Acknowledgement

We wish to say thanks to respected Officials of H.R.D.C Shri A.K. Upadhyay (A.G.M), Shri D. Pant (D.G.M), Shri Raj Singh (Sr. Engineer) and Shri Satya Pal Chauhan (General Foreman) from the deepest sole of our heart for executing the O.J.T-IV program in excellent manner. Which provide us the opportunity to become familiar with products manufactured, manufacturing processes, inspection procedures and skills of the manpower employed in Turbine Manufacturing Shop (Block-3). A And we are also thankful to the esteemed TUM Officials Shri Ishwar deen (G.M,T&D.), Shri S.K. BAJAJ (A.G.M,TUM,Bay-3), Shri P.C.Verma (DGM TUM,Bay-3), Shri ALOK SHUKLA (DGM, BAY-3)Governing Assembly & other respected officers and colleagues for their cooperation, guidance and useful ideas which strengthen us to turn the training program into reality. Their teachings and helps are unforgettable for us.

Name :- Raj kumar Ram Staff No :- 1653423

Index
Sr. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Contents Name Page No. 3 4 5 6 23 27 29 31 32 33

About Training Layout of Block 3 Organization Chart an overview BHEL Hardwar Introduction with products of Block-3 (TUM) Description of various sections visited Turnover of HEEP and Block-3 Unique Facilities available in Shop Shop Planning Flow Chart Modernization Schemes & Technological Development

1. About Training Program

As part of On Job Training modules, OJT-IV Module was of six month duration from12/12/2006 to25/07/2007. During this program we were distributed in small groups and appointed in branch related departments. Fortunately our place of appointment was Turbine Manufacturing Shop in GOVERNING ASSEMBLY DEPT, which gave us the great exposure of inspection techniques involved in inspection of different type of turbines and its accessories. The shop was divided into ten parts for training purpose as follows and four days were given to visit each place1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Light Machine Shop - Bay 3 CPL/CML Governing Assembly Section - Bay 3 Turning, Milling and L & D Section - Bay 3 Planning Blade Assembly Section - Bay 2 Assembly-2 - Bay 2 Heavy Machine Shop-2 - Bay 2 Assembly-1 - Bay 1 Heavy Machine Shop-1 - Bay 1 Over Speed Balancing Tunnel QAX -ADM BUILD TURBINE ENGG -ENGG BULD QCX -BLK-I QC MATERIAL -ADM-III At the end of training we realized that the Turbine Manufacturing shop has become the vital part of our training.

2. Layout of Block-3

APPLICATION RANGE OF STEAM TURBINE TYPE OF SPEED STEAM RPM GENERATOR Fossil Fuel Steam Generator Pressurised Light Water Reactor Heat recovery Steam Generator 3000 3000 3000 POWER OUTPUT MW MAIN STEAM CONDITION BAR
O

SERIES Turbines for Fossil Fuel Power Plants Turbines for Nuclear Power Plants Turbines for Combined Cycle Applications

REHEAT STEAM CONDITION BAR 30-70 8-15 30-50

O

BACK PRESSUR MBAR 20-300 20-300 20-300

100-1000 130-250 500-540 Upto 1000 Upto 300 40-70 30-140 250-300 500-540

500-600 200-250 500-540

H G H M S A S

R M R

S ( T

. K &

. D W &

G ) A T

S G

I I S H ( T U M H R M H A G R M I R M

R E B P A

D C H

I N . ) A I N T T G )

I J . K . ( T U M I V

T R A N

. R . B ( O S B I S & . A B B H

H A T )

S A G

S A T ( T U M I ( T I A U S ( T A . K M

D V S A A

K U M A R I S P A T C I J H S E

S A G

H M R M R G R S D I

S H A G S S S H D H

. K . U M

J A J Y - 3 G T H E S A C

) L H I N

I M S G

. K . S ( T U M A M D M V

I N &

. ) G H

I N D E R ( N T X ) . ( T T A X B ) B E

H R I S D G

. K

4. Introduction with products of Block-3

STEAM TURBINE

HARDWAR

APPLICATION RANGE OF STEAM TURBINE SERIES TYPE OF STEAM SPEED RPM POWER OUTPUT MAIN STEAM CONDITION REHEAT STEAM CONDITION

