Vocational Training Report

"Water Turbine Manufacturing"By

Sharad Jain

Mechanical Engineering,3rd Year (0101ME111047)

1

Acknowledgement

It gives me immense pleasure to present my Project Report before you. I

thankfully acknowledge the HRD Department of BHEL, My Project Guide

"Sir Giriraj Agarwal" for giving me so much co-operation and taught Each

and Every Specification of Machines, Process, and Working Principles of

Parts. I pay my sincere regards to him. Without his support I was not able

to accomplish my training.

I also thanks to all the working staff of WTMD Block, fabrication block for

their helpful guidance and support during the entire period.

I Also extend my Heartfelt gratitude to "Prof Aseem C. Tiwari (HOD,

Mechanical Department) for giving me such an opportunity.

2

1

Certificate

This is to certify that this project report has

been made by "Sharad Jain" of UIT, RGPV ,

Mechanical Engineering, on "The Study of Water

Turbine Manufacturing" under the guidance of

"Sir Giriraj Agarwal".

This Project has been completed successfully.

Yours truly,

Sharad Jain

Mechanical, 3rd Year

UIT, RGPV

Bhopal.

3

1

BHEL OverviewBHEL is an integrated power plant equipment manufacturer and one of the largest

engineering and manufacturing companies in India in terms of turnover. BHEL was

established in 1964, ushering in the indigenous Heavy Electrical Equipment industry in

India - a dream that has been more than realized with a well-recognized track record of

performance. The company has been earning profits continuously since 1971-72 and

paying dividends since 1976-77.

BHEL is engaged in the design, engineering, manufacture, construction, testing,

commissioning and servicing of a wide range of products and services for the core

sectors of the economy, viz. Power, Transmission, Industry, Transportation (Railway),

Renewable Energy, Oil & Gas and Defense. BHEL have 15 manufacturing divisions, two

repair units, four regional offices, eight service centers and 15 regional centers and

currently operate at more than 150 project sites across India and abroad. BHEL place

strong emphasis on innovation and creative development of new technologies. The

research and development (R&D) efforts are aimed not only at improving the

performance and efficiency of our existing products, but also at using state-of-the-art

technologies and processes to develop new products. This enables it to have a strong

customer orientation, to be sensitive to their needs and respond quickly to the changes

in the market.

The high level of quality & reliability of our products is due to adherence to

international standards by acquiring and adapting some of the best technologies from

leading companies in the world including General Electric Company, Alstom SA,

Siemens AG and Mitsubishi Heavy Industries Ltd., together with technologies developed

in our own R&D centers.

Most of Its manufacturing units and other entities have been accredited to Quality

Management Systems (ISO 9001:2008), Environmental Management Systems (ISO

14001:2004) and Occupational Health & Safety Management Systems (OHSAS

18001:2007).

4

1

Water TurbinesA hydraulic turbine is a prime mover (a machine which uses the raw energy of a

substance and converts into mechanical energy) that uses the energy of flowing water

and converts it into the mechanical energy (in the form of rotation of the runner). This

mechanical energy is used in running an electric generator which is directly coupled to

the shaft of the hydraulic turbine; from this electric generator, we get electric power

which can be transmitted over long distances by means of transmission lines and

transmission towers. The hydraulic turbines are also known as ‘water turbines’ since

the fluid medium used in them is water.

CLASSIFICATION OF HYDRAULIC TURBINES

The hydraulic turbines are classified as follows:

1. According type of energy at inlet of the turbine

Impulse turbine & Reaction turbine

2. According to the direction of the flow of water

Tangential flow turbine

Radial flow turbine

Axial flow turbine

Mixed flow turbine

3. According to the head at the inlet of the turbine

High head turbine

Medium head turbine

Low head turbine

4. According to the specific sped of the turbine

Low specific speed turbine

Medium specific speed turbine

High specific turbine

5

1

If at the inlet of the turbine, the energy available is only kinetic energy, the turbine is

known as impulse turbine. As the water flows over the vanes, the pressure is

atmospheric from inlet to outlet of the turbine. In the impulse turbine, all the potential

(pressure) energy of water is converted into kinetic (velocity) energy in the nozzle

before striking the turbine wheel buckets. Hence an impulse turbine requires high head

and low discharge at the inlet. The water as it flows over the turbine blades will be at

the atmospheric pressure. The impulse turbine may be radial flow or tangential flow

type.

