bharat pump compressor blade manufacturing

8/20/2019 Bharat Pump Compressor Blade Manufacturing

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DECLARATION

I AMAN DWIVEDI student of B.Tech student Mechanical Engineering from Dr. KNMIET,

Modinagar, U.P hereby declare that the training reort entitled “MANUFACTURING OF

COMPRESSOR BLADE” is an original !or" and the same has not been submitted to any other

institute.

AMAN DWIVEDI

#oll No. $%&''(&&$)

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ACKNOWLEDGEMENT

It gi*es me immense leasure to resent my Pro+ect #eort before you. I than"fully ac"no!ledge

the staff of Bharat Pums and omressor -td, llahabad for gi*ing me so much co/oeration

and taught lots of ne! things to me, !hich I am sure !ill hel me in my !ar future.

secial than"s to Mr. Rachit Sinha! for his suort during my Industrial Training. I ay my

sincere regards to him. 0ithout his suort I !as not able to accomlish my training. I also

than"s to all the !or"ing staff of fabrication bloc" for their helful guidance and suort during

the eriod.

AMAN DWIVEDI

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TABLE OF CONTENTS

$. Introduction of the comany $

%. omressor Blade 12. #a! materials $&(. Manufacturing Process $$

). 3ingle rystal Production $)

4. oating $'

'. Testing $15. onclusion %$

1. #eferences %%

III


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LIST OF FIGURE

6ig/$7 Main *ie! of the comany $

6ig/%7 Inner *ie! of the comany %

6ig /27 #esirocating Pum '

6ig / (7 omressor blade 1

6ig /)7 Model design of comressor Blade $$

6ig 8 47 9ac"sa! cutting machine $%

6ig /'7 Milling $2

6ig/57 single crystal comressor blade $4

6ig/17 tmosheric Plasma sray $'

6ig/$&7 Testing of comressor blade $1

IV


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BRIEF INTRODUCTION OF T"E COMPAN#

Bharat P$%&' an( C)%&r*'')r' Li%it*( inc. in $1'&, under the ministry of hea*y industries

and ublic enterrise at Naini, the Trans :amuna rea of llahabad !ith the ob+ecti*es to design,manufacture and suly of factory goods in the fluid handling filled including ro*ision of

ser*ices connected there !ith.

Fi+,- Main i*/ )0 th* c)%&an1

BP- !hich caters to the need of core sector of the economy such as oil e;loration and

e;loitation, refineries, etro chemicals, chemicals and fertili


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Fi+2- Inn*r i*/ )0 th* c)%&an1

In *ery short san, the comany absorbed the technology and established it self as a !orld

reno!ned manufacturer of a !ide range of high tech roducts. BP has sulied its roducts to

the total satisfaction of the customers in almost all national ro+ects of comany li"e >N?,

>I-, BP-, I>-, 9P, #6, Nuclear Po!er ororation, Det. >f tomic Energy, IP-, etc.

The comany has a high credibility for =uality of its roducts and ac=uired I3> 1&&$/%&&&,

$(&&&, $5&&&@93PA certification

MAIN PRODUCT OF COMPAN#

BP has a large roduct range, ser*ing almost all core sector industries7/

• entrifugal Pums @as er latest edition of PI 4$&A for #efinery and Petroleum Industry.

• entrifugal Pums for Nuclear Po!er lants.

• #ecirocating Pistons and Plunger Pums as er PI 4'( latest edition.

• #ecirocating 6ueling Machine 3uly Pums for Nuclear Po!er Plants

• 9igh ressure li=uid mmonia #eactor 6eed Pum

• 9igh ressure seamless industrial cylinders. s er I37 '%5)7B31'&• 9igh ressure comressed natural gas @N?A cylinders for on/board alications.

