BHEL BLOCK 3 ppt

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I

NDUSTRIAL

T

RAINING

R

EPORT

ON

Turbine Blade Shop – Block 3

Situated at

B

harat

H

eavy

E

lectricals

Limited

Department Of Mechanical Engineering,

Quantum School Of Technology, Roorkee

Uttarakhand - INDIA

Presented By:

A

DITYA

A

GGARWAL

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Company Overview

 A NAVARATNA PUBLIC SECTOR ENTERPRISE

 ESTABLISHED IN 1964

 ENERGY-RELATED/INFRASTRUCTURE SECTOR

 POWER, TRANSMISSION, INDUSTRY, TRANSPORTATION, RENEWABLE ENERGY, OIL & GAS AND DEFENCE.

 QUALITY 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 EMPLOYEES ALL OVER INDIA

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Manufacturing Plant

BHEL Haridwar has two manufacturing plants:-

Heavy Electrical Equipment Plant (HEEP)

Central Foundry Forge Plant (CFFP).



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:

Upto 50 Tons Per Piece Wt & Steel Forgings: Upto 55

Tons Per Piece Wt.

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Major Products of BHEL,

Haridwar



Steam turbine



Gas turbine



_{Steam Generators}



HRSG- Heat recovery steam generator



Transformers



Locomotives



Circuit Breakers



_Pumps



Motors-

BOTH AC AND DC, LT AND HT

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General Details



Steam Turbines, Gas Turbines and Turbines

Blades



Special Tooling for all products in the Tool Room

located in the same block



Consists 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 .

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Details of Bay I



Size- 36x378 meters.



_{Consists of following machines:-}



Hydraulic lifting platform



_{CNC turning lathe}

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Details of BAY II



Size:- 36x400 meters



_{CNC creep feed grinding machine}

(Gas turbine machining area)



_{External broaching machine}



_{CNC facing lathe}



Wax melting equipment

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Details of Bay III



Size :-24x402 meters



_{CNC stub borer}



CNC milling machine



Universal milling machine



CNC bed type milling machine

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Details of Bay IV



Size:- 24x381 metres



_{Turbine blade machining shop}



Heat treatment zone

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Gas 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

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Manufacturing Facilities

- Gas

Turbine

 Hydraulic Lifting Platform: used for assembly and disassembly of G.T. Rotor.

 CNC Creep Feed Grinding M/c: grinds the hearth serration on rotor disc faces.

 External Broaching Machine: used to make groove on the outer dia of rotor discs for the fitting of moving blades on the discs.

 CNC Facing Lathe: used for facing rotor disc.

 CNC Turning Lathe: used to turn Tie Rods of Gas Turbine.

 Wax Melting Equipment: used to mix and melt Wax to arrest the blade movement during the blade tip machining of stator blade rings.

 Gas Turbine Test Bed: used to finally assemble the gas turbine.

 Combustion Chamber Assembly Platform: used for assembly of Combustion Chambers of Gas Turbine.

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Manufacturing Process –

Gas

Turbine



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.



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.

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About Steam Turbine



A steam turbine is a mech. device that extracts

thermal energy from pressurized steam, and

converts it into rotary motion.



It

has

almost

completely

replaced

the

reciprocating piston steam engine (invented by

Thomas Newcomen and greatly improved by

James Watt) primarily because of its greater

thermal efficiency and higher power-to-weight

ratio.



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.

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Manufacturing Process –

Steam

Turbine

The facilities and parts manufacturing of Steam Turbine are as follows:

 TURBINE CASING MACHINING SECTION: equipped with large size Planer, Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines .

 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.

 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 : 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

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Blade Shop



_{Turbine Blade}

Machining Shop is

located in Bay-IV of

Block-III.



_{A batch production}

shop comprising of

various kinds of CNC

Machines and

Machining Centres.

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Manufacturing Facilities –

Blade

Shop

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.

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Inspection of Blade



_{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 magnification.

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Manufacturing Process -

Blade



The manufacturing

process of turbine

blades primarily

depends on the type of

blade e.g. Bar type,

Brazed type, Gas

Turbine blade

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1. Bar Type Blade

PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED

Blanking of area material

Circular saw/band saw

Sizing to rectangular

shape

Hor. Milling Machine

Thickness grinding

Surface grinder

Rhomboid milling

Duplex milling machine

Taper grinding

Surface grinder

Grinding and polishing of

profile

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2. Brazed Type Blade

PROCESS / OPERATION MACHINE

TOOL/EQUIPMENT

USED

Cutting of drawn profile &

spacer blank

Hor. Milling machine

Thickness grinding

Surface grinder

Cutting-off spacer

Abrasive cutting

Milling of width

Duplex milling machine

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3. Gas Turbine Blade

PROCESS

/

OPERATION

MACHINE

TOOL/EQUIPMENT

USED

Cerrobend casting

Cerrobend casting equip.

Root machining

Hor. Machining center

Length cutting

Circular saw/hor. Milling

m/c

Tenon

Hor. Milling m/c

Grinding and polishing of

fillet

Abrasive belt polishing

m/c

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SPECIFICATIONS OF

MACHINES AVAILABLE IN

BLOCK-III

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Vertical Boring Machine

 Max diameter of work piece accommodated :10000mm

 Max height of work piece :5000mm

 Diameter of table :8750mm

 Max travel of vertical tool head RAM slides :3200mm

 Max travel of vertical tool heads

from centre of table :5250mm

 Max weight of work piece :200 T For N<=6rpm;100T for any

speed

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Centre Lathe



Max diameter over bed

:3200mm



Max diameter over saddle

:250mm



Length between centers

:16m



Max weight of work piece

:100 T

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CNC Lathe



Manufacturer

: Safop, Italy



Swing over carriage

:3500mm



Centre distance

:9000mm



Weight capacity

:120 T



Spindle power

:196KW



External chucking range

:250-2000mm



Hydrostat steady range

:200-1250mm



Max spindle rpm

:200

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CNC Vertical Borer

 Manufacturer :Pietro Carnaghi, Italy

 Machine model :AP 80TM-6500

 Table diameter :6500mm

 Max turning diameter :8000mm

 Min boring diameter :660mm

 Max height for turning and milling :7000mm

 Table Speed :0.2-50 rpm

 Table load capacity :200 T

 Milling spindle speed :3000 rpm at40KW

 Spindle taper :BT 50

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CNC Skoda Horizontal Borer



Spindle diameter

:200mm



Taper spindle

:BT 50



RAM Size :450x450mm



RAM length

:1600mm



Spindle length

:2000mm



Headstock

:5000mm



Table

:4000x3500mm



CNC system

:SIMENS850mm

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