BACK PRESSUR

GENERATOR Turbines for Fossil Fuel Power Plants Turbines for Nuclear Power Plants Turbines for Combined Cycle Applications Fossil Fuel Steam Generator Pressurised Light Water Reactor Heat recovery Steam Generator 3000 3000 3000

MW

BAR

BAR 30-70 8-15 30-50

MBAR 20-300 20-300 20-300

100-1000 130-250 500-540 Upto 1000 Upto 300 40-70 30-140 250-300 500-540

500-600 200-250 500-540

STEAM TURBINES FOR FOSSIL FUEL POWER PLANTS 1. Three cylinder turbines (HMN Series), comprising of High pressure (HP) turbine Intermediate pressure (IP) turbine Low pressure (LP) turbines SALIENT FEATURES

 Turbines for both nozzle control as well as throttle control mode. Turbines can operate with any boiler and are suitable for i. ii. iii. Constant pressure as well as sliding pressure operation Base load as well as two-shift operation Sub critical as well as super critical parameters

All the rotors are monoblock HP & IP casings have double shell construction and LP has threeshell construction. IP turbines with single flow or with double flow. LP turbines are designed for normal as well as high back pressure conditions. Hollow guide blades with suction slits for moisture removal in last LP stage. Bearing pedestals isolated from turbine casings. Combined stop & control valves with individual servomotor. Sophisticated control and monitoring equipment such as Electrohydraulic governing, automatic turbine run up system, turbine stress controller, automatic turbine tester etc. High operational flexibility iv. v. vi. Fast start up and shut down Sharp load changes Operation under wide frequency range (47.5 to 51.5 Hz) 1. Two cylinder turbines comprising of HP and combined (IP&LP) turbines (HE series)

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

STEAM TURBINES FOR COMBINED CYCLES

 Combined cycles offer substantial improvement in thermal cycle efficiency by lowering the heat rejection temperature. Exhaust from gas turbine is used effectively for generating steam in fired or unfired heat recovery steam generator for running a suitable steam turbine. Open cycle gas turbines can be profitably converted to a combined cycle plant even at a later stage depending upon the convenience of the utility. BHEL Hardwar manufactures steam turbines for combined cycle power stations with gas turbines of 66 MW, 159 MW and 255 MW ISO ratings. Steam cycle may be single, dual or triple pressure cycle. With triple pressure cycle and suitable block combination of gas turbines, HRSG and steam turbines, cycle efficiency of about 58% can be achieved. TURBINES WITH ADVANCED STEAM PARAMETERS Application of higher parameters is the most direct way of increasing heat input to the cycle Steam parameters of 300 bar pressure and 600 oC temperature Six percent improvement in thermal cycle efficiency New materials for high temperature applications Impulse diagonal blading for the first stage HP and IP turbines Heat shield at inlet of IP turbine Increased wall sections for increased pressures

10

TURBINE BLADES Cylindrical reaction blades for HP, IP and LP Turbines 3-DS blades, in initial stages of HP and IP Turbine, to reduce secondary losses Twisted blade with integral shroud, in last stages of HP, IP and initial stages of LP turbines, to reduce profile and Tip leakage losses Free standing LP moving blades Tip sections with supersonic design Fir-tree root Flame hardening of the leading edge Banana type hollow guide blade Tapered and forward leaning for optimised mass flow distribution Suction slits for moisture removal COMPUTATIONAL MESH FOR 3D ANALYSIS

MANUFACTURING FACILITIES The plant is fully equipped with the most modern and sophisticated manufacturing and testing facilities to produce sets upto 1000 MW rating. These include: Blade Shop for manufacture of both moving and stationary blades Special purpose CNC machine tools

11

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

RENOVATION & MODERNISATION (R&M) Depending on the actual operating conditions, material properties of the components degrade as function of service life due to one or more time dependent material damage mechanisms such as creep, fatigue, corrosion, erosion, wear embattlement etc. Life extension programme (LEP) is a special package comprising systems and methodologies, which evaluates the residual life of components through sophisticated NDT, FEM stress analysis and metallurgical technique. BHEL carries out life extension programs on steam turbines of various ratings, which forewarn the impending failure and help in reducing costly plant breakdowns by recommending replacement and upgradation of defective components. Many improvements in material and design of critical components with stateof-art design is a part of the life extension process. Thus the performance, availability and efficiency of the plant may be improved by R&M Programs.

