Vocational Training Report

"Water Turbine Manufacturing"

By
Sharad Jain
Mechanical Engineering,3rd Year (0101ME111047)


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Acknowledgement

It gives me immense pleasure to present my Project Report before you. I
thankfully acknowledge the HRD Department of BHEL, My Project Guide
"Sir Giriraj Agarwal" for giving me so much co-operation and taught Each
and Every Specification of Machines, Process, and Working Principles of
Parts. I pay my sincere regards to him. Without his support I was not able
to accomplish my training.

I also thanks to all the working staff of WTMD Block, fabrication block for
their helpful guidance and support during the entire period.
I Also extend my Heartfelt gratitude to "Prof Aseem C. Tiwari (HOD,
Mechanical Department) for giving me such an opportunity.














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Certificate


This is to certify that this project report has been
made by "Sharad Jain" of UIT, RGPV , Mechanical
Engineering, on "The Study of Water Turbine
Manufacturing" under the guidance of "Sir Giriraj
Agarwal".
This Project has been completed successfully.


Yours truly,
Sharad Jain
Mechanical, 3rd Year
UIT, RGPV
Bhopal.



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BHEL Overview

BHEL is an integrated power plant equipment manufacturer and one of the largest engineering
and manufacturing companies in India in terms of turnover. BHEL was established in 1964,
ushering in the indigenous Heavy Electrical Equipment industry in India - a dream that has been
more than realized with a well-recognized track record of performance. The company has been
earning profits continuously since 1971-72 and paying dividends since 1976-77.

BHEL is engaged in the design, engineering, manufacture, construction, testing, commissioning
and servicing of a wide range of products and services for the core sectors of the economy, viz.
Power, Transmission, Industry, Transportation (Railway), Renewable Energy, Oil & Gas and
Defense. BHEL have 15 manufacturing divisions, two repair units, four regional offices, eight
service centers and 15 regional centers and currently operate at more than 150 project sites
across India and abroad. BHEL place strong emphasis on innovation and creative development of
new technologies. The research and development (R&D) efforts are aimed not only at improving
the performance and efficiency of our existing products, but also at using state-of-the-art
technologies and processes to develop new products. This enables it to have a strong customer
orientation, to be sensitive to their needs and respond quickly to the changes in the market.

The high level of quality & reliability of our products is due to adherence to international
standards by acquiring and adapting some of the best technologies from leading companies in the
world including General Electric Company, Alstom SA, Siemens AG and Mitsubishi Heavy Industries
Ltd., together with technologies developed in our own R&D centers.

Most of Its manufacturing units and other entities have been accredited to Quality Management
Systems (ISO 9001:2008), Environmental Management Systems (ISO 14001:2004) and Occupational
Health & Safety Management Systems (OHSAS 18001:2007).

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Water Turbines

A hydraulic turbine is a prime mover (a machine which uses the raw energy of a substance and
converts into mechanical energy) that uses the energy of flowing water and converts it into the
mechanical energy (in the form of rotation of the runner). This mechanical energy is used in
running an electric generator which is directly coupled to the shaft of the hydraulic turbine; from
this electric generator, we get electric power which can be transmitted over long distances by
means of transmission lines and transmission towers. The hydraulic turbines are also known as
water turbines since the fluid medium used in them is water.


CLASSIFICATION OF HYDRAULIC TURBINES

The hydraulic turbines are classified as follows:


1. According type of energy at inlet of the turbine

Impulse turbine & Reaction turbine

2. According to the direction of the flow of water
Tangential flow turbine
Radial flow turbine
Axial flow turbine
Mixed flow turbine

3. According to the head at the inlet of the turbine
High head turbine
Medium head turbine
Low head turbine
4. According to the specific sped of the turbine
Low specific speed turbine
Medium specific speed turbine
High specific turbine


If at the inlet of the turbine, the energy available is only kinetic energy, the turbine is known as
impulse turbine. As the water flows over the vanes, the pressure is atmospheric from inlet to
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outlet of the turbine. In the impulse turbine, all the potential (pressure) energy of water is
converted into kinetic (velocity) energy in the nozzle before striking the turbine wheel buckets.
Hence an impulse turbine requires high head and low discharge at the inlet. The water as it flows
over the turbine blades will be at the atmospheric pressure. The impulse turbine may be radial
flow or tangential flow type.


