V.t Project Report by SANJEET KUMAR

ONE MONTH VOCATIONAL TRAINING AT

Bharat Heavy Electricals Limited

RANIPUR, HARDWAR 249403INDIA

PROJECT REPORT ON

TURBINE MANUFACTURINGSECTION

UNDER THE ABLE GUIDENCE OFMR. S. HALDHAR (Sr. MANAGER)

MR. D. PANT (S.D.G.M)

SUBMITTED BY:-

SANJEET KUMAR

DEPARTMENT OF MANUFACTURING ENGG.NATIONAL INSTITUTE OF FOUNDRY & FORGE

TECHNOLOGY, HATIA, RANCHI- 834003JHARKHAND

Contents

1. Prologue – A. BHEL – An Overview

B. HEEP – An Overview

2. Study on Turbines & Auxiliary Block

3. Study on Material Specification

4. Broad Specification of Major Machines Tools & Machines

(CNC & Non CNC)

5. Other Areas

MANUFACTURING DIVISIONS

Heavy Electricals Plant, Piplani, Bhopal

Electricals Machines Repair Plant (EMRP), Mumbai

Transformer Plant P.O. BHEL, Jhansi.

Bharat Heavy Electricals Limited :– Heavy Electricals Equipment Plant, – Central Foundary Forge Plant., Ranipur, Hardwar

Heavy Equipment Repair Plant, Varanasi.

Insulator Plant, Jagdishpur, Distt. Sultanpur.

Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad

High Pressure Boiler Plant & Seamless Steel Tube Plant, Tiruchirappalli.

Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex, Ranipet.

Industrial Valves Plant, Goindwal.

Electronics Division :– Electronics Systems Division.– Amorphous Silicon Solar Cell Plant (ASSCP).– Electroporcelains Division.– Industrial Systems Group.

.

Component Fabrication Plant, Rudrapur.

Piping Centre, Chennai.

Regional Operations Division, New Delhi

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 centre, over 150 project sites, eight service centre 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.

POWER TRANSMISSION & DISTRIBUTION (T & D)

BHEL offer wide ranging products and systems for T & D applications. Products

manufactured include power transformers, instrument transformers, dry type

transformers, series – and stunt reactor, capacitor tanks, vacuum – and SF circuit

breakers gas insulated switch gears and insulators.

A strong engineering base enables the Company to undertake turnkey delivery of

electric substances up to 400 kV level series compensation systems (for increasing

power transfer capacity of transmission lines and improving system stability and

voltage regulation), shunt compensation systems (for power factor and voltage

improvement) and HVDC systems (for economic transfer of bulk power). BHEL

has indigenously developed the state-of-the-art controlled shunt reactor (for

reactive power management on long transmission lines). Presently a 400 kV Facts

(Flexible AC Transmission System) project under execution.

INDUSTRIES

BHEL is a major contributor of equipment and systems to industries. Cement,

sugar, fertilizer, refineries, petrochemcials, paper, oil and gas, metallurgical and

other process industries lines and improving system stability and voltage

regulation, shunt compensation systems (for power factor and voltage

improvement) and HVDC systems (for economic transfer of bulk power) BHEL

has indigenously developed the state-of-the-art controlled shunt reactor (for

reactive power management on long transmission lines). Presently a 400 kV

FACTS (Felxible AC Transmission System) projects is under execution.

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.

INTERNATIONAL OPERATIONS

BHEL has, over the years, established its references in around 60 countries of the

world, ranging for the United States in the West to New Zealand in the Far East.

These references encompass almost the entire product range of BHEL, covering

turnkey power projects of thermal, hydro and gas-based types, substation projects,

rehabilitation projects, besides a wide variety of products, like transformers,

insulators, switchgears, heat exchangers, castings and forgings, valves, well-head

equipment, centrifugal compressors, photo-voltaic equipment etc. Apart from over

1110MW of boiler capacity contributed in Malaysia, and execution of four

prestigious power projects in Oman, Some of the other major successes achieved

by the Company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus,

Malta, Egypt, Bangladesh, Azerbaijan, Sri Lanka, Iraq etc.

The Company has been successful in meeting demanding customer's requirements

in terms of complexity of the works as well as technological, quality and other

requirements viz extended warrantees, associated O&M, financing packages etc.

BHEL has proved its capability to undertake projects on fast-track basis. The

company has been successful in meeting varying needs of the industry, be it

captive power plants, utility power generation or for the oil sector requirements.

Executing of Overseas projects has also provided BHEL the experience of working

with world renowned Consulting Organisations and inspection Agencies.

In addition to demonstrated capability to undertake turnkey projects on its own,

BHEL possesses the requisite flexibility to interface and complement with

International companies for large projects by supplying complementary equipment

and meeting their production needs for intermediate as well as finished products.

The success in the area of rehabilitation and life extension of power projects has

established BHEL as a comparable alternative to the original equipment

manufactures (OEMs) for such plants.

TECHNOLOGY UPGRADATION AND RESEARCH & DEVELOPMENT

To remain competitive and meet customers' expectations, BHEL lays great

emphasis on the continuous upgradation of products and related technologies, and

development of new products. The Company has upgraded its products to

contemporary levels through continuous in house efforts as well as through

acquisition of new technologies from leading engineering organizations of the

world.

The Corporate R&D Division at Hyderabad, spread over a 140 acre complex, leads

BHEL's research efforts in a number of areas of importance to BHEL's product

range. Research and product development centers at each of the manufacturing

divisions play a complementary role.

BHEL's Investment in R&D is amongst the largest in the corporate sector in India.

Products developed in-house during the last five years contributed about 8.6% to

the revenues in 2000-2001.

BHEL has introduced, in the recent past, several state-of-the-art products

developed in-house: low-NQx oil / gas burners, circulating fluidized bed

combustion boilers, high-efficiency Pelton hydro turbines, petroleum depot

automation systems, 36 kV gas-insulated sub-stations, etc. The Company has also

transferred a few technologies developed in-house to other Indian companies for

commercialisation.

Some of the on-going development & demonstration projects include: Smant wall

blowing system for cleaning boiler soot deposits, and micro-controller based

governor for diesel-electric locomotives. The company is also engaged in research

in futuristic areas, such as application of super conducting materials in power

generations and industry, and fuel cells for distributed, environment-friendly power

generation.

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.

HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT

BHEL, as an integral part of business performance and in its endeavour of

becoming a world-class organization and sharing the growing global concern on

issues related to Environment. Occupational Health and Safety, is committed to

protecting Environment in and around its own establishment, and to providing safe

and healthy working environment to all its employees.

For fulfilling these obligations, Corporate Policies have been formulated as:

ENVIRONMENTAL POLICY

Compliance with applicable Environmental Legislation/Regulation;

Continual Improvement in Environment Management Systems to protect

our natural environment and Control Pollution;

Promotion of activities for conservation of resources by Environmental

Management;

Enhancement of Environmental awareness amongst employees, customers

and suppliers. BHEL will also assist and co-operate with the concerned

Government Agencies and Regulatory Bodies engaged in environmental

activities, offering the Company's capabilities is this field.

