VT-Project Report - Vocational Trainingx

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 and achieved a sales

turnover of Rs. 6347 crore with a pre-tax profit of Rs. 294 crore in 2000-01.

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

centres, over 150 project sites, eight service centres 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 are 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

INDUSTRIES/TRANSPORTATION/OIL &

GAS/

- Reverse Osmoses Desalination

Plants

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 AND AUXILIARY BLOCK-III

1.0 GENERAL

1.1 Block-III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and Turbines

Blades. Special Toolings for all products are also manufactured in the Tool Room

located in the same block. Equipment layout plan is a per Drawing appended in

Section III. Details of facilities are given in Section II.

1.2 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.

1.3 All the parts are conserved, painted and packed before dispatch.

2.0 MANUFACTURING FACILITIES

2.1 HYDRO TURBINES

For manufacturing of Hydro Turbines, Bay-I has the following sections:

(a) Circular Components Machining Section – This section is equipped with a number

of large/ heavy size Horizontal and Vertical Boring Machines, Drilling Machines,

Centre Lathes, Marking Table and Assembly Bed. The major components machined

in this section are Spiral Casing with Stay Ring, Spherical and Disc Valve bodies and

Rotors.

(b) Runner and Servo Motor Housing Machining Section – This section is equipped

with NC/CNC and conventional machines comprising Heavy and Medium size

vertical and Horizontal Boring Machines, Centre Lathes, Grinding machines and

Drilling Machines, Marking Table, Assembly Bed, Assembly Stands for Steam

Turbine and Gas Turbine assemblies and Wooden Platform for overturning heavy

components. Hydro Turbine Runners, Servomotors, cylinders, Labyrinth Ring,

Regulating Ring, Stay Ring, Turbine Cover, Lower Ring, Kaplan Turbine Runner

Body and Blades are machined here.

(c) 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.

(d) Assembly Section – In this section, assembly and testing of Guide Apparatus, Disc

Valve, Spherical Valves, Servo motor shaft and combined Boring of coupling holes

are done.

(e) Preservation and Packing Section – Final preservation and packing of all the Hydro

Turbine components / assemblies is done here.

(f) Small components Machining Section – This is equipped with Planetary Grinding

Machine, Cylindrical Grinding Machines, small size Lathes, Planers, Vertical and

Horizontal Boring Machines. Small components like Bushes, Levers, Flanges etc. and

governing assemblies and machines here.

(g) Governing Elements Assembly and Test Stand Section – This section is equipped

with facilities like oil Pumping Unit, Pressure Receiver, Servomotors etc. for

assembly and Testing of Governing Elements.

2.2 STEAM TURBINES

The facilities and parts manufactured in the various sections of Steam Turbine

manufacture are as follows:

(a) Turbine casing Machining Section – It is equipped with large size Planer, Drilling,

Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines

etc. Fabrication works like casings, Pedestals etc. are received from Fabrication

Block-II.

(b) Rotor Machining Section – It is equipped with large size machining tools like

Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree

Groove Milling Machine etc. Some rotor forgings are imported from Russia and

Germany and some are indigenously manufactured at CFFP, BHEL, Hardwar.

(c) Rotor Assembly Section – This is equipped with Indicating Stand, Small size

Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and

Discs. Machined Rotor, Discs and Blades are assembled here. Balancing and over

speeding of Rotor is done on the dynamic balancing machine.

(d) Turbine casing Assembly Section – Machined casings are assembled and

hydraulically tested by Reciprocating Pumps at two times the operating pressure.

(e) 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.

(f) Painting Preservation and Packing Section – All the parts are painted, preserved

and packed here for final dispatch.

(g) Bearings and Miscellaneous Parts Machining Section – This section is equipped

with small and medium size basic machine tools, e.g., lathes, Milling M/c, Horizontal

Borer, Vertical Borer, drilling M/c etc. for manufacture of bearings and other

miscellaneous parts of turbine.

(h) Sealing and Diaphragm Machining Section – It is equipped with medium size

Vertical Boring, Horizontal Boring, Planning, Drilling Machines etc. wherein castings

of sealing Housings, Liner housings, Forgings of Rotor Discs, castings and fabricated

Diaphragms and components are machined. It is also equipped with CNC machining

center.