If at the inlet of the turbine, the water possesses kinetic energy as well as pressure energy, the
turbine is known as reaction turbine. As the waters flows through the runner, the water is under
pressure and the pressure energy goes on changing into kinetic energy. The runner is completely
enclosed in an air tight casing and the runner and casing is completely full of water.


If the water flows along the tangent of the runner, the turbine is known as tangential flow
turbine. If the water flows in the radial direction through the runner, the turbine is called radial
flow turbine. If the water flows from outwards to inwards, radially the turbine is called inward
radial flow turbine, on the other hand, if the water flows radially from inwards to outwards, the
turbine is known as outward radial flow turbine.


If the water flows through the runner along the direction parallel to the axis of rotation of the
runner, the turbine is called axial flow turbine. If the water flows through the runner in radial
direction but leaves in the direction parallel to axis of rotation of the runner, the turbine is called
mixed flow turbine.

PELTON WHEEL OR IMPULSE TURBINES


The pelton wheel or pelton turbine is a tangential flow impulse turbine. The water strikes the
bucket along the tangent of the runner. The energy available at the inlet of the turbine is only
kinetic energy. The pressure at the inlet and outlet of the turbine is atmosphere. This turbine is
used for high heads and is named after L.A. Pelton, an American Engineer.


CONSTRUCTION AND WORKING OF PELTON WHEEL TURBINE


A pelton wheel consists of a rotor, at the periphery of which is mounted equally spaced double
hemispherical or double ellipsoidal buckets. Water is transferred from a high head source through
penstock which is fitted with a nozzle, through which the water flows out as a high speed jet. A
needle spear moving inside the nozzle controls the water flow through the nozzle and at the same
time provides a smooth flow with negligible energy loss. All the available potential energy is thus
converted into kinetic energy before the jet strikes the buckets of the runner. The pressure all
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over the wheel is constant and equal to atmosphere, so that energy transfer occurs due to purely
impulse action.


The pelton turbine is provided with a casing the function of which is to prevent the splashing of
water and to discharge water to the tail race.


When the nozzle is completely closed by moving the spear in the forward direction the amount of
water striking the runner is reduced to zero but the runner due to inertia continues revolving for
a long time. In order to bring the runner to rest in a short time, a nozzle (brake) is provided
which directs the jet of water on the back of buckets; this jet of water is called braking jet.


Speed of the turbine runner is kept constant by a governing mechanism that automatically
regulates the quantity of water flowing through the runner in accordance with any variation of
load.

The jet emerging from the nozzle hits the splitter symmetrically and is equally distributed into
the two halves of hemispherical bucket as shown. The bucket center line cannot be made exactly
like a mathematical cusp, partly because of manufacturing difficulties and partly because the jet
striking the cusp invariably carries particles of sand and other abrasive material which tend to
wear it down.


Working

Water at high pressure from the penstock pipe enters the nozzle provided with a spear. The
pressure energy of water is converted into velocity energy, as it flows through the nozzle. By
rotating the hand wheel, the spear is moved to control the quantity of water flowing out of the
nozzle. When the spear is pushed forward into the nozzle, the amount of water striking the
buckets is reduced.


The jet of water at high velocity from the nozzle strikes the buckets at the center of the cup. The
impulsive force of the jet striking on the buckets causes the rotation of the wheel in the direction
of the striking jet. Thus, pressure energy of the water is converted into mechanical energy. The
pressure inside the casing is atmospheric.
The pelton wheel operates under a high head of water. Therefore it requires less quantity of
water. Draft tubes are not usually used with it.

REACTION TURBINES
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If at the inlet of the turbine, the water possesses kinetic energy as well as pressure energy, the
turbine is known as reaction turbine. As the waters flows through the runner, the water is under
pressure and the pressure energy goes on changing into kinetic energy. The runner is completely
enclosed in an air tight casing and the runner and casing is completely full of water.

