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    Bhel

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    Shankar Sharma
    This document provides an overview of BHEL's turbine shop located in Haridwar, India. It discusses the company profile, manufacturing facilities, major products including steam turbines, gas turbines, and blades. It then focuses on details of Block 3, which contains bays for machining steam turbines, gas turbines, and blades. Process details are described for manufacturing gas turbines, steam turbines, and blades. Key machinery used includes lathes, milling machines, and grinding equipment. Inspections such as 3D scanning and vibration analysis are conducted to ensure quality.

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    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd

    Bhel

    Uploaded by

    Shankar Sharma
    327 views26 pages
    This document provides an overview of BHEL's turbine shop located in Haridwar, India. It discusses the company profile, manufacturing facilities, major products including steam turbines, gas turbines, and blades. It then focuses on details of Block 3, which contains bays for machining steam turbines, gas turbines, and blades. Process details are described for manufacturing gas turbines, steam turbines, and blades. Key machinery used includes lathes, milling machines, and grinding equipment. Inspections such as 3D scanning and vibration analysis are conducted to ensure quality.

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    This document provides an overview of BHEL's turbine shop located in Haridwar, India. It discusses the company profile, manufacturing facilities, major products including steam turbines, gas turbines, and blades. It then focuses on details of Block 3, which contains bays for machining steam turbines, gas turbines, and blades. Process details are described for manufacturing gas turbines, steam turbines, and blades. Key machinery used includes lathes, milling machines, and grinding equipment. Inspections such as 3D scanning and vibration analysis are conducted to ensure quality.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    327 views26 pages

    Bhel

    Uploaded by

    Shankar Sharma
    This document provides an overview of BHEL's turbine shop located in Haridwar, India. It discusses the company profile, manufacturing facilities, major products including steam turbines, gas turbines, and blades. It then focuses on details of Block 3, which contains bays for machining steam turbines, gas turbines, and blades. Process details are described for manufacturing gas turbines, steam turbines, and blades. Key machinery used includes lathes, milling machines, and grinding equipment. Inspections such as 3D scanning and vibration analysis are conducted to ensure quality.

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    AN INDUSTRIAL REPORT ON TURBINE SHOP AT

    HARIDWAR

    COMPANY PROFILE

    A MAHARATNA 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

    MANUFACTURING PLANTS
    BHEL Haridwar has two manufacturing plants:-

    Heavy Electrical Equipment Plant (HEEP) and 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.

    MAJOR PRODUCTS
    Steam turbine
    Gas turbine Steam Generators

    HRSG- Heat recovery steam generator


    Transformers Locomotives

    Circuit Breakers
    Pumps Motors- BOTH AC AND DC, LT AND HT

    Generators

    TURBINE SHOP BLOCK 3

    GENERAL DETAILS OF BLOCK- 3


    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 .

    DETAILS OF BAY- 1
    Size- 36x378 meters.
    Consists of following machines: Hydraulic lifting platform

    CNC turning lathe


    Combustion chamber assembly platform

    DETAILS OF BAY - 2
    Size:- 36x400 meters CNC creep feed grinding machine
    (Gas turbine m/c area)

    External broaching machine CNC facing lathe Wax melting equipment Gas turbine test bed

    DETAILS OF BAY 3
    Size :-24x402 meters CNC stub borer CNC milling machine Universal milling machine CNC bed type milling machine CNC surface broaching machine

    DETAILS OF BAY - 4
    Size:- 24x381 metres
    Turbine blade machining shop Heat treatment zone

    GAS TURBINE

    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 tanks

    MANUFACTURING FACILITIES
    a) Hydraulic Lifting Platform: used for assembly and disassembly of G.T. Rotor. b) CNC Creep Feed Grinding M/c: grinds the hearth serration on rotor disc faces. c) External Broaching Machine: used to make groove on the outer dia of rotor discs for the fitting of moving blades on the discs. d) CNC Facing Lathe: used for facing rotor disc. e) CNC Turning Lathe: used to turn Tie Rods of Gas Turbine. f) Wax Melting Equipment: used to mix and melt Wax to arrest the blade movement during the blade tip machining of stator blade rings. g) Gas Turbine Test Bed: used to finally assemble the gas turbine. h) Combustion Chamber Assembly Platform: used for assembly of Combustion Chambers of Gas Turbine.

    MANUFACTURING PROCESSES
    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.

    STEAM TURBINE

    MANUFACTURING PROCESSES
    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 4500rpm.

    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 Centers.

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

    INSPECTION DEVICES
    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. Magna spray crack detection equipment.

    MANUFACTURING PROCESS
    The manufacturing process of turbine blades primarily depends on the

    type of blade e.g. Bar type, Brazed type, Gas Turbine blade.

    BAR TYPES BLADES


    PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED

    Blanking of area material Sizing to rectangular shape Thickness grinding

    Circular saw/band saw Hor. Milling Machine Surface grinder

    Rhomboid milling Taper grinding Grinding and polishing profile

    Duplex milling machine Surface grinder of Abrasive belt polishing m/c

    BRAZED TYPE BLADES


    PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED

    Cutting of drawn profile & spacer Hor. Milling machine blank

    Thickness grinding
    Cutting-off spacer Milling of width Grinding and polishing

    Surface grinder
    Abrasive cutting Duplex milling machine Abrasive belt polishing m/c

    GAS TURBINE BLADES


    PROCESS / OPERATION
    Cerrobend casting Root machining Length cutting

    MACHINE TOOL/EQUIPMENT USED


    Cerrobend casting equip. Hor. Machining center Circular saw/hor. Milling m/c

    Tenon
    Grinding and polishing of fillet

    Hor. Milling m/c


    Abrasive belt polishing m/c

    THANK YOU

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