CHAPTER I

INTRODUCTION
1.1 OVER VIEW OF BHEL
Bharath Heavy Electrical Limited (BHEL) (BCE: 500103, NSE:
BHEL) isan Indian state-owned integrated power plant equipment manufacturer
and operates as and engineering and manufacturing company based in New
Delhi, India. Established in 29 august 1956 and production starts from
November 1960, BHEL ushered in the indigenous Heavy Electrical Equipment
industry in India. The company has been earning profits continuously since
1971-1972 and paying dividends since 1976-1977. It is one of the only 7 Mega
Public Sector Underlying (PSUs) of India clubbed under the esteemed
Maharatna status. On 1st February 2013, the Government of India granted
Maharatna status to Bharath Heavy Electricals.
BHEL has share of 59% in Indias total installed governing capacity
contributing 69% to the total power generated from utility sets (excluding nonconventional capacity) as of March 31, 2010. The company has been exporting
its power ad industry segment product and service for over 40 years. BHELs
global references are spread across 75 countries. The cumulative overseas
installed capacity of BHEL manufactured power plants exceeds 9000 MW
across 21 countries including Malaysia, Oman, Iraq, the UAE, Bhutan, Egypt
and New Zealand. Its physical exports range from turkey projects to after sales
services.
The company corporate R&D division at Hyderabad leads BHELs
research in a number of areas of importance to its product range. Research and
development (RD) centers manufacturing divisions play complementary role.
BHEL has introduced, in the recent past, several states of art products.
Commercialization of products and systems developed by way of in housing
1

Research and Development contributed Rs.95, 120 Million corresponding to

around 19.3% of the companys total turnover in 2011-2012. In 2011-2012,
BHEL filed 351 patents and copyrights, enhancing the companys intellectual
capital to 1,786 patents and copyrights filed, which are in productive use in the
companys business. It is engaged in the design, engineering, 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, Renewable Energy, Oil & Gas and Defense.

1.2 MAIN MANUFACTURING FACITIES

Heavy Electrical Plant Bhopal.

Heavy Electrical Equipment Plant, Haridwar, Uttarakhand.
Heavy Electrical Equipment Plant Ramachandrapuram, Hyderabad.
Transformer Plant, BHEL Jhansi (Uttar Pradesh).
High Power Boiler Plant and Seamless Steel Tube Plant, Trichy(Tamil

Nadu).
Boiler Auxiliaries Plant, Rainpet, Vellore (Tamil Nadu).
Electronics Division and electro Porcelain Division, Bangalore
(Karnataka).
Centralized Stamping Unit & Fabrication Plant Jagdishpur (Uttar

Pradesh).
Insulator Plant Jagdishpur (Uttar Pradesh).
Component Fabrication Plant Rudrapur (Uttrakhand).
Industrial Valves Plant, Goindwal (Punjab).
Bharat Heavy Plates and Vessels Limited (Vizag).
BHEL Electrical Machines Ltd., Kasaragod, Kerala

1.3 PRODUCTS
Boiler (steam generator) under collaboration Combustion Engineering,
USA.
2

Gas generator.
Hydro generator.
Steam turbine under collaboration with Siemens, Germany.
Gas turbine under collaboration with GE, USA.
Hydro turbine.
Transportation equipment.
Traction machines.
AC motors.
Transformer.
Switchgear.
Oil field equipment (OFE)-under collaboration with National Oilwell

Varco.
Boiler drum.
Water wall panel, Coils, Super Heaters, Re heaters, SOFA panels, Burner

panels, Piping & Heaters.

Wind mill.
Valves.
Electrostatic precipitator.
R & D products.

1.4 MAJOR COMPETITORS OF BHEL

1.
2.
3.
4.
5.
6.
7.
8.
9.

Ansaldo
Asean Brown Boueri
Beehtel
Block and Neatch
CNMI and EC
Costain
Electrim
Energostio
Electro Consult

Italy
Switzerland
USA
USA
China
UK
Poland
Russia
Italy

10.France tool
11.Fuji
12.GEC Alsthom
13.General Electric
14.Hitachi
15.LMZ
16.Mitsubishi
17.Mitsui
18.NEI

1.5 REGINONAL OFFICES (POWER SECTORS)

1.
2.
3.
4.