Precision Horizontal Boring, Plano-Milling machines etc, are for manufacture of

Governing Casting, Servo Casings and other medium parts of governing and Main

Turbine assemblies.

(i) Governing Machining Section – This section is equipped with medium size and

small size lathes, medium CNC lathe, Milling, Grinding, Drilling, Slotting and

Honing Machines. Governing assembly parts are machined here.

(j) Diaphragm and Governing Assembly Section – It is equipped with deflection

testing equipment for Diaphragms, Dynamic Balancing Machine for balancing

Impeller of Centrifugal Oil Pumps and small fittings and assembly equipment.

Governing test stand is equipped with the facilities like Oil Pumping Unit, Pressure

Receiver, Servomotor, overspeed testing of Emergency Governor etc.

(k) Light machine shop – In addition to normal conventional machine tools it is

equipped with CNC Lathes, CNC Milling, CNC Vertical Boring, Precision Milling,

planetary grinding machines etc. for manufacture of small and medium precision

components of governing and other turbine parts.

2.3 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 holds 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.

3.0 MANUFACTURING PROCESS

3.1 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 unit, which is permanently installed on this bed.

3.2 STEAM TURBINE

Processes carried out in various sections of steam turbine manufacture are based on

the following main phases.

(a) Machine section – Castings, Forgings, welded structures and other blanks are

delivered to this section. The manufacturing process is based on the use of high

efficiency carbide tipped tools, high speed and high feed machining techniques with

maximum utilization of machine – tool capacity and quick acting jigs and fixtures.

(b) Assembly Section – Casings and governing assemblies are hydraulically tested for

leakage on special test Bed. Assembled unit of governing and steam distribution

systems is tested on Governing Test Bed. General Assembly and testing of Steam

Turbine is carried out on the main Test Bed in Bay-II.

(c) Painting, Preservation and Packing – After testing the turbine, it is disassembled

and inspected. Then the parts are painted, conserved and packed for final dispatch.

3.3 GAS TURBINE

The major processes involved in manufacturing Gas Turbine in various sections of

Bk-III are as follows:

a) 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.

b) 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.

c) Rotor Assembly

The rotor is assembled on Hydraulic Lifting Platform and sent to main assembly,

where after checking clearances, it is sent for machining. After balancing, turbine side

of rotor is disassembled, inner casing is fitted and rotor reassembled. This work is also

carried out on Hydraulic Lifting Platform. Finally rotor is sent for assembly on test

bed.

d) 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.

It is directly sent to site after insulation.

B.

BLADE SHOP

1. Introduction:

Major part of Turbine Blade Machining Shop is located in Bay-IV of Block-III. In

this shop various types of Steam Turbine and Gas Turbine Compressor blades are

machined from bar stock, drawn profile, precision and envelope forgings. It is a batch

production shop comprising of various kinds of CNC Machines and Machining

Centers, besides various special purpose and general purpose machines. The layout of

equipments is as per technological sequence of the manufacturing process. Blade shop

implements various On Line Quality Control Techniques through Run Charts and

Control charts. This shop is divided into four distinct areas. Details of facilities are

given in various schedules of Section-II.

2. Manufacturing Facilities:

i) Plain Milling Section

It prepares accurate reference surfaces on the blade blanks by milling and

grinding operation. It also manufactures the brazed type blades by induction

brazing of drawn profile and suitably machined spacers. This section carries

out banking by Band Saws, rhomboid grinding on Duplex grinding machines

and thickness grinding on Surface grinders.

ii) Copy Milling Section

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.

iii) 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.

iv) 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.

v) Inspection Device

- 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 magnifications.

- Fir- tree root inspection device.

- Magna spray crack detection equipment.

vi) Miscellaneous

There are other important facilities e.g. High rack storage system for fixtures.

Compactor system storage for finish blades. Jib cranes and EOT cranes for

material handling. The semi finished batch of blades are kept in special boxes

for inter-operation movements. An AGV (Automated Guided Vehicle) is also

located in LP Section of Blade Shop for better material movement.