If the water flows along the tangent of the runner, the turbine is known as tangential flow
turbine. If the water flows in the radial direction through the runner, the turbine is called radial
flow turbine. If the water flows from outwards to inwards, radially the turbine is called inward
radial flow turbine, on the other hand, if the water flows radially from inwards to outwards, the
turbine is known as outward radial flow turbine.

Casing: As mentioned above that in case of reaction turbine, casing and runner are always full of
water. The water from the penstocks enters the casing which is of spiral shape in which area of
cross section of the casing goes on decreasing gradually. It is made of spiral shape, so that the
water may enter the runner at constant velocity through out the circumference of the runner.
The casing is made of concrete, cast steel or plate steel.


Guide mechanism: It consists of a stationary circular wheel all round the runner of the turbine.
The stationary guide vanes are fixed on the guide mechanism. The guide vanes allow the water to
strike the vanes fixed on the runner without shock at inlet. Also by a suitable arrangement, the
width between two adjacent vanes of guide mechanism can be altered so that the amount of
water striking the runner can be varied.


Runner: It is a circular wheel on which a series of radial curved vanes are fixed. The surfaces of
the vanes are made very smooth. The radial curved vanes are so shaped that the water enters and
leaves the runner without shock. The runner is made of cast steel, cast iron or stainless steel.
They are keyed to the shaft.


Draft tube: The pressure at the exit of the runner of a reaction turbine is generally less than
atmospheric pressure. The water at exit cannot be directly discharged to the tail race. A tube or
pipe of gradually increasing area is used for discharging water from the exit of the turbine to the
tail race. This tube of increasing area is called draft tube.


Working

First, water enters the guide blades, which guide the water to enter the moving blades. In the
moving blades, part of the pressure energy is converted into kinetic energy, which causes rotation
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of the runner. Water leaving the moving blades is at a low pressure. Thus, there is a pressure
difference between the entrance and the exit of the moving blades.This difference in pressure is
called reaction. Pressure acts on moving blades and causes the rotation of the wheel in the
opposite direction.

FRANCIS TURBINE


Francis turbine was developed by the American engineer Francis in 1850. It is an inward flow
radial type reaction turbine. It operates under medium head.


Working

Francis turbine consists of a spiral casing, fixed guide blades, runner, moving blades and draft
tube.


The spiral casing encloses a number of stationary guide blades. The guide blades are fixed around
the circumference of an inner ring of moving blades. Moving blades are fixed to the runner.


Water at high pressure from the penstock pipe enters the inlet in the spiral casing. It flows
radially inwards to the outer periphery of the runner through the guide blades. From the outer
periphery of the runner, water flows inwards through the moving blades and discharges at the
center of the runner at a low pressure. During its flow over the moving blades, water imparts
kinetic energy to the runner, causing the rotation of the runner.


Draft tube is a diverging conical tube fitted at the center of the runner. It enables the discharge
of water at low pressure. The other end of the draft tube is immersed in the discharging side of
the water called tail race.


Kaplan turbine is a low head reaction turbine, in which water flows axially. It was developed by
German Engineer Kaplan in 1916.


All the parts of the Kaplan turbine (viz, spiral casing, guide wheel and guide blades) are similar to
that of the Francis turbine, except the runner blades, runner and draft tube. The runner and
runner blades of the Kaplan turbine resemble with the propeller of the ship. Hence, Kaplan
turbine is also called as Propeller Turbine.
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Working

Water at high pressure enters the spiral casing through the inlet and flows over the guide blades.
The water from the guide blades strokes the runner blades axially. Thus, the kinetic energy is
imparted by water to the runner blades, causing the rotation of the runner. The runner has only 4
or 6 blades.The water discharges at the center of the runner in the axial direction into the draft
tube. The draft tube is of L shape with its discharging end immersed into the tail race.

