BHARAT HEAVY ELECTRICAL LIMITED, HARIDWAR TRANING REPORT IN (TURBINE SECTION)

SUBMITTED BY: Prateek Bhatnagar B.Tech -FINAL YEAR(2012-13) ELECTRICAL & ELECTRONICS ENGINEERING ABES Engineering College, Gzb, TRANING PERIOD-(6th June - 7th July 2012)

SUBMITTED TO: Mr.Y.K. Pandey SENIOR MANAGER TURBINE GOVERNING SECTION BHARAT HEAVY ELECTRICAL LIMITED HARIDWAR

ABES Engineering College, Ghaziabad Training Report

Submitted By: Prateek Bhatnagar B.Tech -FINAL YEAR(2012-13) Electrical & Electronics Engineering ROLL NO-0903221085 ABES Engineering College, Gzb. Training Period-(6th June - 7th July 2012)

SUBMITTED TO: Mr. Amul Kumar HEAD OF DEPARTMENT EEE DEPARTMENT ABES EC,GHAZIABAD

ACKNOWLEDGEMENT
Before we get into detail of the report,I feel the heartfelt responsibility to mention my acknowledgement to several people to whom I owe the success of my venture of training and writing this report. I am grateful to Mr.Y.K.Pandey Sr. MANAGER (TURBINE GOVERNING SECTION) who allowed me to undergo vocational summer training and guided me during training period at BHARAT HEAVY ELECTRICAL LIMITED,HARIDWAR which holds the rank amongst the top Public Sectors in india , exhibiting excellent performance with safest and most friendly enviornment, fulfilling all kinds of standards respective to its name,reputation and fame. I would like to give special thank to all the staff of BHEL TURBINE SECTION for their great and remarkable contribution, support and guidance during training period.Their constant effort made this training really a learning experience. The well planned schedule and structure helped me in understanding the systems and equipments easily and effectively.

Prateek Bhatnagar

CONTENTS

1. BHELAN OVERVIEW 2. HEEPAN OVERVIEW 3. TURBINES & AUXILLIARY BLOCK 4. HYDRO TURBINE 5. STEAM TURBINE 6. GAS TURBINE 7. MANUFACTURING PROCESS 8. BLADE SHOP 9. BROAD SPECIFICATION OF MAJOR MACHINES TOOLS & MACHINES - CNC MACHINE TOOLS 10. NON CNC MACHINE TOOLS

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 197172 and achieved a sales turnover of Rs. 6347 crore with a pre-tax profit of Rs. 294 crore in 2000-01. BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense, etc. The wide network of BHEL's 14 manufacturing division, four power Sector regional centres, over 150 project sites, eight service centres and 18 regional offices, enables the Company to promptly serve its customers and provide them with suitable products, systems and services efficiently and at competitive prices. BHEL has already attained ISO 9000 certification for quality management, and ISO 14001 certification for environment management. POWER GENERATION Power generation sector comprises thermal, gas, hydro and nuclear power plant business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the total installed capacity of 99,146 MW in the country, as against nil till 1969-70. BHEL has proven turnkey capabilities for executing power projects from concept to commissioning, it possesses the technology and capability to produce thermal sets with super critical parameters up to 1000 MW unit rating and gas turbine generator sets of up to 240 MW unit rating. Co-generation and combined-cycle plants have been introduced to achieve higher plant efficiencies. to make efficient use of the high-ash-content

coal available in India, BHEL supplies circulating fluidized bed combustion boilers to both thermal and combined cycle power plants. The company manufactures 235 MW nuclear turbine generator sets and has commenced production of 500 MW nuclear turbine generator sets.

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. HEEP: FACILITIES AND INFRASTRUCTURE Modernization and regular up gradation / up gradation of facilities and other infrastructure is a continuous endeavor at HEEP, BHEL. After initial setting up of the plant during the year 1964-72, in collaboration with the Soviet Union, the plant facilities and infrastructures have since been continuously upgraded under various investment projects viz, Stamping Unit Project, LSTG Project, Motor Project, Governing Components Project, TG Facilities Modernization, TG Facilities Augmentation, Quality Facilities Augmentation, EDP projects, Gas Turbine Project, Facilities have also been added and establishments have been created for new projects in Defense and Aviation Project. Additionally, R&D facilities have also been created under Generators Research Institute, Pollution Control Research Institute, HTL modernization and other such scheme Today the Plant has unique manufacturing and testing facilities, computerized numerically controlled machinetools, Blade shop, heavy duty lathes, milling machines, boring machines, machining centers and many more. The Over Speed Vacuum Balancing Tunnel created for rotors up

to 1300 MW (32T, 6.9 M dia bladed rotor, 6 rpm up to 4500 rpm) is one of the 8 of its kind in the entire world.The total spectrum of sophisticated, unique and other facilities at HEEP, Hardwar are the state-of-the-art in manufacturing processes and can be utilized for a variety of products' manufacture.