3.0 MANUFACTURING PROCESS

The manufacturing process of turbine blades primarily depends on the type of blade

e.g. Bar type, Brazed type, Free standing (Forged type), Gas Turbine Compressor

blades. The bar type and brazed type blades are also known as drum stage glades. The

manufacturing technology of each of these blades along with recommended machine

tools / equipment is furnished below.

3.1 BAR TYPE BLADES

PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED

i. Blanking of area material Circular saw/band saw

ii. Sizing to rectangular shape Hor. Milling Machine

iii. Thickness grinding Surface grinder

iv. Rhomboid milling Duplex milling machine

v. Rhomboid grinding Duplex grinding machine

vi. Milling perpendicularity on both ends Hor. Milling machine

vii. Milling radius on surround Hor. Copy milling m/c

viii. Finish milling of convex and

concave profile

Hor. Copy milling / CNC

Hor. Milling machine

ix. Milling expansion faces of convex

And concave sides at root and shroud

Hor. Copy milling m/c/

CNC milling m/c

x. Root slot/root chamfer and

Radit at root and shround

Milling

2 spindle T-root roughing, m/c and

root radius copy milling m/c, T-root

machining center

xi. Taper grinding Surface grinder

xii. Grinding and polishing of profile

And expansion faces

Abrasive belt polishing m/c

xiii. Final Rounding, chamfering etc. Manual fitting.

3.2 BRAZED TYPE BLADES


i. Cutting of drawn profile & spacer blank Hor. Milling machine

ii. Sizing to rectangular shape Hor. Milling machine

iii. Thickness grinding Surface grinder

iv. Rough and finish milling of internal

profile of spacer


v. Cutting-off spacer Abrasive cutting

vi. Brazing of drawn profile and spacer Right frequency inducting brazing

installation

vii. Milling of width Duplex milling machine

viii. Pin rough and Root slot Vert. Milling m/c

ix. External profile rough and finish

machining


x. Pin turning Pin turning lathe

xi. Grinding and polishing Abrasive belt polishing m/c

xii. Debarring and rounding Manual fitting

3.3 FREE STANDING BLADES


i. Grinding of ref. Belts Abrasive belt polishing

ii. Milling of inlet & outlet edge 3D Vert. Copy milling m/c

iii. Center hole drilling CNC machining Centre

iv. Encapsulating with cerrobend alloy Cerrobend casting equip.

v. Remelting of cerrobend alloy Fir-tree root machining center

vi. Remelting of cerrobend alloy Cerrobend casting equip.

vii. Machining of fillets Vertical 3D copy milling machine

viii. Grinding and polishing Abrasive belt polishing

ix. Cutting-off blade tip Abrasive cutting machine

x. Inlet edge hardening Frame hardening equipments. (if required)

xi. Blade tip rounding Vert. 3-D dcopy milling m/c

xii. Tip thinning (if reqd.) -do-

3.3 GAS TURBINE BLADES


i. Cerrobend casting Cerrobend casting equip.

ii. Root machining Hor. Machining center

iii. Remelting of cerrobend alloy Cerrobend casting equip.

iv. Profile checking Vert. Stand

v. Length cutting Circular saw/hor. Milling m/c

vi. Tenon Hor. Milling m/c

vii. Grinding and polishing of fillet Abrasive belt polishing m/c

A.

QUALITY CONTROL FACILITIES

As in BHEL Customer Focus is of prime significance, Quality Control Function assumes

vital role. Quality Control facilities get priority in investment planning. The Group is

equipped with the state-of-the-art testing, measuring and analytic facilities. This chapter

covers Facilities existing in various sections under Quality Management Deptt.

