Summer Training Project Report

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Bharat Heavy Electricals Limited, Ranipur, Haridwar

Summer Training Project Report

for
Block III Turbine and Auxillary Block
(under the supervision of Mr. S. Haldhar)

Submitted by -
Daoud Zaman Khan
B.Sc. (Engg.) IIIrd Year
Faculty of Engineering
Dayalbagh Educational Institute, Agra

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Contents

S. No.
Topic Page No.
1. Acknowledgements 3
2. BHEL An Overview 4
3. HEEP An Overview 11
4. Brief Description of all the Blocks 16
5. Bay-wise Description of Block III 19
6. Study of Block III 26
7. Study of Blade Shop 30
8. Study of Important/Major Machine Tools and
Machines
36
9. Study of Material Specifications 58
10. Classification of Blades 68
11. Hydro Turbine Laboratory 69
12. Manufacturing Divisions of BHEL 71

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Acknowledgements

Working at BHEL was indeed a great experience and for the successful commencement of my
training I need to thank a lot many of the people in the organisation.

First of all I am to Mr. B. B. Roy (retd. AGM) who gave me the initial guidance for getting myself
selected in the training at the Organisation.

I am very grateful to Mr. S. Haldhar (DGM, Block III) for taking me under his guidance and also
providing me the relevant information so that I could get started with the training in the area
allotted to me.

For my period of training at the BHEL I am also very grateful to the Engineers and Machine
operators of BHEL working at Block III for providing me adequate information so that I could get
proper information and also get myself acquainted with the work environment.

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BHEL An Overview
BHEL is the largest engineering and manufacturing enterprise in India in the energy related infrastructure
sector today. BHEL was established more than 40 years ago when its first plant was setup in Bhopal ushering
in the indigenous Heavy Electrical Equipment Industry in India a dream which has been more than realized
with a well-recognized track record of performance it has been earning profits continuously since 1971-72.
BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission, Industry,
Transportation, Telecommunication, Renewable Energy, Defence, etc. The wide network of BHEL's 14
manufacturing division, four power Sector regional centres, over 150 project sites, eight service centres and
18 regional offices, enables the Company to promptly serve its customers and provide them with suitable
products, systems and services efficiently and at competitive prices. BHEL has already attained ISO 9000
certification for quality management, and ISO 14001 certification for environment management.
POWER GENERATION
Power generation sector comprises thermal, gas, hydro and nuclear power plant business as of 31.03.2001,
BHEL supplied sets account for nearly 64737 MW or 65% of the total installed capacity of 99,146 MW in the
country, as against nil till 1969-70.
BHEL has proven turnkey capabilities for executing power projects from concept to commissioning; it
possesses the technology and capability to produce thermal sets with super critical parameters up to 1000
MW unit rating and gas turbine generator sets of up to 240 MW units rating. Co-generation and combined-
cycle plants have been introduced to achieve higher plant efficiencies. To make efficient use of the high-ash-
content coal available in India, BHEL supplies circulating fluidized bed combustion boilers to both thermal
and combined cycle power plants.
The company manufactures 235 MW nuclear turbine generator sets and has commenced production of 500
MW nuclear turbine generator sets.
Custom made hydro sets of Francis; Pelton and Kaplan types for different head discharge combination are
also engineering and manufactured by BHEL.
In all, orders for more than 700 utility sets of thermal, hydro, gas and nuclear have been placed on the
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Company as on date. The power plant equipment manufactured by BHEL is based on contemporary
technology comparable to the best in the world and is also internationally competitive.
The Company has proven expertise in Plant Performance Improvement through renovation modernisation
and uprating of a variety of power plant equipment besides specialised know how of residual life assessment,
health diagnostics and life extension of plants.
POWER TRANSMISSION & DISTRIBUTION (T & D)
BHEL offer wide ranging products and systems for T & D applications. Products manufactured include power
transformers, instrument transformers, dry type transformers, series and stunt reactor, capacitor tanks,
vacuum and SF circuit breakers gas insulated switch gears and insulators.
A strong engineering base enables the Company to undertake turnkey delivery of electric substances up to
400 kV level series compensation systems (for increasing power transfer capacity of transmission lines and
improving system stability and voltage regulation), shunt compensation systems (for power factor and
voltage improvement) and HVDC systems (for economic transfer of bulk power). BHEL has indigenously
developed the state-of-the-art controlled shunt reactor (for reactive power management on long
transmission lines). Presently a 400 kV Facts (Flexible AC Transmission System) project under execution.
INDUSTRIES
BHEL is a major contributor of equipment and systems to industries. Cement, sugar, fertilizer, refineries,
petro-chemicals, paper, oil and gas, metallurgical and other process industries lines and improving system
stability and voltage regulation, shunt compensation systems (for power factor and voltage improvement)
and HVDC systems (for economic transfer of bulk power) BHEL has indigenously developed the state-of-the-
art controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV
FACTS (Flexible AC Transmission System) projects is under execution.
The range of system & equipment supplied includes: captive power plants, co-generation plants DG power
plants, industrial steam turbines, industrial boilers and auxiliaries. Water heat recovery boilers, gas turbines,
heat exchangers and pressure vessels, centrifugal compressors, electrical machines, pumps, valves, seamless
steel tubes, electrostatic precipitators, fabric filters, reactors, fluidized bed combustion boilers, chemical
recovery boilers and process controls.
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The Company is a major producer of large-size thruster devices. It also supplies digital distributed control
systems for process industries, and control & instrumentation systems for power plant and industrial
applications. BHEL is the only company in India with the capability to make simulators for power plants,
defence and other applications.
The Company has commenced manufacture of large desalination plants to help augment the supply of
drinking water to people.
TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production, installation and
maintenance and after-sales service of Rolling Stock and traction propulsion systems. In the area of rolling
stock, BHEL manufactures electric locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to
3100 HP, both for mainline and shunting duly applications. BHEL is also producing rolling stock for special
applications viz., overhead equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides traction
propulsion systems for in-house use, BHEL manufactures traction propulsion systems for other rolling stock
producers of electric locomotives, diesel-electric locomotives, electrical multiple units and metro cars. The
electric and diesel traction equipment on India Railways are largely powered by electrical propulsion systems
produced by BHEL. The company also undertakes retooling and overhauling of rolling stock in the area of
urban transportation systems. BHEL is geared up to turnkey execution of electric trolley bus systems, light
rail systems etc. BHEL is also diversifying in the area of port handing equipment and pipelines transportation
system.
TELECOMMUNICATION
BHEL also caters to Telecommunication sector by way of small, medium and large switching systems.
RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional and renewable sources of energy
include: wind electric generators, solar photovoltaic systems, solar lanterns and battery-powered road
vehicles. The Company has taken up R&D efforts for development of multi-junction amorphous silicon solar
cells and fuel based systems.
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INTERNATIONAL OPERATIONS
BHEL has, over the years, established its references in around 60 countries of the world, ranging for the
United States in the West to New Zealand in the Far East. These references encompass almost the entire
product range of BHEL, covering turnkey power projects of thermal, hydro and gas-based types, substation
projects, rehabilitation projects, besides a wide variety of products, like transformers, insulators,
switchgears, heat exchangers, castings and forgings, valves, well-head equipment, centrifugal compressors,
photo-voltaic equipment etc. Apart from over 1110MW of boiler capacity contributed in Malaysia, and
execution of four prestigious power projects in Oman, Some of the other major successes achieved by the
Company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan,
Sri Lanka, Iraq etc.
The Company has been successful in meeting demanding customer's requirements in terms of complexity of
the works as well as technological, quality and other requirements viz extended warrantees, associated
O&M, financing packages etc. BHEL has proved its capability to undertake projects on fast-track basis. The
company has been successful in meeting varying needs of the industry, be it captive power plants, utility
power generation or for the oil sector requirements. Executing of Overseas projects has also provided BHEL
the experience of working with world renowned Consulting Organisations and inspection Agencies.
In addition to demonstrated capability to undertake turnkey projects on its own, BHEL possesses the
requisite flexibility to interface and complement with International companies for large projects by supplying
complementary equipment and meeting their production needs for intermediate as well as finished
products.
The success in the area of rehabilitation and life extension of power projects has established BHEL as a
comparable alternative to the original equipment manufacturers (OEMs) for such plants.
TECHNOLOGY UPGRADATION AND RESEARCH & DEVELOPMENT
To remain competitive and meet customers' expectations, BHEL lays great emphasis on the continuous
upgradation of products and related technologies, and development of new products. The Company has
upgraded its products to contemporary levels through continuous in house efforts as well as through
acquisition of new technologies from leading engineering organizations of the world.
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The Corporate R&D Division at Hyderabad, spread over a 140 acre complex, leads BHEL's research efforts in a
number of areas of importance to BHEL's product range. Research and product development centres at each
of the manufacturing divisions play a complementary role.
BHEL's Investment in R&D is amongst the largest in the corporate sector in India. Products developed in-
house during the last five years contributed about 8.6% to the revenues in 2000-2001.
BHEL has introduced, in the recent past, several state-of-the-art products developed in-house: low-NQx oil /
gas burners, circulating fluidized bed combustion boilers, high-efficiency Pelton hydro turbines, petroleum
depot automation systems, 36 kV gas-insulated sub-stations, etc. The Company has also transferred a few
technologies developed in-house to other Indian companies for commercialisation.
Some of the on-going development & demonstration projects include: Small wall blowing system for cleaning
boiler soot deposits, and micro-controller based governor for diesel-electric locomotives. The company is
also engaged in research in futuristic areas, such as application of super conducting materials in power
generations and industry, and fuel cells for distributed, environment-friendly power generation.
HUMAN RESOURCE DEVELOPMENT INSTITUTE
The most prized asset of BHEL is its employees. The Human Resource Development Institute and other HRD
centres of the Company help in not only keeping their skills updated and finely honed but also in adding new
skills, whenever required. Continuous training and retraining, positive, a positive work culture and
participative style of management have engendered development of a committed and motivated work force
leading to enhanced productivity and higher levels of quality.
HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT
BHEL, as an integral part of business performance and in its endeavour of becoming a world-class
organization and sharing the growing global concern on issues related to Environment. Occupational Health
and Safety, is committed to protecting Environment in and around its own establishment, and to providing
safe and healthy working environment to all its employees.
For fulfilling these obligations, Corporate Policies have been formulated as:

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ENVIRONMENTAL POLICY
- Compliance with applicable Environmental Legislation/Regulation;
- Continual Improvement in Environment Management Systems to protect our natural environment
and Control Pollution;
- Promotion of activities for conservation of resources by Environmental Management;
- Enhancement of Environmental awareness amongst employees, customers and suppliers. BHEL will
also assist and co-operate with the concerned Government Agencies and Regulatory Bodies engaged
in environmental activities, offering the Company's capabilities is this field.
OCCUPATIONAL HEALTH AND SAFETY POLICY
- Compliance with applicable Legislation and Regulations;
- Setting objectives and targets to eliminate/control/minimize risks due to Occupational and Safety
Hazards;
- Appropriate structured training of employees on Occupational Health and Safety (OH&S) aspects;
- Formulation and maintenance of OH&S Management programmes for continual improvement;
- Periodic review of OH&S Management System to ensure its continuing suitability, adequacy and
effectiveness;
- Communication of OH&S Policy to all employees and interested parties.
The major units of BHEL have already acquired ISO 14001 Environmental Management System Certification,
and other units are in advanced stages of acquiring the same. Action plan has been prepared to acquire
OHSAS 18001 Occupational Health and Safety Management System certification for all BHEL units.
In pursuit of these Policy requirements, BHEL will continuously strive to improve work particles in the light of
advances made in technology and new understandings in Occupational Health, Safety and Environmental
Science.

