Professional Documents
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Bhel Report
Bhel Report
Training Report in
Turbine Section & Central Foundry & Forging
Plant
SUBMITTED BY:
RAVI PRAKASH SINGH
B.Tech -FINAL YEAR(2007-08)
MECHANICAL ENGINEERING
ROLL NO-0404340029
B.I.E.T-JHANSI
TRANING PERIOD-(9th June - 8th July 2006)
SUBMITTED TO:
Mr.ALOK SHUKLA
SENIOR MANAGER
TURBINE GOVERNING SECTION
BHARAT HEAVY ELECTRICAL LIMITED
HARIDWAR
BUNDELKHAND INSTITUTE OF
ENGINEERING &
TECHNOLOGY,JHANSI
TRANING REPORT IN
TURBINE SECTION
SUBMITTED BY:
RAVI PRAKASH SINGH
B.Tech -FINAL YEAR(2007-08)
MECHANICAL ENGINEERING
ROLL NO-0404340029
B.I.E.T-JHANSI
TRANING PERIOD-(9th June - 8th July 2006)
SUBMITTED TO:
Dr.V K BHATT
Prof & HEAD OF DEPARTMENT
MECHANICAL ENGINEERING DEPARTMENT
B.I.E.T-JHANSI
ACKNOWLEDGEMENT
1. BHELAN OVERVIEW
2. HEEPAN OVERVIEW
4. HYDRO TURBINE
5. STEAM TURBINE
6. GAS TURBINE
7. MANUFACTURING PROCESS
8. BLADE SHOP
GENERAL
The Block consists of four Bays, namely, Bay-I and II of size 36x378 metres
and 36x400 metres respectively and Bay-III and IV of size 24x402 metres
and 24x381 metres respectively. The Block is equipped with the facilities of
EOT Cranes, compressed air, Steam, Overspeed Balancing Tunnel,
indicating stands for steam turbine, rotors, one Test stand for testing 210
MW steam turbines Russian Design, one Test Stand for Hydro Turbine
Guide Apparatus and two separate Test Stands for the testing of Governing
Assemblies of Steam and Hydro Turbines.
4.HYDRO TURBINES
Guide Vanes and Shaft Machining Section This section is equipped with
Heavy duty Lathe machines upto 16 metres bed, CNC turning machines,
Horizontal Boring Machine, Heavy planer, Deep Drilling Machine, Boring
Machines, marking Table, Marking Machines and Assembly Beds. Turbine
shafts, Guide Vanes, Journals and Rotors of Spherical and Disc Valves are
machined here. Rotors of Steam Turbines are also machined in this section.
5.STEAM TURBINES
Test Station - Test station for testing of 210 MW USSR Steam Turbine at no
load is equipped with condensers, Ejector, Oil Pumps, Oil containers Steam
Connections etc, required for testing. Overspeed testing is done for
emergency Governor. Assembly Test Stands for different modules of
Siemens design are equipped with accessory devices.
Painting Preservation and Packing Section All the parts are painted,
preserved and packed here for final dispatch.
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.
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.
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.
This machine is installed in Bay-I Heavy Machine Shop and is used to turn
Tie Rods of Gas Turbine, which have very high length / diameter ratio. Tie-
Rod is a very long bolt (length approx. 10 meter & dia 350-mm) which is
used to assembly and holds the gas turbine rotor discs to form a composite
turbine rotor.
GAS TURBINE
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.
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.
This facility is a 3 Tier Platform installed in Bay-I assembly area and is used
for assembly of Combustion Chambers of Gas Turbine.
7.MANUFACTURING PROCESS
HYDRO TURBINES
STEAM TURBINE
GAS TURBINE
Machining
Castings, Forgings, welded structures and other blanks are received from
concerned agencies in the respective sections. These are machined keeping
in view optimum utilization of machine tools and toolings. Special jigs and
fixtures are made available to facilitate accurate and faster machining.
Proper regime and tool grades have been established to machine the
materials like inconel, which have poor machinablity.
Main Assembly
Final assembly is done on test bed. Parts are assembled to make sub-
assemblies. These sub-assemblies are again machined as per technological
and design requirements and are made ready for final assembly. After
assembly and insulation assembled Gas Turbine is sent to site.
Rotor Assembly
This assembly is carried out on 3 tier platform installed for this purpose in
Bay-I assembly. After machining of all components, ceramic tiles are fitted
in flame tube. Burner and piping etc. is fitted in dome and combustion
chamber is finally assembled. It is directly sent to site after insulation.
8.BLADE SHOP
Introduction:
Manufacturing Facilities:
The Semi blanks prepared from plain milling section are further machined
by copy Milling Machines / CNC machines (CNC Heller and BSK Bed
type Klopp, BFH / BEK Knee type Machines) for concave and convex aero-
dynamic profile forms, (HTC-600, BFK Machines) for expansion angles,
Compound taper grinding of radial plane is carried out by Surface grinders.
It comprises of T-root machining centers for machining of T-root.
LP Section
This area deals with all types of free standing and forged blades for steam
Turbine Compressor. The freestanding blades are cerrobend casted in boxes
to hold the blade with respect to the profile. These blades roots are
subsequently machined on NTH, MPA-80A and T30 Machining Centers.
There is a five station 360o circular copy milling machine for machining the
profile of envelope forged blades / stocks for Steam Turbine and Gas
Turbine Blades. It also has 3D copy Milling and CNC Machines with
digitizing features for Tip-thinning, Fitted milling. The inlet edge of the last
stage of Low pressure Turbine Moving blades are hardened on a Special
Purpose Flame Hardening equipment.
Polishing Section
Blade Contours are ground and polished to achieve the desired surface finish
and other aerofoil requirements.
There are also other small sections e.g. Fitting Section, Tool and Cutter
Grinding, Toolings Repair Section in Blade Shop.
Inspection Device
MANUFACTURING PROCESS
Model : RAPID 6C
Power Rating : 90 KW
Model : DW 1800
Power Rating : 63 KW
Model : W200 HB NC
Traverse : X=12500,
Y=5000,
Z=2000mm
CNC LATHES
Power Rating : 92 KW
Model : BFH-15
Traverse : X=1170 mm
Y=420 mm
Z=420 mm
IIITBM)
Model : BFK-15
Traverse : X=1170 mm
Y=420 mm
Z=420 mm
Power Rating : 11 KW
Traverse : X= 3000 mm
Y= 870 mm
Z= 850 mm
22 KW intermittent
Traverse : X= 1950 mm
Y= 900 mm
Z= 600 mm
No of Spindle : 4
Power Rating : 22 KW
Model : TMD 40 / 50
No. of Ram : 2
OTHER SPECIAL PURPOSE CNC MACHINES
Drive motor : 34 KW
Bore : 203.2 mm
Specifications
BALANCING MACHINE
Model: Dj 90
Specifications
Model: PT 182 H5
SPECIFICATIONS:
CASTING
CASTING