GURU NANAK EDUCATION TRUST OF INSTITUTIONS.

ROORKEE
Ph. 9818869333, Regn No. 3739 Dt 10.12.07, Website:www.hermesindia.in

INDUSTRIAL TRAINING OF ONE MONTH Department: Univ. Roll No.: Semester: Batch: MECHANICAL 9670104002 7th 2009-2013

Name of Student: AKASH KUMAR

Name of Industry: BHEL (HARIDWAR)

Acknowledgment
I have taken efforts in this project report. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them. I am highly indebted to (Mr. P.PANDIT) for their guidance and constant supervision as well as for providing necessary information regarding the Report & also for their support in completing the Report. I would like to express my gratitude towards my parents & member of (Mechanical Engineering) for their kind co-operation and encouragement which help me in completion of this seminar report. I would like to express my special gratitude and thanks to Faculty persons or guide person for giving me such attention and time. My thanks and appreciations also go to my colleague in developing the Report and people who have willingly helped me out with their abilities.

(AKASH KUMAR)

BHEL AN OVERVIEW
BHEL is the largest engineering and manufacturing enterprise in India in the energy related infrastructure sector today. BHEL was established more than 40 years ago when its first plant was setup in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India a dream which has been more than realized with a well recognized track record of performance it has been earning profits continuously since 1971-72. BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense, etc. The wide network of BHEL's 14 manufacturing division, four power Sector regional centres, over 150 project sites, eight service centres and 18 regional offices, enables the Company to promptly serve its customers and provide them with suitable products, systems and services efficiently and at competitive prices. BHEL has already attained ISO 9000 certification for quality management, and ISO 14001 certification for environment management.

POWER GENERATION
Power generation sector comprises thermal, gas, hydro and nuclear power plant business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the total installed capacity of 99,146 MW in the country, as against nil till 1969-70. BHEL has proven turnkey capabilities for executing power projects from concept to commissioning, it possesses the technology and capability to produce thermal sets with super critical parameters up to 1000 MW unit rating and gas turbine generator sets of up to 240 MW unit rating. Co-generation and

combined-cycle plants have been introduced to achieve higher plant efficiencies. to make efficient use of the high-ash-content coal available in India, BHEL supplies circulating fluidized bed combustion boilers to both thermal and combined cycle power plants. The company manufactures 235 MW nuclear turbine generator sets and has commenced production of 500 MW nuclear turbine generator sets. Custom made hydro sets of Francis, Pelton and Kapian types for different head discharge combination are also engineering and manufactured by BHEL. In all, orders for more than 700 utility sets of thermal, hydro, gas and nuclear have been placed on the Company as on date. The power plant equipment manufactured by BHEL is based on contemporary technology comparable to the best in the world and is also internationally competitive. The Company has proven expertise in Plant Performance Improvement through renovation modernisation and uprating of a variety of power plant equipment besides specialised know how of residual life assessment, health diagnostics and life extension of plants.

POWER TRANSMISSION & DISTRIBUTION (T & D)

BHEL offer wide ranging products and systems for T & D applications. Products manufactured include power transformers, instrument transformers, dry type transformers, series and stunt reactor, capacitor tanks, vacuum and SF circuit breakers gas insulated switch gears and insulators. A strong engineering base enables the Company to undertake turnkey delivery of electric substances up to 400 kV level series compensation systems (for increasing power transfer capacity of transmission lines and improving system stability and

voltage regulation), shunt compensation systems (for power factor and voltage improvement) and HVDC systems (for economic transfer of bulk power). BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV Facts (Flexible AC Transmission System) project under execution.

INDUSTRIES
BHEL is a major contributor of equipment and systems to industries. Cement, sugar, fertilizer, refineries, petrochemcials, paper, oil and gas, metallurgical and other process industries lines and improving system stability and voltage regulation, shunt compensation systems (for power factor and voltage improvement) and HVDC systems (for economic transfer of bulk power) BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV FACTS (Felxible AC Transmission System) projects is under execution.

INDUSTRIES
BHEL is a major contributor of equipment and systems to industries, cement, sugar, fertilizer, refinances, petrochemicals, paper, oil and gas, metallurgical and other process industries. The range of system & equipment supplied includes: captive power plants, co-generation plants DG power plants, industrial steam turbines, industrial boilers and auxiliaries. Wate heat recovery boilers, gas turbines, heat exchangers and pressure vessels, centrifugal compressors, electrical machines, pumps, valves, seamless steel tubes, electrostatic precipitators, fabric filters, reactors, fluidized bed combustion boilers, chemical recovery boilers and process controls. The Company is a major producer of large-size thruster devices. It also supplies

digital distributed control systems for process industries, and control & instrumentation systems for power plant and industrial applications. BHEL is the only company in India with the capability to make simulators for power plants, defense and other applications. The Company has commenced manufacture of large desalination plants to help augment the supply of drinking water to people.

TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production, installation, maintenance and after-sales service of Rolling Stock and traction propulsion systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting duly applications. BHEL is also producing rolling stock for special applications viz., overhead equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use, BHEL manufactures traction propulsion systems for other rolling stock producers of electric locomotives, diesel-electric locomotives, electrical multiple units and metro cars. The electric and diesel traction equipment on India Railways are largely powered by electrical propulsion systems produced by BHEL. The company also undertakes retooling and overhauling of rolling stock in the area of urban transportation systems. BHEL is geared up to turnkey execution of electric trolley bus systems, light rail systems etc. BHEL is also diversifying in the area of port handing equipment and pipelines transportation system.

TELECOMMUNICATION

BHEL also caters to Telecommunication sector by way of small, medium and large switching systems.

RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional and renewable sources of energy include: wind electric generators, solar photovoltaic systems, solar lanterns and battery-powered road vehicles. The Company has taken up R&D efforts for development of multi-junction amorphous silicon solar cells and fuel based systems.

INTERNATIONAL OPERATIONS
BHEL has, over the years, established its references in around 60 countries of the world, ranging for the United States in the West to New Zealand in the Far East. These references encompass almost the entire product range of BHEL, covering turnkey power projects of thermal, hydro and gas-based types, substation projects, rehabilitation projects, besides a wide variety of products, like transformers, insulators, switchgears, heat exchangers, castings and forgings, valves, well-head equipment, centrifugal compressors, photo-voltaic equipment etc. Apart from over 1110MW of boiler capacity contributed in Malaysia, and execution of four

prestigious power projects in Oman, Some of the other major successes achieved by the Company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan, Sri Lanka, Iraq etc. The Company has been successful in meeting demanding customer's requirements in terms of complexity of the works as well as technological, quality and other requirements viz extended warrantees, associated O&M, financing packages etc. BHEL has proved its capability to undertake projects on fast-track basis. The company has been successful in meeting varying needs of the industry, be it captive

power plants, utility power generation or for the oil sector requirements. Executing of Overseas projects has also provided BHEL the experience of working with world renowned Consulting Organisations and inspection Agencies. In addition to demonstrated capability to undertake turnkey projects on its own, BHEL possesses the requisite flexibility to interface and complement with International companies for large projects by supplying complementary equipment and meeting their production needs for intermediate as well as finished products. The success in the area of rehabilitation and life extension of power projects has established BHEL as a comparable alternative to the original equipment manufactures (OEMs) for such plants. TECHNOLOGY UPGRADATION AND RESEARCH & DEVELOPMENT To remain competitive and meet customers' expectations, BHEL lays great emphasis on the continuous upgradation of products and related technologies, and development of new products. The Company has upgraded its products to contemporary levels through continuous in house efforts as well as through acquisition of new technologies from leading engineering organizations of the world. The Corporate R&D Division at Hyderabad, spread over a 140 acre complex, leads BHEL's research efforts in a number of areas of importance to BHEL's product range. Research and product development centers at each of the manufacturing divisions play a complementary role. BHEL's Investment in R&D is amongst the largest in the corporate sector in India. Products developed in-house during the last five years contributed about 8.6% to the revenues in 2000-2001.

BHEL has introduced, in the recent past, several state-of-the-art products developed in-house: low-NQx oil / gas burners, circulating fluidized bed combustion boilers, high-efficiency Pelton hydro turbines, petroleum depot automation systems, 36 kV gas-insulated sub-stations, etc. The Company has also transferred a few technologies developed in-house to other Indian companies for commercialisation. Some of the on-going development & demonstration projects include: Smant wall blowing system for cleaning boiler soot deposits, and micro-controller based governor for diesel-electric locomotives. The company is also engaged in research in futuristic areas, such as application of super conducting materials in power generations and industry, and fuel cells for distributed, environment-friendly power generation.

HUMAN RESOURCE DEVELOPMENT INSTITUTE

The most prized asset of BHEL is its employees. The Human Resource Development Institute and other HRD centers of the Company help in not only keeping their skills updated and finely honed but also in adding new skills, whenever required. Continuous training and retraining, positive, a positive work culture and participative style of management, have engendered development of a committed and motivated work force leading to enhanced productivity and higher levels of quality. HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT BHEL, as an integral part of business performance and in its endeavour of becoming a world-class organization and sharing the growing global concern on issues related to Environment. Occupational Health and Safety, is committed to protecting Environment in and around its own establishment, and to providing safe and healthy working environment to all its employees.

For fulfilling these obligations, Corporate Policies have been formulated as: ENVIRONMENTAL POLICY Compliance with applicable Environmental Legislation/Regulation; Continual Improvement in Environment Management Systems to protect our natural environment and Control Pollution; Promotion of activities for conservation of resources by Environmental Management; Enhancement of Environmental awareness amongst employees, customers and suppliers. BHEL will also assist and co-operate with the concerned Government Agencies and Regulatory Bodies engaged in environmental activities, offering the Company's capabilities is this field. OCCUPATIONAL HEALTH AND SAFETY POLICY Compliance with applicable Legislation and Regulations; Setting objectives and targets to eliminate/control/minimize risks due to Occupational and Safety Hazards; Appropriate structured training of employees on Occupational Health and Safety (OH&S) aspects; Formulation and maintenance of OH&S Management programmes for continual improvement; Periodic review of OH&S Management System to ensure its continuing suitability, adequacy and effectiveness; Communication of OH&S Policy to all employees and interested parties.

The major units of BHEL have already acquired ISO 14001 Environmental Management System Certification, and other units are in advanced stages of acquiring the same. Action plan has been prepared to acquire OHSAS 18001 Occupational Health and Safety Management System certification for all BHEL units. In pursuit of these Policy requirements, BHEL will continuously strive to improve work particles in the light of advances made in technology and new understandings in Occupational Health, Safety and Environmental Science. PARTICIPATION IN THE "GLOBAL COMPACT" OF THE UNITED NATIONS The "Global Compact" is a partnership between the United Nations, the business community, international labour and NGOs. It provides a forum for them to work together and improve corporate practices through co-operation rather than confrontation. BHEL has joined the "Global Compact" of United Nations and has committed to support it and the set of core values enshrined in its nine principles:

PRINCIPLES OF THE "GLOBAL COMPACT" HUMAN RIGHTS

1. Business should support and respect the protection of internationally proclaimed human rights; and 2. Make sure they are not complicit in human rights abuses.