ULTRASONIC EXAMINATION OF SHRUNK ON DISC

MICROSTRUCTURE EXAMINATION OF ROTOR

12

QUALITY A MATTER OF COMMITMENT An ISO 9001 Company Quality, a watchword in incoming materials, in-process, machining, assembly and testing. Quality Assurance, Quality Plan, Field Quality being an integral part of the total process. Fully equipped Centre Plant Laboratory to support, sophisticated testing and measuring instruments viz. CNC 3 D Co-ordinate Measuring Machine. NDT facilities: X-ray, Gama ray, Ultrasonic Magnetic particle testing. Recognised by MIS TUV, Germany as a reputed manufacturer of pressure vessels ASME U stamp ASME R Stamp

Quality Conformance Our Quality policy says

13

"TO MAINTAIN A LEADING POSITION AS A SUPPLIER OF QUALITY PRODUCTS, SYSTEMS & SERVICES TO NATIONAL / INTERNATIONAL STANDARDS TO MEET THE REQUIREMENTS OF CUSTOMER" Quality is in fact a way of life in BHEL. Be it in incoming material, in process, machining, assembly or testing, "Quality" is the watchword. Quality Assurance & Control System, Quality Plans and Field Quality Assurance are aids to total quality concept. As a testimony to excellent quality consciousness in BHEL, BVQI with accreditation from UK, Holand and Germany has certified HEEP Hardwar with the prestigious ISO 9001 for all its products and services. We follow various National/ International standards like IEC, ANSI, ASME, DIN etc. at all the stages of product cycle.

HYDRO POWER CLEAN POWER

HARDWAR

14

BHEL AND HYDRO-ELECTRIC POWER A PERSPECTIVE

BHEL appeared on the hydro map of India in 1970 with the commissioning of Obra (3x33 MW) hydro-power station and is now one of the leading suppliers in the field of design and manufacture of hydroelectric equipment. BHELs design practices have been evolved after careful synthesis of know-how obtained from reputed collaborators in the world. These design practices have been updated and supplemented by own innovations and in-house research and development work over more than last three decades. 285 hydro sets (11981.99 MW) with share of 52.90% of total hydro power in the country have been designed, manufactured and installed by BHEL over last three decades as per purchasers requirements. Availability of BHEL sets is 96.8%.

15

RANGE OF HYDRO TURBINE PARAMETERS

TYPE

UNIT RATING RUNNER DIA MIN MAX 75 250 115 200 MIN 1.65 1.39 0.849 3.296 MAX 5.64 4.0 3.5 6.95

SPEED MIN 150 150 250 136.3 MAX 428.6 750 750 500

HEAD MIN 10 43 300 40 MAX 50 450 900 400

KAPLAN FRANCIS PELTON REVERSIBLE

5 5 1.5 60

UNITS: RATING - MW, RUNNER DIA - M, SPEED - RPM, HEAD - M SPIRAL CASING The spiral casing is of logarithmic form and designed to maintain optimum flow conditions. It is manufactured in parts, depending on transport limitations. For larger sizes, spiral-casing segments are welded at site. The welding seams are tested by radiography, UT and the complete casing is tested under hydraulic pressure.

STAY RING & GUIDE APPARATUS

16

Stay rings up to 12.5 m in diameter can be machined on BHELs vertical boring machines. The stay rings are welded in the works. For high head machines, the stay rings are made of low alloy cast steel. The guide apparatus assembly of low and medium-head turbines is carried out on dummy stay ring or its own stay ring. Maximum possible checkassembly of the various matching components of the turbine is carried out in works. Pit-type and tandem-type servomotors have been installed. Rubber-lip and hydrodynamic seals have been used as shaft sealings. Selflubricated self-aligned and water lubricated guide bearings have been used depending upon speed requirements. TURBINE RUNNERS BHEL has the capacity to supply runners for custom-built machines, to suit their operating conditions. The runners are cast in BHELs own Central Foundry Forge Plant or purchased from world reputed foundries. The hub is cast from low-alloy cast steel. BHELs own foundry can take up alloy castings up to 40 Tons. GOVERNOR BHEL supplies electro-hydraulic and electronic governors to suit the various requirements of its customers. BHEL governors are suitable for operation up to 40kg/cm oil pressure system.