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Plant Layout Of Block 1


Bay 1 Bay 2 Bay 3 Bay 4
Bar store Machine Shop
(East)
Machine Shop
(East)
Machine Shop
On loading
area
Governor
Machine Shop
Machine Shop
(West)
Machine Shop
Machine Shop
(central)
Tooling
(Jig Fixtures)
Testing Area Assembly Area
Component
store
Governor Testing
area



CLASSIFICATION OF BLOCK 3

1.HMS (Heavy machining Shop)
-In this shop heavy machine work is done with the help of different NC &CNC machines such as center
lathes, vertical and horizontal boring &milling machines. Asias largest vertical boring machine is
installed here and CNC horizontal boring milling machines from Skoda of Czechoslovakia.
2. Assembly Section (of hydro turbines)
In this section assembly of hydro turbines are done. Blades of turbine are1st assemble on the rotor &
after it this rotor is transported to balancing tunnel where the balancing is done. After balancing the
rotor, rotor &casings both internal & external are transported to the customer. Total assembly of turbine
is done in the company which purchased it byB.H.E.L.
3. OSBT (over speed balancing tunnel)-
In this section, rotors of all type of turbines like LP(low pressure),HP(high pressure)& IP(Intermediate
pressure) rotors of Steam turbine ,rotors of Gas & Hydro turbine are balanced .In a large tunnel, Vacuum
of 2 torr is created with the help of pumps & after that rotor is placed on pedestal and rotted with speed
of 2500-4500 rpm. After it in a computer control room the axis of rotation of rotor is seen with help of
computer.


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Manufacturing Process

INTRODUCTION
Manufacturing process is that part of the production process which is directly concerned with the
change of form or dimensions of the part being produced. It does not include the transportation,
handling or storage of parts, as they are not directly concerned with the changes into the form or
dimensions of the part produced.Manufacturing is the backbone of any industrialized nation.
Manufacturing and technical staff in industry must know the various manufacturing processes,
materials being processed, tools and equipment's for manufacturing different components or
products with optimal process plan using proper precautions and specified safety rules to avoid
accidents. Beside above, all kinds of the future engineers must know the basic requirements of
workshop activities in term of man, machine, material, methods, money and other infrastructure
facilities needed to be positioned properly for optimal shop layouts or plant layout and other
support services effectively adjusted or located in the industry or plant within a well planned
manufacturing organization. Todays competitive manufacturing era of high industrial
development and research, is being called the age of mechanization, automation and computer
integrated manufacturing. Due to new researches in the manufacturing field, the advancement
has come to this extent that every different aspect of this technology has become a full-fledged
fundamental and advanced study in itself. This has led to introduction of optimized design and
manufacturing of new products. New developments in manufacturing areas are deciding to
transfer more skill to the machines for considerably reduction of manual labor.


Manufacturing of Spherical And
Butterfly Valves


This kind of valve is generally used in the hydroelectric power plants as a turbine protection to
guarantee the emergency shutoff of the pressurized water flow of the penstock. Its placed
immediately before the turbine and works automatically to shut off the water flow in case of any
turbine malfunction, lack of power or any specified condition.

The shutter is actuated by hydraulic cylinders moving it from the "ON" to "OFF" position by
rotating of 90 on side trunnions. The valve in the open position has a fluid way which is
essentially a straight cylinder so has approximately the same head losses as would occur in an
equivalent length of pipe. Closure is effected by rotating the shutter 90 degrees, so it stops
completely the fluid way.
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To guarantee the fast closing in lack of power, suitable counterweights are installed on the
shutter arm. Once shutter is closed, the perfect water tightness is guaranteed by Main Operation
Seal: a downstream mobile sealing ring that closes against a fix rings seal on the shutter (both
made of stainless steel with different grade of hardness). The other mobile ring is a Maintenance
Seal: installed in the upstream side of the shutter, is used only in case of maintenance to the
Main Operation downstream seal without the necessity to remove the valve form the site. Both of
them are operated by the pressure of the water in the penstock trough a dedicated the water
control system with piping. Seats NEVER touch the ball during opening or closing.