• omressed Natural gas @N?A cascades

• #ecirocating comressors as er PI/4$5

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RESEARC" AND DEVELOPMENT

BP technicians and engineers are fre=uently in contact !ith other organiil ororation -imited

• 9industan Petroleum ororation -imited

• Bharat Petroleum ororation -imited

• Kochi #efinery -imited

• Numaligarh #efinery

• Mangalore #efinery and Petrochemicals -imited

• hennai Petroleum ororation -imited

• Tamilnadu Petro Products -imited

• Bongaigaon #efinery

• Indian Petrochemicals ororation -imited

• ?as uthority of India -imited

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OIL AND GAS SECTOR

• >il and Natural ?as ororation -imited

• ?as uthority of India -imited

• >il India limited

NUCLEAR POWER

• Det. of tomic Energy

• Bhabha tomic #esearch entre

• Nuclear Po!er ororation -imited

FERTILI4ERS AND C"EMICALS

• Tata hemicals and 6ertili


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PRODUCT PROFILE

$. RECIPROCATING COMPRESSORS PROFILE

BP- design and manufacture custom/built recirocating comressors for a !ide range of

alication and gases such as ammonia synthesis @N% 29%A, arbon dio;ide ethylene, natural

gas. 9ydrocarbon mi;tures, mmonia, >;ygen, air etc. The ma;imum o!er rating is %)&&&K0

and the discharge ressure is u to ()& Pascal. BP en+oys the uni=ue ri*ilege of ha*ing shared

!ith its e; collaborator MCs. Nuo*o Pignone, Italy a !orld giant ha*ing *ast e;erience in this

field for more than three/=uarters of a century. 3ome of the ma+or alications areas co*ered by

recirocating comressors designed and manufactured by BP- include the follo!ing7

FERTILI4ERS

• 3ynthesis of gas omressors for mmonia lant

• mmonia refrigeration comressors for mmonia lant

• >% omressors for urea lant

• >;o/syn gas ma"e u and recycle ser*ices for methanol lants

• 9ydrogen and 9ydrocarbon ser*ice for carolactum lant

• Natural gas comressors for Urea lant

• Bone dry Nitrogen comressors

REFINERIES

• Ma"e u 9ydrogen ser*ice for hydro crac"er lants

• rude o*erhead gas ser*ice for DU lant

• -P? bottling ser*ice comressors -P? bottling lant

• Proane de/ashalting lants

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OIL AND GAS E5PLORATION

• -.P. booster ser*ice comressor for Natural gas

• ssociated gas comressor for -P? e;traction lant

• ?as lift ser*ice comressor for Natural gas

•

?as in+ection ser*ice comressor for N?• ?as storage ser*ice comressor for N?

• ir comressor for !ell acti*ation ser*ice

• ondense off gas ser*ice for gas s!eetening lants

• Proane gas ser*ice for gas rocessing lant

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PETROC"EMICALS

• Pacol comressors for lab lant

• 9ydrocarbon comressors for lab lant

• Ethylene rimary comressor for olyethylene lant

•

ylene comressors for isomeri


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• 0ash um

• arbamate feed ums

REFINERIES

• 3ulhadi


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ABOUT T"E COMPRESSOR BLADE

3ince the +et engine !as in*ented in the $12&s, it has layed a momentous art in the

de*eloment of a*iation. The early designs of +et engines tend to ha*e lo! life e;ectancy

because at that time, the materials used for turbo blades lac"ed the durability !hen !or"ing in

e;treme condition inside the +et engine. Poor material limits the oerational temerature and thus

limiting thrust as !ell as to seed of the engine. No!adays, such roblems are better handled as

more suitable materials are a*ailable and the manufacturing techni=ues used for comressor

blades are de*eloed and refined. This reort !ill attemt to re*eal more about the

manufacturing methods of comressor blades and the !or"ing rincials behind them.

Fi 7 8- C)%&r*'')r 9!a(*

The icture abo*e dislays comressor blades made by three different method7 @aA

con*entionally cast @bA directionally solidified, !ith columnar grains, as can be seen from the

*ertical strea"s and @cA single crystal.

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In this reort, !e !ill discuss con*entional techni=ues in roducing +et comressor blades such

as in*estment casting, single crystal gro!ing rocess, thermal barrier coating and a fe! testing

method to loo" for defects in ne!ly made blades.

RAW MATERIAL-

The ra! material is the main source for the manufacturing of omressor blade

The ra! material used in the manufacturing of omressor blade is stainless steel.

S&*ci0icati)n'-

The ra! material cross/section is of

0idthF $'&mm

9eightF 1&mm

MAIN PROCESS INVOLED-

G The design of the roduct,

G The selection of ra! materials and

G The se=uence of rocess through !hich the roduct !ill be manufactured.

W"# UNCONVENTIONAL MAC"INING CAME INTO E5IST7

G The hardness and strength of the material is *ery high or the material is too brittle.