17

SPHERICAL AND BUTTERFLY VALVES

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

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

18

RENOVATION, MODERNISATION AND UPRATING OF BHEL /NON BHEL SETS

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

NEED FOR RENOVATION AND MODERNISATION

AGED UNITS, POOR, PERFORMANCE, HIGH MAINTENANCE COSTS AND OBSOLETE TECHNOLOGY. LIFE ENHANCEMENT OPTIMUM UTILISATION OF HYDRAULIC CONDITIONS. HIGHER OUTPUT WITH EFFICIENT RUNNERS. STATE OF ART IN DESIGN PHILOSOPHY FOR IMPROVED PERFORMANCE & RELIABILITY.

19

EFFICIENCY IMPROVEMENT IN MAJOR R &M PROJECTS EXECUTED

PROJECT BAIRASIUL DEHAR CHILLA

ORIGINAL RUNNER 87.2% (53.8 MW) 93.4 %(MAX) 93.5%(MAX)

MODIFIED NEW RUNNER 92.3% (68.4 MW) 94.9%(MAX) 95.0%(MAX)

(ALL OUTPUTS IN BRACKETS ARE TURBINE OUTPUTS)

20

GAS TURBINES FOR POWER GENERATION

HARIDWAR

21

BHELS LARGE SIZE GAS TURBINES FUEL FLEXIBILITY Gas Turbine burners are designed to burn a wide variety of fuels ranging from clean fuels like Natural Gas, Distillate Oil, Naphtha and LPG to heavy fuels like LSHS. Gas Turbines can be operated in mix-mode also. HIGH RELIABILITY High reliability and long operating life are the prime basis of the design philosophy adopted for these Gas Turbines. The reliability of M/s SIEMENS/ BHEL designed Gas Turbine is unsurpassed with more than 2 million hours of successful operation for module V94.2 itself. This measure of high reliability has been achieved through a combination of sound design engineering, established manufacturing processes with well defined quality management systems. HIGH EFFICIENCY These Gas Turbines have high efficiency in Open Cycle and in Combined Cycle Operation. The provision of inlet guide vanes improves the combined cycle efficiency at part loads as well. LOW EMISSION While on natural gas very low NOx and negligible CO emissions are achieved without steam/water spray in specially designed Hybrid Burners. Steam/water spray assists in reduction of NOx emissions when firing liquid fuels like Naphtha, Distillate No.2 etc.

22

DESIGN FEATURES OF THE PROVEN MODEL V94.2 GAS TURBINES

23

24

SINGLE CASING AND SINGLE SHAFT The compressor and turbine have a single casing and single rotor, which is supported on two bearings only. The bearings are located outside the pressurized zone providing constant good alignment and excellent running conditions. The compressor has sixteen stages and turbine has four stages. BUILD UP ROTOR The rotor is built up from the discs and hollow shaft held together by Central Tie Rod and Nut. Hirth Serrations on the disc faces help in centering the discs and allow free radial expansion and contraction as well as effective transmission of power . BLADES

Variable pitch, inlet guide vanes allow operation down to half load while maintaining a constant exhaust temperature. Air cooling of the first three stationary and first two moving turbine blade rows protects the blade material against high inlet temperature. The free standing moving blades of the compressor and the turbine are tuned to permit continuous full load operation over a frequency range from 5% to +3%

SILO TYPE COMBUSTION CHAMBERS Two large size Silo type Combustion Chambers ensure complete combustion of hydrocarbons. The high temperature part of Combustion Chamber is provided with the refractory lining. HYBRID BURNERS Each Combustion Chamber is provided with specially designed Hybrid burners suitable for single or dual fuel operation. Burners provide complete combustion of fuel with proper air fuel mixture giving very low Nox emission in the exhaust. EASY MAINTAINABILITY

All the Rotor Blades have axial entries to facilitate change of blades on rotor without dismantling rotor at site. For Rotor Balancing at site, three planes are accessible. Ready access via manholes into both Combustion Chambers permit direct inspection of all the hot gas path components from the burners to the turbine blades.