OCCUPATIONAL HEALTH AND SAFETY POLICY

Compliance with applicable Legislation and Regulations;

Setting objectives and targets to eliminate/control/minimize risks due to

Occupational and Safety Hazards;

Appropriate structured training of employees on Occupational Health and

Safety (OH&S) aspects;

Formulation and maintenance of OH&S Management programmes for

continual improvement;

Periodic review of OH&S Management System to ensure its continuing

suitability, adequacy and effectiveness;

Communication of OH&S Policy to all employees and interested parties.

The major units of BHEL have already acquired ISO 14001 Environmental

Management System Certification, and other units are in advanced stages of

acquiring the same. Action plan has been prepared to acquire OHSAS 18001

Occupational Health and Safety Management System certification for all BHEL

units.

In pursuit of these Policy requirements, BHEL will continuously strive to improve

work particles in the light of advances made in technology and new

understandings in Occupational Health, Safety and Environmental Science.

PARTICIPATION IN THE "GLOBAL COMPACT" OF THE UNITED

NATIONS

The "Global Compact" is a partnership between the United Nations, the business

community, international labour and NGOs. It provides a forum for them to work

together and improve corporate practices through co-operation rather than

confrontation.

BHEL has joined the "Global Compact" of United Nations and has committed to

support it and the set of core values enshrined in its nine principles:

PRINCIPLES OF THE "GLOBAL COMPACT"

HUMAN RIGHTS

1. Business should support and respect the protection of internationally

proclaimed human rights; and

2. Make sure they are not complicit in human rights abuses.

Labour Standards

3. Business should uphold the freedom of association and the effective

recognition of the right to collective bargaining;

4. The elimination of all form of forces and compulsory labour.

5. The effective abolition of child labour, and

6. Eliminate discrimination.

Environment

7. Businesses should support a precautionary approach to environmental

challenges;

8. Undertake initiatives to promote greater environmental responsibility and

9. Encourage the development and diffusion of environmentally friendly

technologies.

By joining the "Global Compact", BHEL would get a unique opportunity of

networking with corporate and sharing experience relating to social responsibility

on global basis.

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

- Reverse Osmoses Desalination

Plants

INDUSTRIES/TRANSPORTATION/OIL

& GAS/

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

SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS CORE SECTORS

Power Generation

THERMAL RATING (MW)NO. OF SETS

TOTAL CAPACITY

(MW)500 30 15000250 9 2250210/200 138 28570120/125/130 20 2420195 1 195110 38 4180100 6 60070/67.5 6 41060 14 84030 5 150TOTAL (THERMAL)

267 54615

GAS FRAME SIZE/SCOPE NO. OF

SETS

TOTAL CAPACITY

(MW)9 5 7306 17 5805 13 3093 6 48V 94.2 2 2866FA 3 207STG 24 1190GEN 4 87TOTAL (GAS) 74 3437

NUCLEAR RATING (MW)NO. OF SETS

TOTAL CAPACITY

(MW)500 2 1000220 10 2200TOTAL (NUCLEAR)

12 3200

TOTAL (THERMAL+GAS+NUCLEAR) 353 61252

HYDRO 402 18735GRAND TOTAL

755 79987

SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS

CORE SECTORS

POWER TRANSMISSION & DISTRIBUTION

In the T&D sector, BHEL is both a leading equipment-manufacturer and a

system-integrator. BHEL-manufactured T&D products have a proven

track record in India and abroad.

In the area of T&D systems, BHEL provides turnkey solutions to utilities.

Substations and shunt compensation installations set up by BHEL are in operation

all over the country. EHV level series compensation schemes have been installed

in KSEB, MSEB, SMPSEB and POWERGRID networks. Complete HVDC

systems can be delivered by BHEL. The technology for state-of-the-art Flexible

AC Transmission Systems (FACTS) is being developed.

INDUSTRIES

Since inception in 1982, the Industry Sector business has grown at an impressive

rate and, today, contributes significantly of BHEL's turnover.

BHEL, today, supplies all major equipment for the industries: AC/DC machines,

alternators, centrifugal compressors, special reactor column, heat exchangers,

pressure vessels, gas turbine based captive co-generation and combined-cycle

power plants, DG power plants, steam turbines and turbo-generators, complete

range of steam generators for process industries, diesel engine-based power plants,

solar water heating systems, photovoltaic systems, electrostatic precipitators, fabric

filters, etc.

The industries which BHEL serves include: Steel, Aluminium, Fertiliser, Refinery,

Petrochemicals, Chemicals, Automobiles, Cement, Sugar, Paper, Mining, Textile

etc.

TRANSPORTATION

In the transportation filed, product range covers: AC locomotives, AC/DC dual-

voltage locomotives, diesel-electric shunting locomotives, traction motors and

transformers, traction elections and controls for AC, DC and dual voltage EMUs,

diesel-electric multiple units, diesel power car and diesel –electric locomotives,

battery-powered vehicles.

A high percentage of the trains operated by Indian Railways are equipped with

traction equipment and controls manufactured and supplied by BHEL.

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. CLIMATIC AND GEOGRAPHICAL:

* Hardwar is in extreme weather zone of the Western Uttar Pradesh of India

and temperature varies from 2oC in Winter (December to January) to 45oC in

Summer (April-June); Relative humidity 20% during dry season to 95-96%

during rainy season.

* Longitude 78o3' East, Latitude 29 o55'5" North.

* Height above Mean Sea Level = 275 metres.

* Situated within 60 to 100 KMs of Foot-hills of the Central Himalayan

Ranges; Ganges flows down within 7 KMs from the Factory area.

* HEEP is located around 7 KMs on the Western side of Hardwar city.

4. COMMUNICATION & TRANSPORTATION:

* Telegraphic Code – "BHARAT TELEC, HARDWAR"

* TLX Lines: 05909-206 / 207

* Telephones : P&T / STD – (0133) 427350-59, 423050-423954

FAX : (0091) (133) 426462 / 425069 / 426082 / 426254

* Direct Board gauge train lines to Calcutta (Howrah), Delhi, Bombay,

Lucknow, Dehradun and other major cities; Railway Siding for goods traffic

connected to Hardwar Railway Station.

5. POWER & WATER SUPPLY SYSTEM:

- 40 MVA sanctioned Electric Power connection from UP Grid (132 KV /

11KV / 6.6 KV) (Connected load – around 185 MVA)

- 26 deep submersible Tube Wells with O.H. Tanks for water supply.

- A 12 MW captive thermal power station is located in the factory

premises.

6. FIRE PROTECTION:

- Managed by CISF with around 40 personnel and a host of latest fire

fighting equipment and fire tenders.

7. MANPOWER:

Total strength is 9904 as on 31.3.96 which includes around 3000 qualified

Engineers and Technicians (including substantial number of Post graduates),

5200 skilled artisans and the rest in other categories.

8. TOWNSHIP AND PERIPHERAL INFRASTRUCTURES:

* A large modern township for employees and allied personnel with social and

welfare amenities.

* Medical: - Main Hospital (200 beds) 1

- Dispensaries in various 9

townships sectors

- Occupational health center 1

* Educational: No. of Schools (including 19

Intermediate levels)

Science Degree College 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.