New Delhi
Kolkata
Nagpur
Chennai

(Northern Region).
(Eastern Region).
(Western Region).
(Southern Region).

1.6 BUSINESS OFFICES

1.
2.
3.
4.
5.
6.
7.
8.
9.

Bangalore.
Baroda.
Bubaneshwar.
Mumbai.
Kolkata.
Chandigarh.
Guwahati.
Jagalpur.
Jaipur.

10. Lucknow.
11. Chennai.
12. New Delhi.
13. Patna.
14. Ranchi.
15. Secundrabad.

1.7 MANUFACTURING UNITS

1.
2.
3.
4.
5.

Bangalore.
Bhopal.
Goindwal.
Haridwar.
Hyderabad.
6. Jagadishpur.

7. Jhansi.
8. Rudhrapur.
9. Ranipet.
10. Tiruchirapalli.

France
Japan
UK
USA
Japan
Russia
Japan.
Japan.
UK

1.8 SERVICE CENTRES

1.
2.
3.
4.
5.

Bangalore.
Baroda.
Kolkata
Pata.
Nagpur.

6. Chandigarh.
7. Secudrabad.
8. New Delhi.

1.9 ABOUT BHEL RANIPET

BHEL, Tiruchirapalli launched its phase III expansion during 1980 for
augmentation of manufacturing capacity. Thus Boiler Auxiliaries Plant, the 13th
manufacturing plant of BHEL was set up at Ranipet as a part of the relocation of
facilities from Tiruchirapalli unit.
BAP is located in 1400 acres site. Ranipet is a town enveloped with many
ancillary units and Boiler Auxiliaries Plant is a jewel adoring the crown of
Ranipet.

1.10 LOCATION
Ranipet is located 120 km away from Chennai towards Bangalore (NH4).
The nearest railway station to Ranipet is Katpadi station which is one of the
prime station form Chennai to Bangalore. At present the major product profile
of this plant is as follows:

ELECTROSTATIC PRECIPITATORS.
AIR PREHEATERS.
FANS.
DESALINATION PLAN.

1.11 TURNOVER
BAP has planned to ramp up its capacity to 1000 MW in the next two
years. With additional investment to advancement, BAP will be in a position to
fully meet 1000 MW capacity. Bap surpassed the coveted mark of Rs.1000 Cr
turnover. The year 2006-2007 witnessed the turnover o Rs.1074.50 Cr in 20002010. This unit has achieved a record profit before tax (BPT) of Rs.1170 Cr
during 2010-2011.

CHAPTER II
Literat
ure survey
Predicting Blade Leading Edge Erosion in an Axial Induced
Draft Fan
Induced draft fans extract coal fired boiler combustion products,
including particles of un-burnt coal and ash. As a consequence of the
particles, the axial fan blades leading edges are subject to erosion.
Erosion results in the loss of the blade leading edge aerodynamic
profile and a reduction of blade chord and effective camber that
together degrade aerodynamic performance. An experimental study
demonstrated that while the degradation of aerodynamic performance
begins gradually, it collapses as blade erosion reaches a critical limit.
This paper presents a numerical study on the evolution of blade
leading edge erosion patterns in an axial induced draft fan.

Ground Based Response of a Spinning, Cyclic Symmetric

Rotor Assembled to a Flexible
6

Stationary Housing Via Multiple Bearings.

This paper is to study ground-based response of a spinning, cyclic
symmetric rotor assembled to flexible housing via multiple bearings.
In particular, interaction of the spinning rotor and the flexible housing
is manifested theoretically, numerically, and experimentally. In the
theoretical analysis, we show that the interaction primarily appears in
coupled rotorbearinghousing modes whose response is dominated
by the housing. Specifically, let a housing-dominant mode have
natural frequency xH and the spin speed of the rotor to be x3. In
rotor-based coordinates, response of the spinning rotor for the
housing-dominant mode will possess frequency splits xH6x3.