GENERATOR AT COLD END 25

HIGHLY EFFICIENT NEWLY DEVELOPED 'A' SERIES GAS TURBINES NEW DESIGN BASED ON PROVEN FEATURES Advanced series of gas turbine designed to meet higher efficiencies have been developed by Siemens and designated as Vxx.3A series of machines. The 3A series machines are state-of-art machines with basic features adapted from previous gas turbine series. Important design features of the 3A gas turbine are: 1. New compressor blading 2. Fewer hot gas path components 3. Film cooled turbine blades 4. Hybrid burner ring (HBR) combustor with 24 burners 5. Lower cooling air requirement and thus more air available for clean combustion 6. Compact construction Advances made in the development of this series of gas turbines are particularly evident in the combustion chamber. The ring type combustion chamber is connected to the turbine outer casing. The hybrid burners form a continuous ring flame thus eliminating the localized hot and cold spots. The objective here is to reduce the pollutant emissions.

V94.3A GAS TURBINE

26

THE MAJOR BENEFITS FOR ADVANCE GAS TURBINE 1. Large saving in operating costs due to lowest fuel consumption 2. Low maintenance costs as a result of readily maintainable machine construction and long intervals between inspections 3. Excellent operating availability and reliability 4. Lower life-cycle cost 5. Effective use of fossil-fuels

ROTOR ASSEMBLY OF V94.3A GAS TURBINE

Technical Parameters of Gas Turbines PARAMETER Base Rating, MW-ISO Turbine Inlet Temperature , C Exhaust Mass Flow, Kg/s (approx.) Exhaust Temperature , C at ISO Efficiency, % V94.2 GT 159 1060 514 543.0 34.74 V94.3A GT 265 1230 659 581 38.5

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

27

CNC BROACHING MACHINE The facilities include:

Most modern Blade Shop for manufacturing of both moving and stationary blades of compressor Highly sophisticated special purpose CNC machine tools Creep Feed Grinding Machine for disc hirth serrations External Broaching Machine for making Blade root grooves on the discs Overspeed & Vacuum Balancing Tunnel, a very unique facility for balancing and overspeeding rotors for turbines and generators upto 1300 MW capacity

OVERSPEED & BALANCING TUNNEL

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

CNC LATHE FOR ROTOR MACHINING

28

5. Description of Various Shops Visited

1. Light Machine Shop: This shop is situated in Bay III of Block 3 and is involved in machining of various light weight parts for Emergency Stop Valve & Control Valve, Interceptor Valve & Control Valve, L.P. Bypass Valve and their Servomotors. Various machines are installed in this shop like Lathes Conventional and CNC, Milling Machine, Grinders, Shapers, Planners, Slotters, Vertical Boring Machine- CNC and Horizontal Boring Machines. 2. Governing Assembly Section: The Governing Assembly section is situated in Bay III of Block 3. Governing is the process of maintaining constant speed of turbine irrespective of load variation. In Governing Assembly Section we assemble the Emergency Stop Valve & Control Valve, Interceptor Valve & Control Valve, L.P. Bypass Valve, Governing Rack, Hydro Turbine Governing Assembly and Gas Turbine Governing Assembly.

29

And tests of all the above said assemblies are also done here. 3. Turning, Milling and L& D Section: This section is also situated in Bay III of Block 3 and engaged in manufacturing of Parts of Governing Assembly section, Bearing & Pedestals, Diaphragms and Guide Blade Carriers etc. In this section different type of machines are available for turning and milling purpose, mostly machines are conventional type except some sophisticated CNC machines. 4. Planning: This Planning section is involved in shop level planning functions for TUM. These functions can be listed as follows * Planning schedules on the basis of monthly plan provided by PPC. * Dispatching or forwarding of authorized work plan to shop. * Prioritization of works. * Procurement of Bought Out Items. 5. Blade Assembly Section: The Blade Assembly section lies in Bay II of Block 3.This section is involved in fitting of blades in turbine rotors as well as casings. As we know that the blades are considered as most sensitive part of Turbine because a blade has to face various forces like impulse force, reaction force, centrifugal force and so on at not only elevated temperature but also on very high speed. That is why this section is very sensitive and important.