Labour Standards
3. Business should uphold the freedom of association and the effective

recognition of the right to collective bargaining; 4. The elimination of all form of forces and compulsory labour. 5. The effective abolition of child labour, and 6. Eliminate discrimination. Environment 7. Businesses should support a precautionary approach to environmental challenges; 8. Undertake initiatives to promote greater environmental responsibility and 9. Encourage the development and diffusion of environmentally friendly technologies. By joining the "Global Compact", BHEL would get a unique opportunity of networking with corporate and sharing experience relating to social responsibility on global basis.

ACTIVITY PROFILE
PRODUCTS Power Generation & Transmission - Steam Turbine-Generator Sets & Auxiliaries - Industrial Fans - Seamless steel Tubes - Fabric Filters

- Boiler and Boiler Auxiliaries - Once-through Boilers - Nuclear Power Generation Equipment

- AC DC Motors, Variable speed - AC Drive - Electronic Control Gear & Automation - Hydro Turbine-Generator Sets & Auxiliaries - Equipment - Mini/Micro Hydro Generator Sets - DDC for Process Industry - Gas Turbine-Generator Sets - Thruster Equipment - Waste Heat Recovery Boilers - Power Devices - Heat Exchangers - Energy Meters - Condensers - Transformer - Bowi Mills and Tube Mills - Switch gear - Gravimetric Feeders - Insulator - Regenerative Air Pre-Heaters - Capacitors - Electrostatic Precipitators - Broad Gauge AC, AC/DC Loco motives - Bag Filters - Diesel-Electric Shunting Locomotives - Valves - Traction Motors & Control Equipment - Pumps - Electric Trolley Buses - Electrical Machines - AC/DC Electric Multiple Units - Piping Systems - Drives and Controls for Metro Systems Power, Distribution & Instrument - Battery-Operated Passengers Transformers Vans - Reactors - X-Mas Trees and Well Heads - Synchronous Condensers - Cathodic Protection Equipment - Switchgear - Digital Switching Systems - Control gear - Rural Automatic Exchange - Distributed Digital Control for Power - Simulators Stations - Bus Ducts - Wind Electric Generators - Rectifiers - Solar Powered Water Pumps

- Porcelain Insulators - Ceralin

Solar Water Heating Systems Photo Votaic Systems Defense Equipment INDUSTRIES/TRANSPORTATION/OIL Reverse Osmoses Desalination & GAS/ Plants TELECOMMUNICATION/RENEWABLE SYSTEMS & SERVICES ENERGY - Steam Turbine-Generator Sets - Turkey Utility Power Stations/ EPC - Gas Turbine-Generator Sets - Contracts - Diesel Engine-Based Generators - Captive Power Plants - Industrial Steam Generators - Co-generation Systems - Heat Recovery Steam Generators - Combined Cycle Power Plants - Fluidised Bed Combustion Boilers - Modernisation & Renovation of Power - Drive Turbine Stations and FLA Studies - Manne Turbines - Switch yards and Substations - Industrial Heat Exchangers - HVDC Transmission Systems - Centrifugal Compressor - Shorts sines condensation Systems - Industrial Valves - Power system analysis - Reactors - Electron comissionly and operation - Columns - Consultancy services - Pressure Vessels - Consultancy Services - Pumps SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS CORE SECTORS Power Generation
THERMAL RATING (MW) 500 NO. OF SETS 30 TOTAL CAPACITY (MW) 15000

250 210/200 120/125/130 195 110 100 70/67.5 60 30 TOTAL (THERMAL) GAS FRAME SIZE/ SCOPE 9 6 5 3 V 94.2 6FA STG GEN TOTAL (GAS) NUCLEAR RATING (MW) 500 220 TOTAL (NUCLEAR) TOTAL (THERMAL+GAS+NUCLEAR) HYDRO GRAND TOTAL

9 138 20 1 38 6 6 14 5 267 NO. OF SETS 5 17 13 6 2 3 24 4 74 NO. OF SETS 2 10 12 353 402 755

2250 28570 2420 195 4180 600 410 840 150 54615 TOTAL CAPACITY (MW) 730 580 309 48 286 207 1190 87 3437 TOTAL CAPACITY (MW) 1000 2200 3200 61252 18735 79987

SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS CORE SECTORS

POWER TRANSMISSION & DISTRIBUTION
In the T&D sector, BHEL is both a leading equipment-manufacturer and a system-

integrator. BHEL-manufactured T&D products have a proven track record in India and abroad. In the area of T&D systems, BHEL provides turnkey solutions to utilities. Substations and shunt compensation installations set up by BHEL are in operation all over the country. EHV level series compensation schemes have been installed in KSEB, MSEB, SMPSEB and POWERGRID networks. Complete HVDC systems can be delivered by BHEL. The technology for state-of-the-art Flexible AC Transmission Systems (FACTS) is being developed.

INDUSTRIES
Since inception in 1982, the Industry Sector business has grown at an impressive rate and, today, contributes significantly of BHEL's turnover. BHEL, today, supplies all major equipment for the industries: AC/DC machines, alternators, centrifugal compressors, special reactor column, heat exchangers, pressure vessels, gas turbine based captive co-generation and combined-cycle power plants, DG power plants, steam turbines and turbo-generators, complete range of steam generators for process industries, diesel engine-based power plants, solar water heating systems, photovoltaic systems, electrostatic precipitators, fabric filters, etc. The industries which BHEL serves include: Steel, Aluminium, Fertiliser, Refinery, Petrochemicals, Chemicals, Automobiles, Cement, Sugar, Paper, Mining, Textile etc.

TRANSPORTATION
In the transportation filed, product range covers: AC locomotives, AC/DC dualvoltage locomotives, diesel-electric shunting locomotives, traction motors and transformers, traction elections and controls for AC, DC and dual voltage EMUs,

diesel-electric multiple units, diesel power car and diesel electric locomotives, battery-powered vehicles. A high percentage of the trains operated by Indian Railways are equipped with traction equipment and controls manufactured and supplied by BHEL.

B. HEEP : AN OVER VIEW

Over the years, Bharat Heavy Electricals Limited has emerged as world class Engineering and Industrial giant, the best of its kind in entire South East Asia. Its business profile cuts across various sectors of Engineering/Power utilities and Industry. The Company today enjoys national and international presence featuring in the "Fortune International-500" and is ranked among the top 12 companies in the world, manufacturing power generation equipment. BHEL has now 14 Manufacturing Divisions, 8 Service Centres and 4 Power Sectors Regional Centres besides a large number of project sites spread over India and abroad. The Company is embarking upon an ambitions growth path through clear vision, mission and committed values to sustain and augment its image as a world class enterprise.

VISION
World-class, innovative, competitive and profitable engineering enterprise providing total business solutions.

MISSION
The leading Indian engineering enterprise providing quality products systems and services in the fields of energy, transportation, infrastructure and other potential areas.

VALUES
Meeting commitments made to external and internal customers. Foster learning creativity and speed of response. Respect for dignity and potential of individuals. Loyality and pride in the company. Team playing. Zeal to excel. Integrity and fairness in all matters.

HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)

At Hardwar, against the picturesque background of Shivalik Hills, 2 important manufacturing units of BHEL are located viz. Heavy Electrical Equipment Plant (HEEP) & Central Foundry Forge Plant (CFFP). The hum of the construction machinery woke up Shivalik Hills during early 60s and sowed the seeds of one of the greatest symbol of Indo Soviet Collaboration Heavy Electrical Equipment Plant of BHEL. Following is the brief profile of Heavy Electrical Equipment Plant:1. * ESTABLISHMENT AND DEVELOPMENT STAGES: Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the area of Scientific, Technical and Industrial Cooperation. * * * DPR prepared in 1963-64, construction started from October '63. Initial production of Electric started from January, 1967. Major construction / erection / commissioning completed by 1971-72 as per original DPR scope. * Stamping Unit added later during 1968 to 1972.

Annual Manufacturing capacity for Thermal sets was expanded from 1500 MW to 3500 MW under LSTG. Project during 1979-85 (Sets upto 500 MW, extensible to 1000/1300 MW unit sizes with marginal addition in facilities with the collaboration of M/s KWU-Siemens, Germany.

Motor manufacturing technology updated with Siemens collaboration during 1984-87.

Facilities

being

modernized

continually

through

Replacements

Reconditioning-Retrofitting, Technological / operational balancing.

2.
*

INVESTMENTS:
Gross Block as on 31.3.95 is Rs. 355.63 Crores (Plant and Machinery Rs. 285.32 Crores).

Net Block as on 31.3.95 is Rs. 113.81 Crores (Plant & Machinery Rs. 76.21 Crores).

3.
*

CLIMATIC AND GEOGRAPHICAL:

Hardwar is in extreme weather zone of the Western Uttar Pradesh of India and temperature varies from 2oC in Winter (December to January) to 45oC in Summer (April-June); Relative humidity 20% during dry season to 95-96% during rainy season.

* * *

Longitude 78o3' East, Latitude 29 o55'5" North. Height above Mean Sea Level = 275 metres. Situated within 60 to 100 KMs of Foot-hills of the Central Himalayan Ranges; Ganges flows down within 7 KMs from the Factory area.

HEEP is located around 7 KMs on the Western side of Hardwar city.

4.
* * *

COMMUNICATION & TRANSPORTATION:

Telegraphic Code "BHARAT TELEC, HARDWAR" TLX Lines: 05909-206 / 207 Telephones : P&T / STD (01334) 427350-59, 423050-423954 FAX : (0091) (1334) 426462 / 425069 / 426082 / 426254

Direct Board gauge train lines to Calcutta (Howrah), Delhi, Bombay, Lucknow, Dehradun and other major cities; Railway Siding for goods traffic connected to Hardwar Railway Station.

5.

POWER & WATER SUPPLY SYSTEM:

40 MVA sanctioned Electric Power connection from UP Grid (132 KV / 11KV / 6.6 KV) (Connected load around 185 MVA) 26 deep submersible Tube Wells with O.H. Tanks for water supply. A 12 MW captive thermal power station is located in the factory premises.

6.

FIRE PROTECTION:
Managed by CISF with around 40 personnel and a host of latest fire fighting equipment and fire tenders.

7.

MANPOWER: Total strength is 9904 as on 31.3.96 which includes around 3000 qualified

Engineers and Technicians (including substantial number of Post graduates), 5200 skilled artisans and the rest in other categories. 8. * TOWNSHIP AND PERIPHERAL INFRASTRUCTURES: A large modern township for employees and allied personnel with social and welfare amenities. * Medical: Main Hospital (200 beds) Dispensaries in various townships sectors * Educational: Occupational health center No. of Schools (including Intermediate levels) Science Degree College * * Residential: Around 6780 quarters. Other amenities: Good Road network Shopping Centres Central Stadium Community Centres A Club Police Stations CISF Complex for over 500 CISF personnel. Convention Hall (a Most modern Air Conditioned Auditorium with 1500 1 19 1 1 9

seating capacity). Parks.

