AN INDUSTRIAL REPORT ON TURBINE SHOP AT BHEL HARIDWAR

PRESENTATION ON INDUSTRIAL TRAINING ATBY:KUMAR GOURAV(2010EME01)RAJU THAPA(2010EME18)AJAY KUMAR(2010EME23)MADAN MURARI(2010EME25)DHARMESH KUMAR(2010EME34)KULVINDER SINGHANUBHAV SHARMAAMAN MAHAJAN

1Training Sections:Bharat Heavy Electricals LimitedBHEL is the Largest power equipment manufacturer in India and 7th Largest in the world.It is engaged in the Design, Engineering, Manufacture, Construction, Testing, Commissioning and Servicing of a wide range of products and services.Covers Power, Transmission, Heavy Industry, Transportation, Renewable Energy, Oil & Gas and defence equipments.This is a MAHARATAN public sector enterprice established in 1964.ENERGY-RELATED/INFRASTRUCTURE SECTORQUALITY MANAGEMENT SYSTEMS (ISO9001:2008)ENVIRONMENTAL MANAGEMENT SYSTEMS (ISO 14001:2004)OCCUPATIONAL HEALTH & SAFETY MANAGEMENT SYSTEMS (OHSAS 18001:2007)HIGHLY SKILLED AND COMMITTED WORKFORCE OF 46,748 EMPLOYEESBHEL HARIDWARStarted in 1960s with the help of Russia and Czech.BHEL has two plants here:HEEP: Heavy Electrical Equipment Plant.CFFP: Central Foundry Forge Plant.Spread in about 5000 Acres.

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

CFFP is engaged in manufacture of Steel Castings: Up to 50 Tons Per Piece Wt. & Steel Forgings: Up to 55 Tons Per Piece Wt. PRODUCT PROFILE

MAJOR PRODUCTS: Steam turbineGas turbineSteam GeneratorsHRSG- Heat recovery steam generator TransformersLocomotivesCircuit BreakersPumps Motors- BOTH AC AND DC, LT AND HT Generators TURBINE SHOP BLOCK 3

GENERAL DETAILS OF BLOCK- 3Steam Turbines, Gas Turbines and Turbines BladesSpecial Tooling for all products in the Tool Room located in the same blockConsists of four Bays, namely, Bay-I and II of size 36x378 meters and 36x400 meters respectively and Bay-III and IV of size 24x402 meters and 24x381 metres respectively

Facilities of EOT Cranes, compressed air, Steam, Overspeed Balancing Tunnel, indicating stands for steam turbine, rotors, one Test stand for testing 210 MW steam turbines .One Test Stand for Hydro Turbine Guide Apparatus and two separate Test Stands for the testing of Governing Assemblies of Steam and Hydro Turbines.All the parts are conserved, painted and packed before dispatch DETAILS OF BAY- 1Size- 36x378 meters.Consists of following machines:-Hydraulic lifting platformCNC turning latheCombustion chamber assembly platform

DETAILS OF BAY - 2 Size:- 36x400 meters CNC creep feed grinding machine (Gas turbine m/c area)External broaching machineCNC facing latheWax melting equipment Gas turbine test bed

DETAILS OF BAY 3 Size :-24x402 metersCNC stub borerCNC milling machine Universal milling machineCNC bed type milling machineCNC surface broaching machine DETAILS OF BAY - 4Size:- 24x381 metres Turbine blade machining shopHeat treatment zone

HYDRO TURBINE

MANUFACTURING FACILITIES

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 .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.

MANUFACTURING PROCESS OF HYDRO TURBINE :-

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.

GAS TURBINE

23GAS TURBINE

24Gas turbine also called a combustion turbine, is a rotary engine that extracts energy from a flow of combustion gas.

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

MANUFACTURING FACILITIESa) 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: 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 holds 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 PlatformThis facility is a 3 Tier Platform installed in Bay-I assembly area and is used for assembly of Combustion Chambers of Gas Turbine.

MANUFACTURING PROCESSES OF GAS TURBINE :-

The major processes involved in manufacturing Gas Turbine in various sections of Bk-III are as follows:

MACHINING: one of the most important material removal methods, in which power driven machine tools, such as lathes, milling machine and drill presses are used with sharp cutting tools to achieve the desired geometry. MAIN ASSEMBLY: Final assembly is done on test bed. Parts are assembled to make sub-assemblies. After assembly and insulation assembled Gas Turbine is sent to site.ROTOR ASSEMBLY: The rotor is assembled on Hydraulic Lifting Platform and sent to main assembly, where after checking clearances, it is sent for machining.

