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
Recommended