9. *

HEEP PRODUCT PROFILE: THERMAL AND NUCLEAR SETS (Turbines, Generators, Condensers and Auxiliaries of unit capacity upto 1000

MW)

HYDRO SETS INCLUDING SPHERICAL AND DISC VALVES (Kaplan, Francis, Pelton and reversible Turbines of all sizes and matching generators and auxiliaries maximum runner dia 6600 mm)

ELECTRICAL MACHINES: (For various industrial applications, pump drives & power station auxiliaries, Unit capacity upto 20000 KW AC / DC)

CONTROL PANELS (For Thermal / Hydro sets and Industrial Drives)

LARGE SIZE GAS TURBINES

(Unit Rating : 60-200 MW)

* *

LIGHT AIRCRAFT DEFENSE PRODUCTS

10.

HEEP: FACILITIES AND INFRASTRUCTURE Modernisation and regular Upgradation / up gradation of facilities and other

infrastructure is a continuous endeavor at HEEP, BHEL. After initial setting up of the plant during the year 1964-72, in collaboration with the Soviet Union, the plant facilities and infrastructures have since been continuously upgraded under various investment projects vise, Stamping Unit Project, LSTG Project, Motor Project, Governing Components Project, TG Facilities Modernisation, TG Facilities Augmentation, Quality Facilities Augmentation, EDP projects, Gas Turbine Project, Facilities have also been added and establishments have been created for new projects in Defense and Aviation Project. Additionally, R &D facilities have also been created under Generators Research Institute, Pollution Control Research Institute, HTL modernization and other such schemes.

Today the Plant has unique manufacturing and testing facilities, computerized numerically controlled machine-tools, Blade shop, heavy duty lathes, milling machines, boring machines, machining centers and many more. The Over Speed Vacuum Balancing Tunnel created for rotors up to 1300 MW (32T, 6.9 M dia bladed rotor, 6 rpm up to 4500 rpm) is one of the 8 of its kind in the entire world.

The total spectrum of sophisticated, unique and other facilities at HEEP, Hardwar are the state-of-the-art in manufacturing processes and can be utilized for a variety of products' manufacture.

TURBINE AND AUXILIARY BLOCK-III

1.0
1.1

GENERAL
Block-III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and Turbines Blades. Special Toolings for all products are also manufactured in the Tool Room located in the same block. Equipment layout plan is a per Drawing appended in Section III. Details of facilities are given in Section II.

1.2

The Block consists of four Bays, namely, Bay-I and II of size 36x378 metres and 36x400 metres respectively and Bay-III and IV of size 24x402 metres and 24x381 metres respectively. The Block is equipped with the facilities of EOT Cranes, compressed air, Steam, Overspeed Balancing Tunnel, indicating stands for steam turbine, rotors, one Test stand for testing 210 MW steam turbines Russian Design, one Test Stand for Hydro Turbine Guide Apparatus and two separate Test Stands for the testing of Governing Assemblies of Steam and Hydro Turbines.

1.3

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

2.0 2.1

MANUFACTURING FACILITIES HYDRO TURBINES

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

(a)

Circular Components Machining Section This section is equipped with a number of large/ heavy size Horizontal and Vertical Boring Machines, Drilling Machines, Centre Lathes, Marking Table and Assembly Bed. The major components machined in this section are Spiral Casing with Stay Ring, Spherical and Disc Valve bodies and Rotors.

(b)

Runner and Servo Motor Housing Machining Section This section is equipped with NC/CNC and conventional machines comprising Heavy and Medium size vertical and Horizontal Boring Machines, Centre Lathes, Grinding machines and Drilling Machines, Marking Table, Assembly Bed, Assembly Stands for Steam Turbine and Gas Turbine assemblies and Wooden Platform for overturning heavy components. Hydro Turbine Runners, Servomotors, cylinders, Labyrinth Ring, Regulating Ring, Stay Ring, Turbine Cover, Lower Ring, Kaplan Turbine Runner Body and Blades are machined here.

(c)

Guide Vanes and Shaft Machining Section This section is equipped with Heavy duty Lathe machines upto 16 metres bed, CNC turning machines, Horizontal Boring Machine, Heavy planer, Deep Drilling Machine, Boring Machines, marking Table, Marking Machines and Assembly Beds. Turbine shafts, Guide Vanes, Journals and Rotors of Spherical and Disc Valves are machined here. Rotors of Steam Turbines are also machined in this section.

(d)

Assembly Section In this section, assembly and testing of Guide Apparatus, Disc Valve, Spherical Valves, Servo motor shaft and combined Boring of coupling holes are done.

(e)

Preservation and Packing Section Final preservation and packing of all the Hydro Turbine components / assemblies is done here.

(f)

Small components Machining Section This is equipped with Planetary Grinding Machine, Cylindrical Grinding Machines, small size Lathes, Planers, Vertical and Horizontal Boring Machines. Small components like Bushes, Levers, Flanges etc. and Governing assemblies and machines here.

(g)

Governing Elements Assembly and Test Stand Section This section is equipped with facilities like oil Pumping Unit, Pressure Receiver, Servomotors etc. for assembly and Testing of Governing Elements.

2.2

STEAM TURBINES
The facilities and parts manufactured in the various sections of Steam Turbine manufacture are as follows:

(a)

Turbine casing Machining Section It is equipped with large size Planer, Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines etc. Fabrication work like casings, Pedestals etc. are received from Fabrication Block-II.

(b)

Rotor Machining Section It is equipped with large size machining tools like Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree Groove Milling Machine etc. Some rotor forgings are imported from Russia and Germany and some are indigenously manufactured at CFFP, BHEL, Hardwar.

(c)

Rotor Assembly Section This is equipped with Indicating Stand, Small size Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and Discs. Machined Rotor, Discs and Blades are assembled here. Balancing and over speeding of Rotor is done on the dynamic balancing machine.

(d)

Turbine casing Assembly Section Machined casings are assembled and hydraulically tested by Reciprocating Pumps at two times the operating pressure.

(e)

Test Station - Test station for testing of 210 MW USSR Steam Turbine at no load is equipped with condensers, Ejector, Oil Pumps, Oil containers Steam Connections etc, required for testing. Overspeed testing is done for emergency Governor. Assembly Test Stands for different modules of Siemens design are equipped with accessory devices.

(f)

Painting Preservation and Packing Section All the parts are painted, preserved and packed here for final dispatch.

(g)

Bearings and Miscellaneous Parts Machining Section This section is equipped with small and medium size basic machine tools, e.g., lathes, Milling M/c, Horizontal Borer, Vertical Borer, drilling M/c etc. for manufacture of bearings and other miscellaneous parts of turbine.

(h)

Sealing and Diaphragm Machining Section It is equipped with medium size Vertical Boring, Horizontal Boring, Planning, Drilling Machines etc. wherein castings of sealing Housings, Liner housings, Forgings of Rotor Discs, castings and fabricated Diaphragms and components are machined. It is also equipped with CNC machining center. Precision Horizontal Boring, Plano-Milling machines etc, are for

manufacture of Governing Casting, Servo Casings and other medium parts of governing and Main Turbine assemblies. (i) Governing Machining Section This section is equipped with medium size and small size lathes, medium CNC lathe, Milling, Grinding, Drilling,

Slotting and Honing Machines. Governing assembly parts are machined here. (j) Diaphragm and Governing Assembly Section It is equipped with deflection testing equipment for Diaphragms, Dynamic Balancing Machine for balancing Impeller of Centrifugal Oil Pumps and small fittings and assembly equipment. Governing test stand is equipped with the facilities like Oil Pumping Unit, Pressure Receiver, Servomotor, overspeed testing of Emergency Governor etc. (k) Light machine shop In addition to normal conventional machine tools it is equipped with CNC Lathes, CNC Milling, CNC Vertical Boring, Precision Milling, planetary grinding machines etc. for manufacture of small and medium precision components of governing and other turbine parts.

2.3

GAS TURBINE
All the components of Gas Turbine are machined and assembled using the facilities available for manufacturing of steam and hydro turbines except the following facilities which are procured exclusively for the manufacturing of Gas Turbine and are installed in the areas specified for gas turbine manufacturing.

a)

Hydraulic Lifting Platform

This facility is used for assembly and disassembly of G.T. Rotor. This is a hydraulically operated platform which travels upto 10 M height to facilitate access to different stages of Rotor. This is installed in Bay-I assembly area.

b)

CNC Creep Feed Grinding M/c.

This is installed in Gas Turbine machining area Bay-II Extn. This M/c grinds the hearth serration on rotor disc faces. Hirth serrations are radial grooves

teeth on both the faces of rotor discs. Torque is transmitted trough these serrations, which are very accurately ground.

c)

External Broaching Machine

This machine is installed in GT machining area and is used to make groove on the outer dia of rotor discs for the fitting of moving blades on the discs.

d)

CNC Facing Lathe

This machine is installed in GT machining area and is used basically for facing rotor disc but can turn other components also.

e)

CNC Turning Lathe

This machine is installed in Bay-I Heavy Machine Shop and is used to turn Tie Rods of Gas Turbine, which have very high length / diameter ratio. TieRod is a very long bolt (length approx. 10 meter & dia 350 mm) which is used to assembly and hold the gas turbine rotor discs to form a composite turbine rotor.

f)

Wax Melting Equipment

This is low temp. electric furnace installed in Gas Turbine blading area in Bay-II. It is used to mix and melt Wax and Colaphonium, which is required to arrest the blade movement during the blade tip machining of stator blade rings.

g)

Gas Turbine Test Bed

This test bed is installed near the Gas Turbine Machining area in Bay-II. This facility is used to finally assemble the gas turbine. Combustion chambers are not assembled here, which are assembled with main assembly at the site.

h)

Combustion Chamber Assembly Platform

This facility is a 3 Tier Platform installed in Bay-I assembly area and is used for assembly of Combustion Chambers of Gas Turbine.

3.0 3.1

MANUFACTURING PROCESS HYDRO TURBINES

The major processes involved in various Hydro Turbine Sections are as

follows: Marking and checking of blanks manual as well as with special marking M/c. Machining on Horizontal Boring, Vertical Boring, Lathes etc. as the case may be on CNC /Conventional Machines. Intermediate assembly operation is carried out on the respective assembly beds provided. -

Then the assembly is machined as per requirement. The sub-assemblies are further assembled for hydraulic/functional testing. Hydraulic testing is done using a power driven triple piston horizontal hydraulic pump which can generate a pressure of 200 Kg/Cm 2. It can also be carried out using a power pack.

On Governing elements / assembly and test stand, the components / subassemblies / assemblies are tested up to a hydraulic pressure of 200 Kg / c m2 using the piston pump. Oil testing upto 40 Kg / c m 2 is carried out with

oil pumping unit, which is permanently installed on this bed.

3.2

STEAM TURBINE
Processes carried out in various sections of steam turbine manufacture are based on the following main phases.