If at the inlet of the turbine, the water possesses kinetic energy as well as pressure

energy, the turbine is known as reaction turbine. As the waters flows through the

runner, the water is under pressure and the pressure energy goes on changing into

kinetic energy. The runner is completely enclosed in an air tight casing and the runner

and casing is completely full of water.

If the water flows along the tangent of the runner, the turbine is known as tangential

flow turbine. If the water flows in the radial direction through the runner, the turbine is

called radial flow turbine. If the water flows from outwards to inwards, radially the

turbine is called inward radial flow turbine, on the other hand, if the water flows radially

from inwards to outwards, the turbine is known as outward radial flow turbine.

If the water flows through the runner along the direction parallel to the axis of rotation

of the runner, the turbine is called axial flow turbine. If the water flows through the

runner in radial direction but leaves in the direction parallel to axis of rotation of the

runner, the turbine is called mixed flow turbine.

PELTON WHEEL OR IMPULSE TURBINES

The pelton wheel or pelton turbine is a tangential flow impulse turbine. The water

strikes the bucket along the tangent of the runner. The energy available at the inlet of

the turbine is only kinetic energy. The pressure at the inlet and outlet of the turbine is

atmosphere. This turbine is used for high heads and is named after L.A. Pelton, an

American Engineer.

CONSTRUCTION AND WORKING OF PELTON WHEEL TURBINE

6

1

A pelton wheel consists of a rotor, at the periphery of which is mounted equally spaced

double hemispherical or double ellipsoidal buckets. Water is transferred from a high

head source through penstock which is fitted with a nozzle, through which the water

flows out as a high speed jet. A needle spear moving inside the nozzle controls the

water flow through the nozzle and at the same time provides a smooth flow with

negligible energy loss. All the available potential energy is thus converted into kinetic

energy before the jet strikes the buckets of the runner. The pressure all over the wheel

is constant and equal to atmosphere, so that energy transfer occurs due to purely

impulse action.

The pelton turbine is provided with a casing the function of which is to prevent the

splashing of water and to discharge water to the tail race.

When the nozzle is completely closed by moving the spear in the forward direction the

amount of water striking the runner is reduced to zero but the runner due to inertia

continues revolving for a long time. In order to bring the runner to rest in a short time,

a nozzle (brake) is provided which directs the jet of water on the back of buckets; this

jet of water is called braking jet.

Speed of the turbine runner is kept constant by a governing mechanism that

automatically regulates the quantity of water flowing through the runner in accordance

with any variation of load.

The jet emerging from the nozzle hits the splitter symmetrically and is equally

distributed into the two halves of hemispherical bucket as shown. The bucket center

line cannot be made exactly like a mathematical cusp, partly because of manufacturing

difficulties and partly because the jet striking the cusp invariably carries particles of

sand and other abrasive material which tend to wear it down.

Working

Water at high pressure from the penstock pipe enters the nozzle provided with a spear.

The pressure energy of water is converted into velocity energy, as it flows through the

nozzle. By rotating the hand wheel, the spear is moved to control the quantity of water

flowing out of the nozzle. When the spear is pushed forward into the nozzle, the

amount of water striking the buckets is reduced.

The jet of water at high velocity from the nozzle strikes the buckets at the center of the

cup. The impulsive force of the jet striking on the buckets causes the rotation of the 7

1

wheel in the direction of the striking jet. Thus, pressure energy of the water is

converted into mechanical energy. The pressure inside the casing is atmospheric.

The pelton wheel operates under a high head of water. Therefore it requires less

quantity of water. Draft tubes are not usually used with it.

REACTION TURBINES

If at the inlet of the turbine, the water possesses kinetic energy as well as pressure

energy, the turbine is known as reaction turbine. As the waters flows through the

runner, the water is under pressure and the pressure energy goes on changing into

kinetic energy. The runner is completely enclosed in an air tight casing and the runner

and casing is completely full of water.