6. Assembly Section Bay-2: This section is also stated in Bay II of Block 3 and is engaged in assembly of 210 MW HP, 500 MW HP , 500 MW LP and Gas Turbines. Its main functions are as follows* Assembly of Turbines. * Hydraulic Test of casings. * Balancing of Rotors. * Various Test of assembled Turbines. 7. Heavy Machine Shop Bay-2: This shop is situated in Bay II of Block 3 and is involved in machining of various Turbine Rotors and Turbine Casings of various modules. This shop has many lathe machines of high turning capacities, vertical boring machines and horizontal boring machines, etc. 8. Assembly Section Bay-1: This section is situated in Bay I of Block 3 and engaged in assembly work of different Turbines, Big Pedestals, Valves for Governing, Hydraulic Test of Bends and Pipes, Gas Turbine Rotors and Gas Turbine Combustion Chambers.

30

9. Heavy Machine Shop Bay-1: This shop is placed in Bay I of Block 3 and here we do various machining works on casings of Turbine and Valve bodies. The turning work on rotors is also done here. This section has various Lathe machines, Vertical Boring Machines and Horizontal Boring Machines with conventional as well as CNC operating systems. 10. Over Speed Balancing Tunnel: It is the place where we do balancing of Turbine & Generator Rotors in respect of vibrations measured in a vacuumed tunnel on approx 3600 rpm and balance the Rotors with adding some small weight blocks. The purpose of OSBT is dynamic balancing and over speeding of Turbine and Turbo generator rotors. Salient Features of OSBT are as follows* * * * * * * * * * * Rotor Weight Rotor Dia Rotor Journal Distance Between Pedestals Balancing Speed Over Speed Range Vacuum Tunnel Length Tunnel Dia Tunnel Shell Thickness Tunnel Wall Thickness -320 T max. -6900 mm max. -950 mm max. -15750 mm max. -3600 rpm -2500 to 4500 rpm -1 Torr or 1 mm Hg -19000 mm -9000 mm -32 mm -2500 mm

6. Financial Turnover Financial Turnover of HEEP Vs T&D

PRODUCTION FIGURES T&D Vs. HEEP
2500

2000

MV (Rs. Cr.)

1500

1000

500

0 T&D TO HEEP SHOP TO HEEP TO

00-01 291 486 718

01-02 393 665 1088

02-03 438 679 1013

03-04 473 745 974 YEAR

04-05 550 867 1407

05-06 714 1183 1641

06-07 1025 1608 2105

31

Financial Turnover of TUM Shop

LAST 5 YEARS TURN OVER
120000

100000

MV (Rs. Lacs)

80000

60000

40000

20000

0 Main Spares Total

01-02 28984 10100 39084

30354 27623 37137 Shop Turnover Physical 10732 41086 16161 43784 11835 48972

02-03

03-04

04-05

05-06 54720 13010 67730

06-07 82031 16879

98910 TOTAL MODULES IN LAST 5 YEARS INCLUDING ST, GT & HT

YEA R

100 80 60

NUMBER OF SETS

40 20 0 HT GT ST

01-02 1 2 15

02-03 0 1 21

03-04 3 0 27

04-05 2 2 13

05-06 0 2 33

06-07 2 0 80

YEAR

32

7. Unique Facilities Available In TurbineManufacturing

CNC Vertical boring machine having 8 M turning capacity. Vertical boring machine having12 M turning capacity. MFD Lathe machine having 18 M bed length and 2.3 M swing over carriage. Horizontal Broaching machine having slide length 1.8 M and pulling power 32 N-m. Creep Feed Grinding machine having indexing accuracy of 1 mm. Over Speed Balancing Tunnel for balancing up to 1000 MW Rotors. Kopp Milling machine for machining of T-Root in L.P. Rotors. 33

Stub Borer machine for boring diameter from 625 mm to 2500 mm in Steam Turbine Casing. Wotan Horizontal Boring machine with 6-axis CNC control.