9. 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

10. 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 BLOCK

Steam turbine

Power plant market requirements have changed in recent years. The tendency for highly flexibleand efficient power plants with long revision intervals, life times ≥200 000h as well as lowinvestment costs have resulted in an increased effort in the improvement of design and materials.One possible way to meet high efficiency requirements is to install sub-critical steam powerplants with live steam temperatures of T ≥565°C and an optimized steam cycle path. As a result,new challenges have arisen for the design of a two cylinder steam turbine line for a capacity up to700 MW. In addition, the realization of critical turbine components need improved design andmaterials, which offer all possibilities for a cost effective and flexible service. At the same time,the combined cycle power plant market demands constantly high performance, reliability andoperating flexibility at moderate prices for competitive life cycle costs. For this power range, twocylinder designs are also typically applied for the steam turbine.This paper outlines the different aspects of a modular design concept. The author’s company hasbeen following this concept in recent years with an aim to accurately fulfilling marketrequirements. It has already been applied to various aspects of the two double-casingconfigurations for both single and double-flow low pressure turbines. This paper providesexamples on how the concept has been realized within various design aspects and features, allwith an underlying target to produce steam turbines that meet all named market requirements atcompetitive prices.

INTRODUCTION

The world’s power generation markets have been deregulated to a large extent over the past few years, and this process is still ongoing. In order to remain competitive, power plants need to have Features that match with the requirements of the changing market. With the focus on cost efficient production of electricity, the most important requirements of today are low overall lifecycle costs, high reliability, availability and operating flexibility. Additionally, specific customer And local site requirements need to be met by the suppliers of power plants and components. At the same time, the market demands continuously decreasing turbine delivery times and prices. Thus, one of the primary requirements of all steam turbine manufacturers is to standardize their products in order to meet the cost and delivery time targets while – at the same time – providing a high level of flexibility to their customers. This also helps to obtain optimum performance levels and product quality.

For steam turbines, the main design parameters are the power output, the steam conditions, the ambient temperature and the power plant configuration. In combined cycle power plants (CCPP) these are strongly related to the number and type of the installed gas turbines. In single-shaft units a gas turbine and a steam turbine commonly drive a single generator. For start-up and shutdown operations, this configuration requires a switch gear to separate the steam turbine from the shaft train. Multi-shaft configurations use independent gas turbine-generator and steam turbinegenerator sets. Commonly, one or two gas turbines power a heat recovery steam generator (HRSG), which drives the steam turbine-generator set.Within a given CCPP configuration, the steam conditions depend on the power output andtemperature level of the applied gas turbine. Hence, as a result of the ongoing gas turbinedevelopment, steam temperatures and mass flows are increasing continuously. Typically, the current generation of CCPPs (e.g. [8]) are designed for main steam conditions of 157 bar and565°C, and reheat temperatures of 565°C. However, due to the numerous gas turbines in themarket, steam turbines need to be able to cover a wide power range for CCPP. This range may also be considerably increased if duct-firing is applied.For sub-critical steam power plants (SPP) the market requires main steam temperatures up to600°C at main steam pressures of 177 bar. Additionally, steam turbines for SPP need to feature steam extractions as well as an overload injection to support an optimum steam cycle design. In recent years the steam turbine division of the Siemens Power Generation Group has focused on the development of two-cylinder designs to cover the complete range of applications in CCPP and SPP up to a steam turbine power output of 700MW. The HE series, with a single flow LP, is applied for lower power range and high back pressures, whereas the KN series covers the upper power range and applications with large LP flows. For both product lines, particular effort has been made to fulfill the market requirements with respect to performance, availability, start-uptimes and delivery times. Due to challenging price levels in the market, this could only beachieved with a modular design concept. The concept allows for high flexibility in the designphase, in order to deliver customer specific designs using standardized modules as a basis.This paper will provide an overview of the two product lines, and give details on the application

of the modular concept within different aspects of steam turbine design.

TWO CYLINDER DESIGNS UP TO 700MW

For the power range from 100MW to 700 MW, Siemens provides two optimized two-cylinder steam turbine designs with single and double flow low pressure sections. Forapplications with lower power output or high back pressures, the HE product line with singleflow LP is used. The flat floor mounted HE steam turbine set consists of a high pressure turbine module (H) and a single flow combined intermediate/low pressure module (E) with axial exhaust.The H-turbine is a single-flow, full-arc admission machine. The steam enters through onecombined control and stop valve. The H-turbine casing uses the proven barrel-type design, which does not have horizontal flanges at the outer casing to ensure a homogenous distribution of the forces regarding main steam pressure and thermal load. Additionally, the design improves the

TWO CYLINDER DESIGNS UP TO 700MW For the power range from 100MW to 700 MW, Siemens provides two optimized two-cylinder steam turbine designs with single and double flow low pressure sections. (Fig. 1). For applications with lower power output or high back pressures, the HE product line with single flow LP is used. The flat floor mounted HE steam turbine set consists of a high pressure turbinemodule (H) and a single flow combined intermediate/low pressure module (E) with axial exhaust. The H-turbine is a single-flow, full-arc admission machine. The steam enters through one combined control and stop valve. The H-turbine casing uses the proven barrel-type design, which does not have horizontal flanges at the outer casing to ensure a homogenous distribution of the forces regarding main steam pressure and thermal load. Additionally, the design improves the

TWO CYLINDER DESIGNS UP TO 700MW For the power range from 100MW to 700 MW, Siemens provides two optimized two-cylindersteam turbine designs with single and double flow low pressure sections. (Fig. 1). Forapplications with lower power output or high back pressures, the HE product line with singleflow LP is used. The flat floor mounted HE steam turbine set consists of a high pressure turbinemodule (H) and a single flow combined intermediate/low pressure module (E) with axialexhaust.The H-turbine is a single-flow, full-arc admission machine. The steam enters through onecombined control and stop valve. The H-turbine casing uses the proven barrel-type design, whichdoes not have horizontal flanges at the outer casing to ensure a homogenous distribution of theforces regarding main steam pressure and thermal load. Additionally, the design improves the

Turbine Modules

For the K-Turbine, the fullapplication range from 100-700 MW(for 60Hz) is covered with fourmodule sizes (Fig. 2). All modulesare based on the same designphilosophy in order to apply similarproven design features to all turbines.The latest design incorporates the K turbineexperience of the past 30years from both Siemens andWestinghouse.The scaling factor between the different turbine modules have beenregard to turbine efficiency. As a result, the K-turbine family covers the complete applicationrange with a constantly high performance.Additionally, the modular design yields further cost and delivery-time benefits to the customer.Firstly, developmental efforts for new K-turbine types is considerably reduced and contractspecific design work is minimized, while at the same time the high level of reliability ismaintained. Secondly, the long lead time items are standardized for 50Hz and 60 Hz applicationsin order to reduce the delivery times. As an example, identical casing patterns can be used for50Hz and 60Hz as well as for CCPP and SPP applications. Due to the design of the patterns,required extractions and overload admission can be added by means of separate parts.

Sub-Modules

The turbine modules are furthermore divided into sub-modules of different sizes, which may becombined as required. This approach has been especially favorable for the E-turbine, since sizeof the IP part is mainly linked to the main steam flow, whereas the size of the LP part alsostrongly depends on the ambient temperature. Therefore the modular concept consists of astandardized axial separation plane between the IP and LP casings and of a welded rotor module.