If the water flows along the tangent of the runner, the turbine is known as tangential

flow turbine. If the water flows in the radial direction through the runner, the turbine is

called radial flow turbine. If the water flows from outwards to inwards, radially the

turbine is called inward radial flow turbine, on the other hand, if the water flows radially

from inwards to outwards, the turbine is known as outward radial flow turbine.

Casing: As mentioned above that in case of reaction turbine, casing and runner are

always full of water. The water from the penstocks enters the casing which is of spiral

shape in which area of cross section of the casing goes on decreasing gradually. It is

made of spiral shape, so that the water may enter the runner at constant velocity

through out the circumference of the runner. The casing is made of concrete, cast steel

or plate steel.

Guide mechanism: It consists of a stationary circular wheel all round the runner of the

turbine. The stationary guide vanes are fixed on the guide mechanism. The guide vanes

allow the water to strike the vanes fixed on the runner without shock at inlet. Also by a

suitable arrangement, the width between two adjacent vanes of guide mechanism can

be altered so that the amount of water striking the runner can be varied.

Runner: It is a circular wheel on which a series of radial curved vanes are fixed. The

surfaces of the vanes are made very smooth. The radial curved vanes are so shaped

that the water enters and leaves the runner without shock. The runner is made of cast

steel, cast iron or stainless steel. They are keyed to the shaft.

Draft tube: The pressure at the exit of the runner of a reaction turbine is generally less

than atmospheric pressure. The water at exit cannot be directly discharged to the tail

8

1

race. A tube or pipe of gradually increasing area is used for discharging water from the

exit of the turbine to the tail race. This tube of increasing area is called draft tube.

Working

First, water enters the guide blades, which guide the water to enter the moving blades.

In the moving blades, part of the pressure energy is converted into kinetic energy,

which causes rotation of the runner. Water leaving the moving blades is at a low

pressure. Thus, there is a pressure difference between the entrance and the exit of the

moving blades.This difference in pressure is called reaction. Pressure acts on moving

blades and causes the rotation of the wheel in the opposite direction.

FRANCIS TURBINE

Francis turbine was developed by the American engineer Francis in 1850. It is an

inward flow radial type reaction turbine. It operates under medium head.

Working

Francis turbine consists of a spiral casing, fixed guide blades, runner, moving blades

and draft tube.

The spiral casing encloses a number of stationary guide blades. The guide blades are

fixed around the circumference of an inner ring of moving blades. Moving blades are

fixed to the runner.

Water at high pressure from the penstock pipe enters the inlet in the spiral casing. It

flows radially inwards to the outer periphery of the runner through the guide blades.

From the outer periphery of the runner, water flows inwards through the moving blades

and discharges at the center of the runner at a low pressure. During its flow over the

moving blades, water imparts kinetic energy to the runner, causing the rotation of the

runner.

Draft tube is a diverging conical tube fitted at the center of the runner. It enables the

discharge of water at low pressure. The other end of the draft tube is immersed in the

discharging side of the water called tail race.

9

1

Kaplan turbine is a low head reaction turbine, in which water flows axially. It was

developed by German Engineer Kaplan in 1916.

All the parts of the Kaplan turbine (viz, spiral casing, guide wheel and guide blades) are

similar to that of the Francis turbine, except the runner blades, runner and draft tube.

The runner and runner blades of the Kaplan turbine resemble with the propeller of the

ship. Hence, Kaplan turbine is also called as Propeller Turbine.

Working

Water at high pressure enters the spiral casing through the inlet and flows over the

guide blades. The water from the guide blades strokes the runner blades axially. Thus,

the kinetic energy is imparted by water to the runner blades, causing the rotation of

the runner. The runner has only 4 or 6 blades.The water discharges at the center of the

runner in the axial direction into the draft tube. The draft tube is of L shape with its

discharging end immersed into the tail race.

