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

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