speed range of the turbine is from 75 to 1000 rpm.
  • 15. MAJOR COMPONENTS OF FRANCIS TURBINE The Scroll casing.  Runner, and Runner Cone Shaft. Draft tube cone., Hydrogenerator shaft. Stay vanes. Guide vanes. Sealing box., pivot ring Regulating ring ,Servomotor. Upper case and Lower case Link and Liver Guide bearing .
  • 18. HYDRO GENERATOR SHAFT DRAFT TUBE CONE
  • 22. PARAMETERS GOVERNING SELECTION OF FRANCIS TURBINE SPECIFIC SPEED AVAILABLE HEAD ROTATIONAL SPEED CAVITATION EFFICIENCY WATER QUALITY
  • 23. 1. SPECIFIC SPEED The specific speed of turbine is the speed of a geometrically similar turbine which would produce unit power ( one kilowatt) under unit head ( one meter) . The specific speed of a turbine is given by manufacturer ( along with rating ) and will always refer to the point of maximum efficiency.. Sr.no. Types of turbine Specific speed 1. Pelton wheel with single jet 80-30 2. Pelton wheel with multiple jet 30-50 3 Francis turbine 50-250 4 Kaplan turbine 250-850
  • 25. CAVITATION Cavitation is formation of the liquid bubbles in the liquid flowing through any hydraulic turbine. Cavitation occurs when the static pressure of the liquid falls below its vapour pressure . Cavitation is most likely to occur near the fast moving blades of the turbine and in the exit region of the turbine
  • 27. PARTS MANUFACTURED FOR CURRENT PROJECT  part manufactured - forged runner Project - AD hydro power ltd. Wt. of the parts - 9200kg  part manufactured - main injector Project - Tapovan Vishnugad hep Wt of the part - 4900kg Part manufactured - Runner hub Projects - Pulichintala project Wt of the part - 32000kg Part manufactured -Runner blades Project -parbati hep stage 3 Wt of the part - 3779kg
  • 28. TRACTION MOTOR MANUFACTURING BLOCK NO. 09 What is traction motor A traction motor is an electric motor used for propulsion of a vehicle, such as an electric locomotive or electric roadway vehicle. Traction motors are used in electrically powered rail vehicles (electric multiple units) and other electric vehicles including electric milk floats, elevators, conveyors, and trolleybuses, as well as vehicles with electrical transmission systems (diesel-electric, electric hybrid vehicles), and battery electric vehicles.
  • 29. TRACTION MOTOR PARTS COMMUTATOR HUB COMMUTATOR CORE
  • 30. STATOR FRAME ROTOR OF MOTOR
  • 31. STATOR FIELD WINDING STATOR MAIN POLE & INTERPOLE
  • 32. CARBON BRUSH HOLDER ARMATURE CORE & WINDING
  • 33. TRACTION MOTORS BEING MANUFACTURED S.NO. TYPE KW VOLTAGE CURRENT POLES RPM APPLICATI ON 1 TM4501 172 324 610 4 490 DE LOCO 2 TM4605 82 155 625 4 220 DESHUNTER 3 TM4907AZ 280 325 1000 4 430 BGDE LOCO 4 TM5002AZ 282 350 925 4 444 3100 HP BGDE LOCO 5 TM3701AZ 167 750 275 6 1100 1500V DC EMU 6 TM4601BX 167 535 600 4 1260 25KV AC LOCO 7 TM4303AZ 192 535 425 4 1240 BG AC EMU
  • 35. TESTING FACILITIES Facilities for hydraulic testing of spiral casting, inlet valves, servomotors, oil pressure units and other units. Governor test stand – combined tesing of electrical mechanical cabinets. Mechanical testing facilities. Vibration and stress analysis. Non destructive testing facilities  Radiography  Ultrasonic  Magna flux
  • 36. MACHINING FACILITIES MACHINE TOOLS NO. LARGEST CAPACITY LATHES 1 MAX Swing 4165mm, MAX, Bet centers 10668mm CNC LATHES 2 MAX, Swing 3000mm, MAX, Bet centers 12000mm CNC VERTICAL BORER 3 MAX Turning 10000mm, WT. of job 240T PLANING MACHINE 4 SIZE OF JOB 9144*4038*12900mm RADIAL DRILLING MACHINE 5 MAX, Size 2743mm VERTICAL BORDERS 6 MAX Turning 12500mm, WT. of job 160T
  • 38. BLOCK DIAGRAM AND COMPONENTS OF CNC
  • 39. MAJOR CNC MACHINES MORANDO CNC LATHE MACHINE A CNC lathe is typically designed to utilize modern versions of carbide tooling and processes. A part can be designed for customization, and the machine’s tool paths are often programmed using the CAD or CAM processes. The resulting coded computer file is then uploaded to the CNC machine, and the machine will then automatically produce the desired parts for which it was programmed to design. A CNC lathe is controlled by a menu- type interface on a computer. The operator who manages the process can actually see a visual simulation of
  • 40. SPECIFICATION OF MORANDO CNC LATHE speed 1.5 to 200 rpm Feed 0.5to 200 mm/min Distance between center 6000mm Height from center 770mm Maximum load between center 35 ton Swing over bed 1520mm
  • 41. CNC ELGA MILLING MACHINE • BUTLER ELGA MILLING CS10 BED TYPE MILLING MACHINE • TABLE : 3300mm*1030mm • TRAVELS : X AXIS 2500mm, VERTICAL 1000mm, CROSS TRAVEL 1000MM • ISO 50 SPINDLE • MACHINE COMES WITH 3 AXIS DIGITAL READOUT
  • 42. HOMMA GRINDING CNC MACHINE FEED 0.64 TO 1700 MM SPEED OF VERTICAL TRAVERSE OF SPINDLE  MAIN BORING AND MILLING SPINDLE  HIGH SPEED SPINDLE 3.5 TO 500 RPM 63 TO 2000 RPM BORING SPINDLE TRAVERSE 3000 mm HORIZONTAL TRAVERSE OF COLUMN ON BED 27600mm FULL BED LENGTH 40800mm
  • 43. VERTICAL BORING MACHINE RUNNER BLADE TURNING MACHINE  MAXIMUM CAPACITY 90 TONS  MAXIMUM JOB DIAMETER - 7696MM  TABLE DIAMETER - 6705MM  LENGTH OF THE JOB THAT CAN BE DONE -7200MM  MAXIMUM DIAMETER - 8000MM  MAXIMUM LENGTH - 8000MM
  • 44. PLASMA CUTTING CNC MACHINE Plasma cutting is a process that cuts through electrically conductive materials by means of an accelerated jet of plasma typical materials cut with a plasma torch include steel, stainless steel, aluminum, brass and copper etc. plasma cutting process is accomplished by a compressed gas ( oxygen, inert gases ) which is blown through a nozzle at high speed towards the work piece. An electric arc is formed between electrode near the nozzle and work piece itself then it delivers sufficient heat to melt through the work piece  Cutting temperature - 32000*Celsius  Max thickness of the plate – 300mm  Max bed length- 7000mm
  • 45. ELECTRO SLAG WELDING MACHINE  Job completed in one pass only.  For job of thickness 40-110mm single nose is used  For job of thickness greater than 110mm double nose is used  Lesser defect as compared to manual arc welding machine  It can lay metal at a rate between 15 and 20 kg per hour  This process is very efficient material handling is minimized since filler material utilization is high