10

1

Plant Layout Of Block 1

Bay 1 Bay 2 Bay 3 Bay 4Bar store Machine Shop

(East)Machine Shop(East)

Machine Shop

On loading area

Governor Machine Shop

Machine Shop (West)

Machine Shop

Machine Shop (central)

Tooling(Jig Fixtures)

Testing Area Assembly Area

Component store

Governor Testing area

CLASSIFICATION OF BLOCK 3

1.HMS (Heavy machining Shop)

-In this shop heavy machine work is done with the help of different NC &CNC machines such

as center lathes, vertical and horizontal boring &milling machines. Asia’s largest vertical

boring machine is installed here and CNC horizontal boring milling machines from Skoda of

Czechoslovakia.

2. Assembly Section (of hydro turbines) –

In this section assembly of hydro turbines are done. Blades of turbine are1st assemble on the

rotor & after it this rotor is transported to balancing tunnel where the balancing is done. After

balancing the rotor, rotor &casings both internal & external are transported to the customer.

Total assembly of turbine is done in the company which purchased it byB.H.E.L.

3. OSBT (over speed balancing tunnel)-

In this section, rotors of all type of turbines like LP(low pressure),HP(high pressure)&

IP(Intermediate pressure) rotors of Steam turbine ,rotors of Gas & Hydro turbine are

balanced .In a large tunnel, Vacuum of 2 torr is created with the help of pumps & after that

rotor is placed on pedestal and rotted with speed of 2500-4500 rpm. After it in a computer

control room the axis of rotation of rotor is seen with help of computer.

11

1

Manufacturing ProcessINTRODUCTION

Manufacturing process is that part of the production process which is directly

concerned with the change of form or dimensions of the part being produced. It does

not include the transportation, handling or storage of parts, as they are not directly

concerned with the changes into the form or dimensions of the part

produced.Manufacturing is the backbone of any industrialized nation. Manufacturing

and technical staff in industry must know the various manufacturing processes,

materials being processed, tools and equipment's for manufacturing different

components or products with optimal process plan using proper precautions and

specified safety rules to avoid accidents. Beside above, all kinds of the future engineers

must know the basic requirements of workshop activities in term of man, machine,

material, methods, money and other infrastructure facilities needed to be positioned

properly for optimal shop layouts or plant layout and other support services effectively

adjusted or located in the industry or plant within a well planned manufacturing

organization. Today’s competitive manufacturing era of high industrial development

and research, is being called the age of mechanization, automation and computer

integrated manufacturing. Due to new researches in the manufacturing field, the

advancement has come to this extent that every different aspect of this technology has

become a full-fledged fundamental and advanced study in itself. This has led to

introduction of optimized design and manufacturing of new products. New

developments in manufacturing areas are deciding to transfer more skill to the

machines for considerably reduction of manual labor.

Manufacturing of Spherical And

Butterfly Valves

This kind of valve is generally used in the hydroelectric power plants as a turbine

protection to guarantee the emergency shutoff of the pressurized water flow of the

penstock. It’s placed immediately before the turbine and works automatically to shut

off the water flow in case of any turbine malfunction, lack of power or any specified

condition.

The shutter is actuated by hydraulic cylinders moving it from the "ON" to "OFF" position

by rotating of 90° on side trunnions. The valve in the open position has a fluid way

12

1

which is essentially a straight cylinder so has approximately the same head losses as

would occur in an equivalent length of pipe. Closure is effected by rotating the shutter

90° degrees, so it stops completely the fluid way.

To guarantee the fast closing in lack of power, suitable counterweights are installed on

the shutter arm. Once shutter is closed, the perfect water tightness is guaranteed by

Main Operation Seal: a downstream mobile sealing ring that closes against a fix rings

seal on the shutter (both made of stainless steel with different grade of hardness). The

other mobile ring is a Maintenance Seal: installed in the upstream side of the shutter, is

used only in case of maintenance to the Main Operation downstream seal without the

necessity to remove the valve form the site. Both of them are operated by the pressure

of the water in the penstock trough a dedicated the water control system with piping.

Seats NEVER touch the ball during opening or closing.