(a)

Machine section Castings, Forgings, welded structures and other blanks are delivered to this section. The manufacturing process is based on the use of high efficiency carbide tipped tools, high speed and high feed machining techniques with maximum utilization of machine tool capacity and quick acting jigs and fixtures.

(b)

Assembly Section Casings and Governing assemblies are hydraulically tested for leakage on special test Bed. Assembled unit of governing and steam distribution systems are tested on Governing Test Bed. General Assembly and testing of Steam Turbine is carried out on the main Test Bed in Bay-II.

(c)

Painting, Preservation and Packing After testing the turbine, it is disassembled and inspected. Then the parts are painted, conserved and packed for final dispatch.

3.3

GAS TURBINE
The major processes involved in manufacturing Gas Turbine in various sections of Bk-III are as follows:

a)

Machining
Castings, Forgings, welded structures and other blanks are received from

concerned agencies in the respective sections. These are machined keeping in view optimum utilization of machine tools and toolings. Special jigs and fixtures are made available to facilitate accurate and faster machining. Proper regime and tool grades have been established to machine the materials like inconel, which have poor machinablity.

b)

Main Assembly
Final assembly is done on test bed. Parts are assembled to make subassemblies. These sub-assemblies are again machined as per technological and design requirements and are made ready for final assembly. After assembly and insulation assembled Gas Turbine is sent to site.

c)

Rotor Assembly
The rotor is assembled on Hydraulic Lifting Platform and sent to main assembly, where after checking clearances, it is sent for machining. After balancing, turbine side of rotor is disassembled, inner casing is fitted and rotor reassembled. This work is also carried out on Hydraulic Lifting Platform. Finally rotor is sent for assembly on test bed.

d)

Combustion Chamber Assembly

This assembly is carried out on 3 tier platform installed for this purpose in Bay-I assembly. After machining of all components, ceramic tiles are fitted in flame tube. Burner and piping etc. is fitted in dome and combustion chamber is finally assembled. It is directly sent to site after insulation.

B. BLADE SHOP
1. Introduction:
Major part of Turbine Blade Machining Shop is located in Bay-IV of BlockIII. In this shop various types of Steam Turbine and Gas Turbine Compressor blades are machined from bar stock, drawn profile, precision and envelope forgings. It is a batch production shop comprising of various kinds of CNC Machines and Machining Centers, besides various special purpose and general purpose machines. The layout of equipments is as per technological sequence of the manufacturing process. Blade shop implements various On Line Quality Control Techniques through Run Charts and Control charts. This shop is divided into four distinct areas. Details of facilities are given in various schedules of Section-II.

2.

Manufacturing Facilities: i) Plain Milling Section

It prepares accurate reference surfaces on the blade blanks by milling and grinding operation. It also manufactures the brazed type blades by induction brazing of drawn profile and suitably machined spacers. This section carries out banking by Band Saws, rhomboid grinding on Duplex grinding machines and thickness grinding on Surface grinders.

ii)

Copy Milling Section

The Semi blanks prepared from plain milling section are further machined by copy Milling Machines / CNC machines (CNC Heller and BSK Bed type Klopp, BFH / BEK Knee type Machines) for

concave and convex aero-dynamic profile forms, (HTC-600, BFK Machines) for expansion angles, Compound taper grinding of radial plane is carried out by Surface grinders. It comprises of T-root machining centers for machining of T-root.

iii)

LP Section
This area deals with all types of free standing and forged blades for steam Turbine Compressor. The free standing blades are cerrobend casted in boxes to hold the blade with respect to the profile. These blades roots are subsequently machined on NTH, MPA-80A and T30 Machining Centers. There is a five station 360o circular copy milling machine for machining the profile of envelope forged blades / stocks for Steam Turbine and Gas Turbine Blades. It also has 3D copy Milling and CNC Machines with digitizing features for Tip-thinning, Fitted milling. The inlet edge of the last stage of Low pressure Turbine Moving blades are hardened on a Special Purpose Flame Hardening equipment.

iv)

Polishing Section Blade Contours are ground and polished to achieve the desired surface finish and other aerofoil requirements. There are also other small sections e.g. Fitting Section, Tool and Cutter Grinding, Toolings Repair Section in Blade Shop.

v)
-

Inspection Device
3 D Coordinate Measuring Machines for taper and rhomboid checking.

Moment weighing Equipment Real time Frequency analyzer for checking frequency of free standing blades.

vi)

Contour plotter for plotting of blade profile with various magnifications. Fir tree root inspection device. Magna spray crack detection equipment. Miscellaneous There are other important facilities e.g. High rack storage system for fixtures. Compactor system storage for finish blades. Jib cranes and EOT cranes for material handling. The semi finished batch of blades are kept in special boxes for inter-operation movements. An AGV (Automated Guided Vehicle) is also located in LP Section of Blade Shop for better material movement.

3.0

MANUFACTURING PROCESS The manufacturing process of turbine blades primarily depends on the type of blade e.g. Bar type, Brazed type, Free standing (Forged type), Gas Turbine Compressor blades. The bar type and brazed type blades are also known as drum stage glades. The manufacturing technology of each of these blades along with recommended machine tools / equipment is furnished below.

3.1

BAR TYPE BLADES

MACHINE USED TOOL/EQUIPMENT

PROCESS / OPERATION

i. Blanking of area material

Circular saw/band saw

ii. Sizing to rectangular shape iii. Thickness grinding iv. Rhomboid milling v. Rhomboid grinding

Hor. Milling Machine Surface grinder Duplex milling machine Duplex grinding machine

vi. Milling perpendicularity on both Hor. Milling machine ends vii. Milling radius on surround viii Finish milling of convex and . concave profile ix. Milling expansion faces of convex Hor. Copy milling m/c Hor. Copy milling / CNC Hor. Milling machine Hor. Copy milling m/c/

And concave sides at root and CNC milling m/c shroud x. Root slot/root chamfer and Radit at root and shround Milling xi. Taper grinding xii. Grinding and polishing of profile And expansion faces xiii Final Rounding, chamfering etc. . Manual fitting. 2 spindle T-root roughing, m/c and root radius copy milling m/c, T-root machining center Surface grinder Abrasive belt polishing m/c

3.2

BRAZED TYPE BLADES

PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED

i. Cutting of drawn profile & spacer Hor. Milling machine blank ii. Sizing to rectangular shape iii. Thickness grinding Hor. Milling machine Surface grinder

iv. Rough and finish milling of internal Hor. Milling machine profile of spacer v. Cutting-off spacer vi. Brazing of drawn profile and spacer Abrasive cutting Right frequency inducting brazing installation vii. Milling of width viii Pin rough and Root slot . ix. External profile rough and finish Hor. Milling machine machining x. Pin turning xi. Grinding and polishing xii. Debarring and rounding Pin turning lathe Abrasive belt polishing m/c Manual fitting Duplex milling machine Vert. Milling m/c

3.3

FREE STANDING BLADES

PROCESS / OPERATION

MACHINE USED

TOOL/EQUIPMENT

i. Grinding of ref. Belts ii. Milling of inlet & outlet edge iii. Center hole drilling iv. Encapsulating with cerrobend alloy v. Remelting of cerrobend alloy vi. Remelting of cerrobend alloy vii. Machining of fillets viii Grinding and polishing . ix. Cutting-off blade tip x. Inlet edge hardening xi. Blade tip rounding xii. Tip thinning (if reqd.)

Abrasive belt polishing 3D Vert. Copy milling m/c CNC machining Centre Cerrobend casting equip. Fir-tree root machining center Cerrobend casting equip. Vertical 3D copy milling machine Abrasive belt polishing

Abrasive cutting machine Frame hardening equip. (if required) Vert. 3-D dcopy milling m/c -do-

3.3

GAS TURBINE BLADES MACHINE USED TOOL/EQUIPMENT

PROCESS / OPERATION

i. Cerrobend casting ii. Root machining iii. Remelting of cerrobend alloy iv. Profile checking v. Length cutting vi. Tenon vii. Grinding and polishing of fillet

Cerrobend casting equip. Hor. Machining center Cerrobend casting equip. Vert. Stand Circular saw/hor. Milling m/c Hor. Milling m/c Abrasive belt polishing m/c

A. QUALITY CONTROL FACILITIES

As in BHEL Customer Focus is of prime significance, Quality Control Function assumes vital role. Quality Control facilities get priority in investment planning. The Group is equipped with the state-of-the-art testing, measuring and analytic facilities. This chapter covers Facilities existing in various sections under Quality Management Deptt. 1.0 FACILITIES IN QUALITY CONTROL TURBINE BLOCK Each Quality Control Station is equipped with conventional measuring instruments as well as sophisticated testing machine to suit the inspection requirements of the related area. Some of the important facilities are:i)

CNC 3D Coordinate Measuring Machine a fully computer controlled modern machine for automatic inspection of complex or precision components of size upto 2000x1200x1000 mm. The important features of this machine are high speed computer, versatile software, universal probe head for scanning, digitization and plotting of known and unknown curves etc.

ii)

2-D Coordinate Measuring Microscope Used for highly accurate and precise measurements of small and intricate components of the turbine. The machine is equipped with multiple feature digital readouts of resolution 0.0001 mm, a separate light generator connected through fiber cables for better accuracy, optical templates for various inspection purposes etc.

iii)

Vibration Measuring Equipments Three no. of vibration measuring equipments are available for checking of blade frequency at

various stages.
iv)

Portable hardness testers it is being used for checking of hardness of plane hardened- Nitrided and stellited components. It can measure upto a range of HV 999.

v)

MPI Machine This is used for carrying out magnetic particle test for crack detection on finished blades.

vi)

Surface Finish Measuring Equipment This is used for checking the surface finish of machined components. Can measure in R, Rz and Ra.

vii) * * * * * *

Hardness Testers of different configurations SAROJ (VICKER CUM BRINELL) SAROJ B-3000 (BRINELL) USSR (ROCKWELL) USSR (BRINELL) SAROJ (ROCKWELL CUM BRINELL) SAROJ (ROCKWELL) HV to BH 5 to 250 KG BH 250 to 3000 Kg HRC 150 Kg BH 250 to 3000 Kg HRC/HB 60 to 250 Kg HRC 60 to 150 Kg

B.

HYDRO TURBINE LABORATORY

1. INTRODUCTION
Hydro Turbine Laboratory at HEEP, Hardwar was set up in late '60s. It comprises of three Test Beds with electronic Instrumentation Laboratory for test bed operation/maintenance and for carrying out Site Investigations. It has a modest Workshop to manufacture hydro turbine models. Till December '95 about 160 number of tests have successfully been performed in the Laboratory which include Contractual as well as Developmental tests on Hydro Turbine Models, Calibration of Hydraulic Valves, Nozzles and Flow Measuring Devices for 210 MW Thermal Sets. Besides performing the main function of design/ development of hydraulic passages of hydro turbines, design of models, their manufacture and testing, the Laboratory has also been engaged in Field Test Studies at various Hydro Power Sites for conducting Index Tests, Head Loss Measurement, Uprating Studies and attending to various Site Problems. 2. 3. 4. 5. DESIGN: MANUFACTURING: TESTING: TESTING CAPABILITIES: Runaway speed tests of reaction and impulse turbine. Determination of MW output of prototype turbine under specified operating conditions. 6.4 INSTRUMENTATION LABORATORY

The Instrumentation Laboratory is equipped with the most modern instrumentation for carrying out accurate measurements during testing in the Laboratory as well as during field testing. The major facilities are: 7. Ultrasonic Flowmeter for field tests. Magnetic Tape Recorder with Waveform Analyzer. Microprocessor based Pressure Pulsation Measuring System. Microprocessor based Wicket Gate Torque Measuring System. Microprocessor based Hydraulic Thrust Measuring system.