G The !or" iece is too fle;ible, slender, or delicate to !ithstand the cutting or grindingforces, or the arts are difficult to fi;ture that is, to clam in !or" holding de*ices.

G The shae of the art is comle;, including such features as internal and e;ternal rofiles

or small diameter holes in fuel in+ection no


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MANUFACTURING PROCESS-

$. #a! Material

%. utting

2. Milling

(. 3urface ?rinding

). N Machining

4. >erations and Tools

'. Huality ontrol

5. Polishing

Fi +:- M)(*! (*'in )0 c)%&r*'')r B!a(*

CUTTING-

3ince the ra! material is huge in length, it can not be directly ta"en to the rocess of

manufacturing. 3o it is arted into number of ieces according to the blade rofile re=uirement.

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The !or" iece re=uired to obtain blade rofile is of the follo!ing dimensions.

-engthF %4)mm

0idth F $)&mm

9eightF 1&mmfter hac"sa! cutting oeration

"ACKSAW CUTTING MAC"INE-

The hac"sa! cutting machine is used for cutting the ra! material, The !or" iece is held on the

hac"sa! machine !ith the hel of chain ulley suorted by three *ertical members.

Fi 7 ;- "ac


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MILLING-

milling machine is a machine tool used to machine solid materials. Milling machines are often

classed in t!o basic forms

G 9ori


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SURFACE GRINDING-

3urface grinding is used to roduce a smooth finish on flat surfaces. It is a !idely Used abrasi*e

machining rocess in !hich a sinning !heel co*ered in rough articles @grinding !heelA cuts

chis of metallic or non/metallic substance from a !or" iece, ma"ing a face of it flat or smooth.

CNC MAC"INING-

=COMPUTERISED NUMERICAL CONTROLLED MAC"INE>

N refers to the automation of machine tools that are oerated by re rogrammed

commands encoded on a storage medium.

COLLETS-

ollets are used for holding the tool in the adator. ollets are fle;ible to allo! tools of different

diameters to fit in to it. ollets are characterince the secimen has fi;ed into the

fi;ture it !onJt be remo*ed till the end of the oeration. 6i;tures can be of *arious shaes it has

to be ensured that it can hold the secimen carefully till the end of the oeration. ItJs shae *aries

!ith the shae of the secimen to be fi;ed and the oerating rocedure.

Huality ontrol7

isual Insection

In *isual insection !e chec" the length, thic"ness and !idth of the gi*en secimen at the

corresonding sections. 0e need to chec" the gi*en secimen, !hether it !ill meet the

re=uirements of our design or not. By using the *enire caliers !e calculate the basic dimensions

of the secimen.

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OB3ECTS USED IN VISUAL INSPECTION-

"EIG"T GAUGE-

G It is used to measure the height of the secimen from the datum surface and to measure

the groo*e and slots. To chec" the deth of the slot and the height of the slot by this

measuring gauge. The readings of the height are sho!n digitally on the dislay arranged

on the gauge.

MAGNETIC V+BLOCK-

The secimen is laced on the /bloc" and then re=uired measurements are ta"en, mar"ing the

secimen is also done in this rocess

BLADE MEASURING GAUGE-

This aaratus is used to measure the final shae of the blade rofile.

CLEANING AND PACKING-

fter the comletion of the final insection, the omressor blade is roceeded into the ne;t

stage of cleaning. In cleaning the blade is rinsed !ith the !ater and the !ater is !ied !ith the

cotton cloth.

SINGLE CR#STAL PRODUCTION-

P$r&)'* )0 %a


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increases cree effect in the material. lso, there e;ists the diffusion of atoms along the grain

boundaries @oble creeA !hich causes changes in grain shaes.

Therefore, comressor blades are made using metal !ith directionally solidified crystal structure

to limit the !ea"ness at grain boundaries. omressor blade !hich has columnar crystals !ith

grain boundaries arallel to its a;is can limit or eliminate shear stress caused by tensile load

!hile rotating.

Fi+?- 'in!* cr1'ta! c)%&r*'')r 9!a(*

By ma"ing single crystal comressor blade, grains boundaries are comletely remo*ed, !hich

ma"e the material ha*e better =ualities comared to e=uia;ed and columnar grains structure.