1.0 FACILITIES IN QUALITY CONTROL – TURBINE BLOCK

Each Quality Control Station is equipped with conventional measuring instruments as

well as sophisticated testing machine to suit the inspection requirements of the related

area. Some of the important facilities are:-

i) CNC 3D Coordinate Measuring Machine – a fully computer controlled

modern machine for automatic inspection of complex or precision components

of size upto 2000x1200x1000 mm. The important features of this machine are

high-speed computer, versatile software, universal probe head for scanning,

digitization and plotting of known and unknown curves etc.

ii) 2-D Coordinate Measuring Microscope – Used for highly accurate and

precise measurements of small and intricate components of the turbine. The

machine is equipped with multiple feature digital readouts of resolution

0.0001 mm, a separate light generator connected through fiber cables for

better accuracy, optical templates for various inspection purposes etc.

iii) Vibration Measuring Equipments – Three no. of vibration measuring

equipments are available for checking of blade frequency at various stages.

iv) Portable hardness testers it is being used for checking of hardness of

plane hardened- Nitrided and stellited components. It can measure upto a

range of HV 999.

v) MPI Machine – This is used for carrying out magnetic particle test for crack

detection on finished blades.

vi) Surface Finish Measuring Equipment – This is used for checking the

surface finish of machined components. Can measure in R, Rz and Ra.

vii) Hardness Testers of different configurations

* SAROJ (VICKER CUM BRINELL) HV to BH 5 to 250 KG

* SAROJ B-3000 (BRINELL) BH 250 to 3000 Kg

* USSR (ROCKWELL) HRC 150 Kg

* USSR (BRINELL) BH 250 to 3000 Kg

* SAROJ (ROCKWELL CUM BRINELL) HRC/HB 60 to 250 Kg

* SAROJ (ROCKWELL) HRC 60 to 150 Kg

B.

HYDRO TURBINE LABORATORY

1. INTRODUCTION

Hydro Turbine Laboratory at HEEP, Hardwar was set up in late '60s. It comprises of

three Test Beds with electronic Instrumentation Laboratory for test bed

operation/maintenance and for carrying out Site Investigations. It has a modest

Workshop to manufacture hydro turbine models. Till December '95 about 160 number

of tests have successfully been performed in the Laboratory which include

Contractual as well as Developmental tests on Hydro Turbine Models, Calibration of

Hydraulic Valves, Nozzles and Flow Measuring Devices for 210 MW Thermal Sets.

Besides performing the main function of design/ development of hydraulic passages

of hydro turbines, design of models, their manufacture and testing, the Laboratory has

also been engaged in Field Test Studies at various Hydro Power Sites for conducting

Index Tests, Head Loss Measurement, Uprating Studies and attending to various Site

Problems.

2. DESIGN:

3. MANUFACTURING:

4. TESTING:

5. TESTING CAPABILITIES:

- Runaway speed tests of reaction and impulse turbine.

- Determination of MW output of prototype turbine under specified operating

conditions.

6.4 INSTRUMENTATION LABORATORY

The Instrumentation Laboratory is equipped with the most modern instrumentation for

carrying out accurate measurements during testing in the Laboratory as well as during

field testing. The major facilities are:

- Ultrasonic Flowmeter for field tests.

- Magnetic Tape Recorder with Waveform Analyzer.

- Microprocessor based Pressure Pulsation Measuring System.

- Microprocessor based Wicket Gate Torque Measuring System.

- Microprocessor based Hydraulic Thrust Measuring system.

7. RESEARCH AND DEVELOPMENT

The continuous inhouse research and development efforts of the Laboratory have

enabled it to establish new measurement methods for carrying out special tests, to

bridge know-how / know-why gaps, to resolve certain site problems and to evolve and

establish better and more efficient designs. The benefits of research and development

activities are passed on to the customers through implementation of new concepts of

existing sites and for future projects.

8. FIELD TESTING

The Laboratory is equipped to perform field efficiency and index tests on prototype

turbines at hydropower sites. Many site problems of hydraulic and mechanical nature

have been successfully solved as a result of extensive filed tests and analysis carried

out by the Laboratory. The Laboratory has successfully carried out uprating studies at

many hydro sites resulting in augmentation of power generating capacity of the units

at no extra or minimum cost. Extensive work has been done by the Laboratory to

tackle the problem of silt erosion of runner blades at several hydro power stations

situated in the Himalayan region.

9. CALIBRATION

The Laboratory is equipped with the required facilities for calibration of load cells,

pressure pulsation transducers, weights, volumetric tanks and torque wrenches.

Calibration of these terms is performed with respect to standards with history

traceable to N.P.L., Delhi.

