Project on bharat heavy electricals limited 4th sem

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


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


USED

i. Cutting of drawn profile & spacer

blank


ii. Sizing to rectangular shape Hor. Milling machine

iii. Thickness grinding Surface grinder

iv. Rough and finish milling of internal

profile of spacer


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


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


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)


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


Weight of the Job : 110 TON

Weight of the m/c : 124 TON


5. Item Description : CNC Centre Lathe

Mode : D-2300 NYFS-1

Supplier : HOESCH MFC, GERMANY

CNC Control System : SINUMERIK 7T




Spindle Speed : 5 – 125 RPM


Weight of the job : 320 TON

Weight of the m/c : 216 TON


6. Item Description : CNC Centre Lathe

Model : KV2-1100 CNC

Supplier : RANVENSBURG, GERMANY

CNC Control System : SINUMERIK 820 T


Centre Height : 900 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


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



L.H. Head

12500 Kg with L 1500 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)



K.S. Rao Director (IS&P)


Integrated Office Complex

Lodhi Road, New Delhi – 110 003

Ishan Shankar Director (Personnel)



M.K. Mittal Director (ER&D)



Project on bharat heavy electricals limited 4th sem

Education

Transcript of Project on bharat heavy electricals limited 4th sem