Induced Draft (ID) Fan Lubrication System Design Review

and Proposed Modification Upgrade at Callide C Power
Station Courses ENG4111/4112 Research Project
Callide C Power Station in Biloela Queensland is a 900
Megawatt (MW) coal fired power station that was commissioned in
2001. Unfortunately Callide C Power Station has been plagued with
continuous operational and reliability problems caused from the
induced draft (ID) fans since initial commissioning. The ID fan
problems have arisen from the bearing lubrication system which
provides oil recirculation to the induction motor bearings and fan
main shaft bearings. Consequently these issues have caused half-load
unit (225 MW) run-backs and full unit (450 MW) trips over the past
decade.

Induced Draft Fan Innovation for Heat Recovery Steam

Generators
A first of its kind, induced draft (ID) heat recovery steam generators
(HRSG) have been in service at a cogeneration facility since 1991.
A preliminary engineering study considered a forced draft (FD) fan to
supply combustion air to the HRSG duct burners (when the
combustion turbine (CT) is out of service) as a traditional design;
however, the study indicated that the FD fan may require the HRSG
duct burner to be shut off following a CT trip and re-ignited after the
FD fan was in service. Although the induced draft HRSG design cost
more than the FD fan design, the induced draft design has improved
the cogeneration facilitys steam generation reliability by enabling the
HRSG to remain in service following a CT trip. This paper briefly
summarizes the preliminary engineering study that supported the
decision to select the ID fan design. The paper also discusses the
control system that operates the fresh-air louvers, duct burners,
HRSG, and ID fan during a CT trip.

CHAPTER III
FANS
3.1 INTRODUCTION
3.1.1 ABOUT A FAN
A fan is one among the many types of turbo machines used for energy
transfer. It can be defined as a rotating machine with a blade impeller, which
maintains a continuous flow of air or gas. It is continuous flow at the entry and
exited also through the impeller is steady. This differs from the flow in a
positive displacement machine where the flow is pulsating.
In todays heavily industrialized world, we face fossil fuel shorting with
accompanying proportionate increase in the cost of energy. A proven method to
conserve energy in mechanical draught plant is to install variable pitch axial
fans.

3.1.2 PRINCIPLE OF WORKING

Energy can be transmitted from machine to the flowing fluid or vice versa
Fans, blowers, compressor, pump are full under one category where the energy
transfer occurs from the machine to flowing fluid i.e.., mechanical energy is
converted into fluid energy. Except pumps all machines are used to handle only
liquids.
Turbines fall under another category, where energy transfer is from the
fluid to the machines. In other words the category consume more power as they
rotate with the help of prime movers and energize the flowing fluid whereas the
turbine rotate due to the fluid energy imported to it and help in generating the
power.
9

3.2 CLASSIFICATION OF FANS

3.2.1 ACCORDING TO PURPOSE
Primary air fans
Forced draft fans
Induced draft fans

a) PRIMARY AIR FANS

Primary air fans supply the air needed to dry and transport pulverized
coal to the furnace of direct fired boiler.

PRIMARY AIR FANS ARE FURTHER CLASSIFIED AS

Hot primary air fan
Cold primary air fan
Hot primary air fans are arranged to draw hot air. Fans boost the
pressure to overcome resistance in ducts, pulverized and fuel piping.
Cold primary air fans are arranged to draw air from the atmospher
eand impart energy to force the air through ducts, air pre heaters,
pulverize sand fuel piping.

b) FORCED DRAUGHT FANS

The forced draft supplies the air required for the combustion of fuels and
normally handle stoichiometric plus excess air and required for satisfactory
burning of fuels. They may handle less to the extent of the quality of air handled
by primary air fans as in the case of cold primary air system, which draws air
from atmosphere.

10

c) INDUCED DRAUGHT FAN

The induced draft fans draw the products of combustion from the boiler
while creating sufficient draft (negative draft) in the furnace for balanced draft
operation. In addition, they must handle any air pre heater leakage and any
infiltration of air in the equipment downstream of the boiler furnace.

Fig: 3.1INDUCED DRAUGHT FANS

3.2.2 ACCORDING TO FLOW OF AIR

Radial fans.
Axial fans.

a)RADIAL FANS
In this type of fans, flow is radial to the axis of rotation of the fans.
Radial fans can be used for primary air forced draught as well as induced
draught applications.
Radial fans further classified based on the configuration of the blade with
respect to the dimensions of the impeller.