CLASSIFICATION OF MANUFACTURING PROCESSES

For producing of products materials are needed. It is therefore important to know the

characteristics of the available engineering materials. Raw materials used

manufacturing of products, tools, machines and equipment's in factories or industries

are for providing commercial castings, called ingots. Such ingots are then processed in

rolling mills to obtain market form of material supply in form of bloom, billets, slabs and

rods. These forms of material supply are further subjected to various manufacturing

processes for getting usable metal products of different shapes and sizes in various

manufacturing shops. All these processes used in manufacturing concern for changing

the ingots into usable products may be classified into six major groups as

Primary shaping processes

Secondary machining processes

Metal Forming processes

Joining processes

Surface finishing processes and

Processes effecting change in properties

PRIMARY SHAPING PROCESSES

Primary shaping processes are manufacturing of a product from an amorphous

13

1

material. Some processes produces finish products or articles into its usual form

whereas others do not, and require further working to finish component to the desired

shape and size. The parts produced through these processes may or may not require to

undergo further operations. Some of the important primary shaping processes are:

(1)Casting(2)Powder metallurgy(3)Plastic technology(4)Gas cutting(5)Bending

and(6)Forging.

SECONDARY OR MACHINING PROCESSES

As large number of components require further processing after the primary processes.

These components are subjected to one or more number of machining operations in

machine shops, to obtain the desired shape and dimensional accuracy on flatland

cylindrical jobs. Thus, the jobs undergoing these operations are the roughly finished

products received through primary shaping processes.

The process of removing the undesired or unwanted material from the work-piece or

job or component to produce a required shape using a cutting tool is known as

machining. This can be done by a manual process or by using a machine called

machine tool (traditional machines namely lathe, milling machine, drilling, shaper,

planner, slotter). In many cases these operations are performed on rods, bars and flat

surfaces in machine shops. These secondary processes are mainly required for

achieving dimensional accuracy and a very high degree of surface finish. The

secondary processes require the use of one or more machine tools, various single or

multi-point cutting tools (cutters), jobholding devices, marking and measuring

instruments, testing devices and gauges etc. forgetting desired dimensional control

and required degree of surface finish on the work-pieces. The example of parts

produced by machining processes includes hand tools machine tools instruments,

automobile parts, nuts, bolts and gears etc. Lot of material is wasted as scrap in the

secondary or machining process. Some of the common secondary or machining

processes are:

Turning

Threading

Knurling

Milling

Drilling

Boring

Planning

14

1

Shaping

Slotting

Sawing

15

1

NON- DESTRUCTIVE TESTING

Failure of the turbine blades was one of the challenges addressed with the help of BHEL

by modifications of LP stage-5 blade, shroud modifications etc., and based on its

success, the same technique was used for other plants to sort out inherent problems.

Grid-induced Outages Grid disturbance induced outages were overcome by house load

schemes and in one-month viz., May 1998, as many as 150 house load operations took

place and units operated withstanding these transients. Healthiness of the control

system and other equipment to withstand external grid transients was remarkable.

The sharp corner in the root section of the blade causes the blade to crack. Failure of

the turbine blades was one of the challenges addressed with the help of BHEL by

modifications of HP stage-5 blade, shroud modifications etc., and based on its success,

the same technique was used for other plants to sort out inherent problems. The

material used was 12Cr-Mo martensitic steel, which is a very high temperature

resistant material.

The microstructure was observed was tempered martensitic structure. These turbine

blades were collected from Madras Atomic Power Station (MAPS) for analysis. These

blades were found to be failed. These blades were used for the present investigation of

defects using ultrasonic phased array and X-ray radiography techniques. Turbine

blades are known to fail due to tempered martensitic embrittlement, fatigue, fretting,

high temperature creep age hardening, fir tree design, high residual stresses etc.

Chemical compositions of the turbine blade:

Element Weight %

Sulphur 0.019 to 0.03

Phosphorus 0.019 to 0.028

Carbon 0.20 to 0.24

Chromium 12.8 + 1.2

Manganese 0.45 to 0.54

Silicone 0.30 to 0.43

Nickel 0.40 to 0.52

Vanadium 0.05

Molybdenum 0.1 to 0.13

Iron Balance

16

1

SPECIFICATIONS OF MACHINES

Narrow Gap Welding Machine

Narrow gap welding (also called narrow groove welding) was developed to weld thick sections

more economically. This welding procedure uses joint preparations with small, included

angles, typically in the range 2-20°, which require less weld metal and less welding time to

fill. Narrow gap techniques have been applied when welding using submerged arc welding

(SAW), gas shielded metal arc welding (MIG/MAG, GMAW) and tungsten inert gas welding

(TIG, GTAW) processes. However, narrow gap welding does require specialized equipment,

because of the limited accessibility to the root of the preparation.