The modular concept yields an optimum number ofrequired components to cover a wide range ofapplications for both CCPP and SPP. For the latter, anadditional set of casing components is available withsteam extractions. Again, the main benefits from themodular concept are reduced prices and delivery timesdue to the standardized long lead time items – while atthe same time a very high performance level ismaintained.

Valves

The HP, IP and LP admission valves comprise stop andcontrol valves arranged at right angles to each other andcombined in a single casing (Fig. 4). For both the E andthe K turbines, the valve assembly is provided with a flange connection at the bottom of the outercasing of the turbine.The modular valve concept consists of a standardized connection to the turbine casings fordifferent sizes. Thus different valve sizes can be assembled to a single turbine size, and a singlevalve fits to different turbine types. Hence an optimum valve arrangement with respect to flowvelocities can always be applied to achieve maximum element efficiency.

Bearings

The HE and the KN steam turbine arrangements both consist of three bearings. All three bearingpedestals are separated from the turbine casings and are supported directly on the foundation.Only one bearing is located between the turbine sections tominimize the effect of foundationdeformation on loads to bearingsand shaft journals. Axial thermalexpansion of the entire rotor trainstarts at the combined journal andthrust bearing as the fixed point. If

required, the bearing pedestal can Only one bearing is locatedbetween the turbine sections tominimize the effect of foundationdeformation on loads to bearingsand shaft journals. Axial thermalexpansion of the entire rotor trainstarts at the combined journal andthrust bearing as the fixed point. Ifrequired, the bearing pedestal can design with optimumefficiencies is delivered to thecustomer.Different to the other elementsof the steam turbine, theprimary goal of standardizationwith regard to HP/IP bladinghas been to standardize the“way to the product” instead ofthe product itself. The basis isa strictly modular concept ofbladepath construction from standard and proven elements (e.g. airfoils, roots, grooves, shrouds,extractions, locking devices). As an example (Fig. 7), the composition of a single blade fromroot, shroud and airfoil is demonstrated. For each element, different types exist for the variousapplications, each type having its own advantages and disadvantages with respect toperformance, mechanics and costs. Within the modular concept all these different types may becombined freely to give an optimum blade for the specific design boundary conditions such asaerodynamics, forces, materials and temperatures. Hence, cylindrical, twisted or bowed airfoilscan be assembled with any of the roots or shrouds. Details on the concept applied for HP/IPblading are given in

MODULAR CONCEPT TO FULFILL TEMPERATURE AND PRESSURE

REQUIREMENTS

Besides the main steam flow, the second major design parameters are the main steam conditions.Main steam temperatures are continuously increasing to optimize the overall performance ofSPPs, and as in gas turbine development, also for CCPPs. At the same time high temperaturesrequire expensive material to withstand the associated optimum pressure levels. In order to keepprice increase moderate for such advanced steam cycles, one focus of the modular concept is toreduce the amount of required high-temperature material to a minimum. The basic designelements of the concept are:to apply identical designs for the main components at different temperature levels (e.g. 565°Cand 600°C) and thereby only to change material.

to weld main components in order to minimize the amount of high-temperature material.to shield components against the hot steam.to cool affected areas.The application of the concept to HEand KN product lines will be outlinedbelow.

K-Turbine Material Concept forTemperatures up to 600°C

The combined HP/IP turbine (KTurbine,Fig. 8) consists of a top and abottom half of inner and outer casingswith horizontal flanges. The thermalload due to the high main steam andreheat steam temperatures andpressures is completely carried by the inner casing. For this reason, the material of the innercasing is selected according to the specific application temperatures. Similarly, the rotor materialis chosen depending on the size of the K-turbine, the application temperature and the rotationalspeed (50 or 60 Hz).Steam TemperatureMain / Reheat SteamVariant 1540°C / 540°CVariant 2566°C / 566°CVariant 3600°C / 600°CFuture600°C / 620°CRotor(50Hz or 60Hz) low alloyedlow alloyedorhigh alloyedhigh alloyed high alloyedInner Casing low alloyed low alloyed high alloyed high alloyedOuter Casing globular castironglobular castironglobular castironglobular castironValve Casingslow alloyed

orhigh alloyedlow alloyedorhigh alloyedhigh alloyed high alloyed

Table 2: K-Turbine and Valve Materials

The design consists of special features which shield the outer casing from the hot main steam andreheat steam temperatures. The valve is connected to the inner casing via a flexible L-ring and athermo sleeve that guides the hot steam directly into the inner casing and the HP or IP bladingrespectively. As a result, the outer casing only needs to withstand the IP-exhaust pressure andtemperature. Therefore the outer casing material for all applications is globular cast iron, whichyields considerable cost reductions.Similarly, the valve casing materials are cost optimized for different design pressure andtemperature regimes.As an example of the modular material concept, an overview of the K-turbine materialcombinations applied for different main steam and reheat steam temperatures.

Welded Rotor Design

A welded design has been appliedto the rotor of the new E-turbine.The required materialproperties for the hot IP sectionwith smaller blades and the coldLP section with large centrifugalforces are completely different.Therefore, only a welded rotordesign enables the use of optimalmaterials for both the hot IPsection and the cold LP section.The combination of two materialsfor the rotor yields an optimum ofmechanical properties over a wide reheat temperature range: up to 565°C 2%-Cr-steel is utilizedfor the IP rotor block and the inner casing. Up to 600°C, the rotor and inner casing material issubstituted by a 10%-Cr-steel. The LP rotor block consists of a 3.5%-Ni-steel. The rotor weldingseam is positioned behind the LP front stages. This offers the advantage to implement a costeffective welding seam at the low diameter of the IP drum.

Cooling of Dummy Piston

To achieve maximum thermodynamic efficiencies, a straight-flow design was chosen for the newE-turbine. In contrast to a reverse-flow concept, the chosen straight-flow design requires a largeIP piston diameter for sufficient axial thrust compensation. Due to the mechanical impact of thislarge piston diameter at reheat temperatures, a forced rotor cooling has been developed for the IPpiston to ensure high life cycles. Cooling steam (350°C) from the cold reheat is blown into a special mixing space in front of theIP piston and mixed with hot reheat steam (between 565°C and 600°C) from the IP inlet toachieve an optimum temperature of 450°C. At this temperature, two advantages for both the IProtor and the IP piston are combined: optimum rotor life cycles and minimum clearances at theIP piston seal. Thereby 2%-Cr-steel can be used for the IP rotor up to temperatures of 565°. Thus,performance and reliability remain at a high level without increasing material costs. The coolingsystem has successfully been tested in E-turbines with high temperature capability in the US market.

MODULAR CONCEPT FOR OPTIMUM LP ENDS FOR A WIDE RANGE OF

CONDENSER PRESSURES

The third major design parameter with respect to modularity is the volume flow through the LPend stages, which is directly connected to the mass flow and the condenser pressure. Theperformance of the last stages and the exhaust diffuser is strongly related to the mean axialvelocity in this area. A number of different LP sizes are therefore required to cover the range ofcondenser pressures without compromising the performance of the LP section. In this case, thefocus of the modular concept is to achieve an optimum balance between maximum LPperformance and moderate costs. Therefore, the main targets where setto define an optimum set of LP standard stages to cover the required range of volume flows.to enable cost effective connections of all required combinations of LP and IP componentsand thereby to maintain optimumperformance.Thereby, a large condenser pressure range of20 to 200mbar is being considered.