11

Fig: 3.2RADIAL FAN.

Forward curved (>900)
Backward curved (<900)
Radial curved (=900)
It can be also classified as;
Single suction
Double suction
For better understanding it can be mentioned that the blade angle at exit is
less than 900, equal to 90 and greater than 90 in backward curved, radial bladed
and forward curved bladed impellers respectively.

a) AXIAL FLOW FANS

In the axial flow fans the main flow is parallel to the axis of rotation of
the both at entry and exit.

12

Fig: 3.3 AXIAL FLOW FAN.

It can be further classified as
Impulsive type
Reaction type
According to the number of stages it can classified as
Single stage
Double stage

i.

IMPULSIVE TYPE
In this case most of the energy coming out from the impeller is kinetic

energy. It is converted into pressure energy and in the out blades and the
diffuser. Hence these types of fans are called as impulse fans.

13

ii.

REACTION TYPE
In this case most of the energy coming out of the impeller is in the form

of pressure energy. It is known as reaction type. Axial fans have profiled blades
and this aerofoil profile increases the pressure energy.
For achieving high pressure rise, staging is generally adopted in axial
impulse fans. The energy is imparted in the form of kinetic energy, which is
converted into pressure energy by the help of diffuser.

I.

SINGLE STAGE
It is generally used for forced draught fans in the boilers having profiled

blade made of aluminium alloys. These blades can be swivelled about their axis
and thereby the flow can be regulated. This is called variable pitching in these
fans the required pressure is developed in the single stage.

II.

DOUBLE STAGE
When the pressure developed by the single stage axial fan is not

sufficient, a two-stage axial flow fan is employed. The operating speed of a two
stage fans is given by
N=n/2 RPM
Where, n = single stage speed
N = double stage speed
This fan is generally used for primary air application in large capacity
boilers. There is one actuating hydraulic cylinders for both the impeller and
hence both the stages are synchronized mechanically.

14

3.3

AXIAL PROFILED FANS

In the axial profiled fans, a large part of the energy transferred to medium

handled is converted in to pressure energy as the medium passes through the

impeller, only the remaining velocity energy after the impeller is converted into
pressure energy by the diffuser.
Axial profile fans are generally driven at constant speed. Varying the
angle of the impeller blades controls the flow.

3.3.1THE MAJOR SUB- ASSEMBLIES OF THIS TYPE OF

FANS

Suction chamber
Shaft with bearing assembly
Impeller assembly
Servomotor assembly
Diffuser assembly
Impeller casing

The static and rotating part of the axial profiled fan housing are,

3.3.1STATIC PARTS

Suction chamber
Housing
Outlet guides vanes assembly
Diffuser

3.3.1 ROTATING PARTS

Impeller.
Shaft with bearing assembly.

3.3.2 SUCTION CHAMBER

The fan suction chamber is of fabricated construction with a rectangular
flanged inlet opening for connecting the expansion joint and a circular opening
15

outlet for connecting the impeller housing by the rubber joint. The outer walls
of the suction chamber are reinforced with stiffness. An addition man hole is
provided to facilitate the removal of intermediate shaft without disturbing the
motor. Inside the suction chamber a bullet shaped construction henceforth
referred as bullet is made to house the main bearing assembly. The suction
chamber is made in such away the load is directly transmitted to the foundation
through the support feet.

3.3.3 SHAFT WITH BEARING ASSEMBLY

The bearing of this fans are placed inside a common housing and they are
shop assemble on to the shaft. It is very compact as the housing is placed inside
the static hub (nose) with guides the flow of impeller. To one end of the shaft
impeller is either flange mounted or tapered mounted depending upon the size
of the flexible coupling.
Main bearing assembly consist of anti-friction bearing assembled on the
shaft. The mono block bearing hosing is bolted to the bearing supports of the
bullet provided in suction chamber of the fan. Three mercury in steel resistance
thermometer and three platinum resistances are provided for indicating or
monitoring the bearing temperatures. Provision is made on the on the bearing
housing body, for fixing the vibrations pickup or continuous monitoring of fan
bearing vibrations. It has mainly,

Bearing housing
Bearing covers
Shaft
Hub disc

3.3.4 SERVOMOTOR ASSEMBLY

A hydraulic servomotor is fixed on to the impeller hub on the discharge
side helps in achieving the actuation of blades. The servomotor consists of a
piston and cylinder assembly with control side and control spool. There are
16

externally controlled by an oil system and electric servomotor with proper

linkages.

