Acknowledgement

We wish to say thanks to respected Officials of H.R.D.C Shri A.K. Upadhyay (A.G.M), Shri D. Pant (D.G.M), Shri Raj Singh (Sr. Engineer) and Shri Satya Pal Chauhan (General Foreman) from the deepest sole of our heart for executing the O.J.T-IV program in excellent manner. Which provide us the opportunity to become familiar with products manufactured, manufacturing processes, inspection procedures and skills of the manpower employed in Turbine Manufacturing Shop (Block-3). A

And we are also thankful to the esteemed TUM Officials Shri Ishwar

deen (G.M,T&D.), Shri S.K. BAJAJ (A.G.M,TUM,Bay-3), Shri P.C.Verma (DGM TUM,Bay-3), Shri ALOK SHUKLA (DGM, BAY-3)Governing Assembly & other respected officers and colleagues for their cooperation, guidance and useful ideas which strengthen us to turn the training program into reality. Their teachings and helps are unforgettable for us.

Name :- Raj kumar Ram

Staff No :- 1653423

1

Index

Sr. No Content’s Name Page No.

1. About Training 32. Layout of Block –3 43. Organization Chart 5 4. an overview BHEL Hardwar 65. Introduction with products of Block-3 (TUM) 236. Description of various sections visited 277. Turnover of HEEP and Block-3 298. Unique Facilities available in Shop 319. Shop Planning Flow Chart 3210. Modernization Schemes & Technological Development 33

2

1. About Training Program

As part of On Job Training modules, OJT-IV Module was of six month duration from12/12/2006 to25/07/2007. During this program we were distributed in small groups and appointed in branch related departments. Fortunately our place of appointment was Turbine Manufacturing Shop in GOVERNING ASSEMBLY DEP’T, which gave us the great exposure of inspection techniques involved in inspection of different type of turbines and its accessories. The shop was divided into ten parts for training purpose as follows and four days were given to visit each place-

1. Light Machine Shop - Bay 32. CPL/CML -3. Governing Assembly Section - Bay 34. Turning, Milling and L & D Section - Bay 35. Planning6. Blade Assembly Section - Bay 27. Assembly-2 - Bay 28. Heavy Machine Shop-2 - Bay 29. Assembly-1 - Bay 110. Heavy Machine Shop-1 - Bay 111. Over Speed Balancing Tunnel12. QAX -ADM BUILD13. TURBINE ENGG -ENGG BULD14. QCX -BLK-I15. QC MATERIAL -ADM-III

At the end of training we realized that the Turbine Manufacturing shop has become the vital part of our training.