RESEARCH AND DEVELOPMENT The continuous inhouse research and development efforts of the Laboratory have enabled it to establish new measurement methods for carrying out special tests, to bridge know-how / know-why gaps, to resolve certain site problems and to evolve and establish better and more efficient designs. The benefits of research and development activities are passed on to the customers through implementation of new concepts of existing sites and for future projects.

8.

FIELD TESTING The Laboratory is equipped to perform field efficiency and index tests on prototype turbines at hydro power sites. Many site problems of hydraulic and mechanical nature have been successfully solved as a result of extensive filed tests and analysis carried out by the Laboratory. The Laboratory has successfully carried out uprating studies at many hydro sites resulting in augmentation of power generating capacity of the units at no extra or

minimum cost. Extensive work has been done by the Laboratory to tackle the problem of silt erosion of runner blades at several hydro power stations situated in the Himalayan region. 9. CALIBRATION The Laboratory is equipped with the required facilities for calibration of load cells, pressure pulsation transducers, weights, volumetric tanks and torque wrenches. Calibration of these terms is performed with respect to standards with history traceable to N.P.L., Delhi. 10. FUTURE PLANS Upgradation and modernization of Hydro Turbine Laboratory has been planned in the following areas: Renovation of Test Beds to the cater for the requirements of IEC-995. Modernisation in the field of instrumentation. Addition of instantaneous in-siti calibration facility. Incorporation of Computerisation and Data Acquisition System Modernisation of Workshop facilities.

C.

HUMAN RESOURCE DEVELOPMENT CENTRE

INTRODUCTION
HRDC Workshop caters to the needs of skill training of various trainees at HRDC. These trainees include Engineering Trainees & ACT Apprentices amongst others. Any other type of trainees who are to be given imported training can be given skill training in areas of machining, turning, fitting, welding, electrical, carpentry & electronics. In a year, about 500 ACT Apprentices are given training on various machines.

VARIOUS SECTIONS OF HRDC WORKSHIP

There are 7 different sections in HRDC Workshop in which facilities exist for training. (i) Turning Section has facilities for practical training of Turner Apprentices & trainees. There are 18 Lathes, which include HMT lathes H22, LB 17, LM 001, Russian lathe No. 163, Kirloskar lather D 1 and one CNC Trainmaster T-70 of HMT make. (ii) Fitting Section has facilities for training in the area of fitting e.g. 36 bench vices for fitting work. (iii) Machining Section has 24 milling machines for skill training, 1 shaper, 1 slotter and 10 grinding machines. A CNC machining center also exists for training in CNC operations. (iv) Welding Section has facilities to give practical training in gas welding and electric welding. The section has transformer, MG set, rectifier & an electrode oven.

(v)

Electrical Section has facilities for providing practical training in electrician field. Areas in which practical training is given are laying of house wiring, joints making & motor winding.

(vi)

Carpentry Section facilities for providing practical training in the field of carpentry. It has various wood working machines, like surface planer lathe, thickness planer, circular saw, pedestal grinder & drilling machines.

(vii) Electronics Trade In this section practical training is given in making circuits & repair work of TVs, tape recorders, amplifiers etc.

FACILITIES IN MANAGEMENT DEVELOPMENT / TRAINING

Audio visual facilities Facilities exist for video projection through a video projection system on a wide screen. Other facilities include a colour TV, a 16 mm film & sound projector, overhead projectors (5 nos.) for transparencies, slide projectors (2 nos.), a video camera, video cassette recorders (2nos.), two-in-one tape recorders (2 nos.), a 35 mm photo camera, a conference system (for 6 persons) and a number of video tapes & 16 mm films on management, technical and functional areas. All these facilities are primarily used for facilitating learning at HRDC.

D.

POLLUTION CONTROL RESEARCH INSTITUTE

To provide directional thrust to environmental control / protection activities, a Pollution Control Research Institute has been set up by BHEL at HEEP, Hardwar with the assistance of United Nations Development Programme (UNDP). The main objective of the Institute is to develop technologies for pollution control in the areas of air, water noise and solid waste to obviate unintended side effects of economic growth. The Institute is concentrating on research and development activities related to environment protection against pollution emanating from industries. PCRI provides consultancy services related to pragmatic approaches / methods to maintain pollution within permissible limits. The other objectives include development of methods for recovery and recycling of industrial wastes. Most modern facilities for monitoring and analysis in the area of air, water, noise and solid waste are available at the Institute. It has full-fledged computer facilities for prediction and forecasting pollution impact. It also has workshop and other support services. The laboratories of Pollution Control Research Institute have been recognized by Ministry of Environment and Forests, Govt. of India; Department of Science and Technology, Govt. of India; Madhya Pradesh Pradushan Nivaran Mandal; UP State Pollution control Board; Bihar State Pollution Control Board; Punjab State Council for Technology; Haryana State Pollution Control Board; Karanataka State Pollution Control Board.

E.

AVIATION PRODUCTS
MANUFACTURING FACILITIES
1. LIGHT TRAINER AIRCRAFT PROJECT In 1991, BHEL Entered into Aviation Sector as part of its diversification efforts and has taken up manufacturing of two-seater light trainer aircraft "SWATI". The aircraft was designed and developed indigenously by R&D Wing of Directorate General of Civil Aviation, India. Requisite organizational facilities and services infrastructure has been developed in Sector X at BHEL, Hardwar. "SWATI" is a general purpose aircraft powered by 116 HP horizontally opposed piston engine with fixed pitch propeller and has wide range of applications like flying training, sports, touring, surveillance, photography, courier & personal use.

2.
2.1

WORKSHOP & FACILITIES:

General: Hangar / Manufacturing Workshop consisting of one bay of size 45x90 mtrs with expansion provision on eastern side have been developed at Aviation Project Site in Sector X.

2.2

Manufacturing: Following major components, sub-assemblies & assemblies are

manufactured in different sections: Fuselage Landing Gear

2.3 i)

Engine Mount Fuel Tank Pair of Wings Pin, Bush, Axle, Stud, etc. Lever, Brackets, Controls, etc. Fin, Rudder, Tailplane, Elevator, etc.

Facilities: Fabrication / Welding Section Equipped with TIG welding machines, this section is meant for fabrication of fuselage, engine mount, landing gear and welding of lugs, brackets and other items on fuselage.

ii)

Wing Manufacturing Section This section is located in WWM shop (Block-VII) of HEEP, as all the required wood working facilities are available in that Shop.

iii)

Machine Shop The Shop is equipped with medium capacity center lathes, milling machines and drilling machine. Small components like pins, bush, axle, wing to wing attachment fitting etc. are routed through this Section.

iv)

C.M. Section (Chrome Moly-Steel Section) Components of CM steel like lugs, brackets, levers, control system etc. are manufactured in this Section. This section is equipped with fitter tables, vices, hand shear machine, screw press etc.

v)

Alclad Section

All components / sub-assemblies made of Alclad material like Fin, Rudder, Tailplane, Elevator, Cowling etc. are manufactured in this Section. This Section is equipped with fitter tables, vices, compressed air, Hand shear machine, Sheet folding machine, 160 T Hydraulic press, 25 T Crank press etc. Fuel tank is manufactured in Sheet Metal Shop of ACM (Block-IV). vi) FRP Section FRP Components like fairing, nose cap upper & lower, drag reduction items etc. are made in this Section. vii) Assembly Section Trial Assembly / Final assembly of components on fuseldge is carried out in this Section like mounting of fin, rudder, tailplane, engine, fuel tank, controls, instruments etc. viii) Test Flying Facilities To establish performance characteristics of aircraft before delivery to the customer, an airstrip of size 23M in width and 914 M in length has been developed in Sector IX near the Project Site.

F.

MEDICAL LINAC PROJECT

Introduction:
Medical Linac, a machine for treatment of Cancer by Radiation Therapy has been taken up for commercial manufacture at HEEP, Hardwar with know-how from (1) Department of Electronics (DoE), Govt. of India, (2) SAMEER, Bombay, (3) Central Scientific Instruments Organisation (CSIO), Chandigarh and (4) Post Graduate Institute of Medical Education & Research (PGIMER), Chandigarh. Medial Lines test station equipped with facilities for testing of Medical Linac machines upto 15 MeV (Mega Electronic Volt) has been established at HEEP, Hardwar and first 4MeV machine jointly manufactured by SAMEER, CSIO, PGIMER and BHEL, Hardwar has been successfully integrated and tested in newly established test station. Efforts are also afoot to declare this test-station as National Test House. Littion USA make Hydrogen brazing furnace, model 4401 (specifications below) has been installed near the Medical Linac test station. This shall be used to carry out brazing process of parts made of Oxygen-free high- conductive (OFHC) copper. Layout proposed for the Medical Linac block is enclosed. No special facilities have been established for manufacture of controls for Excavator. Dedicated equipment like vacuum brazing furnace, double vacuum baking furnace, low power test equipment including vector network analyzer etc. required for the manufacture of complete machine will be added in future.

G. CENTRAL PLANT STORES

General
Materials from suppliers, sub-contractors, other unitsand ancillaries enters the factory premises from eastern gate.

Material Receipt
The materials are unloaded at receipt area, identified in the Central Plant Stores and subsequently shifted to respective custody areas after inspection. In case of heavy materials, receipt areas are adjacent to custody areas.

Material Issue
All the materials are received by Central Plant Stores and issued to users / manufacturing blocks. Manufacturing blocks have their own sub-stores to receive material from Central Plant Stores and further issue it to the shop / sections concerned.

Stores Custodies
The locations, where various types of material are stored by Central Plant Stores, have been classified as custody-I, II, III, IV & V.

Custodies & Materials Stores

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

BROAD SPECIFICATION OF
MAJOR/IMPORTANT MACHINE TOOLS & MACHINES

A : CNC MACHINE TOOLS CNC HORIZONTAL BORERS: 1. Item Description Model Supplier CNC Control System Spindle Dia. Table Max. Load on Table Travers Ram traverse Ram size Power Rating Weight of the m/c ATC Capacity Plan No. Item Description Model Supplier CNC Control System Boring Dai Table Headstock Travel Spindle Speed Power Rating Max. Load Capacity Weight of the m/c Plan No. Item Description Model Supplier CNC Control System : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : CNC Horz. Borer RAPID 6C WOTN, GERMANY FANUC 12M 200mm 4000 x 4000 mm 100 T X=20000, Y=5000, X=1400mm W = 1000 mm 400 x 400 mm 90 KW 111 T 60 Nos. 1-227 (Block-I) CNC Stub Borer DW 1800 HEYLIGENSTAEDT, GERMANY SINUMERIK 7T 625 2500 mm 4000 x 4000 mm 4000 mm 0.5 90 RPM (in 4 Steps) 63 KW 100 T 72 T 27-420 (Block-III) CNC Horz. Borer (2 Nos.) W200 HB NC SKODA, CZECH SINUMERIK 850 M

2.