3.3.5 DIFFUSER ASSEMBLY

The diffuser is a welded structure with a core inside. This helps in
converting the kinetic energy to pressure energy. The linkages for the
servomotor are taken through eyes provided on the diffuser. Outlet blades are
also housed inside the diffuser. Actually diffuser core is supported by the outlet
blades on the inlet side of the diffuser and by the struts on the discharge side of
the diffuser. There is a man hole provided for alternating to the servomotor
linkages etc.

3.3.6 IMPELLER CASING

The impeller casing is connected to the suction chamber by rubber
expansion joint. The inner diameter of the impeller is machined to close
tolerance, so that proper and uniform and radial clearance between the impeller
and housing can be maintained. An inspection door is provided on the casing
facilitate and dismantling of the blades without the removal of the impeller
casing.

CHAPTER IV
ASSEMBLY METHODS
4.1 EXISTING METHOD
17

In this method, the workers use only the crane for assembling the blade
bearing shaft into the impeller. It is very slow and expensive method of
assembling the blade shaft. In order to overcome the difficulties faced by the
workers there are some improved methods are developed which is discussed in
the proposed method. In this method, they use different size of cranes. They are,
Big size crane with the capacity of 20 tons.
Medium size crane with capacity of 10 tons.
Small size crane with capacity of 3 tons.

Fig 4.1: CRANE.

4.2 PROPOSED METHOD

In order to reduce the difficulties faced by the worker during the
assembling of blade shaft into the impeller, some improved methods are
developed. There are,
Assembly stand.
18

 Trolley.

4.2.1 ASSEMBLY STAND

Assembly stand or mounting for the modular or straight line assembly of
machine; it is used in the single station and production line assembly of medium
size and large objects or plate, such as motors and machine tool.
In production line assembly, the object may be transported from one stand
to another stand by means of bridge crane, which are used mostly in machine
tool building. The production line assembly of large size article can be in such a
way that it is not necessary to move the objects from one assembly stand to
another.

Fig: 4.2 ASSEMBLY STAND.

4.2.1.1 PARTS AND FUNCTION OF ASSEMBLY STAND

4.2.1.1.1 BEARING BLOCK
a) Base

19

The base is the main frame work for the components consists in the stand.
In other words we can say that it is like platform for the parts consists in it. The
base could withstand the heavy static load to be placed over it.
b) Bearing
Bearing is the most important part in this assembly stand. It is used to
avoid the direct contact between two relative surfaces in order to avoid the
frictional force. Here the Axial Thrust Ball Bearing is used for this stand, as the
load act towards axially. It helps in rotating the table.

Fig: 4.3 AXIAL THRUST BALL BEARING.

c) Rollers
Rollers are used in many industries to transport the object from one place
to another place without using the conveyors. There are different types of
rollers, apart from that; here the cylindrical rollers are used. The purpose of
using these rollers is to give additional support to the impellers and to turn
easily the impeller.

4.2.2 TROLLEY

20

Fig: 4.4 TROLLEY.

4.2.2.1 PARTS OF THE TROLLEY

a) Pin rod
Pin rod is a rod which is small in length. This rod is provided with the
dimension as idle dimension of the hole provided in the blade bearing shaft so
as to hold the shaft with it.
b) Wheel
Generally the wheels are provided to locomotive the vehicle from one place to
another. Likewise, here also the wheels are provided to move the trolley from
one place to another. Here in the trolley, six wheels are provided to carry the
lengthy blade bearing shaft easily.

c) Rack & Pinion

The Rack and Pinion mechanism is used in the trolley to assemble the
blade bearing shaft easily.
21

Fig: 4.5 RACK & PINION.

CHAPTER V
DIMENSION OF ASSEMBLY STAND

22

The dimensions used for the simple assembly stand for the following
components are;
Bearing block assembly.
Trolley assembly.
Overall assembly.

5.1 BEARING BLOCK ASSEMBLY

23

Fig: 5.1 BEARING BLOCK ASSEMBLY.