CLASSIFICATION OF MANUFACTURING PROCESSES

For producing of products materials are needed. It is therefore important to know the
characteristics of the available engineering materials. Raw materials used manufacturing of
products, tools, machines and equipment's in factories or industries are for providing commercial
castings, called ingots. Such ingots are then processed in rolling mills to obtain market form of
material supply in form of bloom, billets, slabs and rods. These forms of material supply are
further subjected to various manufacturing processes for getting usable metal products of
different shapes and sizes in various manufacturing shops. All these processes used in
manufacturing concern for changing the ingots into usable products may be classified into six
major groups as
Primary shaping processes

Secondary machining processes

Metal Forming processes

Joining processes

Surface finishing processes and


Processes effecting change in properties


PRIMARY SHAPING PROCESSES


Primary shaping processes are manufacturing of a product from an amorphous material. Some
processes produces finish products or articles into its usual form whereas others do not, and
require further working to finish component to the desired shape and size. The parts produced
through these processes may or may not require to undergo further operations. Some of the
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important primary shaping processes are:(1)Casting(2)Powder metallurgy(3)Plastic
technology(4)Gas cutting(5)Bending and(6)Forging.


SECONDARY OR MACHINING PROCESSES

As large number of components require further processing after the primary processes. These
components are subjected to one or more number of machining operations in machine shops, to
obtain the desired shape and dimensional accuracy on flatland cylindrical jobs. Thus, the jobs
undergoing these operations are the roughly finished products received through primary shaping
processes.
The process of removing the undesired or unwanted material from the work-piece or job or
component to produce a required shape using a cutting tool is known as machining. This can be
done by a manual process or by using a machine called machine tool (traditional machines namely
lathe, milling machine, drilling, shaper, planner, slotter). In many cases these operations are
performed on rods, bars and flat surfaces in machine shops. These secondary processes are mainly
required for achieving dimensional accuracy and a very high degree of surface finish. The
secondary processes require the use of one or more machine tools, various single or multi-point
cutting tools (cutters), jobholding devices, marking and measuring instruments, testing devices
and gauges etc. forgetting desired dimensional control and required degree of surface finish on
the work-pieces. The example of parts produced by machining processes includes hand tools
machine tools instruments, automobile parts, nuts, bolts and gears etc. Lot of material is wasted
as scrap in the secondary or machining process. Some of the common secondary or machining
processes are:

Turning

Threading

Knurling

Milling

Drilling

Boring

Planning

Shaping

Slotting

Sawing
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NON- DESTRUCTIVE TESTING


Failure of the turbine blades was one of the challenges addressed with the help of BHEL by
modifications of LP stage-5 blade, shroud modifications etc., and based on its success, the same
technique was used for other plants to sort out inherent problems. Grid-induced Outages Grid
disturbance induced outages were overcome by house load schemes and in one-month viz., May
1998, as many as 150 house load operations took place and units operated withstanding these
transients. Healthiness of the control system and other equipment to withstand external grid
transients was remarkable.

The sharp corner in the root section of the blade causes the blade to crack. Failure of the turbine
blades was one of the challenges addressed with the help of BHEL by modifications of HP stage-5
blade, shroud modifications etc., and based on its success, the same technique was used for
other plants to sort out inherent problems. The material used was 12Cr-Mo martensitic steel,
which is a very high temperature resistant material.

The microstructure was observed was tempered martensitic structure. These turbine blades were
collected from Madras Atomic Power Station (MAPS) for analysis. These blades were found to be
failed. These blades were used for the present investigation of defects using ultrasonic phased
array and X-ray radiography techniques. Turbine blades are known to fail due to tempered
martensitic embrittlement, fatigue, fretting, high temperature creep age hardening, fir tree
design, high residual stresses etc.
Chemical compositions of the turbine blade:


Element Weight %
Sulphur 0.019 to 0.03
Phosphorus 0.019 to 0.028
Carbon 0.20 to 0.24
Chromium 12.8 + 1.2
Manganese 0.45 to 0.54
Silicone 0.30 to 0.43
Nickel 0.40 to 0.52
Vanadium 0.05
Molybdenum 0.1 to 0.13
Iron Balance

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SPECIFICATIONS OF MACHINES


Narrow Gap Welding Machine

Narrow gap welding (also called narrow groove welding) was developed to weld thick sections more
economically. This welding procedure uses joint preparations with small, included angles, typically in the
range 2-20, which require less weld metal and less welding time to fill. Narrow gap techniques have
been applied when welding using submerged arc welding (SAW), gas shielded metal arc welding
(MIG/MAG, GMAW) and tungsten inert gas welding (TIG, GTAW) processes. However, narrow gap welding
does require specialized equipment, because of the limited accessibility to the root of the preparation.