TURBINE AND AUXILIARY BLOCKIII

GENERAL Block-III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and Turbines Blades. Special Toolings for all products are also manufactured in the Tool Room located in the same block. Equipment layout plan is as per Drawing appended in Section III. Details of facilities are given in Section II. The Block consists of four Bays, namely, Bay-I and II of size 36x378 metres and 36x400 metres respectively and Bay-III and IV of size 24x402 metres and 24x381 metres respectively. The Block is equipped with the facilities of EOT Cranes, compressed air, Steam, Overspeed Balancing Tunnel, indicating stands for steam turbine, rotors, one Test stand for testing 210 MW steam turbines Russian Design, one Test Stand for Hydro Turbine Guide Apparatus and two separate Test Stands for the testing of Governing Assemblies of Steam and Hydro Turbines.

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

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.

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.

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

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

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

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

Governing Elements Assembly and Test Stand Section This section is equipped with facilities like oil Pumping Unit, Pressur Receiver.

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 works like casings, Pedestals etc. are received from Fabrication Block-II. Rotor Machining Section It is equipped with large size machining tools like Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree Groove Milling Machine etc. Some rotor forgings are imported from Russia and Germany and some are indigenously manufactured at CFFP, BHEL, Hardwar. 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. Turbine casing Assembly Section Machined casings are assembled and hydraulically tested by Reciprocating Pumps at two times the operating pressure. Test Station - Test station for testing of 210 MW USSR Steam Turbine at no load is equipped with condensers, Ejector, Oil Pumps, Oil containers Steam Connections etc, required for testing. Overspeed testing is done for emergency Governor. Assembly Test Stands for different modules of Siemens design are equipped with accessory devices. Painting Preservation and Packing Section All the parts are painted, preserved and packed here for final dispatch.

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

ROTOR ASSEMBLY OF V94.3A STEAM TURBINE

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

other medium assemblies.

parts

of

governing

and

Main

Turbine

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

GAS TURBINE
All the components of Gas Turbine are machined and assembled using the facilities available for manufacturing of

steam and hydro turbines except the following facilities which are procured exclusively for the manufacturing of Gas Turbine and are installed in the areas specified for gas turbine manufacturing.

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

CNC Creep Feed Grinding M/c. This is installed in Gas Turbine machining area Bay-II Extn. This M/c grinds the hearth serration on rotor disc faces. Hirth serrations are radial grooves teeth on both the faces of rotor discs. Torque is transmitted trough these serrations, which are very accurately ground.

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

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

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

GAS TURBINE
Wax Melting Equipment This is low temp. electric furnace installed in Gas Turbine blading area in Bay-II. It is used to mix and melt Wax and

Colaphonium, which is required to arrest the blade movement during the blade tip machining of stator blade rings. 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.

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.

MANUFACTURING PROCESS

HYDRO TURBINES The major processes involved in various Hydro Turbine Sections are as follows: Marking and checking of blanks manual as well as with special marking M/c. Machining on Horizontal Boring, Vertical Boring, Lathes etc. as the case may be on CNC /Conventional Machines. Intermediate assembly operation is carried out on the respective assembly beds provided. The sub-assemblies are further assembled for hydraulic/functional testing. Hydraulic testing is done using a power driven triple piston horizontal hydraulic pump, which can generate a pressure of 200 Kg/Cm 2. It can also be carried out using a power pack. On Governing elements / assembly and test stand, the components / sub-assemblies / assemblies are tested up to a hydraulic pressure of 200 Kg / c m2 using the piston pump. Oil testing upto 40 Kg / c m2 is carried out with oil pumping unit, which is permanently installed on this bed. STEAM TURBINE Processes carried out in various sections of steam turbine manufacture are based on the following main phases. Machine section Castings, Forgings, welded structures and other blanks are delivered to this section. The manufacturing process is based on the use of high efficiency carbide tipped tools, high speed and high feed machining techniques with maximum utilization of machine tool capacity and quick acting jigs and fixtures.