LP Blading

Since the axial velocity after the last blade isprimarily related to the exit area (and not tolength of the last blade), a homogenousdistribution of exit areas has been chosen forthe Siemens family of LP standard stages . For each of the given exit areas, a

Free Standing LP End Blades

In general, the last two rows of LP moving blades are designed as free-standing blades withcurved fir-tree roots for a homogenous stress distribution. The highly-efficient three-dimensionalairfoil design consists of super-sonic tip section for the large end blades (Fig. 10). The inlet edgeis flame or laser hardened, respectively, to prevent from droplet erosion.Additional erosion protection measures are applicable to the last stationary blades. They aredesigned as hollow blades that either consist of drainage slots (Fig. 11) to remove moisture fromthe blade surface or can be heated with steam. An advanced three-dimensional airfoil design isapplied in order to increase stage reaction at the blade hub and hence improve performance atlow loadIn order to allow for larger axialmovement due to thermal expansion,non-interlocking labyrinth seals areapplied within the LP section of theturbine. The seal design provides anoptimum sealing efficiency within arelatively short seal length.

LP Exhaust Casing for Single Flow ETurbine

The modular concept of the E-turbineprovides only three different LP exhaustcasings to cover the complete exit arearange specified in table 1. The sixrelated sets of standard LP stages are

installed by means of standardizedinterfaces. Also, the axial joint between the LP exhaust casing and the IP outer casing is a standard interface that allows any combination

of sizes of the two casings. Fig. 12 shows the LP exhaust casing module for the 12.5m2

exhaustsection.

Exhaust Geometry Optimization

Detailed computational fluid analyses are performed in the design phase, in order to optimize thegeometry of the LP turbine exhaust as well as the transition region to the condenser. Inconjunction with measurements on models and on turbines in the field, effort is focused onincreasing exhaust pressure recovery and hence improving the overall steam turbineperformance.As an example, Fig. 13 shows the results of an exhaust analysis with flow lines for a classicturbine deck arrangement with the condensers mounted below the turbine. The steam flowdownstream of the last turbine stage passing into the exhaust hood shows considerable vortices,which were also observed in the flow in the exhaust casing itself. As vortices cause energy lossin the flow, guide vanes have been installed to improve flow and thereby reduce pressure losses.

SUMMARY

For a power range from 100MW up to 700MW Siemens provides the HE and KN steam turbineproduct lines for both CCPP and SPP. Both turbo sets consist of a two casing design. The HE isapplied where a single flow LP section issufficient to take the steam flow at optimumvelocities. For large power output and lowcondenser pressures the KN product line with adouble flow LP turbine is applied.Both designs are based on a modular design

concept. Details have been given in the paper onhow the concept is applied to compensate forthe effects of the major design parameters poweroutput, temperature and condenser pressure.Thereby, the main targets are to reduce thenumber of variants of major components and tominimize the material cost impact of hightemperatures.

The concept has successfully been applied within the HE and KN product lines and is seen afundamental basis to fulfill the challenging requirements in today’s steam turbine market. Thereduced number of major components ensures short delivery times and low costs. At the sametime the concept stands for reliability due to the application of proven Siemens technology andsimilar designs through-out each set of module sizes. Special design features such as the weldedE-turbine rotor contribute to short start-up times and operational flexibility. All configurationsconsist of Siemens latest LP standard stage designs. In the HP and IP sections a highperformancefully three-dimensional reaction blading is applied, which is designed on a contractspecific basis to provide maximum blade path efficiency.Hence, Siemens’ two casing designs have been optimized to fulfill the market’s most importantrequirements of low overall life cycle costs, high reliability, availability and operating flexibility

in order to support the customer focus on cost efficient production of electricity.

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.

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.

BROAD SPECIFICATION OF

MAJOR/IMPORTANT MACHINE TOOLS &

MACHINES

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





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


CNC MILLING MACHINES

7. Item Description : CNC Horz. Milling M/c (6 Nos.)

Model : BFH-15

Supplier : BATLIBOI, INDIA


Table : 1500 x 400 mm

Traverse : X=1170 mm

Y=420 mm

Z=420 mm

Spindle Speed : 45 to 2000 RPM


Max. Load Capacity : 630 Kg

Weight of the m/c : 4200 Kg

Plan No. : 2-449, 2-453, 2-454, 2-459, 2-460 (Block-

III:TBM)

8. Item Description : Universal Milling M/cs (2Nos.)

Model : BFK-15

Supplier : BATLIBOI, INDIA


Table : 1500 x 400 mm

Traverse : X=1170 mm

Y=420 mm

Z=420 mm

Spindle Speed : 45-2000 RPM


Max. Load Capacity : 630 Kg

Weight of the m/c : 4200 Kg

Plan No. : 2-463, 2-466 (Block-III: TBM)

9. Item Description : CNC Bed Type Milling M/c

Model : FSQ 80 CNC

Supplier : TOSKURIM, CZECH


Table : 3000 x 800 mm

TEE SLOT 28H7

Traverse : X= 3000 mm

Y= 870 mm

Z= 850 mm

Spindle Speed Range : H – 2500 RPM

Spindle Drive Power : 18 KW continuous

22 KW intermittent

Spindle Head Size : 620 x 500 incldg ram

543 x 420 encldg ram


Table Load : 2500 Kg


CNC MACHINING CENTRES

10. Item Description : SPL. Purpose 6 Station T-Root Machining

Centre (2nos.)

Supplier : MIH, JAPAN

CNC Control System : FANUC 7M

Indexing Table : 1900 mm dia

Indexing Position : 6 Nos.

Plan No. : 2-356, 2-41 (Block-III: TBM)

11. Item Description : SPL Purpose FIR Tree Root M/cing Cenre

Model : NTH 200

Supplier : RIGID, SWITZERLAND

CNC Control System : SINUMERIK 7M

Table : 1400 x 1400 mm

Traverse : X= 1950 mm

Y= 900 mm

Z= 600 mm

Spindle Speed : 30600 RPM

No of Spindle : 4


Plan No. 2-354 (Block-III TBM)

CNC VERTICAL BORERS

12. Item Description : CNC Vertical Borer

Model : TMD – 40 / 50

Supplier : OSAKA MACHINES, JAPAN

CNC Control System : FANUC 6TB, 3TC

Table dia : 4000 mm

Turning dia : 5000 mm

Turning Height : 4200 mm

Spindle Speed : 0.23-30 RPM

No. of Ram : 2


Max. Load Capacity : 70T

Machine Weight : 100 T

Max. Ram Travel (Vertical) : 2200 mm


13. Item Description : CNC Vertical Borer (2 Nos.)

Model : 40 DZ

Supplier : SCHIESS, GERMANY

CNC Control System : SINUMERIK 850 T

Table : 4000 mm

Max. Turning dia : 5000 mm

Max. Turning Height : 4200 mm

Ram size : 300 x 250 mm

Table Speed : 0.63 – 63 RPM

Max. Vertical Travel of Ram : 2200 mm


Table Load Carrying Capacity: 80 T


Plan No. : 1-235 (Block-I), 2-472 (Block-III)