5.2 TROLLEY ASSEMLY

24

Fig: 5.2 TROLLEY ASSEMBLY.

5.3 OVERALL ASSEMBLY

25

Fig: 5.3 OVERALL ASSEMBLY.

5.4LOCKNUT TIGHTENING

CHAPTER VI
CAD SOFTWARE
26

6.1 INTRODUCTION
With dramatic change in the computing power and wider availability of
software tools for design and production, engineers are now using Computer
Aided Design (CAD) to automate their design and production processes. These
technologies are now used every day for engineering tasks.
The design process starts with identification of a new design need that is
identified by marketing personal after getting feedback from the customer
demands.
It is the technology concerned with using computer system assist in the
creation, modification, analysis and optimization of design. Any computer
program that embodies computergraphics and an application program
facilitating engineering functions in design process can be classified as CAD
software.

6.2 SOFTWARE USED

6.2.1 CATIA (COMPUTER AIDED THREE DIMENSIONAL
INTEGRATED APPLICATION) SOFTWARE
CATIA (Computer Aided Three-Dimensional Interactive Application)
started as an in-house development in 1977 by French aircraft manufacturer
Avions Marcel Dassault, at that time customer of the CAD/CAM CAD software
to develop Dassault's Mirage fighter jet. It was later adopted in the aerospace,
automotive, shipbuilding, and other industries.
Initially

named

CATI

(Conception

Assistee

Tri

dimensionally

Interactive).Interactive Aided Three-dimensional Design), it was renamed

27

CATIA in 1981 when Dassault created a subsidiary to develop and sell the
software and signed a non-exclusive distribution agreement with IBM.
In 1998, V5 was released and was an entirely rewritten version of CATIA
with support for UNIX, Windows NT and Windows XP (since 2001).In the
years prior to 2000, problems caused by incompatibility between versions of
CATIA (Version 4 and Version 5) led to $6.1B in additional costs due to years of
project delays in production of the Airbus A380.

6.2.2 SCOPE OF APPLICATION

Commonly referred to as a 3D Product Lifecycle Management software
suite, CATIA supports multiple stages of product development (CAX),
including

conceptualization,

design

(CAD),

engineering

(CAE)

and

manufacturing (CAM). CATIA facilitates collaborative engineering across

disciplines around its 3DEXPERIENCE platform, including surfacing & shape
design, electrical fluid & electronics systems design, Mechanical engineering
and systems engineering .
CATIA facilitates the design of electronic, electrical, and distributed
systems such as fluid and HVAC systems, all the way to the production of
documentation for manufacturing.

Mechanical engineering
Design
Fluid systems
Industries

CHAPTER VII

28

CATIA SOFTWARE
7.1 PARTS OFBEARING BLOCK

(a) CYLINDRICAL STAND.

(b) ROLLER.

29

(c) ROLLER SUPPORT

Fig: 7.1 PARTS OF BEARING BLOCK

7.2 ASSEMBLED BEARING BLOCK

Fig: 6.2 ASSEMBLED BEARING BLOCK.

7.3 PARTS OF TROLLEY

30

(a) VERTICAL PLATE.

(b) HORIZONTAL PLATE.

31

(c) WHEEL AND CENTRE ROD.

(d) PISTON.
Fig: 7.3 PARTS OF TROLLEY.

7.4 ASSEMBLED TROLLEY

32

Fig: 7.4 ASSEMBLEDTROLLEY.

7.4.1 GUIDE WAY FOR TROLLEY

Fig: 7.4.1 GUIDE WAY FOR TROLLEY.

33

7.5 FULLY ASSEMBLED STAND

Fig: 7.5 FULLY ASSEMBLED STAND.

7.6 LOCKNUT TIGHTENING TOOL

Fig: 7.6 LOCKNUT TIGHTENING TOOL.