3

2. Layout of Block-3

4

APPLICATION RANGE OF STEAM TURBINE

SERIES

TYPE OFSTEAM

GENERATOR

SPEEDRPM

POWER OUTPUT

MW

MAIN STEAM CONDITION

REHEAT STEAM CONDITION

BACK PRESSURE

MBARBAR OC BAR OC

Turbines for Fossil Fuel Power Plants

Fossil Fuel Steam

Generator

3000 100-1000 130-250 500-540 30-70 500-600 20-300

Turbines for Nuclear Power

Plants

Pressurised Light Water

Reactor

3000 Upto 1000 40-70 250-300 8-15 200-250 20-300

Turbines for Combined Cycle

Applications

Heat recovery Steam

Generator

3000 Upto 300 30-140 500-540 30-50 500-540 20-300

5

4. Introduction with products of Block-3

6

STEAM TURBINE

HARDWAR

APPLICATION RANGE OF STEAM TURBINE

SERIES TYPE OFSTEAM

SPEEDRPM

POWER OUTPUT

MAIN STEAM CONDITION

REHEAT STEAM CONDITION

BACK PRESSURE

7

GENERATOR MW MBARBAR OC BAR OC

Turbines for Fossil Fuel Power Plants

Fossil Fuel Steam

Generator

3000 100-1000 130-250 500-540 30-70 500-600 20-300

Turbines for Nuclear Power

Plants

Pressurised Light Water

Reactor

3000 Upto 1000 40-70 250-300 8-15 200-250 20-300

Turbines for Combined Cycle

Applications

Heat recovery Steam

Generator

3000 Upto 300 30-140 500-540 30-50 500-540 20-300

STEAM TURBINES FOR FOSSIL FUEL POWER PLANTS

1. Three cylinder turbines (HMN Series), comprising of

← High pressure (HP) turbine

← Intermediate pressure (IP) turbine

← Low pressure (LP) turbinesSALIENT FEATURES

8

← Turbines for both nozzle control as well as throttle control mode.

← Turbines can operate with any boiler and are suitable for

i. Constant pressure as well as sliding pressure operation

ii. Base load as well as two-shift operation

iii. Sub critical as well as super critical parameters

← All the rotors are monoblock

← HP & IP casings have double shell construction and LP has three-shell construction.

← IP turbines with single flow or with double flow.

← LP turbines are designed for normal as well as high back pressure conditions.

← Hollow guide blades with suction slits for moisture removal in last LP stage.

← Bearing pedestals isolated from turbine casings.

← Combined stop & control valves with individual servomotor.

← Sophisticated control and monitoring equipment such as Electro-hydraulic governing, automatic turbine run up system, turbine stress controller, automatic turbine tester etc.

← High operational flexibility

iv. Fast start up and shut down

v. Sharp load changes

vi. Operation under wide frequency range (47.5 to 51.5 Hz)

1. Two cylinder turbines comprising of combined (HP&IP) and LP turbine (KN series)

1. Two cylinder turbines comprising of HP and combined (IP&LP) turbines (HE series)

STEAM TURBINES FOR COMBINED CYCLES

← Combined cycles offer substantial improvement in thermal

9

cycle efficiency by lowering the heat rejection temperature.

← Exhaust from gas turbine is used effectively for generating steam in fired or unfired heat recovery steam generator for running a suitable steam turbine.

← Open cycle gas turbines can be profitably converted to a combined cycle plant even at a later stage depending upon the convenience of the utility.

← BHEL Hardwar manufactures steam turbines for combined cycle power stations with gas turbines of 66 MW, 159 MW and 255 MW ISO ratings.

← Steam cycle may be single, dual or triple pressure cycle.

← With triple pressure cycle and suitable block combination of gas turbines, HRSG and steam turbines, cycle efficiency of about 58% can be achieved.

 TURBINES WITH ADVANCED STEAM PARAMETERS

Application of higher parameters is the most direct way of increasing heat input to the cycle

Steam parameters of 300 bar pressure and 600 oC temperature

Six percent improvement in thermal cycle efficiency

New materials for high temperature applications

Impulse diagonal blading for the first stage HP and IP turbines

Heat shield at inlet of IP turbine

Increased wall sections for increased pressures

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TURBINE BLADES

← Cylindrical reaction blades for HP, IP and LP Turbines

← 3-DS blades, in initial stages of HP and IP Turbine, to reduce secondary losses

← Twisted blade with integral shroud, in last stages of HP, IP and initial stages of LP turbines, to reduce profile and Tip leakage losses

← Free standing LP moving blades

← Tip sections with supersonic design

← Fir-tree root

← Flame hardening of the leading edge

← Banana type hollow guide blade

← Tapered and forward leaning for optimised mass flow distribution

← Suction slits for moisture removal

COMPUTATIONAL MESH FOR 3D ANALYSIS

 

MANUFACTURING FACILITIESThe plant is fully equipped with the most modern and sophisticated manufacturing and testing facilities to produce sets upto 1000 MW rating. These include:

Blade Shop for manufacture of both moving and stationary blades

Special purpose CNC machine tools

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Overspeed & Vacuum Balancing Tunnel-a unique facility for balancing and overspeeding of rotors for turbines

RENOVATION & MODERNISATION (R&M)

Depending on the actual operating conditions, material properties of the components degrade as function of service life due to one or more time dependent material damage mechanisms such as creep, fatigue, corrosion, erosion, wear embattlement etc.