Specification :

Edge Preparation
Depth Of Joint : Max 350 mm
Wire Size : 3 to 5 mm
Feed rate of Wire : 1 to 4 mm/cm
Maximum Horizontal
Movement : 6m

Maximum Vertical
Movement : 6m




Mario Carnaghi ( Italy )
Vertical Boring Machine


CNC Control Fanuc 32i
Table Diameter 98.4
Maximum Swing 118.1
Maximum Turning Height 98.4
Table Payload 88,000 lbs
Table Speed 1.5 150 rpm
Spindle Drive 140 HP
ATC 12 Positions
Coolant yes
Splashguard
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Motofil (Portugal)
Robotic Welding

Hydraulic Control

6 Axis Control

CNC Controlled Robotic Arm

Wire feeder controller

Copper coated MS Wire

Argon + CO2 Gas Cylinder

Step Down Transformer




Centre Lathe :(Biggest of all BHEL)
Max diameter over bed :3200mm
Max diameter over saddle :250mm
Length between centers :16m
Max weight of work piece :100 T
Spindle bore :96mm


Manufacturer: SAFOP
Swing over carriage :3500mm
Centre distance :9000mm
Weight capacity :120 T
Spindle power :196KW
External chucking range :250-2000mm
Hydrostat steady range :200-1250mm
Max spindle rpm :200


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CNC Indicating stand :

Manufacturer : Heinrich Georg, Germany
Turning diameter :5.3m
Turning length :15m
Weight capacity :160 T

CNC Vertical Borer :

Manufacturer : M/S Pietro Carnaghi, Italy
Machine model :AP 80TM-6500
Table diameter :6500mm
Max turning diameter :8000mm
Min boring diameter :660mm
Max height for turning and milling :7000mm
Table Speed :0.2-50 rpm
Table load capacity :200 T
Milling spindle speed :3.4-3000 rpm at40KW
Spindle taper :BT 50
CNC system :SINUMERIK 840D


CNC Facing Lathe : KH-200-CNC
Swing over bed :2300mm
Swing over carriage :1800mm
Max distance between faced plate and carriage :2000mm
Max weight of job held in chuck :6000kg
Face plate diameter :1800mm
Spindle speed :1.4-400rpm
Main spindle drive :95.5KW
Step boring Machine :
Max boring diameter :2500mm
Min boring diameter :625mm
Table :4000mmx4000mm
Max weight of job :100 T
Headstock travel :4000mm



Double Column Vertical Borer :

Table diameter :4000mm
Max traverse of cross rail :4250mm
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Max weight of work piece :4200mm
LH Left hand Ram
RH Right Hand Ram

Max weight of job :50 T



CNC Skoda Horizontal Borer :
Spindle diameter :200mm
Taper spindle :BT 50
RAM size :450x450mm
RAM length :1600mm
Spindle length :2000mm
Headstock :5000mm
Table :4000x3500mm
CNC system :SIMENS 850mm
Job : I.P. Outer

Horizontal Borer : LSTG 8006

Spindle diameter :250mm
Height of machining bed :600mm
Max boring depth with spindle :2000mm
Max extension of RAM :1600mm
Width of bed guide ways :2500mm
Actual length of headstock with vertical lift :2150mm
Actual length of column horizontal feed :15000mm
Lowest position of spindle axis upon bed guide ways :1475mm
Machine weight with electrical equipment's :140 T
Height of machine :10.3m


CNC Lathe : 1-120 Ravens burg

Main spindle bore :150mm
Distance between centers :12m
Turning diameter over bed cover :1400mm
Turning diameter over carriage :1100mm
Work piece weight unsupported :4000kg
Work piece weight between centers :20 T