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

OVERSPEED & BALANCING TUNNEL

Painting, Preservation and Packing After testing the turbine, it is disassembled and inspected. Then the parts are painted, conserved and packed for final dispatch. GAS TURBINE The major processes involved in manufacturing Gas Turbine sections of Bk-III are as Machining Castings, Forgings, welded structures and other blanks are received from concerned agencies in the respective sections. These are machined keeping in view optimum utilization of machine tools and toolings. Special jigs and fixtures are made available to facilitate accurate and faster machining. Proper regime and tool grades have been established to machine the materials like inconel, which have poor machinablity. Main Assembly Final assembly is done on test bed. Parts are assembled to make sub-assemblies. These sub-assemblies are again machined as per technological and design requirements and are made ready for final assembly. After assembly and insulation assembled Gas Turbine is sent to site. Rotor Assembly The rotor is assembled on Hydraulic Lifting Platform and sent to main assembly, where after checking clearances, it is sent for machining. After balancing, turbine side of rotor is disassembled, inner casing is fitted and rotor reassembled. This work is also carried out on Hydraulic Lifting Platform. Finally rotor is sent for assembly on test bed. Combustion Chamber Assembly This assembly is carried out on 3 tier platform installed for this purpose in Bay-I assembly. After machining of all

components, ceramic tiles are fitted in flame tube. Burner and piping etc. is fitted in dome and combustion chamber is finally assembled. It is directly sent to site after.

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 Centers, besides various special purpose and general purpose machines. The layout of equipments is as per technological sequence of the manufacturing process. Blade shop implements various On Line Quality Control Techniques through Run Charts and Control charts. This shop is divided into four distinct areas. Details of facilities are given in various schedules of SectionII. Manufacturing Facilities: 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. Copy Milling Section The Semi blanks prepared from plain milling section are further machined by copy Milling Machines / CNC machines (CNC Heller and BSK Bed type Klopp, BFH / BEK Knee type Machines) for concave and convex aero-dynamic profile forms, (HTC-600, BFK Machines) for expansion angles, Compound taper grinding of radial plane is carried out by Surface grinders. It comprises of T-root machining centers for machining of T-root.

LP Section This area deals with all types of free standing and forged blades for steam Turbine Compressor. The freestanding blades are cerrobend casted in boxes to hold the blade with respect to the profile. These blades roots are subsequently machined on NTH, MPA-80A and T30 Machining Centers. There is a five station 360o circular copy milling machine for machining the profile of envelope forged blades / stocks for Steam Turbine and Gas Turbine Blades. It also has 3D copy Milling and CNC Machines with digitizing features for Tipthinning, Fitted milling. The inlet edge of the last stage of Low pressure Turbine Moving blades are hardened on a Special Purpose Flame Hardening equipment. Polishing Section Blade Contours are ground and polished to achieve the desired surface finish and other aerofoil requirements. There are also other small sections e.g. Fitting Section, Tool and Cutter Grinding, Toolings Repair Section in Blade Shop. 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. 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.

BROAD SPECIFICATION OF MAJOR/IMPORTANT MACHINE TOOLS & MACHINES

A: CNC MACHINE TOOLS CNC HORIZONTAL BORERS:
1. Item Description Model Supplier CNC Control System Spindle Dia. Table Max. Load on Table Travers X=1400mm Ram traverse Ram size Power Rating Weight of the m/c ATC Capacity Plan No. 2. Item Description Model : : : : : : : : : : : CNC Horz. Borer RAPID 6C WOTN, GERMANY : FANUC 12M

200mm 4000 x 4000 mm : : 100 T X=20000, W = 1000 mm Y=5000,

400 x 400 mm : 111 T : 60 Nos. 90 KW

1-227 (Block-I) CNC Stub Borer DW 1800

Supplier

HEYLIGENSTAEDT, GERMANY

CNC LATHE FOR ROTOR MACHINING

CNC Control System Boring Dai Table Headstock Travel Spindle Speed Power Rating Max. Load Capacity Weight of the m/c Plan No. 3. Item Description Model Supplier CNC Control System Spindle Dia. Traverse : : : : : : : :

: SINUMERIK 7T 625 2500 mm 4000 x 4000 mm 4000 mm : 0.5 90 RPM (in 4 Steps) : 63 KW : 100 T 72 T

27-420 (Block-III) : : CNC Horz. Borer (2 Nos.) W200 HB NC

SKODA, CZECH : SINUMERIK 850 M 200 mm

X=12500, Y=5000, Z=2000mm

CNC LATHES

4.