Life extension programme (LEP) is a special package comprising systems and methodologies, which evaluates the residual life of components through sophisticated NDT, FEM stress analysis and metallurgical technique.

BHEL carries out life extension programs on steam turbines of various ratings, which forewarn the impending failure and help in reducing costly plant breakdowns by recommending replacement and upgradation of defective components.

Many improvements in material and design of critical components with state-of-art design is a part of the life extension process. Thus the performance, availability and efficiency of the plant may be improved by R&M Programs.

ULTRASONIC EXAMINATION OF SHRUNK ON DISC

MICROSTRUCTURE EXAMINATION OF ROTOR

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QUALITY – A MATTER OF COMMITMENT

An ISO 9001 Company

Quality, a watchword in incoming materials, in-process, machining, assembly and testing.

Quality Assurance, Quality Plan, Field Quality being an integral part of the total process.

Fully equipped Centre Plant Laboratory to support, sophisticated testing and measuring instruments viz. CNC 3 D Co-ordinate Measuring Machine.

NDT facilities: X-ray, Gama ray, Ultrasonic Magnetic particle testing.

Recognised by MIS TUV, Germany as a reputed manufacturer of pressure vessels

ASME U stamp

ASME R Stamp

Quality Conformance

Our Quality policy says

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"TO MAINTAIN A LEADING POSITION AS A SUPPLIER OF QUALITY PRODUCTS, SYSTEMS & SERVICES TO NATIONAL / INTERNATIONAL

STANDARDS TO MEET THE REQUIREMENTS OF CUSTOMER"

Quality is in fact a way of life in BHEL. Be it in incoming material, in process, machining, assembly or testing, "Quality" is the watchword. Quality Assurance & Control System, Quality Plans and Field Quality Assurance are aids to total quality concept.

As a testimony to excellent quality consciousness in BHEL, BVQI with accreditation from UK, Holand and Germany has certified HEEP Hardwar with the prestigious ISO 9001 for all its products and services.

We follow various National/ International standards like IEC, ANSI, ASME, DIN etc. at all the stages of product cycle.

HYDRO POWERCLEAN POWER

HARDWAR

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BHEL AND HYDRO-ELECTRIC POWER

A PERSPECTIVE

BHEL appeared on the hydro map of India in 1970 with the commissioning of Obra (3x33 MW) hydro-power station and is now one of the leading suppliers in the field of design and manufacture of hydroelectric equipment.

BHEL’s design practices have been evolved after careful synthesis of know-how obtained from reputed collaborators in the world. These design practices have been updated and supplemented by own innovations and in-house research and development work over more than last three decades.

285 hydro sets (11981.99 MW) with share of 52.90% of total hydro power in the country have been designed, manufactured and installed by BHEL over last three decades as per purchaser’s requirements. Availability of BHEL sets is 96.8%.

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RANGE OF HYDRO TURBINE PARAMETERS 

TYPE UNIT RATINGRUNNER DIA SPEED HEAD

  MIN MAX MIN MAX MIN MAX MIN MAX

KAPLAN 5 75 1.65 5.64 150 428.6 10 50

FRANCIS 5 250 1.39 4.0 150 750 43 450

PELTON 1.5 115 0.849 3.5 250 750 300 900

REVERSIBLE 60 200 3.296 6.95 136.3 500 40 400

UNITS: RATING - MW, RUNNER DIA - M, SPEED - RPM, HEAD - MSPIRAL CASING

The spiral casing is of logarithmic form and designed to maintain optimum flow conditions. It is manufactured in parts, depending on transport limitations. For larger sizes, spiral-casing segments are welded at site. The welding seams are tested by radiography, UT and the complete casing is tested under hydraulic pressure.