10. FUTURE PLANS

Upgradation and modernization of Hydro Turbine Laboratory has been planned in the

following areas:

- Renovation of Test Beds to the cater for the requirements of IEC-995.

- Modernisation in the field of instrumentation.

- Addition of instantaneous in-siti calibration facility.

- Incorporation of Computerisation and Data Acquisition System

- Modernisation of Workshop facilities.

C.

HUMAN RESOURCE DEVELOPMENT CENTRE

INTRODUCTION

HRDC Workshop caters to the needs of skill training of various trainees at HRDC.

These trainees include Engineering Trainees & ACT Apprentices amongst others. Any other

type of trainees who are to be given imported training can be given skill training in areas of

machining, turning, fitting, welding, electrical, carpentry & electronics. In a year, about 500

ACT Apprentices are given training on various machines.

VARIOUS SECTIONS OF HRDC WORKSHIP

There are 7 different sections in HRDC Workshop in which facilities exist for

training.

(i) Turning Section – has facilities for practical training of Turner Apprentices &

trainees. There are 18 Lathes, which include HMT lathes H22, LB 17, LM 001,

Russian lathe No. 163, Kirloskar lather D 1 and one CNC Trainmaster T-70 of HMT

make.

(ii) Fitting Section – has facilities for training in the area of fitting e.g. 36 bench vices for

fitting work.

(iii) Machining Section – has 24 milling machines for skill training, 1 shaper, 1 slotter

and 10 grinding machines. A CNC machining center also exists for training in CNC

operations.

(iv) Welding Section – has facilities to give practical training in gas welding and electric

welding. The section has transformer, MG set, rectifier & an electrode oven.

(v) Electrical Section – has facilities for providing practical training in electrician field.

Areas in which practical training is given are laying of house wiring, joints making &

motor winding.

(vi) Carpentry Section – facilities for providing practical training in the field of

carpentry. It has various wood working machines, like surface planer lathe, thickness

planer, circular saw, pedestal grinder & drilling machines.

(vii) Electronics Trade – In this section practical training is given in making circuits &

repair work of TVs, tape recorders, amplifiers etc.

FACILITIES IN MANAGEMENT DEVELOPMENT / TRAINING

Audio visual facilities – Facilities exist for video projection through a video

projection system on a wide screen. Other facilities include a colour TV, a 16 mm

film & sound projector, overhead projectors (5 nos.) for transparencies, slide

projectors (2 nos.), a video camera, video cassette recorders (2nos.), two-in-one tape

recorders (2 nos.), a 35 mm photo camera, a conference system (for 6 persons) and a

number of video tapes & 16 mm films on management, technical and functional areas.

All these facilities are primarily used for facilitating learning at HRDC.

D.

POLLUTION CONTROL RESEARCH INSTITUTE

To provide directional thrust to environmental control / protection activities, a Pollution

Control Research Institute has been set up by BHEL at HEEP, Hardwar with the assistance of

United Nations Development Programme (UNDP).

The main objective of the Institute is to develop technologies for pollution control in the

areas of air, water noise and solid waste to obviate unintended side effects of economic

growth. The Institute is concentrating on research and development activities related to

environment protection against pollution emanating from industries. PCRI provides

consultancy services related to pragmatic approaches / methods to maintain pollution within

permissible limits. The other objectives include development of methods for recovery and

recycling of industrial wastes.

Most modern facilities for monitoring and analysis in the area of air, water, noise and solid

waste are available at the Institute. It has full-fledged computer facilities for prediction and

forecasting pollution impact. It also has workshop and other support services.

The laboratories of Pollution Control Research Institute have been recognized by Ministry of

Environment and Forests, Govt. of India; Department of Science and Technology, Govt. of

India; Madhya Pradesh Pradushan Nivaran Mandal; UP State Pollution control Board; Bihar

State Pollution Control Board; Punjab State Council for Technology; Haryana State Pollution

Control Board; Karanataka State Pollution Control Board.

E.