COMBUSTION CHAMBER ASSEMBLY: This assembly is carried out on 3 tier platform installed for this purpose in Bay-I assembly. After machining of all components, ceramic tiles are fitted in flame tube. Burner and piping etc. is fitted in dome and combustion chamber is finally assembled.

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

steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. . Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator about 80% of all electricity generation in the world is by use of steam turbines. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process.

500 MW Steam Turbine: HP Turbine:Module:H30-100-2Steam Pressure:170Kg/sq.cmSteam temperature:537 deg.celReheating temperature:537 deg.celWeight :86400 KgLength of Rotor:4.61mHeight:2.15mLP Turbine:Module:N30-2x10sq.mWeight:3.5 TLength of Rotor:8.7mWidth:10.7mHeight:4.6mIP Turbine:Length:4.425mWidth:5mHeight:4.8mSteam pressure:41Kg/sq.cmSteam temperature:537 deg.cel

HOW IT WORKS :-MANUFACTURING FACILITIES IN STEAM TURBINE :-TURBINE CASING MACHINING SECTION: equipped with large size Planer, Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines . Fabrication works like casings, Pedestals etc. are received from Fabrication Block-II.ROTOR MACHINING SECTION : Equipped with large size machining tools like Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree Groove Milling Machine etc. Some rotor forgings are imported from Russia and Germany and some are indigenously manufactured at CFFP, BHEL, Hardwar.

ROTOR ASSEMBLY SECTION : Equipped with Indicating Stand, Small size Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and Discs.Turbine casing Assembly Section Machined casings are assembled and hydraulically tested by Reciprocating Pumps at two times the operating pressure.Test Station - 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.Painting Preservation and Packing Section All the parts are painted, preserved and packed here for final dispatch.

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.TURBINE CASING ASSEMBLY SECTION : Machined casings are assembled and hydraulically tested by Reciprocating Pumps at two times the operating pressure.TEST STATION : Equipped with condensers, Ejector, Oil Pumps, Oil containers Steam Connections etc, required for testing.

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

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.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.MANUFACTURING PROCESS IN STEAM TURBINEProcesses 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 is 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.

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

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

Types of Blades:

T2 bladesT4 bladesTX blades3DS bladesF- bladesGT-Compress bladesBrazed bladesRussian design bladesZ-Shroud bladesCompressor blades (Sermental coated)LP Moving blade 500MW VARIOUS BLADE PROFILE

MANUFACTURING FACILITIES blade shop is divided into four distinct areas:-PLAIN MILLING SECTION: it prepares accurate reference surfaces on the blade blanks by milling and grinding operation.COPY MILLING SECTION: the semi blanks prepared from plain milling section are further machined by copy milling machines for concave and convex aero-dynamic profile forms.LP SECTION: this area deals with all types of free standing and forged blades for steam turbine compressor.POLISHING SECTION: blade contours are ground and polished to achieve the desired surface finish and other aerofoil requirements.

INSPECTION DEVICES3 D Coordinate Measuring Machines for taper and rhomboid checking.Moment weighing Equipment.Real time Frequency analyzer for checking frequency of free standing blades.Contour plotter for plotting of blade profile with various magnification.Magna spray crack detection equipment. MANUFACTURING PROCESS The manufacturing process of turbine blades primarily depends on the type of blade e.g. Bar type, Brazed type, Gas Turbine blade.

BAR TYPES BLADESPROCESS / OPERATIONMACHINE TOOL/EQUIPMENT USEDBlanking of area materialCircular saw/band sawSizing to rectangular shapeHor. Milling MachineThickness grindingSurface grinderRhomboid millingDuplex milling machineTaper grindingSurface grinderGrinding and polishing of profileAbrasive belt polishing m/c BRAZED TYPE BLADESPROCESS / OPERATIONMACHINE TOOL/EQUIPMENT USEDCutting of drawn profile & spacer blankHor. Milling machineThickness grindingSurface grinderCutting-off spacerAbrasive cuttingMilling of widthDuplex milling machineGrinding and polishingAbrasive belt polishing m/c GAS TURBINE BLADESPROCESS / OPERATIONMACHINE TOOL/EQUIPMENT USEDCerrobend castingCerrobend casting equip.Root machiningHor. Machining centerLength cuttingCircular saw/hor. Milling m/cTenonHor. Milling m/cGrinding and polishing of filletAbrasive belt polishing m/cDIFFERENT MACHINES USED IN TURBINE MANUFACTURINGCNC HORIZONTAL BORERS

UNIVERSAL VERTICAL TURNING & BORING MACHINE

GROOVE MILLING MACHINE

UNIVERSAL LATHE MACHINE

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