STAY RING & GUIDE APPARATUS

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Stay rings up to 12.5 m in diameter can be machined on BHEL’s vertical boring machines. The stay rings are welded in the works. For high head machines, the stay rings are made of low alloy cast steel. The guide apparatus assembly of low and medium-head turbines is carried out on dummy stay ring or its own stay ring.

Maximum possible check-assembly of the various matching components of the turbine is carried out in works. Pit-type and tandem-type servomotors have been installed. Rubber-lip and hydrodynamic seals have been used as shaft sealings. Self-lubricated self-aligned and water lubricated guide bearings have been used depending upon speed requirements.

 TURBINE RUNNERS

BHEL has the capacity to supply runners for custom-built machines, to suit their operating conditions. The runners are cast in BHEL’s own Central Foundry Forge Plant or purchased from world reputed foundries. The hub is cast from low-alloy cast steel. BHEL’s own foundry can take up alloy castings up to 40 Tons.

GOVERNORBHEL supplies electro-hydraulic and electronic governors to suit the various requirements of its customers. BHEL governors are suitable for operation up to 40kg/cm² oil pressure system.

 

17

SPHERICAL AND BUTTERFLY VALVES

Main Inlet valves and penstock valves of butterfly type (for low head applications) and spherical valves (for high head applications) are designed and supplied by BHEL.

Valves of sizes ranging from 500 mm to 5300 mm diameter and for heads up to 1020 m have been supplied. BHEL has also designed and developed double seal type and lattice door type B.F valves.

18

RENOVATION, MODERNISATION AND UPRATING OF BHEL /NON BHEL SETS

STATE OF ART R & M RESULTING IN EFFICIENT OPERATION, BETTER ENERGY RECOVERY AND SOLUTION TO GENERIC PROBLEMS COVERING ALL ASPECTS OF TECHNO-ECONOMIC ANALYSIS ON TURNKEY BASIS.

NEED FOR RENOVATION AND MODERNISATION

AGED UNITS, POOR, PERFORMANCE, HIGH MAINTENANCE COSTS AND OBSOLETE TECHNOLOGY.

LIFE ENHANCEMENT

OPTIMUM UTILISATION OF HYDRAULIC CONDITIONS.

HIGHER OUTPUT WITH EFFICIENT RUNNERS.

STATE OF ART IN DESIGN PHILOSOPHY FOR IMPROVED PERFORMANCE & RELIABILITY.

 

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EFFICIENCY IMPROVEMENT IN MAJOR R &M PROJECTS EXECUTED

PROJECT ORIGINAL RUNNER

MODIFIED NEW RUNNER

BAIRASIUL 87.2% (53.8 MW)

92.3% (68.4 MW)

DEHAR 93.4 %(MAX) 94.9%(MAX)

CHILLA 93.5%(MAX) 95.0%(MAX)

(ALL OUTPUTS IN BRACKETS ARE TURBINE OUTPUTS)

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GAS TURBINESFOR

POWER GENERATION

HARIDWAR

21

BHEL’S LARGE SIZE GAS TURBINES

FUEL FLEXIBILITY

Gas Turbine burners are designed to burn a wide variety of fuels ranging from clean fuels like Natural Gas, Distillate Oil, Naphtha and LPG to heavy fuels like LSHS. Gas Turbines can be operated in mix-mode also.

HIGH RELIABILITY

High reliability and long operating life are the prime basis of the design philosophy adopted for these Gas Turbines. The reliability of M/s SIEMENS/ BHEL designed Gas Turbine is unsurpassed with more than 2 million hours of successful operation for module V94.2 itself.

This measure of high reliability has been achieved through a combination of sound design engineering, established manufacturing processes with well defined quality management systems.

HIGH EFFICIENCY

These Gas Turbines have high efficiency in Open Cycle and in Combined Cycle Operation. The provision of inlet guide vanes improves the combined cycle efficiency at part loads as well.