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PARTICIPATION IN THE "GLOBAL COMPACT" OF THE UNITED NATIONS
The "Global Compact" is a partnership between the United Nations, the business community, international
labour and NGOs. It provides a forum for them to work together and improve corporate practices through
co-operation rather than confrontation.
BHEL has joined the "Global Compact" of United Nations and has committed to support it and the set of core
values enshrined in its nine principles:
PRINCIPLES OF THE "GLOBAL COMPACT"
HUMAN RIGHTS
1. Business should support and respect the protection of internationally proclaimed human rights; and
2. Make sure they are not complicit in human rights abuses.
Labor Standards
3. Business should uphold the freedom of association and the effective recognition of the right to
collective bargaining;
4. The elimination of all form of forces and compulsory labour.
5. The effective abolition of child labour, and
6. Eliminate discrimination.
Environment
7. Businesses should support a precautionary approach to environmental challenges;
8. Undertake initiatives to promote greater environmental responsibility and
9. Encourage the development and diffusion of environmentally friendly technologies.
By joining the "Global Compact", BHEL would get a unique opportunity of networking with corporate and
sharing experience relating to social responsibility on global basis.

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HEEP An Overview
Over the years, Bharat Heavy Electricals Limited has emerged as world class Engineering and Industrial giant,
the best of its kind in entire South East Asia. Its business profile cuts across various sectors of
Engineering/Power utilities and Industry. The Company today enjoys national and international presence
featuring in the "Fortune International-500" and is ranked among the top 12 companies in the world,
manufacturing power generation equipment. BHEL has now 14 Manufacturing Divisions, 8 Service Centres
and 4 Power Sectors Regional Centres besides a large number of project sites spread over India and abroad.
The Company is embarking upon an ambitious growth path through clear vision, mission and committed
values to sustain and augment its image as a world class enterprise.
VISION
World-class, innovative, competitive and profitable engineering enterprise provides total business solutions.
MISSION
The leading Indian engineering enterprise providing quality products systems and services in the fields of
energy, transportation, infrastructure and other potential areas.
VALUES
- Meeting commitments made to external and internal customers.
- Foster learning creativity and speed of response.
- Respect for dignity and potential of individuals.
- Loyalty and pride in the company.
- Team playing.
- Zeal to excel.
- Integrity and fairness in all matters.
HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)
At Hardwar, against the picturesque background of Shivalik Hills, 2 important manufacturing units of BHEL
are located viz. Heavy Electrical Equipment Plant (HEEP) & Central Foundry Forge Plant (CFFP). The hum of
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the construction machinery woke up Shivalik Hills during early 60s and sowed the seeds of one of the
greatest symbol of Indo Soviet Collaboration Heavy Electrical Equipment Plant of BHEL. Following is the
brief profile of Heavy Electrical Equipment Plant:-
1. ESTABLISHMENT AND DEVELOPMENT STAGES:
* Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the area of Scientific,
Technical and Industrial Cooperation.
* DPR prepared in 1963-64, construction started from October '63.
* Initial production of Electric started from January, 1967.
* Major construction / erection / commissioning completed by 1971-72 as per original DPR scope.
* Stamping Unit added later during 1968 to 1972.
* Annual Manufacturing capacity for Thermal sets was expanded from 1500 MW to 3500 MW under
LSTG. Project during 1979-85 (Sets upto 500 MW, extensible to 1000/1300 MW unit sizes) with
marginal addition in facilities with the collaboration of M/s KWU-Siemens, Germany.
* Motor manufacturing technology updated with Siemens collaboration during 1984-87.
* Facilities being modernized continually through Replacements / Reconditioning-Retrofitting,
Technological / operational balancing.
2. INVESTMENTS:
* Gross Block as on 31.3.95 is Rs. 355.63 Crores (Plant and Machinery Rs. 285.32 Crores).
* Net Block as on 31.3.95 is Rs. 113.81 Crores (Plant & Machinery Rs. 76.21 Crores).
3. CLIMATIC AND GEOGRAPHICAL:
* Hardwar is in extreme weather zone of the Western Uttar Pradesh of India and temperature varies
from 2
o
C in Winter (December to January) to 45
o
C in Summer (April-June); Relative humidity 20%
during dry season to 95-96% during rainy season.
* Longitude 78
o
3' East, Latitude 29
o
55'5" North.
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* Height above Mean Sea Level = 275 metres.
* Situated within 60 to 100 KMs of Foot-hills of the Central Himalayan Ranges; Ganges flows down
within 7 KMs from the Factory area.
* HEEP is located around 7 KMs on the Western side of Hardwar city.
4. COMMUNICATION & TRANSPORTATION:
* Telegraphic Code "BHARAT TELEC, HARDWAR"
* TLX Lines: 05909-206 / 207
* Telephones: P&T / STD (01334) 427350-59, 423050-423954
FAX: (0091) (1334) 426462 / 425069 / 426082 / 426254
* Direct Board gauge train lines to Calcutta (Howrah), Delhi, Bombay, Lucknow, Dehradun and other
major cities; Railway Siding for goods traffic connected to Hardwar Railway Station.
5. POWER & WATER SUPPLY SYSTEM:
- 40 MVA sanctioned Electric Power connection from UP Grid (132 KV / 11KV / 6.6 KV) (Connected
load around 185 MVA)
- 26 deep submersible Tube Wells with O.H. Tanks for water supply.
- A 12 MW captive thermal power station is located in the factory premises.
6. FIRE PROTECTION:
- Managed by CISF with around 40 personnel and a host of latest fire fighting equipment and fire
tenders.
7. MANPOWER:
Total strength is 9904 as on 31.3.96 which includes around 3000 qualified Engineers and Technicians
(including substantial number of Post graduates), 5200 skilled artisans and the rest in other
categories.
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8. TOWNSHIP AND PERIPHERAL INFRASTRUCTURES:
* A large modern township for employees and allied personnel with social and welfare amenities.
* Medical: - Main Hospital (200 beds) 1
- Dispensaries in various 9
Townships sectors
- Occupational health centre 1
* Educational: No. of Schools (including 19
Intermediate levels)
Science Degree College 1
* Residential: Around 6780 quarters.
* Other amenities:
- Good Road network, Shopping Centres, Central Stadium, Community Centres, A Club, Police
Stations, CISF Complex for over 500 CISF personnel, Convention Hall (a most modern Air
Conditioned Auditorium with 1500 seating capacity) and Parks.
9. HEEP PRODUCT PROFILE:
* THERMAL AND NUCLEAR SETS
(Turbines, Generators, Condensers and Auxiliaries of unit capacity upto 1000 MW)
* HYDRO SETS INCLUDING SPHERICAL AND DISC VALVES
(Kaplan, Francis, Pelton and reversible Turbines of all sizes and matching generators and auxiliaries
maximum runner dia 6600 mm)
* ELECTRICAL MACHINES:
(For various industrial applications, pump drives & power station auxiliaries, Unit capacity upto
20000 KW AC / DC)
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* CONTROL PANELS
(For Thermal / Hydro sets and Industrial Drives)
* LARGE SIZE GAS TURBINES
(Unit Rating: 60-200 MW)
* LIGHT AIRCRAFT
* DEFENSE PRODUCTS
10. HEEP: FACILITIES AND INFRASTRUCTURE
Modernisation and regular upgradation / up gradation of facilities and other infrastructure is a
continuous endeavour at HEEP, BHEL. After initial setting up of the plant during the year 1964-72, in
collaboration with the Soviet Union, the plant facilities and infrastructures have since been continuously
upgraded under various investment projects viz, Stamping Unit Project, LSTG Project, Motor Project,
Governing Components Project, TG Facilities Modernisation, TG Facilities Augmentation, Quality Facilities
Augmentation, EDP projects, Gas Turbine Project, Facilities have also been added and establishments have
been created for new projects in Defence and Aviation Project. Additionally, R &D facilities have also been
created under Generators Research Institute, Pollution Control Research Institute, HTL modernization and
other such schemes.
Today the Plant has unique manufacturing and testing facilities, computerized numerically controlled
machine-tools, Blade shop, heavy duty lathes, milling machines, boring machines, machining centres and
many more. The Over Speed Vacuum Balancing Tunnel created for rotors upto 1300 MW (32T, 6.9 M dia
bladed rotor, 6 rpm upto 4500 rpm) is one of the 8 of its kind in the entire world.
The total spectrum of sophisticated, unique and other facilities at HEEP, Hardwar are the state-of-
the-art in manufacturing processes and can be utilized for a variety of products' manufacture.

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Brief Description of all the Blocks
Block I-
Block-I, also known as Electrical Machines Block, is designed to manufacture Hydro generators, Turbo
generators and large & medium size AC and DC machines. Testing facilities for Turbo generators, Heavy
motors and medium-size electrical motors are available in the Block itself. There is also a special Test Bed for
testing of turbo generators of capacity of 500 MW and above. Apart from facilities and equipment for
manufacture of turbo generators and electrical machines, the Block also has a Babitting Section. Babitting
of bearing liners for Turbo generators, Turbines, Hydro generators, AC Motors and DC Motors is carried out
in this section. The Block has its own over speed balancing installation; where the dynamic balancing of
Turbo generator-rotors of less than 500 MW rating is done. Rotors having higher rating are balanced in OSBT
of Block-III.
Fabricated components are received from fabrication blocks (Block-II, IV, VI, VIII), while other castings,
forgings are received from CFFP and other sources for Turbo generators, Hydro generators and Electrical
motors. Stampings are received from Stampings manufacture section; Block-VI and coils, bars, insulating
details and sheet metal components are received from Block-IV. These are then machined, assembled, tested
and dispatched.

Block II-
Block-II, also known as Fabrication Block, is a feeder block for various products- Steam Turbines, Hydro
Turbines, Turbo generators, Hydrogenerators, Electrical Machines, Apparatus and Control Gear, Aircraft and
SRGM (Smooth Recoil Gun Mounting). The main processes in this Block are cutting, bending and welding of
metal sheets etc. to form fabricated structures. The Block also has useful equipments like Hydraulic Bending
Presses and Straightening Rollers. Other notable facilities include a CNC six-spindle drilling machine, a
plasma-flame cutting machine, shot-blasting apparatus and various furnaces. The Block also has facilities for
NDT (Non Destructive Testing) of various components. The following Non-Destructive tests can be conducted
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DP Test (Die Penetration Test), MPI (Magnetic Particle Inspection), UT (Ultrasonic Testing) and Radiography
which includes X-ray and -ray testing.

Block IV-
Block-IV, also called as CIM&ACM (Coil and Insulation Manufacturing & Apparatus and Control Gear
Manufacturing), is a feeder block to Block-I. It is a feeder block for Class F windings for Turbogenerators,
Hydrogenerators and Class F and H insulation for AC and DC motors. It also supplies all insulation
components for Turbogenerators, Hydrogenerators, and motors. Control panels for Turbogenerators,
Hydrogenerators, Industrial drives for motors, and Turbogenerators auxiliaries, contactor relays and master
controllers are also manufactured in this Block.