8. Shop Planning Flow Chart

34

9. Modernization Schemes & Technological Development

SN Modernization Scheme 1 2 3 Modernization of ST manufacturing Facilities - Stage-I Modernization of ST manufacturing Facilities - Stage-II Modernization of ST manufacturing Facilities - Stage-III (capacity augmentation to 5250 MW) No. of Sanctioned Status M/Cs Investment Rs Lacs 6 4018 Completed 4 4 3272 4881 Ongoing -comp. Dec07 Ongoing comp. Dec07

35

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

FACILITIES COMMISSIONED UNDER STAGE - I OF ST MODERNIZATION PROJECT

SN DESCRIPTION 1 2 3 4 5 6 Vertical Band Saw Machine Tool Presetting CNC Lathe (SOC 1500mm, CD 6.5m) CNC Vertical Borer (dia. 6.5m, ht. 7m) Special Boring & Facing Heads of CNC (WOTAN 5C Rapid) Horizontal Borer Special Programmable Boring and Facing Heads for CNC Skoda Horizontal Borer APPLICATION For Slitting of IP IC Flanges For precise setting of insert tool For machining of 500MW Valve Covers For machining of large Casings For machining of ESV & IVCV Casings For machining of ESV & IVCV Casings

Investment = Rs. 40.18 Crores

FACILITIES UNDER STAGE - II OF ST MODERNIZATION PROJECT

COST(Rs. SN DESCRIPTION Lacs) 1 Universal Portable Radial 370 Drilling Machine (capacity 75mm) 2 CNC Gantry Milling Machine 2615 (size 13x6x1.5m, table 12x4m) 3 CNC Machining Center 150 (spindle dia. 100mm, table 630x630mm) 4 80 Tonne Transfer Trolley 52 APPLICATION For drilling of inclined holes For machining of ST casings For machining precision governing components For inter-bay transfer of fabricated components

36

Contingency TOTAL

85 3272

Total Investment = Rs. 32.72 Crores

FACILITIES UNDER STAGE - III AUGMENTATION OF ST FACILITIES FOR ANNUAL CAPACITY OF 5250MW
COST(Rs. SN DESCRIPTION Lacs) 1 CNC Rotor Turning lathe 2455 (SOC 3500mm, CD 18000mm) 2 CNC Vertical Borer (dia. 343 2.5m) 3 CNC Horizontal Borer 1323 (spindle dia. 160 mm) 4 CNC Indicating Stand 760 TOTAL 4881 Total Investment = Rs. 48.81 Crores STATUS PO Placed Under finalization PO Placed PO Placed

Technological Development
Establishment of technology for assembly of advanced class blading for ST inner casings (all ratings). Establishment of technological process for machining of advanced class blade shrouds of 500 MW HP & IP Casings in boxed up condition. Development of technology for Hydraulic testing of integral inlet insert of imported fully machined IPOC 500 MW Kahalgaon at 53 bars. Development & Institutionalization of measurement of flow path of 500/250 MW HP/IP Turbines as a parallel measure for reduction of cycle time. 37

Establishment of new RCB tools for coupling holes of 500 MW LPR on CNC Skoda Ram Borer (2-473) Improvement in manufacturing process of Yokes and Valve covers by introduction of mirror templates. Establishing drilling / reaming of pin holes without using breech nut in HPOC. Establishment of alternate procedure for assembly of FBP in shop using technological MOP casing. Machining of IP Outer Casing of 500 MW on Stub Borer reducing cycle time of Vertical Boring by 12 days. Etablishing alternate work center for machining of 14 nos. Russian diaphragms (instead of VB, machining on CNC facing lathe). Development of alternate work centre for machining of Stop Valve Servomotor Casings for Governing & U-Sealing rings for HP Turbines on Facing Lathe. Modification in oil catchers to prevent oil leakages during balancing of Russian Rotors. Development of alternate machine for turning of LP Rotor for 500 MW on old retro fitted Russian machine. Design review and finalization of technology for 25th stage Rotor assembly of 210 MW Russian ST for R&D, Hyderabad. Provision of single technological shaft for balancing of HP Rotor 210 MW Russian replacing 3 different technological pieces. Establishing technology for manufacture of split type Spherical Valve Rotor as against existing integrated design for Maneribhali HEP project. Indigenization of Half Rings for Libya-3 & 4 Gas Turbines. Technology developed for manufacturing solenoid valves and MIL grade cables.

38

Establishing hardening / carburizing process for SRGM components. Time reduction in job setting for Shank & Carriage of SRGM by use of a single fixture. Manufacturing of proximity switches developed indigenously. DNC monitoring of CNC machines.

39

40

41