LOW EMISSION

While on natural gas very low NOx and negligible CO emissions are achieved without steam/water spray in specially designed Hybrid Burners. Steam/water spray assists in reduction of NOx emissions when firing liquid fuels like Naphtha, Distillate No.2 etc.

DESIGN FEATURES OF THE PROVEN MODEL V94.2 GAS TURBINES

SINGLE CASING AND SINGLE SHAFT

22

The compressor and turbine have a single casing and single rotor, which is supported on two bearings only. The bearings are located outside the pressurized zone providing constant good alignment and excellent running conditions. The compressor has sixteen stages and turbine has four stages.

BUILD UP ROTOR

The rotor is built up from the discs and hollow shaft held together by Central Tie Rod and Nut. Hirth Serrations on the disc faces help in centering the discs and allow free radial expansion and contraction as well as effective transmission of power .

BLADES

Variable pitch, inlet guide vanes allow operation down to half load while maintaining a constant exhaust temperature. Air cooling of the first three stationary and first two moving turbine blade rows protects the blade material against high inlet temperature.

The free standing moving blades of the compressor and the turbine are tuned to permit continuous full load operation over a frequency range from –5% to +3%

SILO TYPE COMBUSTION CHAMBERS

Two large size Silo type Combustion Chambers ensure complete combustion of hydrocarbons. The high temperature part of Combustion Chamber is provided with the refractory lining.

HYBRID BURNERS

Each Combustion Chamber is provided with specially designed Hybrid burners suitable for single or dual fuel operation. Burners provide complete combustion of fuel with proper air fuel mixture giving very low Nox emission in the exhaust.

EASY MAINTAINABILITY

All the Rotor Blades have axial entries to facilitate change of blades on rotor without dismantling rotor at site.

For Rotor Balancing at site, three planes are accessible.

Ready access via manholes into both Combustion Chambers permit direct inspection of all the hot gas path components from the burners to the turbine blades.

GENERATOR AT COLD END

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The Generator is connected at cold end and is used as a motor for initial start up of turbine. This results in saving of equipment and space.

SHORT START UP TIME

HIGHLY EFFICIENT NEWLY DEVELOPED 'A' SERIES GAS TURBINES

NEW DESIGN BASED ON PROVEN FEATURES

Advanced series of gas turbine designed to meet higher efficiencies have been developed by Siemens and designated as Vxx.3A series of machines. The 3A series machines are state-of-art machines with basic features adapted from previous gas turbine series. Important design features of the 3A gas turbine are:

1. New compressor blading

2. Fewer hot gas path components

3. Film cooled turbine blades

4. Hybrid burner ring (HBR) combustor with 24 burners

5. Lower cooling air requirement and thus more air available for clean combustion

6. Compact construction

V94.3A GAS TURBINE

Advances made in the development of this series of gas turbines are particularly evident in the combustion chamber. The ring type combustion chamber is connected to the turbine outer casing. The hybrid burners form a continuous ring flame thus eliminating the localized hot and cold spots. The objective here is to reduce the pollutant emissions.

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THE MAJOR BENEFITS FOR ADVANCE GAS TURBINE

1. Large saving in operating costs due to lowest fuel consumption

2. Low maintenance costs as a result of readily maintainable machine construction and long intervals between inspections

3. Excellent operating availability and reliability

4. Lower life-cycle cost

5. Effective use of fossil-fuels

ROTOR ASSEMBLY OF V94.3A GAS TURBINE

 

Technical Parameters of Gas Turbines

PARAMETER V94.2 GT V94.3A GT

Base Rating, MW-ISO 159 265

Turbine Inlet Temperature , °C 1060 1230

Exhaust Mass Flow, Kg/s (approx.) 514 659

Exhaust Temperature , °C at ISO 543.0 581

Efficiency, % 34.74 38.5

MANUFACTURING FACILITIESThe plant is fully equipped with the modern and sophisticated machine-tools and testing equipment to produce steam turbine sets upto 1000MW ratings and Gas Turbine sets upto 300MW ratings.