14. Item Description : CNC Vertical Borer

Model : 32 DS 250

Supplier : SCHIESS, GERMANY


Table : 2500 mm

Table Load Carrying Capacity: 25T

Max. Turning Dia : 3200 mm

Max. Turning Height : 2200 mm

Ram Size : 210 x 250 mm

Max. Travel of Ram : 1400 mm

Table Speed : 0.8 – 160 RPM




OTHER SPECIAL PURPOSE CNC MACHINES

15. CNC SURFACE BROACHING M/C

Make : Marbaix Lapointe, UK

Model : Champion 32 /10, 300

CNC System : SINUMERIC 850 M

Broaching capacity (pulling force) : 320 KN

Broaching slide stroke : 10.3 mm

Broaching slide width : 1500 mm

Max tool length (continuous /row) : 9650 mm

Broaching Speed (cutting stroke) : 1-25 M/min

Broaching Speed (return stroke) : 60 M/min

Drive power rating : 135 KW

Broaching slide movement : Electro-mechanical

Maximum noise level : < 80 Dbs

Max. dia of the disc (mountable) : 2300 mm

Max. weight of the job : 3000 Kgs

Indexing & rotating tables : 1500 mm, 1000 mm

Indexing accuracy : +/- 3 Arc sec.

Plan No. : 2-485

16. CREEP FEED GRINDING M/C

Make : ELB CHLIFE, GERMANY

Model : ELTAC SFR 200 CNC

CNC System : SINUMERIC 3 GG

Work-piece diameter : 200 – 2000 mm

Work height : 2400 mm

Rotary & indexing table dia. : 2050 mm

Indexing accuracy : +/- 1 ARC SEC

Max. load capacity : 20000 KG

Y-axis (grinding head movement)

Vert. Traverse : 750 mm

Z- axis (grinding head support)

Movement on cross rail)

Horizontal traverse : 2400 mm

Traverse feed rate : 02 – 1200 mm /min

Grinding head main support

Drive motor : 34 KW

Grinding wheel max. dia. : 500 mm

Max. width : 100 mm

Bore : 203.2 mm

Surface speed : 16-35 M/Sec.

Plan No. : 2-491

17. BROACH SHARPENING M/C

Make : LANDRIANI, ITALY

CNC System : SELCA

Work-piece diameter : Upto 250 mm

Work Length : 200 mm

Plan No. : 2-487

BROAD SPECIFICATIONS OF

MAJOR / IMPORTANT MACHINE TOOLS & MACHINES

B: NON-CNC MACHINE TOOLS

(1) PRECISION HEAVY DUTY LATHE

Manufacturer : Karamatorsk Heavy Machine Tool Works (USSR); Model

KS-1614

Specifications

1. Maximum Swing 2000mm

2. Maximum Diameter of work piece over the Saddle 1500 mm

3. Maximum Distance between Centres 8000mm

4. Diameter of Spindle bore 80 mm

5. Maximum Taper when machining by the method of

Combined Feeds

0.15 mm

6. Maximum Length between Centres when machining by the

method of Combined Freeds

1200 mm

7. Maximum Weight of work piece 20000 kg

8. Maximum Length of Machine over the Saddle 8000 kg

9. Maximum Summary Effort of Cutting 10,000 kg

10

.

Limit Dimension of Thread Cut:

Thread Pitch Max Length of Thread,

Min Max mm

Metric Threade Pitch (in mm) 1 96 6300

British Trhread Pitch (Per inch) 20 3/8 6300

Name of Part Powe

r

Displacement in mm

Manual Per Rev. of

Dial

One Division

Of Dial

Represent

Rapid

Traverse

M/min

Carriage 2.02

Transverse Slide 1130 1130 8 0.1 mm 1.03

Longitudinal

Slide

600 600 6 0.1 mm 0.48

Tool Slide 150 6 0.1 mm -

Rotary Part 90o 5 o 0.5 -

Maximum Displacement of the Tailstock Spindle 260 mm

Maximum Transverse Displacement of the Tailstock 17 mm

Rotating Built –in Centre Available

Power Extraction of the Tailstock Spindle Available

Rapid Traverse of the Tailstock 3.44 M/min

12. Overall Dimension:

Length 13900 mm Width 3845 mm Height 2865 mm

13. Plant No. 2-182 (Block-III)

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)

BALANCING MACHINE

Manufacturer: SCHENK (West Germany)

Model : Dj 90

Specifications

1. Weight of rotor 10,000 to

80,000 kg

2. Minimum weight without considerable loss of measuring

sensitivity, provided the berings can accommodate such

small rotors.

5000 kg

3. Maximum weight for one bearing pedestal 45,000 kg

4. Height of rotor axis above machine bed 1600 mm

5. Rotor diameter (free swing over machine bed) not

considering the funnel

4000 mm

6. Diameter of journal Max. 540 mm

7. Diameter of journal, with special sleeve bearing cups made

from high grade material.

Max. 600 mm

8. Minimum distance between bearings for less than 10 tons

rotor

1500 mm

9. Minimum distance between bearings for more than 10 tons

rotor

1900 mm

10. Maximum distance between coupling plague and center of

the scond bearing pedestals

13500 mm

11. Rotational Speeds Min. 800 rpm

(a) For rotors from 5 to 10 tons Max. 4000 rpm

Min. 700 rpm

(b) For rotors from 10 to 20 tons Max. 3600 rpm

Min. 600 rpm

(c) For rotors from 20 to 80 tons Max. 3600 rpm

12. Maximum test speed and overspeeds

(a) For rotors upto 50 tons

(b) For rotors upto 50 to 80 tons

4500 rpm

3600 rpm

13. Maximum centrifugal force admissible on each bearing

pedestals for short period of time

50,000 Kg

14. Balancing accuracy to be obtained depending on Selling

Weight

0.3 to 3 micron

15. Sensitivity of indication depending on rotor weight, speed

and selling weight

0.1-8

div/micron

16. Accuracy of the angle indication 1 o – 2o

17. Stiffness of bearing pedestals, when mounted on machine

bed

(a) With unclamped bearings 1.2 Kg/micron

(0.85

micron/Kg)

(b) With clamped bearing 100 Kg/micron

(0.01 micron

/Kg).