0ith no grain boundary, comressor blades are not !ea"ened by grain boundary sliing and

thus erform better at high temerature. Moreo*er, since most imurities and disorders

concentrate at grains boundaries, single crystal comressor blades are more resistant to high

temerature corrosion.

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COATING-

8.,> Intr)($cti)n-

nother imro*ement that can be made to the comressor blade is adding the thermal barrier

coatings @TBsA. TBs are comle; defected thic" film made of


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substrate surface is usually roughen by an abrasi*e rocess such as grit blasting. The molten

articles settle on the destined surface =uic"ly solidify and create a !all of slatsJ of tyically

$&&/$)& microns in diameter and a fe! micrometers in thic"ness. Each slat is attached to the

substrate surface because of hysical interloc"ing of the slat and irregularities on the surface.

Internal assages and cooling holes cannot be coated by lasma sray.

3ince the solidification of each article haens =uic"ly and indeendently, the structure formed

as a result consists of slats interfaces and unfilled regions !hich creates orosity in the coating.

Therefore, the TB has lo! thermal conducti*ity and non/linear stress/strain beha*ior.

s !e can see, the rocessing arameters decide much of the characteristic of the deosited

microstructure. 3uch arameters include the characteristic of the sray stream @articlesJ

tra+ectory, "inetic and thermal state and degree of meltingA location and state of substrate

@roughness, temerature, osition, geometry and mo*ementA and seed of torch and art. To sum

u, roerties of both the o!der and torch lay significant roles in determining the

characteristic of the TB @orosity, interface, grain si


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shado!ing. Thus, the microstructure attern can be ad+ust in the coating rocess to meet the

comressor blade roerty re=uirements.

To sum u, the EBPD coating techni=ue has the ad*antage of being able to roduce coating

!ith columnar structure !ith strain tolerance and seudo/lasticity. omared to Plasma 3ray

TBs, TB using EBPD has better corrosion resistance and smoother surface, !hich creates

better aerodynamics roerties for the comressor blades. 6urthermore, the cooling channels !ill

stay oen throughout the coating rocess. Ne*ertheless, the method still has certain

disad*antages in terms of limited material choice @due to *aor ressure roblemA, higher cost

and thermal conducti*ity and lo! utility rate of ra! material.

TESTING-

Before the comressor blade can be used, it must go through tests for defects in the material and

the blade structure itself.

Fi+,- T*'tin )0 c)%&r*'')r 9!a(*

6irst, the blade dimensions ha*e to be chec"ed to ma"e sure it fits the design re=uired

secifications. This tas" is carried out by a oordinate/measuring machine. The machine !ill

ta"e measurements of certain oints on surface of the blade and chec" if it fits the design. ny

blade !ith high measurement de*iation from the design !ill be re+ected.

fter that, the blade !ill be tested !ith dye enetrant to find for any crac"s on the surface of the

blade.

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lso, the interior of the blade can be insected using fiber otic method. Before being ut to use,

the blade !ill be ut through an engine running test !hich they !ill be ut into a real !or"ing

condition in a +et engine test.

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CONCLUSION

0ith ad*ances in manufacturing methods, comressor blades are no! made !ith higher =ualitythan e*er before. By using In*estment casting, !e are able to create intricate comressor blade

designs !ith internal cooling assages and holes. Moreo*er, the comressor material rocessing

techni=ues also enable us to from comressor blades of single crystal structure !hich ha*e better

caability to !or" in e;tremely high temerature of the +et engine. Thermal Barrier oating

@TBA is another imro*ement to the =uality of the comressor blade. The use of TBs can hel

rotect the comressor blade from the e;treme heat of the engine and corrosion.

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REFERENCES-

• Materials 3cience and Engineering Proerties by harles ?ilmore

• #oger #eed, Uni*ersity of Birmingham %&&'

• M. ?elL D. N. Duhl and . 6. ?iamei, Pratt L 0hitney, $15&

• D. . Po!er, ohnson Matthey Noble Metal, #oyston, $11)

• 3an+ay 3amath, U!e 3chul< , Maria >helia arligo , and 3ei+i Kuroda, %&$%

• Manufacturing Processes for Engineering Materials, )th ed, %&&5

• 9enry -. Bernstein, ?as omressor Materials ssociates, 3an ntonio, Te;as

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bharat pump compressor blade manufacturing

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