3.

Spindle Dia. Traverse

: :

200 mm X=12500, Y=5000, Z=2000mm CNC LATHES

4.

Items Description Model Supplier CNC Control System Centre Distance Swing Over Carriage Swing Over Bed Spindle Speed Power Rating Weight of the Job Weight of the m/c Plan No. Item Description Mode Supplier CNC Control System Centre Distance Swing Over Carriage Swing Over Bed Spindle Speed Power Rating Weight of the job Weight of the m/c Plan No. Item Description Model Supplier CNC Control System

: : : : : : : : : : : : : : : : : : : : : : : : : : : :

CNC Centre Lathe D-1800 NYF HOESCH MFD, GERMANY SINUMERIK 3T 8000 mm 1800 mm 2400 mm 0 125 RPM 92 KW 110 TON 124 TON 2-394 (Block-III) CNC Centre Lathe D-2300 NYFS-1 HOESCH MFC, GERMANY SINUMERIK 7T 18000 mm 2300 mm 2900 mm 5 125 RPM 110 KW 320 TON 216 TON 2-360 (Block-III) CNC Centre Lathe KV2-1100 CNC RANVENSBURG, GERMANY SINUMERIK 820 T

5.

6.

Centre Distance : 12000 mm Centre Height : 900 mm Swing Over Carriage : 1100 mm Swing Over Bed : 1400 mm Max. Turning Length : 12000 mm Spindle Speed : 2-600 RPM Longitudinal Cutting Feed (Z-Axis) : 1-5000 mm / min. Transfer Cutting Feed (X-Axis) : 1-5000 mm/min. Main Spindle Drive Motor : 95.5 KW DC Max. Feed Force Z/X Axis : 45000 N No. of Tool carriers : 3 Plan No. : 1-120 (Block-III) CNC MILLING MACHINES Item Description : CNC Horz. Milling M/c (6 Nos.) Model : BFH-15 Supplier : BATLIBOI, INDIA CNC Control System : SINUMERIK 810 M Table : 1500 x 400 mm Traverse : X=1170 mm Y=420 mm Z=420 mm Spindle Speed : 45 to 2000 RPM Power Rating : 11 KW Max. Load Capacity : 630 Kg Weight of the m/c : 4200 Kg Plan No. : 2-449, 2-453, 2-454, 2-459, 2-460 (BlockIII:TBM) Item Description Model Supplier CNC Control System : : : : Universal Milling M/cs (2Nos.) BFK-15 BATLIBOI, INDIA SINUMERIK 810 M

7.

8.

Table Traverse

: :

Spindle Speed Power Rating Max. Load Capacity Weight of the m/c Plan No. 9. Item Description Model Supplier CNC Control System Table Traverse

: : : : : : : : : : :

1500 x 400 mm X=1170 mm Y=420 mm Z=420 mm 45-2000 RPM 11 KW 630 Kg 4200 Kg 2-463, 2-466 (Block-III: TBM) CNC Bed Type Milling M/c FSQ 80 CNC TOSKURIM, CZECH SINUMERIK 810 M 3000 x 800 mm TEE SLOT 28H7 X= 3000 mm Y= 870 mm Z= 850 mm H 2500 RPM 18 KW continuous 22 KW intermittent 620 x 500 incldg ram 543 x 420 encldg ram 24 Nos. 2500 Kg 2-484 (Block-III)

Spindle Speed Range Spindle Drive Power Spindle Head Size ATC Capacity Table Load Plan No.

: : : : : :

CNC MACHINING CENTRES 10. Item Description Supplier : : SPL. Purpose 6 Station T-Root Machining Centre (2nos.) MIH, JAPAN

CNC Control System Indexing Table Indexing Position Plan No. 11. Item Description Model Supplier CNC Control System Table Traverse

: : : : : : : : : :

FANUC 7M 1900 mm dia 6 Nos. 2-356, 2-421 (Block-III: TBM) SPL Purpose FIR Tree Root M/cing Cenre NTH 200 RIGID, SWITZERLAND SINUMERIK 7M 1400 x 1400 mm X= 1950 mm Y= 900 mm Z= 600 mm 30600 RPM 4 22 KW 2-354 (Block-III TBM)

Spindle Speed No of Spindle Power Rating Plan No.

: : :

12.

CNC VERTICAL BORERS Item Description : CNC Vertical Borer Model : TMD 40 / 50 Supplier : OSAKA MACHINES, JAPAN CNC Control System : FANUC 6TB, 3TC Table dia : 4000 mm Turning dia : 5000 mm Turning Height : 4200 mm Spindle Speed : 0.23-30 RPM No. of Ram : 2 Power Rating : 75 KW Max. Load Capacity : 70T Machine Weight : 100 T Max. Ram Travel (Vertical) : 2200 mm Plan No. : 2-422 (Block-III)

13.

Item Description : Model : Supplier : CNC Control System : Table : Max. Turning dia : Max. Turning Height : Ram size : Table Speed : Max. Vertical Travel of Ram Power Rating : Table Load Carrying Capacity: ATC Capacity : Plan No. : Item Description : Model : Supplier : CNC Control System : Table : Table Load Carrying Capacity: Max. Turning Dia : Max. Turning Height : Ram Size : Max. Travel of Ram : Table Speed : Power Rating : ATC Capacity : Plan No. :

CNC Vertical Borer (2 Nos.) 40 DZ SCHIESS, GERMANY SINUMERIK 850 T 4000 mm 5000 mm 4200 mm 300 x 250 mm 0.63 63 RPM : 2200 mm 71 KW 80 T 12 Nos. 1-235 (Block-I), 2-472 (Block-III) CNC Vertical Borer 32 DS 250 SCHIESS, GERMANY SINUMERIK 850T 2500 mm 25T 3200 mm 2200 mm 210 x 250 mm 1400 mm 0.8 160 RPM 56 KW 12 Nos. 2-483 (Block-III)

14.

OTHER SPECIAL PURPOSE CNC MACHINES 15. CNC SURFACE BROACHING M/C Make : Marbaix Lapointe, UK Model : Champion 32 /10, 300

CNC System : Broaching capacity (pulling force) : Broaching slide stroke : Broaching slide width : Max tool length (continuous /row) : Broaching Speed (cutting stroke) : Broaching Speed (return stroke) : Drive power rating : Broaching slide movement : Maximum noise level : Max. dia of the disc (mountable) : Max. weight of the job : Indexing & rotating tables : Indexing accuracy : Plan No. : 16. CREEP FEED GRINDING M/C Make : Model : CNC System : Work-piece diameter : Work height : Rotary & indexing table dia. : Indexing accuracy : Max. load capacity : Y-axis (grinding head movement) Vert. Traverse : Z- axis (grinding head support) Movement on cross rail) Horizontal traverse : Traverse feed rate : Grinding head main support Drive motor :

SINUMERIC 850 M 320 KN 10.3 mm 1500 mm 9650 mm 1-25 M/min 60 M/min 135 KW Electro-mechanical < 80 Dbs 2300 mm 3000 Kgs 1500 mm, 1000 mm +/- 3 Arc sec. 2-485

ELB CHLIFE, GERMANY ELTAC SFR 200 CNC SINUMERIC 3 GG 200 2000 mm 2400 mm 2050 mm +/- 1 ARC SEC 20000 KG 750 mm

2400 mm 02 1200 mm /min 34 KW

Grinding wheel max. dia. Max. width Bore Surface speed Plan No. 17. BROACH SHARPENING M/C Make CNC System Work-piece diameter Work Length Plan No.

: : : : :

500 mm 100 mm 203.2 mm 16-35 M/Sec. 2-491

: : : : :

LANDRIANI, ITALY SELCA Upto 250 mm 200 mm 2-487

BROAD SPECIFICATIONS OF MAJOR / IMPORTANT MACHINE TOOLS & MACHINES B: NON-CNC MACHINE TOOLS (1) PRECISION HEAVY DUTY LATHE Manufacturer : Karamatorsk Heavy Machine Tool Works (USSR); Model KS-1614 Specifications 1. 2. 3. Maximum Swing Maximum Diameter of work piece over the Saddle Maximum Distance between Centres 2000mm 1500 mm 8000mm

4. 5.

Diameter of Spindle bore Maximum Taper when machining by the method of Combined Feeds

80 mm 0.15 mm

6.

Maximum Length between Centres when machining by the method of Combined Freeds

1200 mm

7. 8. 9.

Maximum Weight of work piece Maximum Length of Machine over the Saddle Maximum Summary Effort of Cutting

20000 kg 8000 kg 10,000 kg

10. Limit Dimension of Thread Cut: Thread Pitch Min Metric Threade Pitch (in mm) 1 Max Length of Thread, Max 96 3/8 mm 6300 6300

British Trhread Pitch (Per inch) 20

Name of Part

Powe r

Displacement in mm

One Division Of Dial

Rapid Traverse M/min

Manual Dial

Per Rev. of Represent

Carriage Transverse Slide Longitudinal Slide Tool Slide Rotary Part 150 90o 6 5o 0.1 mm 0.5 260 mm 17 mm Available Available 3.44 M/min 1130 600 1130 600 8 6 0.1 mm 0.1 mm

2.02 1.03 0.48

Maximum Displacement of the Tailstock Spindle Maximum Transverse Displacement of the Tailstock Rotating Built in Centre Power Extraction of the Tailstock Spindle Rapid Traverse of the Tailstock 12. Overall Dimension: Length 13900 mm Width 3845 mm 13. Plant No. 2-182 (Block-III) Height 2865 mm

UNIVERSAL VERTICAL TURNING & BORING MACHINE Manufacturer : Kolomna Machine Tool Works (USSR) Model KY 152 Specifications

1.

Maximum Dia. of workpiece accommodated 10000/12500 mm

2. 3. 4.

Dia. of central table Maximum travel of vertical Tool Heads from center of table Maximum weight of workpiece accommodated on central table (a) With table speed limited to n (n 6) r.pm. (b) At any speed

8750 mm 5250 mm

200 T 100 T

5.

Maximum cutting force with different length of tool over-hang (L) from head face R.H. Head 16000 Kg with L 1500 mm 7500 Kg with L 2000 mm 2000 Kg with L 3000 mm 1200 Kg with L 3700 mm L.H. Head 12500 Kg with L 1500 mm 7500 Kg with L 2000 mm 2000 Kg with L 3000 mm 1200 Kg with L 3700 mm

6. 7. 8.