Block V-
Block-V, also called as Fabrication and Forge Block is again a feeder block. Fabrication work being done in
this block is of Steam Turbine parts like Condenser, Water Box (Front and Rear), assemblies of LP cylinder,
Storage Tanks etc.; Hydro Turbine parts, Hydrogenerator and motor assemblies and components. Forging of
carbon, alloy and stainless steels are manufactured in this block. It is equipped with pneumatic hammers,
gas-fired furnaces and hydraulic manipulators.

Block VI-
Block-VI, also called as Fabrication Block, is also a feeder block. Manufacturing of all types of dies, including
stamping dies and press forms is carried out in one bay, while stamping for Turbogenerators,
Hydrogenerators and motors are manufactured in other bay. The Block is equipped with Welding, Drilling,
Shot Blasting and CNC Flame cutting facilities. The items manufactured in this block are Condensers, Steam
Turbine components (Oil Tanks and Hollow Guide Blades), Hydro Turbine components (Stay Rings),
Hydrogenerator and motors (Stator Frames) etc.

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Block VII-
Block-VII, also called as Woodworking section, is also a feeder block. Bay-I, known as Packaging section
manufactures packages for packaging and dispatch of various products. Bay-II manufactures wings (made of
Spruce wood) for Light Trainer Aircraft, Swati, manufactured by Aviation Group.

Block VIII-
Block-VIII, also called as Heat Exchanger Block, is designed to manufacture Heat Exchanger Units for Steam
Turbines, Hydro Turbines, Turbogenerators, Hydrogenerators etc. Blanks cut to size and shapes are received
from Block-II and Block-VI. These are assembled, welded and machined. The items manufactured here are
LP Heater, Ejectors, Gland Steam Coolers, Oil Coolers, Oil Tanks, Bearing Covers, Turbine shaft Covers, Oil
Bath, Thrust Bearings and stator frames of motors.
All blocks have a most modern and streamlined layout with mechanized material handling facilities like
inter-bay and inter-block transfer bogies, rail tracks connecting the main blocks with railway system, Electric
Overhead Travelling (EOT) cranes etc. An open gantry connecting all major manufacturing blocks for ease of
inter-block material movement is also provided.

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Bay wise description of Block III
Block III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and Turbine Blades. Special
tooling is also manufactured in the Tool Room located in the same block. Block III consists of four
bays viz. Bay-I, II, III and IV. It is therefore equipped with a large number of general purpose and
special purpose machine tools to do the machining jobs.
The following is the baywise description of the various machine tools in each of the bays:-

BAY-I:
Bay-I, earlier known as the Hydro turbine shop, is now known as HMS-I (Heavy Machine ShopI).
The various machines in this bay are as follows:

1. Horizontal Boring Machines (Layout No. 1-1, 1-2, 1-11, 1-14, 1-15, 1-28)
These are general purpose horizontal borers, mostly of Russian origin and have now been
retrofitted with DROs (Digital Read Out panels). Their capacity ranges from medium to heavy. A
large variety of operations e.g. boring, tapping, thread whirling on casings viz. HP, IP, ESV & CV etc.
is carried out on these machines. Also, many operations of Hydro turbine runner are carried out on
these machines.

2. CNC Horizontal Boring Machine (Layout No. 1-118)
This horizontal borer supplied by M/s. Skoda, Czech Republic is equipped with Sinumerik 850M
CNC system (Computer Numeric Control System). It has a travel of 12500 mm., has a table size of
4000*3500 mm. and can take a job weighing upto 60 tonnes. Heavier jobs like casings of HP, IP
modules are machined on this setup.

3. Vertical Boring Machines (Layout No. 1-10, 1-18)
These are also general purpose vertical borers, mostly of Russian origin and have now been
retrofitted with DROs. Their variety ranges from medium to heavy duty. Operations like contour
machining scrape milling of joint plane and machining of servomotor housings are carried out on
these machines.

4. Marking Table and Apparatus (Layout No. 1-5, 1-6)
Marking table is one of the most important apparatus, because the accuracy of marking and
subsequent machining depends on the marking table. The marking tables surface is flat upto 0.02
mm/metre and its flatness is to be certified from competent authority every two years. All the jobs
before being sent for machining are brought to this table for marking first.

5. Planer (Layout No. 1-20)
The planer is capable of providing a maximum cutting force of 10,000 kg. and is equipped with 4
tool heads, 2 each in vertical and horizontal directions. The machine is again of Russian origin, being
supplied by M/s. Yefremov Plant, Tiazhstankogidro, USSR.

6. DC Vertical Borer (Layout No. 1-4)
Also called as Universal Turning and Boring Mill, the machine has been supplied by M/s. Kolomna
Machine Tool Works, USSR and has now been retrofitted with DRO panel. It can accommodate a
workpiece of diameter upto 12500 mm. and weighing upto 200 tonnes. The maximum travel of
vertical tool heads from the center of table is 5200 mm.Large jobs like IP outer casing, water box,
condenser plates, runner of hydro turbines etc. are machined on this machine.
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7. Ram-Borers (Layout No. 1-112, 1-119)
These are horizontal boring machines, supplied by M/s. Skoda, Czech Republic. These are called
as Ram borers due to the fact that they have a high amount of rigidity built in the spindle. Due to
this construction, these machines can sustain huge amount of cuts. The spindle can traverse a
distance of 16000 mm. without being subject to cantilever effects. These machines can handle jobs
of weight up to 160 tonnes. Jobs like boring holes in Control Valves casing, Gas turbine combustion
chamber are done on these machines.

8. OT Platform (Layout No. 1-9)
It is a wooden platform used for overturning of heavy components.

9. Radial Boring machines (Layout No. 1-16, 1-7)
These machines have the added advantage over vertical boring machines that their arm can
swing, in a radius of upto 1500 mm. The spindle of these machines can move axially a distance of
500mm. These machines are portable in nature, and with the help of EOTs (Electrical Overhead
Travelling Cranes) maybe taken to the place desired.

10. Cylindrical Grinder (Layout No. 1-184)
This is a cylindrical grinder, supplied by M/s. National Economic Administrative District Machine
Tool Works, Kharkov, USSR. It has a swing of 800 mm. and can accommodate a job weighing upto 5
tonnes in weight. It is used for grinding stay vanes (of Hydro turbines) and also casings of
servomotors (of Steam turbines).

11. Deep Drilling Machine (Layout No. 1-105)
This again is a special purpose machine, of Russian origin and used for drilling holes in stay vanes
(of Hydro turbines).

This horizontal borer, supplied by M/s. Wotan, Germany is equipped with Fanuc 12M CNC
system. It has a special tool magazine, which can accommodate upto 40 tools. This machine is being
used for machining of control valves casings. The machine also boasts of an automated chip
removal system (conveyor belt type).

13. Centre Lathes (Layout No. 1-21, 1-22, 1-23)
These are general purpose center lathes, of Russian origin, used for machining of journals and
rotors of spherical and disc valves (of Hydro turbines), Guide vanes etc. These have now been fitted
with DRO control panels.

14. CNC Lathe (Layout No. 1-120)
This CNC lathe has been supplied by M/s. Ravensburg, Germany and is equipped with Sinumerik
820T CNC system. The lathe can accommodate a job of size upto 12000 mm. and 20 tonnes in
weight. It has 3 tool carriers. It is used to turn Tie Rods of Gas Turbine, which have very high
length/diameter ratio. Tie-Rod is a very long bolt (length approx. 10 meter & diameter 350 mm.)
which is used to assemble and hold the gas turbine rotor discs to form a composite turbine rotor.
The machine had been installed especially for machining of Gas turbine Tie-rods, but now is also
being used for machining of short rotors of Steam turbines (e.g. HP rotor). The machine also boasts
of an automated chip removal system (conveyor belt type).

21

15. Heavy Duty Lathe (Layout No. 1-29)
This Russian lathe has been manufactured by M/s. Karamatorsk Heavy Machine Tool Works,
USSR and is under NC control. While the maximum swing is 3200 mm., the distance between
centers is 16000 mm. This lathe is used for a variety of purposes ranging from machining of Hydro
turbine shafts to measurement of runouts of 210 MW Russian design LP rotors.

16. Assembly Beds (Layout No. 1-31, 1-41, 1-35)
These assembly beds are used for the assembly of Guide apparatus, stay ring, etc. of Hydro
turbines.

17. Pit for vertical assembly of Gas turbine rotors
The pit has a hydraulically lifted platform which can travel upto 10 metre in height to facilitate
access to different stages of the rotor. During assembly of Gas turbine rotors, utmost care is needed
to correctly match the Hirth Serrations on the discs face. The platform allows this to be achieved
with ease.

18. Combustion Chamber Assembly Platform
The combustion chamber of a Gas turbine has a metallic shell, lined on the inside by refractory
tiles. These tiles are fitted in the metallic shell in this 3-tier platform.

BAY-II:
Bay-II, earlier known as the Steam turbine shop, is now known as HMS-II (Heavy Machine Shop
II). The various machines in this bay are as follows:

1. Marking Table (Layout No. 2-187)
Marking table is one of the most important apparatus, because the accuracy of marking and
subsequent machining depends on the marking table. The marking tables surface is flat upto 0.02
mm/meter and its flatness is to be certified from competent authority every two years. All the jobs
before being sent for machining, are brought to this table for marking first.

2. Planer (Layout No. 2-189)
The planer, supplied by The Yefremov Plant, Tiazhstankogidro-Press, USSR, is the largest in India
of its type. It can traverse a distance of 12 metres and can accommodate jobs weighing upto 100
tonnes. It has 4 toolheads, 2 each in vertical and horizontal direction, which can provide a maximum
cutting force of 40 tonnes. The machine is powered by 2 motors, each of rating 130 kW and is used
for machining of HP and IP casings.

3. Precision Heavy Duty Lathe (Layout No. 2-181, 2-182, 2-186)
These lathes have been supplied by M/s. Karamatorsk Heavy Machine Tool Works, USSR and
have a swing of 2000 mm. The maximum distance between centers is 8000 mm. and these can
accommodate a job weighing upto 20 tonnes. These lathes are fitted with DRO control panels and
are being used for machining of HP and IP rotors (of 200, 210 MW Steam turbines).

This is the biggest lathe in entire BHEL Hardwar, and has been supplied by M/s. Hoesch-MFD,
Germany. Its distance between centers is 18000 mm. and it can accommodate a job weighing upto
320 tonnes. It is being used for machining for LP rotors (KWU Design) of 500, 200, 210 MW Steam
turbines. It is equipped with Sinumerik 7T CNC system and has three tool carriers. The machine also
boasts of an automated chip removal system (conveyor belt type).
22

This lathe has also been supplied by M/s. Hoesch-MFD, Germany and is equipped with Sinumerik
3T CNC system. Its distance between centers is 8000 mm. and it can accommodate a job weighing a
maximum of 110 tonnes. It is being used for machining of HP, IP rotors of 500, 200, 210 MW Steam
turbines (KWU Design).

6. Ram Borers (Layout No. 2-387, 2-317)
These are horizontal borers manufactured by M/s. Skoda, Czech Republic and have now been
retrofitted with NC Control system. These have the property of extremely rigid spindle arm, which
enables these machines to take a very heavy amount of cut, while at the same time maintaining
extremely high accuracy levels. The spindle arm has been so designed, so as to be unaffected by
cantilever effects, even over a traversing distance of 8000 mm. These machines are being used for
boring, tapping, thread whirling etc. operations on casings HP and IP.