AVIATION PRODUCTS

MANUFACTURING FACILITIES

1. LIGHT TRAINER AIRCRAFT PROJECT

In 1991, BHEL Entered into Aviation Sector as part of its diversification efforts and

has taken up manufacturing of two-seater light trainer aircraft "SWATI". The aircraft

was designed and developed indigenously by R&D Wing of Directorate General of

Civil Aviation, India. Requisite organizational facilities and services infrastructure

has been developed in Sector X at BHEL, Hardwar.

"SWATI" is a general purpose aircraft powered by 116 HP horizontally opposed

piston engine with fixed pitch propeller and has wide range of applications like flying

training, sports, touring, surveillance, photography, courier & personal use.

2. WORKSHOP & FACILITIES:

2.1 General:

Hangar / Manufacturing Workshop consisting of one bay of size 45x90 mtrs with

expansion provision on eastern side have been developed at Aviation Project Site in

Sector X.

2.2 Manufacturing:

Following major components, sub-assemblies & assemblies are manufactured in

different sections:

- Fuselage

- Landing Gear

- Engine Mount

- Fuel Tank

- Pair of Wings

- Pin, Bush, Axle, Stud, etc.

- Lever, Brackets, Controls, etc.

- Fin, Rudder, Tailplane, Elevator, etc.

2.3 Facilities:

i) Fabrication / Welding Section

Equipped with TIG welding machines, this section is meant for fabrication of

fuselage, engine mount, landing gear and welding of lugs, brackets and other items on

fuselage.

ii) Wing Manufacturing Section

This section is located in WWM shop (Block-VII) of HEEP, as all the required wood

working facilities are available in that Shop.

iii) Machine Shop

The Shop is equipped with medium capacity center lathes, milling machines and

drilling machine. Small components like pins, bush, axle, wing to wing attachment

fitting etc. are routed through this Section.

iv) C.M. Section (Chrome Moly-Steel Section)

Components of CM steel like lugs, brackets, levers, control system etc. are

manufactured in this Section. This section is equipped with fitter tables, vices, hand

shear machine, screw press etc.

v) Alclad Section

All components / sub-assemblies made of Alclad material like Fin, Rudder, Tailplane,

Elevator, Cowling etc. are manufactured in this Section. This Section is equipped with

fitter tables, vices, compressed air, Hand shear machine, Sheet folding machine, 160

T Hydraulic press, 25 T Crank press etc. Fuel tank is manufactured in Sheet Metal

Shop of ACM (Block-IV).

vi) FRP Section

FRP Components like fairing, nose cap upper & lower, drag reduction items etc. are

made in this Section.

vii) Assembly Section

Trial Assembly / Final assembly of components on fuseldge is carried out in this

Section like mounting of fin, rudder, tailplane, engine, fuel tank, controls, instruments

etc.

viii) Test Flying Facilities

To establish performance characteristics of aircraft before delivery to the customer, an

airstrip of size 23M in width and 914 M in length has been developed in Sector IX

near the Project Site.

F.

MEDICAL LINAC PROJECT

Introduction:

Medical Linac, a machine for treatment of Cancer by Radiation Therapy has been taken up

for commercial manufacture at HEEP, Hardwar with know-how from (1) Department of

Electronics (DoE), Govt. of India, (2) SAMEER, Bombay, (3) Central Scientific Instruments

Organisation (CSIO), Chandigarh and (4) Post Graduate Institute of Medical Education &

Research (PGIMER), Chandigarh.

Medial Linac test station equipped with facilities for testing of Medical Linac machines upto

15 MeV (Mega Electronic Volt) has been established at HEEP, Hardwar and first 4MeV

machine jointly manufactured by SAMEER, CSIO, PGIMER and BHEL, Hardwar has been

successfully integrated and tested in newly established test station. Efforts are also afoot to

declare this test-station as National Test House.

Littion USA – make Hydrogen brazing furnace, model 4401 (specifications below) has been

installed near the Medical Linac test station. This shall be used to carry out brazing process of

parts made of Oxygen-free high- conductive (OFHC) copper.

Layout proposed for the Medical Linac block is enclosed. No special facilities have been

established for manufacture of controls for Excavator.

Dedicated equipment like vacuum brazing furnace, double vacuum baking furnace, low –

power test equipment including vector network analyzer etc. required for the manufacture of

complete machine will be added in future.