Rated cutting dia on central table Maximum cutting torque on central table Speed range of central table rotation

6300 mm 80000 Kg.M Minimum = 0.112 r p.m. Maximum 11.2 r.p.m.

9. 10.

Travel rate of column assembly Plan No.

190 mm /minute 1-13 (Block-I) 1-24 (Block-III)

BALANCING MACHINE Manufacturer: SCHENK (West Germany) Model : Dj 90 Specifications 1. Weight of rotor 10,000 to 80,000 kg 2. Minimum weight without considerable loss of measuring sensitivity, provided the berings can accommodate such small rotors. 3. 4. 5. Maximum weight for one bearing pedestal Height of rotor axis above machine bed Rotor diameter (free swing over machine bed) not considering the funnel 6. 7. Diameter of journal Diameter of journal, with special sleeve bearing cups made from high grade material. Max. 540 mm Max. 600 mm 45,000 kg 1600 mm 4000 mm 5000 kg

8.

Minimum distance between bearings for less than 10 tons rotor

1500 mm

9.

Minimum distance between bearings for more than 10 tons rotor

1900 mm

10. Maximum distance between coupling plague and center of the scond bearing pedestals 11. Rotational Speeds (a) For rotors from 5 to 10 tons

13500 mm

Min. 800 rpm Max. 4000 rpm Min. 700 rpm

(b) For rotors from 10 to 20 tons

Max. 3600 rpm Min. 600 rpm

(c) For rotors from 20 to 80 tons 12. Maximum test speed and overspeeds (a) For rotors upto 50 tons (b) For rotors upto 50 to 80 tons 13. Maximum centrifugal force admissible on each bearing pedestals for short period of time 14. Balancing accuracy to be obtained depending on Selling

Max. 3600 rpm

4500 rpm 3600 rpm 50,000 Kg

0.3 to 3 micron

Weight 15. Sensitivity of indication depending on rotor weight, speed and selling weight 16. Accuracy of the angle indication 17. Stiffness of bearing pedestals, when mounted on machine bed (a) With unclamped bearings 1.2 Kg/micron (0.85 micron/Kg) (b) With clamped bearing 100 Kg/micron (0.01 micron /Kg). 0.1-8 div/micron 1 o 2o

SPECIAL DRILLING & BORING MACHINE Manufacturer: Machine Tool Works, Ryazan (USSR) Model: PT 182 H5 SPECIFICATIONS:

1. 2. 3. 4.

Swing over bed Drilling dia Boring dia Swing of job in rest Max Min

800 mm 40-80 mm 80-250 mm 300 mm 110 mm 300 110 mm 3000 mm 2000 Kg Headstock Stemstock 1 1 Horizontal From bed wasy From floor 400 mm 1100 mm 750 r.p.m. 71. r.p.m. 24 Available Max. 730 r.p.m.

5.

Swing of job in Headstock chuck

Max. Min.

6. 7. 8.

Maximum length of job Maximum weight of job Number of spindles

9.

Spindle location

10. Distance to spindle axis:

11. Head stock Spindle speed

Max Min.

Number of steps of spindle speed Spindle braking 12. Stemstock Spindle speeds

Min. 123 r.p.m. Number of steps of spindle speed Stemstock feed Max. Min. 6 1680 mm / min 168 mm / min Number of feed steps 13. Overall dimensions Length Width Height Weight 14. Plan No 13500 mm 2300 mm 1700 mm 23844 Kg. 1-105 (BlockIII) Stepless

SPECIAL INTERNAL GRINDING MACHINE Manufacturer: Saratov Machine Binding Works (USSR) Model : MB 6020 T SPECIFICATIONS

1.

Diameter of ground holes (a) Maximum (b) Minimum 320 mm 90 mm 560 mm 600 Kg 1100 mm

2. 3. 4. 5.

Maximum length of grinding (with maximum hole diameter) Maximum weight of work Distance from spindle axis to floor level Distance from spindle axis to table (a) Maximum (b) Minimum

300 mm 100 mm

6.

Cantilever vertical travel (a) Per one revolution of handwheel (b) Speed of rapid vertical traverse (from motor) (c) Per dial graduation 0.133 mm 190 mm / min. 0.01 mm 500 x 1200 mm

7.

Table working surface dimensions

8.

Table cross-traverse

(a) To operator from intermediate (zero) position (b) From operator from intermediate (zero) position (c) Total (d) For one revolution of hand wheel (e) For one dial graduation (f) Speed of rapid traverse (from motor) UNIVERSAL THREAD GRINDING MACHINE Manufacturer: Moscow Jig Boring Machine Plant (USSR) Model : 5822B3 SPECIFICATIONS 1. 2. Maximum diameter of work admitter Nominal diameter of thread being ground Min Max Min Max 4. Maximum length of thread being

200 mm 200 mm 400 mm 0.2 mm 0.01 mm 280 mm / min

160 mm 25 mm 125 mm 0.5 mm 6 mm

3.

Thread pitch

ground, (a) By single-ribbed wheel (b) By multiple ribbed wheel 5. Maximum taper of thread: 75 mm 55 mm 1o 47' 24" or 1:16 6. Table Maximum longitudinal table traverse, (a) By hand (b) By power Table rapid withdrawal speed 425 mm 415 mm (variable: maximum about 1.2 m/min) 7. Taper (a) Headstock spindle (b) Tailstock spindle MT 4 MT 5

8.

Grinding Wheelhead Maximum cross feed (a) By hand (b) By power Movement per dial division Movement per dial revolution 125 mm 50 mm 0.005 mm 1 mm

PLANER
Manufacturer : The Yefemov Plant TIAZHSTANKOGIDRO-PRESS (USSR) Model : 7A288-T SPECIFICATIONS 1. 2. 3. 4. Max. width of planning Max. height under cross rail Distance between housings Max. travel of slides below cross rail and inside housing (a) for vertical tool heads (b) for side tool heads 5. Max. allowable weight of workpiece 700 mm 700 mm 100 T 4000 mm 4000 mm 4250 mm

6.

Max. cutting force Arrangement for mechanizing and automating the machine operation is available

40000 Kg.

7.

Table Dimension of working surface of table, (a) Width (b) Length Table Stroke, Max. Min. Safety devices to stop table after worm disengaging. 3600 mm 12000 mm 12000 mm 3000 mm Available.

8.

Tool Heads Number of tool heads (a) Vert. (b) Side Travel of tool heads, mm. V.Tool Heads 2 2 Side Tool Heads R.H. 3750 700 L.H. 3750 700

(i) (ii)

Max. vertical travel Max. horizontal travel

700 5000

(iii )

Travel per turn of hand-wheel lever, (in mm) Vertical travel Horizontal travel 1.14 0.52 4.25 1.14 4.25 1.14

(iv) Dial division value Vertical Horizontal (v) Rapid travel Speed mm Vertical Horizontal 1.25 2.5 2.5 1.25 2.5 1.25 0.1 0.2 0.2 0.1 0.2 0.1

9. (i)

Cutter Head: Max. dimension of tool holder Vertical Tool head (a) Width (b) Height 120 mm 120 mm Side Tool head 120 mm 120 mm

(ii)

Max. angle of slide Swiveling

(a) To the right (b) To the left (iii ) Dial division value

60 o 60 o 10

45o 45o 10

(iv) Swiveling of cutter head plate (v) Cutter head automatic lifting during return stroke of table Cross Rail: Maximum travel Rapid travel speed Time of cross rail automatic fixing Main drive motor 11. Plan No.

10 o Available

10 o Available

10.

4000 mm Not less than 0.3 M/min 20 to 30 sec. 2 x 130 KW 2-189 (Block-III)

BOARD OF DIRECTORS
K.G. Ramachandran Chairman & Managing Director Bharat Heavy Electricals Limited BHEL House, Siri Fort, New Delhi 110 049 A.V. Singh Additional Secretary & Financial Advisor Ministry of Industry. Deptt. of Heavy Industry

Udyog Bhawan, New Delhi 110 011 Pradeep Kumar Joint Secretary Ministry of Industry. Deptt of Heavy Industry Udyog Bhawan, New Delhi 110 011 Dr. Jamshed J. Irani Managing Director Tata Iron & Steel Company Limited Jamshedpur 831 001 Shekhar Datta Ex-Managing Director & President Greaves Limited, E/8, Sea Face Park Bhulabhai Desai Road, Mumbai 400 001 Ms. Tarjani Vakil Ex-CMD, EXIM Bank of India A-1, Ishwar Das Mansion, Nana Chowk Mumbai 400 007 J. Jayaraman Ex-CMD, Cochin Refineries Limited 39/4, Ashwin Apartment C.P. Ramaswamy Road, Chennai 600 018 K.C. Lahiry Director (Power) Bharat Heavy Electricals Limited BHEL House, Siri Fort, New Delhi 110 049 K.S. Rao Director (IS&P) Bharat Heavy Electricals Limited Integrated Office Complex Lodhi Road, New Delhi 110 003 Ishan Shankar Director (Personnel) Bharat Heavy Electricals Limited BHEL House, Siri Fort, New Delhi 110 049 M.K. Mittal Director (ER&D) Bharat Heavy Electricals Limited BHEL House, Siri Fort, New Delhi 110 049

MATERIALS SPECIFICATION
X20 Cr 13

A.
1.

13% Cr. Stainless Steel Bars (Hardened & Tempered)

: This specification governs the quality of

General

stainless steel bars of grade X20 Cr. 13 2. Application : For machining of moving and guide blades of steam Turbine. 3. Condition of Delivery : Hot rolled / Forged & hardened and tempered. The bars shall be straight and free from waviness. 4. Complete with standards: There is no Indian standard covering this material.

5.

DIMENSIONS & TOLERANCES :

Dimension : Bars shall be supplied to the dimensions specified in the purchase order unless otherwise specified in the order. The bars shall be supplied in random length of 3 to 6 meters with a maximum of 10% shorts down to meter.

Forged bars shall be supplied in length of 1.5 to 3 meters. Tolerance : The tolerance on cross sectional dimensions shall be as per table. 5.1. Hot Rolled Bars : Tolerance on hot rolled flat bars shall be as specified below :

s b "b" width across flates Allowable deviation on "s" thickness

mm Up to 35 "b" mm + 1.5 mm Up to 20 Allowable devi. on 'S' mm +1

Over 35 and Upto 75

+2

Over 20 and Upto 40

+2

Over 75

+3

Over 40

+3

Note : Other tolerances shall be as per DIN 1017. Twisting and bending off the bars shall not exceed 0.001X length of the bar. Bulging on the sides shall not be more than 0.01 x b and 0.01 x s respectively. 5.2 Forged Bar : Tolerances on size for forged bars shall be +8% of the size.

6. MANUFACTURE :
6.1 The steel shall be manufactured in basic electric furnace process and subsequently vacuum degassed or electric slag refined (ESR). Any other process of meeting shall be subjected to mutual agreement between supplier & BHEL. 6.2 For manufacture of flat bars, if initial material is other than ignot (e.g. continuous casting), supplier shall mention it in his quotation for prior approval from BHEL.

7.