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

(c) Total 400 mm

(d) For one revolution of hand wheel 0.2 mm

(e) For one dial graduation 0.01 mm

(f) Speed of rapid traverse (from motor) 280 mm / min

UNIVERSAL THREAD GRINDING MACHINE

Manufacturer: Moscow Jig Boring Machine Plant (USSR)

Model : 5822B3

SPECIFICATIONS

1. Maximum diameter of work admitter 160 mm

2. Nominal diameter of thread being

ground

Min

Max

25 mm

125 mm

3. Thread pitch Min

Max

0.5 mm

6 mm

4. Maximum length of thread being

ground,

(a) By single-ribbed wheel 75 mm

(b) By multiple ribbed wheel 55 mm

5. Maximum taper of thread: 1o 47' 24"

or 1:16

6. Table

Maximum longitudinal table traverse,

(a) By hand 425 mm

(b) By power 415 mm

Table rapid withdrawal speed (variable:

maximum

about 1.2

m/min)

7. Taper

(a) Headstock spindle MT 4

(b) Tailstock spindle MT 5

8. Grinding Wheelhead

Maximum cross feed

(a) By hand 125 mm

(b) By power 50 mm

Movement per dial division 0.005 mm

Movement per dial revolution 1 mm

PLANER

Manufacturer : The Yefemov Plant TIAZHSTANKOGIDRO-PRESS (USSR)

Model : 7A288-T

SPECIFICATIONS

1. Max. width of planning 4000 mm

2. Max. height under cross rail 4000 mm

3. Distance between housings 4250 mm

4. Max. travel of slides below cross rail and inside housing

(a) for vertical tool heads 700 mm

(b) for side tool heads 700 mm

5. Max. allowable weight of workpiece 100 T

6. Max. cutting force

Arrangement for mechanizing and automating the machine

operation is available

40000 Kg.

7. Table

Dimension of working surface of table,

(a) Width 3600 mm

(b) Length 12000 mm

Table Stroke, Max. 12000 mm

Min. 3000 mm

Safety devices to stop table after worm

disengaging.

Available.

8. Tool Heads

Number of tool heads (a) Vert. 2

(b) Side 2

Travel of tool heads, mm. V.Tool Side Tool Heads

Heads R.H. L.H.

(i) Max. vertical travel 700 3750 3750

(ii) Max. horizontal travel 5000 700 700

(iii

)

Travel per turn of hand-wheel lever, (in

mm)

Vertical travel 1.14 4.25 4.25

Horizontal travel 0.52 1.14 1.14

(iv) Dial division value

Vertical 0.1 0.2 0.2

Horizontal 0.2 0.1 0.1

(v) Rapid travel

Speed mm

Vertical 1.25 2.5 2.5

Horizontal 2.5 1.25 1.25

9. Cutter Head:

(i) Max. dimension of tool holder Vertical Side

Tool head Tool head

(a) Width 120 mm 120 mm

(b) Height 120 mm 120 mm

(ii) Max. angle of slide Swiveling

(a) To the right 60 o 45o

(b) To the left 60 o 45o

(iii

)

Dial division value 10 10

(iv) Swiveling of cutter head plate 10 o 10 o

(v) Cutter head automatic lifting during return

stroke of table

Available Available

10. Cross Rail:

Maximum travel 4000 mm

Rapid travel speed Not less than 0.3 M/min

Time of cross rail automatic fixing 20 to 30 sec.

Main drive motor 2 x 130 KW

11. Plan No. 2-189 (Block-III)

MATERIALS SPECIFICATIONX20 – Cr – 13

A. 13% Cr. Stainless Steel Bars (Hardened & Tempered)

1. General : This specification governs the quality of

stainless steel bars of grade X20 – Cr. –13

2. Application : For machining of moving and guide blades of

steam Turbine.

3. Condition of Delivery : Hot rolled / Forged & hardened and tempered.

The bars shall be straight and free from

waviness.

4. Complete with standards: There is no Indian standard covering this

material.

5. DIMENSIONS & TOLERANCES :

Dimension : Bars shall be supplied to the dimensions

specified in the purchase order unless otherwise

specified in the order. The bars shall be

supplied in random length of 3 to 6 meters with

a maximum of 10% shorts down to meter.

Forged bars shall be supplied in length of 1.5 to 3 meters.

Tolerance : The tolerance on cross sectional dimensions

shall be as per table.

5.1. Hot Rolled Bars : Tolerance on hot rolled flat bars shall be as

specified below :

b

s

"b" width across flates

mm

Allowable deviation on

"b" mm

"s" thickness

mm

Allowable devi.

on 'S' mm

Up to 35 + 1.5 Up to 20 +1

Over 35 and Upto 75 + 2 Over – 20 and

Upto – 40

+ 2

Over 75 + 3 Over 40 + 3

Note : Other tolerances shall be as per DIN 1017. Twisting and bending off the

bars shall not exceed 0.001X length of the bar. Bulging on the sides shall

not be more than 0.01 x b and 0.01 x s respectively.

5.2 Forged Bar : Tolerances on size for forged bars shall be +8%

of the size.

6. MANUFACTURE :

6.1 The steel shall be manufactured in basic electric furnace process and

subsequently vacuum degassed or electric slag refined (ESR). Any other

process of meeting shall be subjected to mutual agreement between

supplier & BHEL.

6.2 For manufacture of flat bars, if initial material is other than ignot (e.g.

continuous casting), supplier shall mention it in his quotation for prior

approval from BHEL.

7. HEAT TREATMENT :

7.1 The bars shall be heat treated to get the desired mechanical properties

specified in this specification. The hardening temperature shall be in the

range of 980 – 10300C and the tempering temperature shall not be below

6500C As per DIN-19440.

7.2. Minimum possible residual stress shall be aimed with slow cooling and

longer duration of tempering treatment.

7.3. If the bars require straightening after heat treatment, the bars shall be

stress relieved after straightening operation at 300C below the actual

tempering temperature.

8. FREEDOM FROM DEFECTS :

8.1 The bar shall be free from lamination cracks, scabs, seams, shrinkage

porosity, inclusions and other harmful defects.

8.2 Decarburisation and other material defects shall not exceed the

dimensional tolerances and machining allowances.

9. FINISH :

9.1 The bar surface be smooth, free from laps, rolled in scale etc. Dents roll

marks. Scratches are permitted provided their depth does not exceed

half the tolerance limits specified in table.

9.2 Repair of surface flaws by welding in not permitted

9.3 The edges of bars shall be cut square by swaing or shearing.

10. CHEMICAL COMPOSITION : The chemical composition of material

shall be as follows (table analysis in %)

Element Min. Max.

Carbon 0.17 0.22

Silicon 0.10 0.50

Manganese 0.30 0.80

Chromium 12.50 14.00

Nickel 0.30 0.80

Sulphur -- 0.020

Phosphorus -- 0.030

11. SELECTION OF TEST SAMPLES :

11.1 Chemical analysis shall be reported on each heat basis..

11.2 For Mechanical Test

11.2.1 One tensile & 3 impact test samples shall be selected for

mechanical testing per melt per heat treatment batch basis from lot

of size.

11.2.2 The uniform strength of a delivery shall be certified through

hardness test. In case of bars with sectional dimensions more than

120mm, all the bar shall be tested for hardness. In case of bars with

sectional dimension less than or equal to 120mm hardness shall be

checked on 10% of the bars or 10 numbers of bars which ever is

higher.

11.2.3 The mechanical and notch impact test is to be done in longitudinal

direction on the hardest and softest bars. Test sample shall be to

Km. at 1/3rd below the surface of the bars.

12. Mechanical Properties :

12.1 The material shall comply with the following mechanical properties

at room temperature.

0.2% : 600 N/MM2 Min

Tensile strength : 800 – 950 N/mm2

% Elongation on 5.65 : 15 min.

% reduction in area : 50 min. *

Impact (mean of 3.1S0 – V sample): 20 J min.