7. CNC Stub Borer (Layout No. 2-420)
This horizontal borer supplied by M/s. Heyligenstaedt, Germany is equipped with Sinumerik 7T
CNC system. Its boring diameter ranges from 625 to 2500 mm. and it can take a job weighing upto
100 tonnes. To accommodate jobs of various sizes, its table rests on CI (Cast Iron) blocks, which
enable the table to be moved up and down. The machine has a very high degree of rigidity built in it
and cuts down the machining time to 25% of the time taken on conventional horizontal or vertical
borers. To control the surface properties of the job, and also to control the temperature rise (which
occurs due to heat build up caused by a large amount of cut), the entire setup is housed in an air-
conditioned chamber. It is being used for roughing of HP and IP inner casings. The machine is one of
the eight of its kind in the entire world.

8. Horizontal Boring Machines (Layout No. 2-185, 2-197, 2-198)
These are general purpose horizontal borers, mostly of Russian origin, and have now been
retrofitted with DRO control panels. Their capacity ranges from medium to heavy. Boring of holes in
HP and IP casings is done on these machines. Also the machining of Guide Blade carriers of Gas
turbines is being undertaken on these machines.

9. OT Platform
It is a wooden platform used for overturning of heavy components.

10. CNC Vertical Borer (Layout No. 2-328)
This vertical boring machine has been supplied by M/s. Homma, Japan and is equipped with
Fanuc 7T CNC system. It has a turning diameter of 4000 mm. and a maximum ram travel of 2200
mm. Machining of holes in HP and IP casings is done on these machines. Also the machining of
Guide Blade carriers of Gas turbines is being undertaken on these machines.

11. Kopp Milling machine (Layout No. 2-389, 2-390)
This milling machine has been supplied by M/s. Kopp, Germany and is being used exclusively for
machining of fir-tree roots in Steam turbine rotors. Fir-tree roots are being currently employed in LP
rotors of 500 MW and 200 MW rating. The machine is equipped with two milling heads that can be
used simultaneously without sacrificing accuracy. This is especially important because of the fact
that LP rotor, being double flow, is symmetrical about the central plane and thus machining of both
sides can be done simultaneously. The machine is fitted with a NC control system and is very
accurate. Fir-tree roots are being machined with the help of form cutters.
23

12. CNC Vertical Borer (Layout No. 2-422)
This vertical boring machine is of Japanese origin and has been supplied by M/s. Osaka Machines,
Japan. It is equipped with Fanuc 6TB, 3TC CNC system. The machine is capable of taking on jobs of
upto 70 tonnes in weight and has 2 boring heads, each of which has a travel of 2200 mm. in vertical
direction. The machine is being used for machining of inner casings of Steam turbines and guide
blade carriers of Gas turbines.
13. Band-Saw Machine
The machine has been recently acquired and has been supplied by M/s. Pehaka, Germany. The
machine is NC controlled and has a laser marking system built in. The machine is being currently
used for making slits in inner casings (to allow for stress-relieving).

14. CNC Vertical Boring machine (Layout No. 2-472)
The machine has been supplied by M/s. Schiess, Germany and is equipped with Sinumerik 850T
CNC system. It has a table diameter of 4000 mm. and max. turning height of 4200 mm. The ram
measures 300*250 mm. and it can take a load of upto 80 tonnes. The machine is being used for
machining of inner casings of Steam turbines and guide blade carriers of Gas turbines.

15. Rotor Assembly (Layout No. D-2)
The rotor assembly area is where the rotors are finally assembled. Here, the manufactured
blades from Bay-IV and the machined rotor are brought in. The fitting of blades and sealing strips
then takes place here.

16. Radial Drilling Machine (Layout No. 2-208)
This machine is portable in nature, and with the help of EOTs maybe taken to the place desired. It
is used for drilling holes in workpieces, as and when required.

17. Rotor Turning Device (Layout No. 2-211)
This machine has an electric motor installed in it and also a platform that can rotate by 90
0
. This is
being used for turning over blade discs of Gas turbine rotors. The rotor disc is picked up by an EOT
and placed on the platform which is in horizontal position. The platform is then rotated by 90
0
and
the disc taken out from the platform. It is now turned over and then placed back on the platform.
The platform is then returned back to its horizontal position. The disc can now by picked up by EOT
again, having been turned over.

18. Indicating Stand (Layout No. 2-412)
The fully bladed LP rotor of 500 MW turbine measures 3853.2 mm. at the point of maximum
diameter. This large a rotor cant even be accommodated on machine no. 2-360 (Sl. No. 4, Bay-II).
Therefore, for machining of shroud and measurements of runouts, this ingenious arrangement has
been made. In this arrangement, a headstock and tailstock have been paired with a flat surface. The
rotor is fixed in these and the tool-post is then calibrated. This arrangement is not very rigid and
thus, can be used only for taking very light cuts.

This horizontal borer has been supplied by M/s. Skoda, Czech Republic and it is equipped with
Sinumerik 850M CNC system. Its spindle diameter measures 200 mm. and it can take a maximum
load of 60 tonnes. This machine is being used exclusively for machining Gas turbine components
e.g. Casing, Bearing housing etc.

24

20. Gas turbine blading area
The Gas turbine blading area is being used exclusively for assembly of Gas turbine rotor discs and
Guide blade carriers. One of the machines, which has been recently acquired is used for caulking of
blades in discs. This machine is fully automated and the ram is hydraulically energized. Another
noteworthy machine here is Wax Melting Equipment. It is a low temperature electric furnace which
is used to mix and melt Wax and Colaphonium, which is required to arrest the blade movement
during the blade tip machining of stator blade rings.

21. CNC Facing Lathe (Layout No. 2-474)
This lathe which has been supplied by M/s. Ravensburg, Germany is equipped with Sinumerik
820T CNC system. It has a maximum turning length of 2000 mm. It is used basically for facing rotor
discs but can turn other components also. The machine also boasts of an automated chip removal
system (conveyor belt type).

22. Creep-feed Grinding machine (Layout No. 2-491)
This machine has been supplied by M/s. ElbSchliff, Germany and has been equipped with
Sinumerik 3GG CNC system. . This machine grinds the Hirth serration on rotor disc surfaces. Hirth
serrations are radial grooves teeth on both the faces of the rotor discs. Torque is transmitted
through these serrations, which are very accurately ground. The machines accuracy is of the order
of +/- 1 Arc/sec. and it can take a maximum load of 20 ton.

23. CNC Surface Broaching machine (Layout No. 2-485)
The machine has been supplied by M/s. MarbaixLapoint, UK and is equipped with Sinumerik
850M CNC system. It has a broaching capacity of 320 kN, and a broaching stroke of 10.3 meter with
a cutting stroke speed of 25 m/min. The machine has a very high accuracy of +/- 3 Arc/sec. It is used
to make groove on the outer diameter of rotor discs for the fitting of moving blades on the discs.
The machine is only one of the two of its kind in the world; with the other one being possessed
by M/s. Creusot-Loire, France.

24. Broach Sharpening machine (Layout No. 2-487)
This machine has been bought from M/s. Landriani, Italy and is equipped with Selca CNC system.
It can accommodate a workpiece of maximum diameter upto 250 mm. and length upto 200 mm.

BAY-III:
Bay-III is known as Governing and Light Machine Shop. The shop organization is described
below:

1. Bearings and Miscellaneous Parts Machining Section-
This section is equipped with small and medium size basic machine tools e.g. lathes, Milling
machines, Horizontal Borer, Vertical Borer, Drilling machine etc. for manufacture of bearings and
other miscellaneous parts of turbine. Here, machining of Torus/Spherical piece and spherical
support takes place, along with manufacturing of bearings from forging blanks.

2. Sealing and Diaphragm Machining Section-
It is equipped with medium size Vertical Boring, Horizontal Boring, Plaining, Drilling machines etc.
wherein castings of Sealing housings, Liner housings, Forgings of Rotor Discs, castings and fabricated
25

Diaphragms and components of camframes are machined. It is also equipped with CNC machining
center. Precision Horizontal Boring, Plano-Milling machines etc. are for manufacture of Governing
Casings, Servo Casings and other medium parts of governing and main Turbine assemblies.
One of the most important machining operations taking place in this section is the machining of
U and I sealing rings (used in Steam turbines). This is a technically demanding process because of
the fact that these rings are made of Mnemonic metals, which have Nickel content higher than
50%. Presence of such high amounts of nickel greatly reduces the machinability of these metals.
This problem is addressed by using extremely slow feed rates.

3. Governing Machining Section-
This section is equipped with medium size and small size lathes, CNC lathes, Milling, Grinding
(Internal, External and Surface), Drilling, Slotting and Honing machines. Governing assembly parts
are machines here. Honing of valve spindles as well as their superfinishing also takes place in this
section.

4. Diaphragm and Governing Assembly Section-
It is equipped with deflection testing equipment for Diaphragms, Dynamic Balancing machine for
balancing impeller of centrifugal oil pumps and small fittings and assembly equipment. Governing
test stand is equipped with facilities like Oil pumping unit, Pressure receiver, Servomotor,
Overspeed testing of Emergency governor.

5. Light Machine Shop-
In addition to normal conventional machine tools, it is equipped with CNC lathes, CNC milling,
CNC Vertical Boring, precision milling, planetary grinding machines etc. for the manufacture of small
and medium precision of governing and other turbine parts.
Inconel (alloy having Nickel content higher than 65%) components machining also takes place
in this section. These Inconel components are used in Gas Turbines.

26

Block III Turbine and Auxiliary Block
Block III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and Turbine Blades. Special tooling
are also manufactured in the Tool Room located in the same block.

The Block consists of 4 Bays, viz. Bay-I and II of size 36X378 metres and 36X400 metres respectively and
Bay-III and IV of size 24X402 metres and 24X381 metres respectively. The Block is equipped with the facilities
of Electric Overhead Travelling (EOT) Cranes, compressed air, Steam, Over speed Balancing Tunnel (OSBT),
indicating stand for Steam turbine rotors, one Test stand for testing 210 MW steam turbines Russian design,
one Test stand for Hydro Turbine Guide Apparatus and two separate Test Stands for the testing of Governing
Assemblies of Steam and Hydro Turbines.

MANUFACTURING FACILITIES
1. HYDRO TURBINES
For manufacturing of Hydro Turbines, Bay-I has the following sections:
(a) Circular Components machining Section-
This section is equipped with a number of large/heavy size Horizontal and Vertical Boring Machines,
Drilling Machines, Centre Lathes, Marking Table and Assembly Bed. The major components machined in this
section are Spiral Casing with Stay Ring, Spherical and Disc Valve bodies and Rotors.
(b) Runner and Servo Motor Housing Machining Section-
This section is equipped with NC/CNC and conventional machines comprising Heavy and Medium size
Vertical and Horizontal Boring Machines, Centre Lathes, Grinding machines and Drilling machines, Marking
Table, Assembly Bed, Assembly Stands for Steam Turbine and Gas Turbine assemblies and wooden platform
for overturning heavy components.
Hydro Turbine Runners, Servomotors, cylinders, Labyrinth Ring, Regulating Ring, Stay Ring, Turbine Cover,
Lower Ring, Kaplan Turbine Runner Body and Blades are machined here.
Steam Turbine components like cylinders and rotors along with Gas Turbine components like
Combustion chamber outer casing, Flame Tube, Dome, Tie-rod, Guide Blade carriers and Bearing
Pedestals are also machined in this section.