HEAT TREATMENT :
7.1 The bars shall be heat treated to get the desired mechanical properties specified in this specification. The hardening temperature shall be in the range of 980 10300C and the tempering temperature shall not be below 6500C As per DIN-19440. 7.2. Minimum possible residual stress shall be aimed with slow cooling and longer duration of tempering treatment.

7.3.

If the bars require straightening after heat treatment, the bars shall be stress relieved after straightening operation at 300C below the actual tempering temperature.

8. FREEDOM FROM DEFECTS : 8.1 The bar shall be free from lamination cracks, scabs, seams, shrinkage porosity, inclusions and other harmful defects. 8.2 Decarburisation and other material defects shall not exceed the dimensional tolerances and machining allowances.

9. FINISH :
9.1 The bar surface be smooth, free from laps, rolled in scale etc. Dents roll marks. Scratches are permitted provided their depth does not exceed half the tolerance limits specified in table. 9.2 9.3 10. Repair of surface flaws by welding in not permitted The edges of bars shall be cut square by swaing or shearing. CHEMICAL COMPOSITION : The chemical composition of

material shall be as follows (table analysis in %)

Element Carbon Silicon

Min. 0.17 0.10

Max. 0.22 0.50

Manganese Chromium Nickel Sulphur Phosphorus

0.30 12.50 0.30 ---

0.80 14.00 0.80 0.020 0.030

11.

SELECTION OF TEST SAMPLES :

11.1 11.2 Chemical analysis shall be reported on each heat basis.. For Mechanical Test

11.2.1 One tensile & 3 impact test samples shall be selected for mechanical testing per melt per heat treatment batch basis from lot of size. 11.2.2 The uniform strength of a delivery shall be certified through hardness test. In case of bars with sectional dimensions more than 120mm, all the bar shall be tested for hardness. In case of bars with sectional dimension less than or equal to 120mm hardness shall be checked on 10% of the bars or 10 numbers of bars which ever is higher. 11.2.3 The mechanical and notch impact test is to be done in longitudinal direction on the hardest and softest bars. Test sample shall be to Km. at 1/3rd below the surface of the bars.

12.

Mechanical Properties :
The material shall comply with the following mechanical properties

12.1

at room temperature. 0.2% : 600 N/MM2 Min :

S0

Tensile strength % Elongation on 5.65 % reduction in area

800 950 N/mm2 15 min. 50 min. * 20 J min.

: :

Impact (mean of 3.1S0 V sample): Hardness (HB-30) * The smallest value shall be at least 14 J. 12.2 :

280

Tensile test shall be carried out in accordance with IS : 1608 or equivalent international standard.

12.3

Impact test shall be carried out on 3 ISO-V samples in accordance with IS : 1757 or equivalent international standard only one test value out of three, can be below the specified value ; but in no case it should be below 2/3rd of the minimum specified value; but in no case it should be below 2/3rd of the minimum specified impact value.

12.4

Hardness test (Brinell) shall be carried out according to IS : 1500 or equivalent international standard.

13.

NON DESTRUCTIVE TEST : Following NDT shall be carried out.

13.1 UT of the prematerial combined with 100% magnetic partial testing of all bars in delivery condition. 13.2 Complete UT of all bars in delivery condition.

13.2.1

In case of testing as per 14(a) U.T. shall be carried out as per HW 0850 192 (SEP 1923) test class D3 and MPI of all bars except of face areas. In case of testing as per 14(b) UT shall be carried out as per HW 0850 192 (SEP 1923) test class D2.

13.2.2 13.2.3 13.2.4

Mix up test (verification test) of all bars. Visual inspection of all bars Acceptance Criteria a) Magnetic Particle Test : When MT is

carried out as per clause 14.1. Surface defects with expected depth > 1 mm are unacceptable. Indication > 5 mm are unacceptable. Defect indication observed during MT, can be removed by grinding (dressing up) but with in 1mm depth. b) Ultrasonic Test : Quality class 2b with

following modification that individual indication > 2mm EFB (KSR) and back wall losses > 3dB are unacceptable.

X2 CrMoV1 21

B. 600 N/MM2 minimum 0.2% Proof stress Heat resistant steel bars for steam turbine blades
1. General : Hot rolled and forged bars of steel grades X22

CrMoV1 21. 2. Application : Bars are required for machining of guide and moving blades for steam turbines. 3. Dimension & Tolerance :

b
"b" width across flates mm Up to 35 & Over 35 Allowable deviation on "b" mm 1.5 "s" thickness mm Up to 20 & Over 20 Upto 75 Over 75 4. Chemical Composition : Element Carbon Silicon Manganese Chromium Malybeonum % min. 0.18 0.10 0.30 11.00 0.80 +2 +3 Upto 40 Over 40

s
Allowable devi. on 'S' mm +1

+2 +3

% max. 0.24 0.50 0.80 12.50 1.20

Vanadium Nickel Sulphur Phosphorous 5.

0.25 0.30 ---

0.35 0.80 0.020 0.030

MECHANICAL PROPERTIES : 0.2 % proof stress Tensile Strength % Elongation % Reduction in area Notch Impact Value : : : : : 600 N/mm2 min. 800-950 N/MM2 14 Min. 40% Min. 27 J * Min. * Average of 3 IS0 V Samples.

C.
1.

600 N/MM2 0.2% PROOF STRESS FORGED BLADES

: This specification governs the quality of guide and moving blades forged from steel grade X 20 or 13.

General

2. 3.

Application

The blades are used for steam turbines. The forged blades shall be supplied in heat treated

Condition of Delivery:

forged blade shall be supplied with center holes made in accordance with respective technical requirements or ordering drawing. 4. Dimensions & Tolerance: The dimension and tolerances shall be as per ordering drawing accompanying the order. 5. Manufacture : The steel shall be manufactured in the blade electrical furnace and for subsequently refined to ensure turbine blade quality. The forgings shall be made as envelope forging or precision forging, subsequently machine / grinder to achieve the ordering drawing dimensions and surface finish. 6. Heat Treatment : 6.1. 6.2. The forging shall be heat treated to get desired mechanical properties. The tempering temperature shall not be below 650 0 C. The minimum residual are to be aimed through sufficient duration of the tempering treatment and the slow cooling rate from the tempering temperature. 6.3. The blades are to be straightened after heat treatment, each straightening operation is to be followed by a stress relieving temperature and in no case below 6100C followed by slow cooling. 7. Freedom from Defects : Blades shall be free from folds due to forging ; cracks, tearing and other material defects,

elonganed non-metallic and jusions, seams etc. any blade blade containing such defects shall be rejected.

8.

Surface finish

The blade shall be supplied in a desoaled and deburred condition. The surface finish shall comply with the requirements specified on the drawing. In the surface is ground prior to blasting the the surface finish must be anouired in compliance with the finish specified on the drawing. Grinding may be performed to a depth not more than H/2 and ground areas shall be blended over a length of LP/2. However H Shall not be exceeded.

H LP

: :

Allowable profile deviation on the pressure side. Profile length measured from leading edge to trailing edge.

9.

Chemical Composition : The chemical analysis of the material shall confirm to the following : Element Carbon Silicon Manganese Chromium Nickel Sulphur Phosphorous % min. 0.17 0.10 0.30 12.50 0.30 --All tests and on % max. 0.22 0.50 0.80 14.00 0.80 0.020 0.030 examination specimens shall taken be in

10.

Selection of Test Sample :

performed

accordance with annexure 1 from at least

one blade of each drawing per melts and heat treatment batch. 11. Mechanical properties : 11.1 The mechanical properties of the blade material shall conform to the following : 0.2 % proof stress Tensile Strength % Elongation % Reduction in area Impact Value (Average of 3, ISO V Sample) Brinell hardness HB 30 : : 20 J Min. 280 Max. : : : :

600 N/mm2

800-950 N/MM2 15 Min. 50 Min.

11.2 Tensile Test : The tensile test piece shall confirm to the gauge length.
L 0 = 5.65 S0

11.3 Impact test shall be carried out on standard test piece as per ISO V notch according to IS : 1757. 11.4 Hardness Test : The brinell hardness test HB 30 shall be carried out according to IS : 1500. 12. Non Destructive Test : 12.1 Blade shall only be manufactured from ultrasonically examined rare material.

12.2 In order to ensure freedom from defects. All blades shall be subjected to magnetic particle examination prior to shipment. 13. Dimenional Checks for Acceptance : 13.1 The supplier shall check 100% of the forgings w.r.t. to all parameters. 13.2 Dimensions parameters to be checked for acceptance. Following dimensional parameters of each of the check sections as specified in ordering drawing shall be inspected after fixing / clamping the forging in vertical stand to check conformance of profile of individual section as well as in relation to each other.
o

From tolerance for pressure = H

side
o

From tolerance for suction = R, max difference R

side
o

From tolerance for Inlet edge = H =

Twist Tolerance ( H, R) max.

Profile thickness of each section.

D Max. / D /

D1 Max. profile length of each section. Root dimensions.

Base dimensions.

 Base plate contour. Axial and tangential shift of profile with respect to root. Overall length of forging. Surface finish.

13.3 Procedure for dimensional checks :

Check of inlet edge: The profile of inlet edge shall be checked by using split profile gauges. Check of Profile : All the dimensional parameters mentioned at

(13.2) shall be checked using a vertical measuring stand. Drilling of BHEL Centre holes Checking of BHEL Centres.

A. CLASSIFICATION OF BLADES

L.P. Moving Blade Forged Ist Stage.

L.P. Moving Blade 500 MW Last Stage. 100 MW 25th Stage Impulse Blade. Compressor blade Sermental coated. Compressor Blade 'O' stage. Gas Turbine Compressor Blade. T-2 Blade. T-4 Blade. 3DS Blade. Brazed Blade Russian Design Blades. Z Shroud Blade. Twisted Blade. Present Range of Blades. Future Range of Blades.

MANUFACTURING DIVISIONS
Heavy Electricals Plant, Piplani, Bhopal Electricals Machines Repair Plant (EMRP), Mumbai Transformer Plant P.O. BHEL, Jhansi.

Bharat Heavy Electricals Limited : Heavy Electricals Equipment Plant, Central Foundary Forge Plant., Ranipur, Hardwar Heavy Equipment Repair Plant, Varanasi. Insulator Plant, Jagdishpur, Distt. Sultanpur. Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad High Pressure Boiler Plant & Seamless Steel Tube Plant, Tiruchirappalli. Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex, Ranipet. Industrial Valves Plant, Goindwal. Electronics Division : Electronics Systems Division. Amorphous Silicon Solar Cell Plant (ASSCP). Electro porcelains Division. Industrial Systems Group. BANGALORE Component Fabrication Plant, Rudrapur. Piping Centre, Chennai. Regional Operations Division, New Delhi

CONTENTS
1. Prologe A. BHEL B. HEEP An Overview An Overview

2.

Study on Turbines & Auxiliary Block

3.

Study on Material Specification

4.

Study On Blade Shop

5.

Broad Specification of Major Machines Tools & Machines (CNC & Non CNC)

6.

Other Areas