Specification :

Edge Preparation

Depth Of Joint : Max 350 mm

Wire Size : 3 to 5 mm

Feed rate of Wire : 1 to 4 mm/cm

Maximum Horizontal

Movement : 6m

Maximum Vertical

Movement : 6m

Mario Carnaghi ( Italy )

Vertical Boring Machine

CNC Control Fanuc 32i

Table Diameter 98.4″

Maximum Swing 118.1″

Maximum Turning Height 98.4″

Table Payload 88,000 lbs

Table Speed 1.5 – 150 rpm

Spindle Drive 140 HP

ATC 12 Positions

17

1

Coolant yes

Splashguard

Motofil (Portugal)

Robotic Welding Hydraulic Control

6 Axis Control

CNC Controlled Robotic Arm

Wire feeder controller

Copper coated MS Wire

Argon + CO2 Gas Cylinder

Step Down Transformer

Centre Lathe :(Biggest of all BHEL)· Max diameter over bed :3200mm

· Max diameter over saddle :250mm

· Length between centers :16m

· Max weight of work piece :100 T

· Spindle bore :96mm

Manufacturer: SAFOP· Swing over carriage :3500mm

· Centre distance :9000mm

· Weight capacity :120 T

· Spindle power :196KW

· External chucking range :250-2000mm

· Hydrostat steady range :200-1250mm

· Max spindle rpm :200

18

1

CNC Indicating stand :

Manufacturer : Heinrich Georg, Germany

Turning diameter :5.3m

Turning length :15m

Weight capacity :160 T

CNC Vertical Borer :

Manufacturer : M/S Pietro Carnaghi, Italy

Machine model :AP 80TM-6500

· Table diameter :6500mm

· Max turning diameter :8000mm

· Min boring diameter :660mm

· Max height for turning and milling :7000mm

· Table Speed :0.2-50 rpm

· Table load capacity :200 T

· Milling spindle speed :3.4-3000 rpm at40KW

· Spindle taper :BT 50

· CNC system :SINUMERIK 840D

CNC Facing Lathe : KH-200-CNC· Swing over bed :2300mm

· Swing over carriage :1800mm

· Max distance between faced plate and carriage :2000mm

· Max weight of job held in chuck :6000kg

· Face plate diameter :1800mm

· Spindle speed :1.4-400rpm

· Main spindle drive :95.5KW

Step boring Machine :

· Max boring diameter :2500mm

· Min boring diameter :625mm

· Table :4000mmx4000mm

· Max weight of job :100 T

Headstock travel :4000mm

Double Column Vertical Borer :

19

1

· Table diameter :4000mm

· Max traverse of cross rail :4250mm

· Max weight of work piece :4200mm

LH Left hand Ram

RH Right Hand Ram

· Max weight of job :50 T

CNC Skoda Horizontal Borer :· Spindle diameter :200mm

· Taper spindle :BT 50

· RAM size :450x450mm

· RAM length :1600mm

· Spindle length :2000mm

· Headstock :5000mm

· Table :4000x3500mm

· CNC system :SIMENS 850mm

· Job : I.P. Outer

Horizontal Borer : LSTG 8006

· Spindle diameter :250mm

· Height of machining bed :600mm

· Max boring depth with spindle :2000mm

· Max extension of RAM :1600mm

· Width of bed guide ways :2500mm

· Actual length of headstock with vertical lift :2150mm

· Actual length of column horizontal feed :15000mm

· Lowest position of spindle axis upon bed guide ways :1475mm

· Machine weight with electrical equipment's :140 T

· Height of machine :10.3m

CNC Lathe : 1-120 Ravens burg

· Main spindle bore :150mm

· Distance between centers :12m

· Turning diameter over bed cover :1400mm

· Turning diameter over carriage :1100mm

· Work piece weight unsupported :4000kg

20

1

· Work piece weight between centers :20 T

Horizontal Boring Machine : 1-28· Diameter of spindle :150mm

· Working surface of table :2250x1250mm

· Max travel of table :1200mm

· Max vertical travel of headstock :2000mm

Horizontal Boring Machine :