Hardness (HB-30) : 280

* The smallest value shall be at least 14 J.

12.2 Tensile test shall be carried out in accordance with IS : 1608 or

equivalent international standard.

12.3 Impact test shall be carried out on 3 ISO-V samples in accordance

with IS : 1757 or equivalent international standard only one test

value out of three, can be below the specified value ; but in no case

it should be below 2/3rd of the minimum specified value; but in no

case it should be below 2/3rd of the minimum specified impact

value.

12.4 Hardness test (Brinell) shall be carried out according to IS : 1500 or

equivalent international standard.

13. NON DESTRUCTIVE TEST : Following NDT shall be carried out.

13.1 UT of the prematerial combined with 100% magnetic partial testing

of all bars in delivery condition.

13.2 Complete UT of all bars in delivery condition.

13.2.1 In case of testing as per 14(a) U.T. shall be carried out as per HW

0850 192 (SEP 1923) test class D3 and MPI of all bars except of

face areas. In case of testing as per 14(b) UT shall be carried out as

per HW 0850 192 (SEP 1923) test class D2.

13.2.2 Mix up test (verification test) of all bars.

13.2.3 Visual inspection of all bars

13.2.4 Acceptance Criteria

a) Magnetic Particle Test : When MT is carried out as per clause

14.1.

Surface defects with expected depth > 1 mm are unacceptable.

Indication > 5 mm are unacceptable.

Defect indication observed during MT, can be removed by grinding

(dressing up) but with in 1mm depth.

b) Ultrasonic Test : Quality class 2b with following modification that

individual indication > 2mm EFB (KSR) and back wall losses >

3dB are unacceptable.

X2 – CrMoV1 21

B. 600 N/MM2 minimum 0.2% Proof stress Heat resistant steel bars

for steam turbine blades

1. General : Hot rolled and forged bars of steel grades X22

CrMoV1 21.

2. Application : Bars are required for machining of guide and

moving blades for steam turbines.

3. Dimension & Tolerance :

"b" width across flates

mm

Allowable deviation

on "b" mm

"s" thickness

mm

Allowable devi.

on 'S' mm

Up to 35 & Over 35 ± 1.5 Up to 20 &

Over 20

+1

Upto 75 + 2 Upto – 40 + 2

Over 75 + 3 Over 40 + 3

4. Chemical Composition :

Element % min. % max.

Carbon 0.18 0.24

Silicon 0.10 0.50

Manganese 0.30 0.80


Malybeonum 0.80 1.20

Vanadium 0.25 0.35

Nickel 0.30 0.80

b

Sulphur -- 0.020

Phosphorous -- 0.030

5. MECHANICAL PROPERTIES :

0.2 % proof stress : 600 N/mm2 min.

Tensile Strength : 800-950 N/MM2

% Elongation : 14 Min.

% Reduction in area : 40% Min.

Notch Impact Value : 27 J * Min.

* Average of 3 IS0 – V Samples.

C. 600 N/MM2 0.2% PROOF STRESS FORGED BLADES

1. General : This specification governs the quality of guide and

moving blades forged from steel grade X 20 or 13.

2. Application : The blades are used for steam turbines.

3. Condition of Delivery: The forged blades shall be supplied in heat treated

forged blade shall be supplied with center holes

made in accordance with respective technical

requirements or ordering drawing.

4. Dimensions & Tolerance: The dimension and tolerances shall be as per

ordering drawing accompanying the order.

5. Manufacture : The steel shall be manufactured in the blade

electrical furnace and for subsequently refined to

ensure turbine blade quality. The forgings shall be

made as envelope forging or precision forging,

subsequently machine / grinder to achieve the

ordering drawing dimensions and surface finish.

6. Heat Treatment :

6.1. The forging shall be heat treated to get desired mechanical properties.

6.2. The tempering temperature shall not be below 6500 C. The minimum

residual are to be aimed through sufficient duration of the tempering

treatment and the slow cooling rate from the tempering temperature.

6.3. The blades are to be straightened after heat treatment, each

straightening operation is to be followed by a stress relieving

temperature and in no case below 6100C followed by slow cooling.

7. Freedom from Defects : Blades shall be free from folds due to forging ;

cracks, tearing and other material defects,

elonganed non-metallic and jusions, seams etc.

any blade blade containing such defects shall be

rejected.

8. Surface finish : The blade shall be supplied in a desoaled and

deburred condition. The surface finish shall

comply with the requirements specified on the

drawing. In the surface is ground prior to blasting

the the surface finish must be anouired in

compliance with the finish specified on the

drawing. Grinding may be performed to a depth

not more than H/2 and ground areas shall be

blended over a length of LP/2. However H Shall

not be exceeded.

H : Allowable profile deviation on the pressure side.

LP : Profile length measured from leading edge to

trailing edge.

9. Chemical Composition : The chemical analysis of the material shall

confirm to the following :

Element % min. % max.

Carbon 0.17 0.22

Silicon 0.10 0.50

Manganese 0.30 0.80


Nickel 0.30 0.80

Sulphur -- 0.020

Phosphorous -- 0.030

10. Selection of Test Sample : All tests and examination shall be

performed on specimens taken in

accordance with annexure 1 from at least

one blade of each drawing per melts and

heat treatment batch.

11. Mechanical properties :

11.1 The mechanical properties of the blade material shall conform to the

following :

0.2 % proof stress : 600 N/mm2

Tensile Strength : 800-950 N/MM2

% Elongation : 15 Min.

% Reduction in area : 50 Min.

Impact Value (Average of

3, ISO – V Sample) : 20 J Min.

Brinell hardness HB 30 : 280 Max.

11.2 Tensile Test : The tensile test piece shall confirm to the gauge length.

11.3 Impact test shall be carried out on standard test piece as per ISO – V

notch according to IS : 1757.

11.4 Hardness Test : The brinell hardness test HB 30 shall be carried out

according to IS : 1500.

12. Non Destructive Test :

12.1 Blade shall only be manufactured from ultrasonically examined rare

material.

12.2 In order to ensure freedom from defects. All blades shall be subjected to

magnetic particle examination prior to shipment.

13. Dimenional Checks for Acceptance :

13.1 The supplier shall check 100% of the forgings w.r.t. to all parameters.

13.2 Dimensions parameters to be checked for acceptance.

Following dimensional parameters of each of the check sections as

specified in ordering drawing shall be inspected after fixing / clamping

the forging in vertical stand to check conformance of profile of

individual section as well as in relation to each other.

o From tolerance for pressure side = H

o From tolerance for suction side = R, max differenceR

o From tolerance for Inlet edge = H

o Twist Tolerance = (H, R) max.

Profile thickness of each section. = D Max. / D / D1

Max. profile length of each section.

Root dimensions.

Base dimensions.

Base plate contour.

Axial and tangential shift of profile with respect to root.

Overall length of forging.

Surface finish.

13.3 Procedure for dimensional checks :

Check of inlet edge : The profile of inlet edge shall be checked by

using split profile gauges.

Check of Profile : All the dimensional parameters mentioned at

(13.2) shall be checked using a vertical measuring stand.

Drilling of BHEL Centre holes

Checking of BHEL Centres.

Documents

V.t Project Report by SANJEET KUMAR