25

CNC BROACHING MACHINE

OVERSPEED & BALANCING TUNNEL

The facilities include: Most modern Blade Shop for

manufacturing of both moving and stationary blades of compressor

Highly sophisticated special purpose CNC machine tools

Creep Feed Grinding Machine for disc hirth serrations

External Broaching Machine for making Blade root grooves on the discs

Overspeed & Vacuum Balancing Tunnel, a very unique facility for balancing and overspeeding rotors for turbines and generators upto 1300 MW capacity

The new facilities for specific requirements of new products are continuously updated.  

CNC LATHE FOR ROTOR MACHINING

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5. Description of Various Shops Visited

1. Light Machine Shop: This shop is situated in Bay III of Block 3 and is involved in machining of various light weight parts for Emergency Stop Valve & Control Valve, Interceptor Valve & Control Valve, L.P. Bypass Valve and their Servomotors.

Various machines are installed in this shop like Lathes – Conventional and CNC, Milling Machine, Grinders, Shapers, Planners, Slotters, Vertical Boring Machine- CNC and Horizontal Boring Machines.

2. Governing Assembly Section: The Governing Assembly section is situated in Bay III of Block 3. “Governing is the process of maintaining constant speed of turbine

irrespective of load variation.”In Governing Assembly Section we assemble the Emergency Stop

Valve & Control Valve, Interceptor Valve & Control Valve, L.P. Bypass Valve, Governing Rack, Hydro Turbine Governing Assembly and Gas Turbine Governing Assembly.

And tests of all the above said assemblies are also done here.

27

3. Turning, Milling and L& D Section: This section is also situated in Bay III of Block 3 and engaged in manufacturing of Parts of Governing Assembly section, Bearing & Pedestals, Diaphragms and Guide Blade Carriers etc.

In this section different type of machines are available for turning and milling purpose, mostly machines are conventional type except some sophisticated CNC machines. 4. Planning: This Planning section is involved in shop level planning functions for TUM. These functions can be listed as follows –* Planning schedules on the basis of monthly plan provided by PPC.* Dispatching or forwarding of authorized work plan to shop.* Prioritization of works.* Procurement of Bought Out Items.

5. Blade Assembly Section: The Blade Assembly section lies in Bay II of Block 3.This section is involved in fitting of blades in turbine rotors as well as casings.

As we know that the blades are considered as most sensitive part of Turbine because a blade has to face various forces like impulse force, reaction force, centrifugal force and so on at not only elevated temperature but also on very high speed. That is why this section is very sensitive and important.

6. Assembly Section Bay-2: This section is also stated in Bay II of Block 3 and is engaged in assembly of 210 MW HP, 500 MW HP , 500 MW LP and Gas Turbines. Its main functions are as follows-* Assembly of Turbines.* Hydraulic Test of casings.* Balancing of Rotors.* Various Test of assembled Turbines.

7. Heavy Machine Shop Bay-2: This shop is situated in Bay II of Block 3 and is involved in machining of various Turbine Rotors and Turbine Casings of various modules.

This shop has many lathe machines of high turning capacities, vertical boring machines and horizontal boring machines, etc.

8. Assembly Section Bay-1: This section is situated in Bay I of Block 3 and engaged in assembly work of different Turbines, Big Pedestals, Valves for Governing, Hydraulic Test of Bends and Pipes, Gas Turbine Rotors and Gas Turbine Combustion Chambers.

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9. Heavy Machine Shop Bay-1: This shop is placed in Bay I of Block 3 and here we do various machining works on casings of Turbine and Valve bodies. The turning work on rotors is also done here.

This section has various Lathe machines, Vertical Boring Machines and Horizontal Boring Machines with conventional as well as CNC operating systems.