· Boring spindle taper :BT50

· Boring spindle diameter :160mm

· Headstock vertical travel :3000mm

· Longitudinal RAM travel :700mm

· Longitudinal spindle travel :1000mm

· Column cross travel :10m

· Rotary table travel :3000mm

· Table load :40 T

Horizontal Boring Machine : 1-11· Boring spindle internal taper material :200

· Boring spindle diameter :320mm

· Max spindle travel :2500mm

· Vertical head travel :6000mm

· Transverse column travel :6000mm

· Max longitudinal column travel :800mm

· Machine wattage :90KW

Double Column Rotary Table Vertical Borer :

· Max diameter of work piece accommodated :10m/12.5m

· Max height of work piece accommodated :5m

· Diameter of table :8.75m

· Max travel of vertical tool head RAM slides :3.2m

· Max travel of vertical tool head from Centre of table :5.25m

· Max weight of work piece :200T for N<=8rpm;100T for any speed

· Diameter of boring spindle of combined head :160mm

· Travel of boring spindle :1250mm

· Taper hole of boring spindle :100mm

Horizontal borer : 1-2· Spindle diameter :220mm

· Working surface

· Max vertical travel :3mm

21

1

· Max transverse travel of column :6m

· Max longitudinal travel of column :6m

· Max longitudinal travel of spindle :1.8m

CNC Lathe : 2-360 Hoesch· Max load :320 T

· Max length between centers :18m

· Swing over bed :3.2m

Horizontal Borer : 2-198· Spindle diameter :220mm

· Max vertical travel :3m

· Max transverse travel of column :6m

· Max longitudinal travel of column :6m

· Max longitudinal travel of spindle :1.8m

· Working surface :1800x500mm

Creep Feed Grinding Machine :· Diameter of job :2m

· Job height :2.4m

· Table rpm :10rpm(max)

· Table diameter :2050mm

· Swing diameter :2500mm

· CNC control :SIEMENS-3GG

Broaching Machine :

· Broaching capacity :32 T

· Broaching stroke :10.3m

· Broaching slide width 1500mm

· Broaching specific cutting stroke :1.25m/min

· Broaching specific return stroke :60m/min

· Max diameter of disc :2300mm

· Max move of table :600mm

· Helix angle/skew angle setting :+45/-45

· Cone angle :0-20

CNC Lathe :

Manufacturer : Innse Berardi, Italy

· Swing over carriage :1500mm

· Swing over bed :2000mm

22

1

· Capacity :30 T

· Cost :16 crore

· CNC system :SINUMERIK 840D

Over Speed Balancing of Turbines Main features :

· Type of pedestals :DH 90/DH 12

· Rotor weight :Min 4 MT, Max 320 MT

· Rotor diameter :Max 6900mm

· Rotor journal diameter :Min 250mm,Max 950mm

· Bearing Centre distance :Min 3000mm,Max 15700mm

· Balancing speed :180-3600rpm

· Min vibration limit :1 micron

· Max vacuum :1 torr

Tunnel Features :

· Tunnel length :19000mm

· Tunnel diameter :6900mm

· Max thickness of tunnel :2500mm

· Steel plate thickness :32mm

· Cost of balancing equipment(FE) :444 lakhs

· Total cost of balancing tunnel :770 lakhs

Main Features of Drive :

· Drive motors (2 no.) :950V DC, 500rpm,3.5 MW each

· Total drive power :7 MW(2x3.5)

MG set of Drive :

· Synchronous motors :11 KV,9MW,50Hz,500rpm

· DC Generator (2 no.) :950V,500rpm,3.8MW each

3d coordinate measuring machine in new blade shop:

Model reference: 22129 LIETZ Germany

Plan no 3-068

Measuring range:

X axis 2200mm

Y axis 1200mm

23

1

Z axis 900 mm

Volumetric error: (max) 1.5 micron

Resolution: 0.05 micron

Max weight of job: 2250 kg

Accuracy: 1.5+L/350 micro

24