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Horizontal Boring Machine : 1-28
Diameter of spindle :150mm
Working surface of table :2250x1250mm
Max travel of table :1200mm
Max vertical travel of headstock :2000mm
Horizontal Boring Machine :
Boring spindle taper :BT50
Boring spindle diameter :160mm
Headstock vertical travel :3000mm
Longitudinal RAM travel :700mm
Longitudinal spindle travel :1000mm
Column cross travel :10m
Rotary table travel :3000mm
Table load :40 T

Horizontal Boring Machine : 1-11
Boring spindle internal taper material :200
Boring spindle diameter :320mm
Max spindle travel :2500mm
Vertical head travel :6000mm
Transverse column travel :6000mm
Max longitudinal column travel :800mm
Machine wattage :90KW
Double Column Rotary Table Vertical Borer :
Max diameter of work piece accommodated :10m/12.5m
Max height of work piece accommodated :5m
Diameter of table :8.75m
Max travel of vertical tool head RAM slides :3.2m
Max travel of vertical tool head from Centre of table :5.25m

Max weight of work piece :200T for N<=8rpm;100T for any speed
Diameter of boring spindle of combined head :160mm
Travel of boring spindle :1250mm
Taper hole of boring spindle :100mm

Horizontal borer : 1-2
Spindle diameter :220mm
Working surface
Max vertical travel :3mm
Max transverse travel of column :6m
Max longitudinal travel of column :6m
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Max longitudinal travel of spindle :1.8m


CNC Lathe : 2-360 Hoesch
Max load :320 T
Max length between centers :18m
Swing over bed :3.2m



Horizontal Borer : 2-198
Spindle diameter :220mm
Max vertical travel :3m
Max transverse travel of column :6m
Max longitudinal travel of column :6m
Max longitudinal travel of spindle :1.8m
Working surface :1800x500mm


Creep Feed Grinding Machine :
Diameter of job :2m
Job height :2.4m
Table rpm :10rpm(max)
Table diameter :2050mm
Swing diameter :2500mm
CNC control :SIEMENS-3GG
Broaching Machine :
Broaching capacity :32 T
Broaching stroke :10.3m
Broaching slide width 1500mm
Broaching specific cutting stroke :1.25m/min
Broaching specific return stroke :60m/min
Max diameter of disc :2300mm
Max move of table :600mm
Helix angle/skew angle setting :+45/-45
Cone angle :0-20
CNC Lathe :
Manufacturer : Innse Berardi, Italy
Swing over carriage :1500mm
Swing over bed :2000mm
Capacity :30 T
Cost :16 crore
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CNC system :SINUMERIK 840D




Over Speed Balancing of Turbines
Main features :
Type of pedestals :DH 90/DH 12
Rotor weight :Min 4 MT, Max 320 MT
Rotor diameter :Max 6900mm
Rotor journal diameter :Min 250mm,Max 950mm
Bearing Centre distance :Min 3000mm,Max 15700mm
Balancing speed :180-3600rpm
Min vibration limit :1 micron
Max vacuum :1 torr
Tunnel Features :
Tunnel length :19000mm
Tunnel diameter :6900mm
Max thickness of tunnel :2500mm
Steel plate thickness :32mm
Cost of balancing equipment(FE) :444 lakhs
Total cost of balancing tunnel :770 lakhs


Main Features of Drive :
Drive motors (2 no.) :950V DC, 500rpm,3.5 MW each
Total drive power :7 MW(2x3.5)


MG set of Drive :
Synchronous motors :11 KV,9MW,50Hz,500rpm
DC Generator (2 no.) :950V,500rpm,3.8MW each

3d coordinate measuring machine in new blade shop:
Model reference: 22129 LIETZ Germany
Plan no 3-068
Measuring range:
X axis 2200mm
Y axis 1200mm
Z axis 900 mm
Volumetric error: (max) 1.5 micron
Resolution: 0.05 micron
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Max weight of job: 2250 kg
Accuracy: 1.5+L/350 micro