10. Over Speed Balancing Tunnel: It is the place where we do balancing of Turbine & Generator Rotors in respect of vibrations measured in a vacuumed tunnel on approx 3600 rpm and balance the Rotors with adding some small weight blocks.

The purpose of OSBT is dynamic balancing and over speeding of Turbine and Turbo generator rotors.

Salient Features of OSBT are as follows-

* Rotor Weight -320 T max.* Rotor Dia -6900 mm max.* Rotor Journal -950 mm max.* Distance Between Pedestals -15750 mm max.* Balancing Speed -3600 rpm* Over Speed Range -2500 to 4500 rpm* Vacuum -1 Torr or 1 mm Hg* Tunnel Length -19000 mm* Tunnel Dia -9000 mm* Tunnel Shell Thickness -32 mm* Tunnel Wall Thickness -2500 mm

6. Financial Turnover

Financial Turnover of HEEP Vs T&D

29

PRODUCTION FIGURES T&D Vs. HEEP

0

500

1000

1500

2000

2500

YEAR

MV

(Rs.

Cr.)

T&D TO 291 393 438 473 550 714 1025

HEEP SHOP TO 486 665 679 745 867 1183 1608

HEEP TO 718 1088 1013 974 1407 1641 2105

00-01 01-02 02-03 03-04 04-05 05-06 06-07

Financial Turnover of TUM Shop

Shop Turnover Physical

30

LAST 5 YEARS TURN OVER

0

20000

40000

60000

80000

100000

120000

YEAR

MV

(Rs.

Lac

s)

Main 28984 30354 27623 37137 54720 82031

Spares 10100 10732 16161 11835 13010 16879

Total 39084 41086 43784 48972 67730 98910

01-02 02-03 03-04 04-05 05-06 06-07

TOTAL MODULES IN LAST 5 YEARS INCLUDING ST, GT & HT

0

20

40

60

80

100

YEAR

NU

MB

ER O

F SE

TS

HT 1 0 3 2 0 2

GT 2 1 0 2 2 0

ST 15 21 27 13 33 80

01-02 02-03 03-04 04-05 05-06 06-07

7. Unique Facilities Available In Turbine- Manufacturing

CNC Vertical boring machine having 8 M turning capacity.

Vertical boring machine having12 M turning capacity. MFD Lathe machine having 18 M bed length and 2.3 M

swing over carriage. Horizontal Broaching machine having slide length 1.8 M

and pulling power 32 N-m. Creep Feed Grinding machine having indexing accuracy

of ± 1 mm. Over Speed Balancing Tunnel for balancing up to 1000

MW Rotors. Kopp Milling machine for machining of T-Root in L.P.

Rotors.

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Stub Borer machine for boring diameter from 625 mm to 2500 mm in Steam Turbine Casing.

Wotan Horizontal Boring machine with 6-axis CNC control.

8. Shop Planning Flow Chart

32

9. Modernization Schemes & Technological Development

SN Modernization Scheme No. of M/Cs

Sanctioned InvestmentRs Lacs

Status

1 Modernization of ST manufacturing Facilities - Stage-I

6 4018 Completed

2 Modernization of ST manufacturing Facilities - Stage-II

4 3272 Ongoing -comp. Dec’07

3 Modernization of ST manufacturing Facilities - Stage-III (capacity augmentation to 5250 MW)

4 4881 Ongoing – comp. Dec’07

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Additional proposal for special purpose HB machine for milling of Fir-Tree grooves in LP Rotors of ST (estimated cost of Rs. 1769 Lacs) has also been initiated. (Offers under technical discussion)

FACILITIES COMMISSIONED UNDER STAGE - I OF ST MODERNIZATION PROJECT

SN DESCRIPTION APPLICATION1 Vertical Band Saw Machine For Slitting of IP IC Flanges