(c) Guide Vanes and Shaft Machining Section-
This section is equipped with Heavy Duty Lathes up to 16 metres bed, CNC turning machines, Horizontal
Boring Machine, Heavy Planer, Deep Drilling Machine, Boring Machines and Assembly Beds. Turbine shafts,
Guide Vanes, Journals and Rotors of Spherical and Disc valves are machined here. Rotors of Steam Turbines
are also machined in this section.
(d) Assembly Section-
In this section, assembly and testing of Guide Apparatus, Disc Valves, Spherical Valves, Servomotor shaft
and combined boring of Coupling Holes are done.
(e) Preservation and Packing Section-
Final preservation and packing of all the Hydro Turbine components/assemblies is done here.
27

(f) Small components machining Section-
This section is equipped with Planetary Grinding machine, Cylindrical Grinding machine, Small size
lathes, Planers and Vertical and Horizontal Boring machines. Small components like Bushes, Levers,
Flanges etc. and Governing Assemblies are machined here.

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

2. STEAM TURBINES
The facilities and parts manufactured in the various sections of Steam Turbine manufacture are as follows:
Turbine casing machining Section-
It is equipped with large size Planer, Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and
Vertical Boring machines etc. Fabrication work like casings, pedestals etc. are received from Fabrication Block
II.
Rotor Machining Section-
It is equipped with large size machine tools like Turning Lathe, CNC Lathes, Horizontal Boring machines,
special purpose Fir-Tree Groove Milling machine etc. Some rotor forgings are imported from Russia,
Germany, and Italy etc. And some are indigenously manufactured at CFFP, BHEL, and Hardwar.
(a) Rotor Assembly Section-
This is equipped with Indicating Stand; small size Grinding, Milling, Drilling machines, Press and
other devices for fitting Rotors and Discs. Machined Rotor, discs and Blades are assembled here.
Balancing and Over speeding of Rotor is done on the dynamic balancing machine.

(b) Turbine Casing Assembly Section-
Machined casings are assembled and hydraulically tested by reciprocating pumps at two times
the operating pressure.

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

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

(e) Bearings and Miscellaneous Parts Machining Section-
This section is equipped with small and medium size basic machine tools e.g. lathes, Milling
machines, Horizontal Borer, Vertical Borer, Drilling machine etc. for manufacture of bearings and
other miscellaneous parts of turbine.

28

(f) Sealing and Diaphragm Machining Section-
It is equipped with medium size Vertical Boring, Horizontal Boring, Planing, Drilling machines etc.
wherein castings of Sealing housings, Liner housings, Forgings of Rotor Discs, castings and fabricated
Diaphragms and components of cam frames are machined. It is also equipped with CNC machining
centre.
Precision Horizontal Boring, Plano-Milling machines etc. are for manufacture of Governing
Casings, Servo Casings and other medium parts of governing and main Turbine assemblies.

(g) Governing Machining Section-
This section is equipped with medium size and small size lathes, CNC lathes, Milling, Grinding,
Drilling, Slotting and Honing machines. Governing assembly parts are machines here.

(h) Diaphragm and Governing Assembly Section-
It is equipped with deflection testing equipment for Diaphragms, Dynamic Balancing machine for
balancing impeller of centrifugal oil pumps and small fittings and assembly equipment. Governing
test stand is equipped with facilities like Oil pumping unit, Pressure receiver, Servomotor, Over
speed testing of Emergency governor.

(i) Light Machine Shop-
In addition to normal conventional machine tools, it is equipped with CNC lathes, CNC milling,
CNC Vertical Boring, precision milling, planetary grinding machines etc. for the manufacture of small
and medium precision of governing and other turbine parts.

3. GAS TURBINES
All the components of Gas Turbine are machined and assembled using the facilities available for
manufacturing of Steam and Hydro turbines except the following facilities which are procured
exclusively for the manufacturing of Gas Turbine and are installed in the areas specified for Gas
Turbine manufacturing:

(a) Hydraulic lifting Platform-
This facility is used for assembly and disassembly of G.T. rotor. This is a hydraulically operated
platform which travels upto 10 meter height to facilitate access to different stages of rotor. This is
installed in Bay-I assembly area.

(b) CNC Creep Feed Grinding Machine-
This is installed in Gas Turbine machining area Bay-II extension. This machine grinds the hirth
serration on rotor disc surfaces. Hirth serrations are radial grooves teeth on both the faces of the
rotor discs. Torque is transmitted through these serrations, which are very accurately ground.
(c) External Broaching Machine-
This machine is installed in G.T. machining area and is used to make groove on the outer diameter
of rotor discs for the fitting of moving blades on the discs.

(d) CNC Facing Lathe-
This machine is installed in G.T. machining area and is used basically for facing rotor disc but can
turn other components also.

(e) CNC Turning Lathe-
This machine is installed in Bay-I Heavy Machine Shop and is used to turn Tie Rods of Gas
Turbine, which have very high length/diameter ratio. Tie-Rod is a very long bolt (length approx. 10
29

meter & dia. 350 mm.) which is used to assemble and hold the gas turbine rotor discs to form a
composite turbine rotor.

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

(g) Gas Turbine Test Bed-
This test bed is installed near the Gas Turbine machining area in Bay-II. This facility is used to
finally assemble the gas turbine. Combustion Chambers are not assembled here, which are
assembled with main assembly at the site.

(h) Combustion Chamber Assembly Platform-
This facility is a 3-tier platform installed in Bay-I assembly area and is used for assembly of
Combustion Chambers of Gas Turbine.

30

Blade Shop
Introduction:
Major part of Turbine Blade Machining Shop is located in Bay-IV of Block-III. In this shop various
types of Steam Turbine and Gas Turbine Compressor blades are machined from bar stock, drawn
profile, precision and envelope forgings. It is a batch production shop comprising of various kinds of
CNC Machines and Machining Centres, besides various special purpose and general purpose
machines. The layout of equipments is as per technological sequence of the manufacturing process.
Blade shop implements various On Line Quality Control Techniques through Run Charts and Control
charts. This shop is divided into four distinct areas. Details of facilities are given in various schedules
of Section-II.
2. Manufacturing Facilities:
i) Plain Milling Section
It prepares accurate reference surfaces on the blade blanks by milling and grinding
operation. It also manufactures the brazed type blades by induction brazing of drawn profile
and suitably machined spacers. This section carries out banking by Band Saws, rhomboid
grinding on Duplex grinding machines and thickness grinding on Surface grinders.
ii) Copy Milling Section
The Semi blanks prepared from plain milling section are further machined by copy Milling
Machines / CNC machines (CNC Heller and BSK Bed type Klopp, BFH / BEK Knee type
Machines) for concave and convex aero-dynamic profile forms, (HTC-600, BFK Machines) for
expansion angles, Compound taper grinding of radial plane is carried out by Surface grinders.
It comprises of T-root machining centres for machining of T-root.
iii) LP Section
This area deals with all types of free standing and forged blades for steam Turbine
Compressor. The free standing blades are cerrobend casted in boxes to hold the blade with
respect to the profile. These blades roots are subsequently machined on NTH, MPA-80A and
31

T30 Machining Centres. There is a five station 360
o
circular copy milling machine for
machining the profile of envelope forged blades / stocks for Steam Turbine and Gas Turbine
Blades. It also has 3D copy Milling and CNC Machines with digitizing features for Tip-thinning,
Fitted milling. The inlet edge of the last stage of Low pressure Turbine Moving blades are
hardened on Special Purpose Flame Hardening equipment.
iv) Polishing Section
Blade Contours are ground and polished to achieve the desired surface finish and other
aerofoil requirements.
There are also other small sections e.g. Fitting Section, Tool and Cutter Grinding, Tooling
Repair Section in Blade Shop.
v) Inspection Device
- 3 D Coordinate Measuring Machines for taper and rhomboid checking.
- Moment weighing Equipment
- Real time Frequency analyzer for checking frequency of free standing blades.
- Contour plotter for plotting of blade profile with various magnifications.
- Fir tree root inspection device.
- Magna spray crack detection equipment.
vi) Miscellaneous
There are other important facilities e.g. High rack storage system for fixtures. Compactor
system storage for finished blades. Jib cranes and EOT cranes for material handling. The semi
finished batches of blades are kept in special boxes for inter-operation movements. An AGV
(Automated Guided Vehicle) is also located in LP Section of Blade Shop for better material
movement.

32

3.0 MANUFACTURING PROCESS
The manufacturing process of turbine blades primarily depends on the type of blade e.g. Bar type,
Brazed type, free standing (Forged type), Gas Turbine Compressor blades. The bar type and brazed
type blades are also known as drum stage glades. The manufacturing technology of each of these
blades along with recommended machine tools / equipment is furnished below.
3.1 BAR TYPE BLADES
PROCESS / OPERATION MACHINE TOOL/EQUIPMENT USED
i. Blanking of area material Circular saw/band saw
ii. Sizing to rectangular shape Hor. Milling Machine
iii. Thickness grinding Surface grinder
iv. Rhomboid milling Duplex milling machine
v. Rhomboid grinding Duplex grinding machine
vi. Milling perpendicularity on both ends Hor. Milling machine
vii. Milling radius on surround Hor. Copy milling m/c
viii. Finish milling of convex and
concave profile
Hor. Copy milling / CNC
Hor. Milling machine
ix. Milling expansion faces of convex
And concave sides at root and shroud
Hor. Copy milling m/c/
CNC milling m/c
x. Root slot/root chamfer and
Radit at root and shround
Milling
2 spindle T-root roughing, m/c and
root radius copy milling m/c, T-root
machining centre
xi. Taper grinding Surface grinder
33

xii. Grinding and polishing of profile
And expansion faces
Abrasive belt polishing m/c
xiii. Final Rounding, chamfering etc. Manual fitting.
3.2 BRAZED TYPE BLADES
i. Cutting of drawn profile & spacer blank Hor. Milling machine
ii. Sizing to rectangular shape Hor. Milling machine
iii. Thickness grinding Surface grinder
iv. Rough and finish milling of internal profile
of spacer
Hor. Milling machine
v. Cutting-off spacer Abrasive cutting
vi. Brazing of drawn profile and spacer Right frequency inducting brazing installation
vii. Milling of width Duplex milling machine
viii. Pin rough and Root slot Vert. Milling m/c
ix. External profile rough and finish machining Hor. Milling machine
x. Pin turning Pin turning lathe
xi. Grinding and polishing Abrasive belt polishing m/c
xii. Debarring and rounding Manual fitting

34

3.3 FREE STANDING BLADES
i. Grinding of ref. Belts Abrasive belt polishing
ii. Milling of inlet & outlet edge 3D Vert. Copy milling m/c
iii. Center hole drilling CNC machining Centre
iv. Encapsulating with cerrobend alloy Cerrobend casting equip.
v. Re-melting of cerrobend alloy Fir-tree root machining center
vi. Re-melting of cerrobend alloy Cerrobend casting equip.
vii. Machining of fillets Vertical 3D copy milling machine
viii. Grinding and polishing Abrasive belt polishing
ix. Cutting-off blade tip Abrasive cutting machine
x. Inlet edge hardening Frame hardening equip. (if required)
xi. Blade tip rounding Vert. 3-D copy milling m/c
xii. Tip thinning (if reqd.) -do-