G.

CENTRAL PLANT STORES

General

Materials from suppliers, sub-contractors, other unitsand ancillaries enter the factory

premises from eastern gate.

Material Receipt

The materials are unloaded at receipt area, identified in the Central Plant Stores and

subsequently shifted to respective custody areas after inspection. In case of heavy materials,

receipt areas are adjacent to custody areas.

Material Issue

All the materials are received by Central Plant Stores and issued to users / manufacturing

blocks. Manufacturing blocks have their own sub-stores to receive material from Central

Plant Stores and further issue it to the shop / sections concerned.

Stores Custodies

The locations, where Central Plant Stores stores various types of material, have been

classified as custody-I, II, III, IV & V.

Custodies & Materials Stores

Custodies and the main categories of materials stored are as below:

BROAD SPECIFICATION OF

MAJOR/IMPORTANT MACHINE TOOLS & MACHINES

A: 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-

IIITBM)

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

CNC Control System SINUMERIK 810 M

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 Power 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 Max. 300

Headstock chuck Min. 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

40000 Kg.

operation is available

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)

BOARD OF DIRECTORS

Ashok K.Puri Chairman & Managing DirectorBharat Heavy Electricals LimitedBHEL House, Siri Fort, New Delhi – 110 049

Naresh Chaturvedi Additional Secretary & Financial AdvisorMinistry of Industry. Deptt. of Heavy IndustryUdyog Bhawan, New Delhi – 110 011

Dlip Raj Singh Chaudhary Joint Secretary

Ministry of Industry. Deptt of Heavy IndustryUdyog Bhawan, New Delhi – 110 011

Dr. Jamshed J. Irani Managing DirectorTata Iron & Steel Company LimitedJamshedpur – 831 001

Shekhar Datta Ex-Managing Director & PresidentGreaves Limited, E/8, Sea Face ParkBhulabhai Desai Road, Mumbai – 400 001

Ms. Tarjani Vakil Ex-CMD, EXIM Bank of IndiaA-1, Ishwar Das Mansion, Nana ChowkMumbai – 400 007

J. Jayaraman Ex-CMD, Cochin Refineries Limited39/4, Ashwin ApartmentC.P. Ramaswamy Road, Chennai – 600 018

K.Ravi. Kumar Director (Power)Bharat Heavy Electricals LimitedBHEL House, Siri Fort, New Delhi – 110 049

A.K.Mathur Director (IS&P)Bharat Heavy Electricals LimitedIntegrated Office ComplexLodhi Road, New Delhi – 110 003

S.K.Jain Director (Personnel)Bharat Heavy Electricals LimitedBHEL House, Siri Fort, New Delhi – 110 049

Ramji Rai Director (ER&D)Bharat Heavy Electricals LimitedBHEL House, Siri Fort, New Delhi – 110 049

MATERIALS SPECIFICATION

X20 – 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" 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

b

s

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 & +1

s

b

Over 20

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

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 forging 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.

A.

CLASSIFICATION OF BLADES

L.P. Moving Blade Forged Ist Stage.

L.P. Moving Blade 500 MW Last Stage.

100 MW 25th Stage Impulse Blade.

Compressor blade Sermental coated.

Compressor Blade 'O' stage.

Gas Turbine Compressor Blade.

T-2 Blade.

T-4 Blade.

3DS Blade.

Brazed Blade

Russian Design Blades.

Z – Shroud Blade.

Twisted Blade.

Present Range of Blades.

Future Range of Blades.

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.

BANGALORE.

Component Fabrication Plant, Rudrapur.

Piping Centre, Chennai.

Regional Operations Division, New Delhi

CONTENTS

1. Prologe – A. BHEL – An Overview

B. HEEP – An Overview

2. Study on Turbines & Auxiliary Block

3. Study on Material Specification

4. Study On Blade Shop

5. Broad Specification of Major Machines Tools & Machines

(CNC & Non CNC)

6. Other Areas

VT-Project Report - Vocational Trainingx

Documents

power transformers

power factor

power projects

industries bhel

power generations transmission

captive power plants

reactive power management

bhel supplies