2 Tool Presetting For precise setting of insert tool3 CNC Lathe (SOC 1500mm, CD

6.5m)For machining of 500MW Valve Covers

4 CNC Vertical Borer (dia. 6.5m, ht. 7m)

For machining of large Casings

5 Special Boring & Facing Heads of CNC (WOTAN – 5C Rapid) Horizontal Borer

For machining of ESV & IVCV Casings

6 Special Programmable Boring and Facing Heads for CNC Skoda Horizontal Borer

For machining of ESV & IVCV Casings

Investment = Rs. 40.18 Crores

FACILITIES UNDER STAGE - II OF ST MODERNIZATION PROJECT

SN DESCRIPTIONCOST(Rs. Lacs) APPLICATION

1 Universal Portable Radial Drilling Machine (capacity 75mm)

370 For drilling of inclined holes

2 CNC Gantry Milling Machine (size 13x6x1.5m, table 12x4m)

2615 For machining of ST casings

3 CNC Machining Center (spindle dia. 100mm, table 630x630mm)

150 For machining precision governing components

4 80 Tonne Transfer Trolley 52 For inter-bay transfer of fabricated components

Contingency 85  

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TOTAL 3272  

Total Investment = Rs. 32.72 Crores

FACILITIES UNDER STAGE - III AUGMENTATION OF ST FACILITIES FOR ANNUAL CAPACITY OF 5250MW

SN DESCRIPTIONCOST(Rs. Lacs) STATUS

1 CNC Rotor Turning lathe (SOC 3500mm, CD 18000mm)

2455 PO Placed

2 CNC Vertical Borer (dia. 2.5m)

343 Under finalization

3 CNC Horizontal Borer (spindle dia. 160 mm)

1323 PO Placed

4 CNC Indicating Stand 760 PO PlacedTOTAL 4881  Total Investment = Rs. 48.81 Crores

Technological Development

• Establishment of technology for assembly of advanced class blading for ST inner casings (all ratings).

• Establishment of technological process for machining of advanced class blade shrouds of 500 MW HP & IP Casings in boxed up condition.

• Development of technology for Hydraulic testing of integral inlet insert of imported fully machined IPOC 500 MW Kahalgaon at 53 bars.

• Development & Institutionalization of measurement of flow path of 500/250 MW HP/IP Turbines as a parallel measure for reduction of cycle time.

35

• Establishment of new RCB tools for coupling holes of 500 MW LPR on CNC Skoda Ram Borer (2-473)

• Improvement in manufacturing process of Yokes and Valve covers by introduction of mirror templates.

• Establishing drilling / reaming of pin holes without using breech nut in HPOC.

• Establishment of alternate procedure for assembly of FBP in shop using technological MOP casing.

• Machining of IP Outer Casing of 500 MW on Stub Borer reducing cycle time of Vertical Boring by 12 days.

• Etablishing alternate work center for machining of 14 nos. Russian diaphragms (instead of VB, machining on CNC facing lathe).

• Development of alternate work centre for machining of Stop Valve Servomotor Casings for Governing & U-Sealing rings for HP Turbines on Facing Lathe.

• Modification in oil catchers to prevent oil leakages during balancing of Russian Rotors.

• Development of alternate machine for turning of LP Rotor for 500 MW on old retro fitted Russian machine.

• Design review and finalization of technology for 25th stage Rotor assembly of 210 MW Russian ST for R&D, Hyderabad.

• Provision of single technological shaft for balancing of HP Rotor 210 MW Russian replacing 3 different technological pieces.

• Establishing technology for manufacture of split type Spherical Valve Rotor as against existing integrated design for Maneribhali HEP project.

• Indigenization of Half Rings for Libya-3 & 4 Gas Turbines.• Technology developed for manufacturing solenoid valves and

MIL grade cables.

• Establishing hardening / carburizing process for SRGM

36

components.

• Time reduction in job setting for Shank & Carriage of SRGM by use of a single fixture.

• Manufacturing of proximity switches developed indigenously.

• DNC monitoring of CNC machines.

37

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