CHAPTER VIII
34

FLOW CHART DETAILS

8.1 EXISTING MODEL OF ASSEMBLY
At present the assembly is done with a help of table and placed over it. In
this method there is a table of length about 2400mm and thickness 50mm. This
table is made up of steel. First of all steel plate of such thickness is very
expensive. A pipe of diameter 100mm is keep at the centre of the table. This is
the description of the table.
The pipe present on the table protruded above to a height of about 20mm,
over this projection there is a cup like arrangement with height of 20mm and
diameter of 200mm. Over this cup shaped protrusion a bearing is seated.
The bearing is a axial thrust. This type of bearing is chosen to withstand a
axial load. As the impeller is mounted over the bearing and the weight of the
impeller is over 10tons which to be load axially. Needle type of roller bearings
is used. The bearing outer diameter is 135mm. To withstand such a heavy load
this much big bearing are used. This bearing can take a static load of about
61750N.

8.1.1 PROCESS FLOW OF EXISTING METHOD

35
START

Impeller placement on stand

Collections of assembly components
Dismantling of sub assembly

Placing of counter weight

Waiting for EOT crane

Fixing a bearing and Locknut placement

Blade shaft insertion on bores using crane

Adjustment alignment

Locknut tightening
Is the last bore
Go to the next
bore

Stop

8.1.2 DISADVANTAGES OF EXISTING MODEL

36

Selection of steel plate of such thickness is tough.

The plate of such thickness is high.
The table may topple over if more than the allowed weight is added.
Hence fitting is to be done carefully.
It is time consumes process.

8.1.3 BOTTLE NECKS OF EXISTING METHOD

START
37

Impeller placement on stand

Collections of assembly components
Dismantling of sub assembly

Placing of counter weight

Waiting for EOT crane

Fixing a bearing and Locknut placement

Blade shaft insertion on bores using

crane

Adjustment and alignment

Locknut tightening

Is the last bore

Go to the next
bore

Stop

8.2 THE NEW INNOVATIVE METHOD OF MODEL

38

In this method instead of table a plate of 50mm is used as the base. It is

not taken to the entry span of the impeller. It is taken only up to a diameter of
1200mm. Thus the cost of the material will be made less.
On the four sides of the base four plates of same thickness is as that of the
base is taken. This is taken as a rectangular plate with dimensions 200*600 in
mm. Over these plate rollers are placed about it.
These rollers are kept at a height of 150mm from base. These rollers are
of the dimensions, diameter 50mm and length 500mm. These rollers are kept in
order to withstand the height of the impeller.
At the centre of the base a bottom race to hold the bearing is kept. To
withstand the weight of the impeller it is also given a thickness of about 50mm.
This also given a inner hole for inserting the support shaft.

8.2.1 PROCESS FLOW OF PROPOSED METHOD

START
39

Impeller placement on stand

Collections of assembly components
Dismantling of sub assembly
Placing of counter weight
Fixing a bearing
Locknut placement
Blade shaft insertion on bores using
specialized assembly tool
Adjustment and alignment
Locknut tightening
Is the last bore
Go to the next
bore

Stop

8.2.2 BENEFITS

40

 Cycle time reduced to 0.5 is shifts from 2.5 shifts/assy.

Employ fatigue reduced.
Quality of job enhanced.

8.3 FINANCIAL BENEFITS

8.3.1 CYCLE TIME
Process cycle time for existing method x is calculated by
x = (20 + 10 + 10) + 18 * (15 + 10 + 10 + 10 + 5 + 10 + 2)
= 1156 min / 60
= 19.267 hrs.
Process cycle time for proposed method y is calculated by
y =(20 + 10 + 10) + 18 * (10 + 10 + 6 + 8 + 4 + 10)
= 904 min / 60
= 15.07 hrs.

8.3.2 PROCESS CYCLE COST

Process cycle cost for existing method is calculated by
= 19.267 hrs * M * 4
= 19.267 * 200 * 4
= Rs.15, 413.6
Where, Workers wages (M) = Rs.200.
Crane time is calculated by

41

T = 20 + 18 * (15 + 10 + 2)
= 20 + (37 * 18)
= 11.43 hrs.
Crane cost is calculated by
= 11.43 * 2 * M
= 11.43 * 2 * 251
= Rs.5, 737.86
Where, Crane operators wages (M) = Rs.251
Total cost for existing method is calculated by
= Rs.5, 737.86 + Rs.15, 413.6
= Rs.21, 151.46
Process cycle cost for proposed method is calculated by
= 15.07 * M * 4
= 15.07 * 200 * 4
= Rs.12, 056
Crane time is calculated by
T = 20 + 18 * (10 + 2)
= 236 min * 60
= 3.93 hrs.