35

3.3 GAS TURBINE BLADES
i. Cerrobend casting Cerrobend casting equip.
ii. Root machining Hor. Machining center
iii. Re-melting of cerrobend alloy Cerrobend casting equip.
iv. Profile checking Vert. Stand
v. Length cutting Circular saw/hor. Milling m/c
vi. Tenon Hor. Milling m/c
vii. Grinding and polishing of fillet Abrasive belt polishing m/c

36

Broad Specification of Major/Important Machine Tools
and Machines
A: CNC MACHINE TOOLS
CNC HORIZONTAL BORERS:
1. Item Description : CNC Horz. Borer
Model : RAPID 6C
Supplier : WOTN, GERMANY
CNC Control System : FANUC 12M
Spindle Dia. : 200mm
Table : 4000 x 4000 mm
Max. Load on Table : 100 T
Travers : X=20000, Y=5000, X=1400mm
Ram traverse : W = 1000 mm
Ram size : 400 x 400 mm
Power Rating : 90 KW
Weight of the m/c : 111 T
ATC Capacity : 60 Nos.
Plan No. : 1-227 (Block-I)

2. Item Description : CNC Stub Borer
Model : DW 1800
Supplier : HEYLIGENSTAEDT, GERMANY
CNC Control System : SINUMERIK 7T
Boring Dai : 625 2500 mm
Table : 4000 x 4000 mm
Headstock Travel : 4000 mm
Spindle Speed : 0.5 90 RPM (in 4 Steps)
37

Max. Load Capacity : 100 T
Weight of the m/c : 72 T
Plan No. : 27-420 (Block-III)
3. Item Description : CNC Horz. Borer (2 Nos.)
Model : W200 HB NC
Supplier : SKODA, CZECH
CNC Control System : SINUMERIK 850 M
Spindle Dia. : 200 mm
Traverse : X=12500,
Y=5000,
Z=2000mm

CNC LATHES
4. Items Description : CNC Centre Lathe
Model : D-1800 NYF
Supplier : HOESCH MFD, GERMANY
Centre Distance : 8000 mm
Swing Over Carriage : 1800 mm
Swing Over Bed : 2400 mm
Spindle Speed : 0 125 RPM
Weight of the Job : 110 TON
Weight of the m/c : 124 TON

5. Item Description : CNC Centre Lathe
Mode : D-2300 NYFS-1
Supplier : HOESCH MFC, GERMANY
38

Spindle Speed : 5 125 RPM
Weight of the job : 320 TON
Weight of the m/c : 216 TON
6. Item Description : CNC Centre Lathe
Model : KV2-1100 CNC
Supplier : RANVENSBURG, GERMANY
CNC Control System : SINUMERIK 820 T
Centre Height : 900 mm
Max. Turning Length : 12000 mm
Spindle Speed : 2-600 RPM
Longitudinal Cutting Feed (Z-Axis) : 1-5000 mm / min.
Transfer Cutting Feed (X-Axis) : 1-5000 mm/min.
Main Spindle Drive Motor : 95.5 KW DC
Max. Feed Force Z/X Axis : 45000 N
No. of Tool carriers : 3

CNC MILLING MACHINES
7. Item Description : CNC Horz. Milling M/c (6 Nos.)
Model : BFH-15
Supplier : BATLIBOI, INDIA
39

Table : 1500 x 400 mm
Traverse : X=1170 mm
Y=420 mm
Z=420 mm
Spindle Speed : 45 to 2000 RPM
Max. Load Capacity : 630 Kg
Weight of the m/c : 4200 Kg
Plan No. : 2-449, 2-453, 2-454, 2-459, 2-460 (Block-
III:TBM)

8. Item Description : Universal Milling M/cs (2Nos.)
Model : BFK-15
Supplier : BATLIBOI, INDIA
Table : 1500 x 400 mm
Traverse : X=1170 mm
Y=420 mm
Z=420 mm
Spindle Speed : 45-2000 RPM
Max. Load Capacity : 630 Kg
Weight of the m/c : 4200 Kg
Plan No. : 2-463, 2-466 (Block-III: TBM)

9. Item Description : CNC Bed Type Milling M/c
Model : FSQ 80 CNC
40

Supplier : TOSKURIM, CZECH
Table : 3000 x 800 mm
TEE SLOT 28H7
Traverse : X= 3000 mm
Y= 870 mm
Z= 850 mm
Spindle Speed Range : H 2500 RPM
Spindle Drive Power : 18 KW continuous
22 KW intermittent
Spindle Head Size : 620 x 500 incldg ram
543 x 420 encldg ram
Table Load : 2500 Kg

CNC MACHINING CENTRES
10. Item Description : SPL. Purpose 6 Station T-Root Machining Centre (2nos.)
Supplier : MIH, JAPAN
CNC Control System : FANUC 7M
Indexing Table : 1900 mm dia
Indexing Position : 6 Nos.
Plan No. : 2-356, 2-41 (Block-III: TBM)

11. Item Description : SPL Purpose FIR Tree Root M/cing Cenre
Model : NTH 200
Supplier : RIGID, SWITZERLAND
CNC Control System : SINUMERIK 7M
41

Table : 1400 x 1400 mm
Traverse : X= 1950 mm
Y= 900 mm
Z= 600 mm
Spindle Speed : 30600 RPM
No of Spindle : 4
Plan No. 2-354 (Block-III TBM)

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

13. Item Description : CNC Vertical Borer (2 Nos.)
Model : 40 DZ
Supplier : SCHIESS, GERMANY
42

CNC Control System : SINUMERIK 850 T
Table : 4000 mm
Max. Turning dia : 5000 mm
Max. Turning Height : 4200 mm
Ram size : 300 x 250 mm
Table Speed : 0.63 63 RPM
Max. Vertical Travel of Ram : 2200 mm
Table Load Carrying Capacity : 80 T
Plan No. : 1-235 (Block-I), 2-472 (Block-III)

14. Item Description : CNC Vertical Borer
Model : 32 DS 250
Supplier : SCHIESS, GERMANY
Table : 2500 mm
Table Load Carrying Capacity: 25T
Max. Turning Dia : 3200 mm
Max. Turning Height : 2200 mm
Ram Size : 210 x 250 mm
Max. Travel of Ram : 1400 mm
Table Speed : 0.8 160 RPM

OTHER SPECIAL PURPOSE CNC MACHINES
15. CNC SURFACE BROACHING M/C
Make : Marbaix Lapointe, UK
43

Model : Champion 32 /10, 300
CNC System : SINUMERIC 850 M
Broaching capacity (pulling force) : 320 KN
Broaching slide stroke : 10.3 mm
Broaching slide width : 1500 mm
Max tool length (continuous /row) : 9650 mm
Broaching Speed (cutting stroke) : 1-25 M/min
Broaching Speed (return stroke) : 60 M/min
Drive power rating : 135 KW
Broaching slide movement : Electro-mechanical
Maximum noise level : < 80 Dbs
Max. dia of the disc (mountable) : 2300 mm
Max. weight of the job : 3000 Kgs
Indexing & rotating tables | : 1500 mm, 1000 mm
Indexing accuracy : +/- 3 Arc sec.
Plan No. : 2-485

16. CREEP FEED GRINDING M/C
Make : ELB CHLIFE, GERMANY
Model : ELTAC SFR 200 CNC
CNC System : SINUMERIC 3 GG
Work-piece diameter : 200 2000 mm
Work height : 2400 mm
Rotary & indexing table dia. : 2050 mm
Indexing accuracy : +/- 1 ARC SEC
Max. load capacity : 20000 KG
Y-axis (grinding head movement)
Vert. Traverse : 750 mm
44

Z- axis (grinding head support)
Movement on cross rail)
Horizontal traverse : 2400 mm
Traverse feed rate : 02 1200 mm /min
Grinding head main support
Drive motor : 34 KW
Grinding wheel max. dia. : 500 mm
Max. width : 100 mm
Bore : 203.2 mm
Surface speed : 16-35 M/Sec.
Plan No. : 2-491

17. BROACH SHARPENING M/C
Make : LANDRIANI, ITALY
CNC System : SELCA
Work-piece diameter : Upto 250 mm
Work Length : 200 mm
Plan No. : 2-487

B: NON-CNC MACHINE TOOLS
(1) PRECISION HEAVY DUTY LATHE
Manufacturer: Karamatorsk Heavy Machine Tool Works (USSR); Model KS-1614
Specifications
1. Maximum Swing 2000mm
2. Maximum Diameter of work piece over the Saddle 1500 mm
45

3. Maximum Distance between Centres 8000mm
4. Diameter of Spindle bore 80 mm
5. Maximum Taper when machining by the method of Combined Feeds 0.15 mm
6. Maximum Length between Centres when machining by the method of
Combined Feeds
1200 mm
7. Maximum Weight of work piece 20000 kg
8. Maximum Length of Machine over the Saddle 8000 kg
9. Maximum Summary Effort of Cutting 10,000 kg
10. Limit Dimension of Thread Cut:
Thread Pitch Max Length of Thread,
Min Max mm
Metric Thread Pitch (in mm) 1 96 6300
British Thread Pitch (Per inch) 20 3/8 6300

Name of Part Power Displacement in mm

Manual Per Rev. of Dial
One Division
Of Dial
Represent
Rapid
Traverse
M/min
Carriage 2.02
46

Transverse Slide 1130 1130 8 0.1 mm 1.03
Longitudinal Slide 600 600 6 0.1 mm 0.48
Tool Slide 150 6 0.1 mm -
Rotary Part 90
o
5
o
0.5 -
Maximum Displacement of the Tailstock Spindle 260 mm
Maximum Transverse Displacement of the Tailstock 17 mm
Rotating Built in Centre Available
Power Extraction of the Tailstock Spindle Available
Rapid Traverse of the Tailstock 3.44 M/min
12. Overall Dimension:
Length 13900 mm Width 3845 mm Height 2865 mm
13. Plant No. 2-182 (Block-III)
UNIVERSAL VERTICAL TURNING & BORING MACHINE
Manufacturer: Kolomna Machine Tool Works (USSR)
Model KY 152
Specifications
1. Maximum Dia. of work piece accommodated 10000/12500 mm
2. Dia. of central table 8750 mm
3. Maximum travel of vertical Tool Heads from centre of table 5250 mm
4. Maximum weight of work piece accommodated on central table
47

(a) With table speed limited to n (n s 6) r.pm. 200 T
(b) At any speed 100 T
5. Maximum cutting force with different length of tool over-hang (L) from head face R.H. Head
16000 Kg with Ls 1500 mm
7500 Kg with L s 2000 mm
L.H. Head
12500 Kg with Ls 1500 mm
6. Rated cutting dia on central table 6300 mm
7. Maximum cutting torque on central table 80000 Kg.M
8. Speed range of central table rotation Minimum = 0.112 r p.m.
Maximum 11.2 r.p.m.
9. Travel rate of column assembly 190 mm /minute
10. Plan No. 1-13 (Block-I)
1-24 (Block-III)
BALANCING MACHINE
Manufacturer: SCHENK (West Germany)
Model: Dj 90
48