Crane cost is calculated by

42

= 3.93 * 2 * 251
= Rs.1, 972.86
Total cost for proposed method is calculated by
= Rs.1, 972.86 + Rs.12, 056
=Rs.14, 028.86
Cycle cost reduction for 1 impeller is calculated by
= Rs.21, 151.46 Rs.14, 028.86
= Rs.7, 122.6
Cycle cost reduction for 50 impeller (per annum) is calculated by
= Rs.7, 122.6 * 50
= Rs.3, 561, 30.
Percentage of reduction is calculated by
= (Rs14, 028.86 / Rs.21, 151.46) * 100
= 66.32 %

8.4 TANGIBLE BENEFITS

Cycle time reduction for impeller assembly reduced by 66.32 %
Net saving per annum Rs. 3, 561, 30.

8.5 INTANGIBLE BENEFITS

Communication skills improved.
43

Employee satisfaction increased.

Team sprit cultural developed.
Self confidence enhanced.
Problem solving ability improved.

44

S.N
O

PROCESS

EXISTING PROPOSE
D

FINAL
RESULT

1.

Cycle Time

19.26 hrs

15.7 hrs

4.19 hrs

2.

Cycle Cost

Rs. 15,413

Rs.12,056

Rs.3357

3.

Crane Time

13.43 hrs

4 hrs

9.43 hrs

4.

Crane Cost

RS.5,737

Rs.1,972

Rs.3,765

8.6 RESULT ANALYSIS

45

CHAPTER IX
9.1 CONCLUSION
Our project is very simple and easy to work it when the compared to the
previous method. Our project reduces the time taken to setting of jobs.
Labour work is reduced and therefore the number of the workers involved in
the assembling time is reduced. This method is also found to be effective and
accurate than previous method. Using these mountings we can surely avoid the
disasters and fatigue of worker. Thus our project is successfully done.

46

9.2 REFERENCE:
1. PREDICTING BLADE LEADING EDGE EROSION IN
AN AXIAL INDUCED DRAFT FAN. Anthony G.sheard
2. INDUCED DRAFT FAN LUBRICATION SYSTEM.
Stuart baker 28 october, 2010
3. INDUCED DRAFT FAN INNOVATION FOR HEAT
RECOVERY

STEAM

GENERATORS.

o.w.Beasly,

E.C.Hutchins,P.R.Predick and J.M.Vavrek. 24 april, 2008

4. THE ENERGY SAVING ANALYSIS ON INDUCED FAN
OF POWER PLANT. R. Wang and W.Y.YU, Vol.5, 2008,
pp. 29-30
5. ENERGY CONVERSTION

REFORM OF BOILER

FANS IN POWER PLANT. J.H.WU, Vol.10, No. 1, 2008,

pp. 42-45.
6. ENERGY SAVING ANALYSIS OF BOILER FANS IN
POWER PLANT. L. Dong, Vol. 4, 2008, pp, 57-59
7. DISCUSSION ON THE REDUCTION OF

THE

STATION SERVICE POWER CONSUMPTION RATE

FOR 800 MW POWER GENERATION UNIT.

H.

Yuan, Vol. 4 ,pp.87-89.

8. APPLICATION OF HYRADULIC COUPLERS TO
ENERGY SAVING FOR POWER PLANTS.Y.F. Yue , Vol.
9 ,2006, pp. 87-89.
9. APPLICATION OF INVERTER ON BOILER WIND
FAN. C .X . Liu ,Vol . 4, 2010, pp59-60.
10. APPLICATION OF HIGH VOLTAGE INVETER ON
BOILER FANS IN POWER PLANT. G.H. Zhang and H. P
Wang, Vol. 1, 2009, pp. 51-52.
47

11.

DISCUSSION ON THE SYSTEM OF TURBINE

DRIVEN INDUCED FAN OF POWER GENERATION

UNIT. P. Zhang, Vol. 8 ,2010, pp. 17-19.
12. THERMAL POWER UNITS. T. K. Zheng , Beijing
2001, pp. 63-64.

48