Specifications
1. Weight of rotor 10,000 to 80,000
kg
2. Minimum weight without considerable loss of measuring sensitivity
provided the bearings can accommodate such small rotors.
5000 kg
3. Maximum weight for one bearing pedestal 45,000 kg
4. Height of rotor axis above machine bed 1600 mm
5. Rotor diameter (free swing over machine bed) not considering the funnel 4000 mm
6. Diameter of journal Max. 540 mm
7. Diameter of journal, with special sleeve bearing cups made from high
grade material.
Max. 600 mm
8. Minimum distance between bearings for less than 10 tons rotor 1500 mm
9. Minimum distance between bearings for more than 10 tons rotor 1900 mm
10. Maximum distance between coupling plague and center of the second
bearing pedestals
13500 mm
11. Rotational Speeds Min. 800 rpm
(a) For rotors from 5 to 10 tons Max. 4000 rpm
Min. 700 rpm
(b) For rotors from 10 to 20 tons Max. 3600 rpm
49

Min. 600 rpm
(c) For rotors from 20 to 80 tons Max. 3600 rpm
12. Maximum test speed and over speeds
(a) For rotors up to 50 tons
(b) For rotors up to 50 to 80 tons
4500 rpm
3600 rpm
13. Maximum centrifugal force admissible on each bearing pedestals for short
period of time
50,000 Kg
14. Balancing accuracy to be obtained depending on Selling Weight 0.3 to 3 micron
15. Sensitivity of indication depending on rotor weight, speed and selling
weight
0.1-8 div/micron
16. Accuracy of the angle indication 1
o
2
o

17. Stiffness of bearing pedestals, when mounted on machine bed
(a) With unclamped bearings 1.2 Kg/micron
(0.85 micron/Kg)
(b) With clamped bearing 100 Kg/micron
(0.01 micron /Kg).
SPECIAL DRILLING & BORING MACHINE
Manufacturer: Machine Tool Works, Ryazan (USSR)
Model: PT 182 H5
50

SPECIFICATIONS:
1. Swing over bed 800 mm
2. Drilling dia 40-80 mm
3. Boring dia 80-250 mm
4. Swing of job in rest Max
Min
300 mm
110 mm
5. Swing of job in
Headstock chuck
Max.
Min.
300
110 mm
6. Maximum length of job 3000 mm
7. Maximum weight of job 2000 Kg
8. Number of spindles Headstock
Stem stock
1
1
9. Spindle location Horizontal
10. Distance to spindle axis: From bed wasy
From floor
400 mm
1100 mm
11. Head stock Spindle speed Max
Min.
750 r.p.m.
71. r.p.m.
Number of steps of spindle speed
Spindle braking
24
Available
12. Stem stock Spindle speeds Max.
Min.
730 r.p.m.
123 r.p.m.
51

Number of steps of spindle speed
Stem stock feed

Max.
Min.
6
1680 mm / min
168 mm / min
Number of feed steps Step less
13. Overall dimensions
Length 13500 mm
Width 2300 mm
Height 1700 mm
Weight 23844 Kg.
14. Plan No 1-105 (Block-III)

SPECIAL INTERNAL GRINDING MACHINE
Manufacturer: Saratov Machine Binding Works (USSR)
Model: MB 6020 T
SPECIFICATIONS
1. Diameter of ground holes
(a) Maximum
(b) Minimum
320 mm
90 mm
2. Maximum length of grinding (with maximum hole diameter) 560 mm
52

3. Maximum weight of work 600 Kg
4. Distance from spindle axis to floor level 1100 mm
5. Distance from spindle axis to table
(a) Maximum
(b) Minimum
300 mm
100 mm
6. Cantilever vertical travel
(a) Per one revolution of hand wheel 0.133 mm
(b) Speed of rapid vertical traverse (from motor) 190 mm / min.
(c) Per dial graduation 0.01 mm
7. Table working surface dimensions 500 x 1200 mm
8. Table cross-traverse
(a) To operator from intermediate (zero) position 200 mm
(b) From operator from intermediate (zero) position 200 mm
(c) Total 400 mm
(d) For one revolution of hand wheel 0.2 mm
(e) For one dial graduation 0.01 mm
(f) Speed of rapid traverse (from motor) 280 mm / min
53

UNIVERSAL THREAD GRINDING MACHINE
Manufacturer: Moscow Jig Boring Machine Plant (USSR)
Model: 5822B3
SPECIFICATIONS
1. Maximum diameter of work admitter 160 mm
2. Nominal diameter of thread being ground Min
Max
25 mm
125 mm
3. Thread pitch Min
Max
0.5 mm
6 mm
4. Maximum length of thread being ground,
(a) By single-ribbed wheel 75 mm
(b) By multiple ribbed wheel 55 mm
5. Maximum taper of thread: 1
o
47' 24"
or 1:16
6. Table
Maximum longitudinal table traverse,

(a) By hand 425 mm
(b) By power 415 mm
54

Table rapid withdrawal speed (variable:
maximum
about 1.2 m/min)
7. Taper
(a) Headstock spindle MT 4
(b) Tailstock spindle MT 5
8. Grinding Wheelhead
Maximum cross feed

(a) By hand 125 mm
(b) By power 50 mm
Movement per dial division 0.005 mm
Movement per dial revolution 1 mm
PLANER
Manufacturer: The Yefemov Plant TIAZHSTANKOGIDRO-PRESS (USSR)
Model: 7A288-T
SPECIFICATIONS
1. Max. width of planning 4000 mm
2. Max. height under cross rail 4000 mm
55

3. Distance between housings 4250 mm
4. Max. travel of slides below cross rail and inside housing
(a) for vertical tool heads 700 mm
(b) for side tool heads 700 mm
5. Max. allowable weight of work piece 100 T
6. Max. cutting force
Arrangement for mechanizing and automating the machine operation is
available
40000 Kg.
7. Table
Dimension of working surface of table,
(a) Width 3600 mm
(b) Length 12000 mm
Table Stroke, Max. 12000 mm
Min. 3000 mm
Safety devices to stop table after worm disengaging. Available.
8. Tool Heads
Number of tool heads (a) Vert. 2
(b) Side 2
Travel of tool heads, mm. V.Tool Side Tool Heads
Heads R.H. L.H.
56

(i) Max. vertical travel 700 3750 3750
(ii) Max. horizontal travel 5000 700 700
(iii) Travel per turn of hand-wheel lever, (in mm)
Vertical travel 1.14 4.25 4.25
Horizontal travel 0.52 1.14 1.14
(iv) Dial division value
Vertical

0.1

0.2

0.2
Horizontal 0.2 0.1 0.1
(v) Rapid travel
Speed mm

Vertical 1.25 2.5 2.5
Horizontal 2.5 1.25 1.25

9. Cutter Head:
(i) Max. dimension of tool holder Vertical Side
Tool head Tool head
(a) Width 120 mm 120 mm
(b) Height 120 mm 120 mm
(ii) Max. angle of slide Swivelling
57

(a) To the right 60
o
45
o

(b) To the left 60
o
45
o

(iii) Dial division value 10 10
(iv) Swivelling of cutter head plate 10
o
10
o

(v) Cutter head automatic lifting during return stroke of
table
Available Available
10. Cross Rail:
Maximum travel 4000 mm
Rapid travel speed Not less than 0.3 M/min
Time of cross rail automatic fixing 20 to 30 sec.
Main drive motor 2 x 130 KW
11. Plan No. 2-189 (Block-III)

58

Material Specifications
X
20
Cr 13
A. 13% Cr. Stainless Steel Bars (Hardened & Tempered)
1. General : This specification governs the quality of stainless steel bars of
grade X
20
Cr. 13
2. Application : For machining of moving and guide blades of steam Turbine.
3. Condition of Delivery : Hot rolled / Forged & hardened and tempered. The bars shall be
straight and free from waviness.
4. Complete with standards: There is no Indian standard covering this material.
5. DIMENSIONS & TOLERANCES:
Dimension : Bars shall be supplied to the dimensions specified in the purchase
order unless otherwise specified in the order. The bars shall be
supplied in random length of 3 to 6 meters with a maximum of
10% shorts down to meter.
Forged bars shall be supplied in length of 1.5 to 3 meters.
Tolerance : The tolerance on cross sectional dimensions shall be as per table.
5.1. Hot Rolled Bars : Tolerance on hot rolled flat bars shall be as specified below:

"b" width across flates mm Allowable deviation on "b"
mm
"s" thickness mm Allowable deviation
on 'S' mm
Up to 35 + 1.5 Up to 20 +1
59

Over 35 and Up to 75 + 2 Over 20 and Up
to 40
+ 2
Over 75 + 3 Over 40 + 3
Note: Other tolerances shall be as per DIN 1017. Twisting and bending off the bars shall not exceed 0.001X
length of the bar. Bulging on the sides shall not be more than 0.01 x b and 0.01 x s respectively.
5.2 Forged Bar : Tolerances on size for forged bars shall be +8% of the size.
6. MANUFACTURE :
6.1 The steel shall be manufactured in basic electric furnace process and subsequently vacuum
degassed or electric slag refined (ESR). Any other process of meeting shall be subjected to
mutual agreement between supplier & BHEL.
6.2 For manufacture of flat bars, if initial material is other than ingot (e.g. continuous casting),
supplier shall mention it in his quotation for prior approval from BHEL.
7. HEAT TREATMENT:
7.1 The bars shall be heat treated to get the desired mechanical properties specified in this
specification. The hardening temperature shall be in the range of 980 1030
0
C and the
tempering temperature shall not be below 650
0
C As per DIN-19440.
7.2. Minimum possible residual stress shall be aimed with slow cooling and longer duration of
tempering treatment.
7.3. If the bars require straightening after heat treatment, the bars shall be stress relieved after
straightening operation at 30
0
C below the actual tempering temperature.
8. FREEDOM FROM DEFECTS:
8.1 The bar shall be free from lamination cracks, scabs, seams, shrinkage porosity, inclusions and
other harmful defects.
60

8.2 Decarburisation and other material defects shall not exceed the dimensional tolerances and
machining allowances.
9. FINISH:
9.1 The bar surface be smooth, free from laps, rolled in scale etc. Dents roll marks. Scratches are
permitted provided their depth does not exceed half the tolerance limits specified in table.
9.2 Repair of surface flaws by welding in not permitted
9.3 The edges of bars shall be cut square by sawing or shearing.
10. CHEMICAL COMPOSITION: The chemical composition of material shall be as follows (table
analysis in %)
Element Min. Max.
Carbon 0.17 0.22
Silicon 0.10 0.50
Manganese 0.30 0.80
Chromium 12.50 14.00
Nickel 0.30 0.80
Sulphur -- 0.020
Phosphorus -- 0.030
11. SELECTION OF TEST SAMPLES:
11.1 Chemical analysis shall be reported on each heat basis..
11.2 For Mechanical Test
61

11.2.1 One tensile & 3 impact test samples shall be selected for mechanical testing per melt per
heat treatment batch basis from lot of size.
11.2.2 The uniform strength of a delivery shall be certified through hardness test. In case of bars
with sectional dimensions more than 120mm, the entire bar shall be tested for hardness.
In case of bars with sectional dimension less than or equal to 120mm hardness shall be
checked on 10% of the bars or 10 numbers of bars whichever is higher.
11.2.3 The mechanical and notch impact test is to be done in longitudinal direction on the hardest
and softest bars. Test sample shall be to Km. at 1/3rd below the surface of the bars.
12. Mechanical Properties:
12.1 The material shall comply with the following mechanical properties at room temperature.
0.2% : 600 N/MM
2
Min
Tensile strength : 800 950 N/mm
2

% Elongation on 5.65
S
0
: 15 min.
% reduction in area : 50 min. *
Impact (mean of 3.1S0 V sample) : 20 J min.
Hardness (HB-30) :
s
280
12.2 Tensile test shall be carried out in accordance with IS: 1608 or equivalent international
standard.
12.3 Impact test shall be carried out on 3 ISO-V samples in accordance with IS: 1757 or
equivalent international standard only one test value out of three, can be below the
specified value; but in no case it should be below 2/3rd of the minimum specified value;
but in no case it should be below 2/3rd of the minimum specified impact value.
12.4 Hardness test (Brinell) shall be carried out according to IS: 1500 or equivalent international
standard.
13. NON DESTRUCTIVE TEST: Following NDT shall be carried out.
62

13.1 UT of the pre material combined with 100% magnetic partial testing of all bars in delivery
condition.
13.2 Complete UT of all bars in delivery condition.
13.2.1 In case of testing as per 14(a) U.T. shall be carried out as per HW 0850 192 (SEP 1923) test
class D
3
and MPI of all bars except of face areas. In case of testing as per 14(b) UT shall be
carried out as per HW 0850 192 (SEP 1923) test class D
2
.
13.2.2 Mix up test (verification test) of all bars.
13.2.3 Visual inspection of all bars
13.2.4 Acceptance Criteria
a) Magnetic Particle Test: When MT is carried out as per clause 14.1.
- Surface defects with expected depth > 1 mm are unacceptable.
- Indication > 5 mm is unacceptable.
Defect indication observed during MT, can be removed by grinding (dressing up) but with in
1mm depth.
b) Ultrasonic Test: Quality class 2b with following modification that individual indication >
2mm EFB (KSR) and back wall losses > 3dB are unacceptable.

X
2
CrMoV1 21
B. 600 N/MM
2
minimum 0.2% Proof stress Heat resistant steel bars for steam turbine blades
1. General : Hot rolled and forged bars of steel grades X22 CrMoV1 21.
2. Application : Bars are required for machining of guide and moving blades for
steam turbines.

s
63

3. Dimension & Tolerance :

"b" width across flates mm Allowable deviation on "b"
mm
"s" thickness mm Allowable devi. on
'S' mm
Up to 35 & Over 35 1.5 Up to 20 & Over
20
+1
Upto 75 + 2 Upto 40 + 2
Over 75 + 3 Over 40 + 3
4. Chemical Composition :
Element % min. % max.
Carbon 0.18 0.24
Silicon 0.10 0.50
Manganese 0.30 0.80
Malybeonum 0.80 1.20
Vanadium 0.25 0.35
Nickel 0.30 0.80
Sulphur -- 0.020
Phosphorous -- 0.030

b
64

5. MECHANICAL PROPERTIES:
0.2 % proof stress : 600 N/mm
2
min.
Tensile Strength : 800-950 N/MM
2

% Elongation : 14 Min.
% Reduction in area : 40% Min.
Notch Impact Value : 27 J * Min.
600 N/MM
2
0.2% PROOF STRESS Forged Blades
1. General : This specification governs the quality of guide and moving blades
forged from steel grade X 20 or 13.
2. Application : The blades are used for steam turbines.
3. Condition of Delivery: The forged blades shall be supplied in heat treated forged blade shall be
supplied with center holes made in accordance with respective
technical requirements or ordering drawing.
4. Dimensions & Tolerance: The dimension and tolerances shall be as per ordering drawing
accompanying the order.
5. Manufacture : The steel shall be manufactured in the blade electrical furnace and for
subsequently refined to ensure turbine blade quality. The forgings
shall be made as envelope forging or precision forging, subsequently
machine / grinder to achieve the ordering drawing dimensions and
surface finish.
6. Heat Treatment:
6.1. The forging shall be heat treated to get desired mechanical properties.
6.2. The tempering temperature shall not be below 650
0
C. The minimum residual are to be
aimed through sufficient duration of the tempering treatment and the slow cooling rate from
65

the tempering temperature.
6.3. The blades are to be straightened after heat treatment; each straightening operation is to be
followed by a stress relieving temperature and in no case below 610
0
C followed by slow
cooling.
7. Freedom from Defects: Blades shall be free from folds due to forging; cracks, tearing and other
material defects, elongated non-metallic and fusions, seams etc. any
blade containing such defects shall be rejected.
8. Surface finish : The blade shall be supplied in a desoaled and de-burred condition.
The surface finish shall comply with the requirements specified on the
drawing. In the surface is ground prior to blasting the surface finish
must be anouired in compliance with the finish specified on the
drawing. Grinding may be performed to a depth not more than AH/2
and ground areas shall be blended over a length of LP/2. However AH
shall not be exceeded.
AH : Allowable profile deviation on the pressure side.
LP : Profile length measured from leading edge to trailing edge.
9. Chemical Composition: The chemical analysis of the material shall confirm to the following:
Element % min. % max.
Carbon 0.17 0.22
Silicon 0.10 0.50
Manganese 0.30 0.80
Nickel 0.30 0.80
Sulphur -- 0.020
66

Phosphorous -- 0.030
10. Selection of Test Sample: All tests and examination shall be performed on specimens
taken in accordance with annexure 1 from at least one blade
of each drawing per melts and heat treatment batch.
11. Mechanical properties:
11.1 The mechanical properties of the blade material shall conform to the following:
0.2 % proof stress :
>
600 N/mm
2

Tensile Strength : 800-950 N/MM
2

% Elongation : 15 Min.
% Reduction in area : 50 Min.
Impact Value (Average of 3, ISO V Sample) : 20 J Min.
Brinell hardness HB 30 : 280 Max.
11.2 Tensile Test: The tensile test piece shall confirm to the gauge length.

L 5.65 S
0 0
=

11.3 Impact test shall be carried out on standard test piece as per ISO V notch according to IS: 1757.
11.4 Hardness Test: The Brinell hardness test HB 30 shall be carried out according to IS: 1500.
12. Non Destructive Test:
12.1 Blade shall only be manufactured from ultrasonically examined rare material.
12.2 In order to ensure freedom from defects. All blades shall be subjected to magnetic particle
examination prior to shipment.
13. Dimensional Checks for Acceptance:
13.1 The supplier shall check 100% of the forgings w.r.t. to all parameters.
67

13.2 Dimensions parameters to be checked for acceptance.
- Following dimensional parameters of each of the check sections as specified in ordering
drawing shall be inspected after fixing / clamping the forging in vertical stand to check
conformance of profile of individual section as well as in relation to each other.
o From tolerance for pressure side = AH
o From tolerance for suction side = AR, max difference AR
o From tolerance for Inlet edge = AH
o Twist Tolerance = ( AH, AR) max.
- Profile thickness of each section. = AD Max. / AD / AD1
- Max. Profile length of each section.
- Root dimensions.
- Base dimensions.
- Base plate contour.
- Axial and tangential shift of profile with respect to root.
- Overall length of forging.
- Surface finish.
13.3 Procedure for dimensional checks:
- Check of inlet edge: The profile of inlet edge shall be checked by using split profile gauges.
- Check of Profile : All the dimensional parameters mentioned at (13.2) shall be checked using
a vertical measuring stand.
- Drilling of BHEL Centre holes
- Checking of BHEL Centres.
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Classification of Blades
L.P. Moving Blade Forged First Stage.
L.P. Moving Blade 500 MW Last Stage.
100 MW 25
th
Stage Impulse Blades.
Compressor blade Sermental coated.
Compressor Blade 'O' stage.
Gas Turbine Compressor Blade.
T-2 Blade.
T-4 Blade.
3DS Blade.
Brazed Blade
Russian Design Blades.
Z Shroud Blade.
Twisted Blade.
Present Range of Blades.
Future Range of Blades.

69

Hydro-Turbine Laboratory
1. INTRODUCTION
Hydro Turbine Laboratory at HEEP, Hardwar was set up in late '60s. It comprises of three Test Beds
with electronic Instrumentation Laboratory for test bed operation/maintenance and for carrying out
Site Investigations. It has a modest Workshop to manufacture hydro turbine models. Till December
'95 about 160 numbers of tests have successfully been performed in the Laboratory which includes
Contractual as well as Developmental tests on Hydro Turbine Models, Calibration of Hydraulic Valves,
Nozzles and Flow Measuring Devices for 210 MW Thermal Sets. Besides performing the main
function of design/ development of hydraulic passages of hydro turbines, design of models, their
manufacture and testing, the Laboratory has also been engaged in Field Test Studies at various Hydro
Power Sites for conducting Index Tests, Head Loss Measurement, Uprating Studies and attending to
various Site Problems.
2. DESIGN:
3. MANUFACTURING:
4. TESTING:
5. TESTING CAPABILITIES:
- Runaway speed tests of reaction and impulse turbine.
- Determination of MW output of prototype turbine under specified operating conditions.
6.4 INSTRUMENTATION LABORATORY
The Instrumentation Laboratory is equipped with the most modern instrumentation for carrying out
accurate measurements during testing in the Laboratory as well as during field testing. The major
facilities are:
- Ultrasonic Flow meter for field tests.
- Magnetic Tape Recorder with Waveform Analyzer.
70

- Microprocessor based Pressure Pulsation Measuring System.
- Microprocessor based Wicket Gate Torque Measuring System.
- Microprocessor based Hydraulic Thrust Measuring system.
7. RESEARCH AND DEVELOPMENT
The continuous in house research and development efforts of the Laboratory have enabled it to
establish new measurement methods for carrying out special tests, to bridge know-how / know-why
gaps, to resolve certain site problems and to evolve and establish better and more efficient designs.
The benefits of research and development activities are passed on to the customers through
implementation of new concepts of existing sites and for future projects.
8. FIELD TESTING
The Laboratory is equipped to perform field efficiency and index tests on prototype turbines at hydro
power sites. Many site problems of hydraulic and mechanical nature have been successfully solved as
a result of extensive filed tests and analysis carried out by the Laboratory. The Laboratory has
successfully carried out uprating studies at many hydro sites resulting in augmentation of power
generating capacity of the units at no extra or minimum cost. Extensive work has been done by the
Laboratory to tackle the problem of silt erosion of runner blades at several hydro power stations
situated in the Himalayan region.
9. CALIBRATION
The Laboratory is equipped with the required facilities for calibration of load cells, pressure pulsation
transducers, weights, volumetric tanks and torque wrenches. Calibration of these terms is performed
with respect to standards with history traceable to N.P.L., Delhi.

71

Manufacturing Divisions of BHEL
Heavy Electricals Plant, Piplani, Bhopal
Electricals Machines Repair Plant (EMRP), Mumbai
Transformer Plant P.O. BHEL, Jhansi.
Bharat Heavy Electricals Limited :
Heavy Electricals Equipment Plant,
Central Foundry Forge Plant, Ranipur, Hardwar
Heavy Equipment Repair Plant, Varanasi.
Insulator Plant, Jagdishpur, Distt. Sultanpur.
Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad
High Pressure Boiler Plant & Seamless Steel Tube Plant, Tiruchirappalli.
Boiler Auxiliaires Plant, Indira Gandhi Industriel Complex, Ranipet.
Industrial Valves Plant, Goindwal.
BANGALORE
Electronics Division :
Electronics Systems Division.
Amorphous Silicon Solar Cell Plant (ASSCP).
Electroporcelains Division.
Industrial Systems Group. .
Component Fabrication Plant, Rudrapur.
Piping Centre, Chennai.
Regional Operations Division, New Delhi

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Bharat Heavy Electricals Limited, Ranipur, Haridwar

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