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

: :

CNC Centre Lathe D-1800 NYF

HOESCH MFD, GERMANY : SINUMERIK 3T : 8000 mm : : : : : : 1800 mm

2400 mm 0 125 RPM 92 KW 110 TON 124 TON

2-394 (Block-III)

5.

Item Description Mode Supplier CNC Control System Centre Distance :

: :

CNC Centre Lathe D-2300 NYFS-1

HOESCH MFC, GERMANY : SINUMERIK 7T : 18000 mm

Swing Over Carriage Swing Over Bed Spindle Speed Power Rating Weight of the job Weight of the m/c Plan No. : : : : : :

2300 mm

2900 mm 5 125 RPM 110 KW 320 TON 216 TON

2-360 (Block-III)

6.

Item Description Model Supplier CNC Control System Centre Distance Centre Height Swing Over Carriage Swing Over Bed Max. Turning Length Spindle Speed :

: :

CNC Centre Lathe KV2-1100 CNC

RANVENSBURG, GERMANY : SINUMERIK 820 T : 12000 mm : 900 mm : : 1100 mm

1400 mm : : 12000 mm 2-600 RPM 1-5000 mm / 1-5000

Longitudinal Cutting Feed (Z-Axis) : min. Transfer Cutting Feed (X-Axis) mm/min. :

Main Spindle Drive Motor Max. Feed Force Z/X Axis No. of Tool carriers Plan No. :

95.5 KW DC : 45000 N

1-120 (Block-III)

CNC MILLING MACHINES 7. Item Description Nos.) Model Supplier CNC Control System Table Traverse : : : : CNC Horz. Milling M/c (6 BFH-15

BATLIBOI, INDIA : : SINUMERIK 810 M 1500 x 400 mm

X=1170 mm Y=420 mm Z=420 mm

Spindle Speed Power Rating Max. Load Capacity Weight of the m/c Plan No. 460 (Block:

: : : :

45 to 2000 RPM 11 KW 630 Kg 4200 Kg

2-449, 2-453, 2-454, 2-459, 2IIITBM)

8. Item Description (2Nos.) Model Supplier CNC Control System Table Traverse : :

: :

Universal BFK-15

Milling

M/cs

BATLIBOI, INDIA : : SINUMERIK 810 M 1500 x 400 mm

X=1170 mm Y=420 mm Z=420 mm

Spindle Speed Power Rating Max. Load Capacity Weight of the m/c Plan No. :

: : : :

45-2000 RPM 11 KW 630 Kg 4200 Kg

2-463, 2-466 (Block-III: TBM)

9.

Item Description Model Supplier CNC Control System Table :

: :

CNC Bed Type Milling M/c FSQ 80 CNC

TOSKURIM, CZECH SINUMERIK 810 M : 3000 x 800 mm

TEE SLOT 28H7

Traverse

X= 3000 mm Y= 870 mm

Z= 850 mm Spindle Speed Range Spindle Drive Power : : H 2500 RPM continuous

18 KW

22 KW Spindle Head Size :

intermittent

620 x 500 incldg ram

543 x 420 encldg ram ATC Capacity Table Load Plan No. : : : 24 Nos. 2500 Kg

2-484 (Block-III)

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

2-356, 2-41 (Block-III: TBM)

11. Item Description Root M/cing Cenre Model Supplier CNC Control System Table Traverse : :

: :

SPL

Purpose

FIR

Tree

NTH 200

RIGID, SWITZERLAND : : SINUMERIK 7M 1400 x 1400 mm

X= 1950 mm Y= 900 mm Z= 600 mm

Spindle Speed No of Spindle Power Rating Plan No.

: : :

30600 RPM 4 22 KW

2-354 (Block-III TBM)

CNC VERTICAL BORERS 12. Item Description Model Supplier CNC Control System Table dia Turning dia : : : : CNC Vertical Borer TMD 40 / 50

OSAKA MACHINES, JAPAN : FANUC 6TB, 3TC

4000 mm : 5000 mm

Turning Height Spindle Speed No. of Ram : :

: 4200 mm 0.23-30 RPM 2

OTHER SPECIAL PURPOSE CNC MACHINES

13. CNC SURFACE BROACHING M/C Make Model CNC System : Marbaix Lapointe, UK : Champion 32 /10, 300 : SINUMERIC 850 M : 320 KN

Broaching capacity (pulling force) Broaching slide stroke Broaching slide width

: 10.3 mm : 1500 mm : : : 9650 mm 1-25 M/min 60 M/min

Max tool length (continuous /row) Broaching Speed (cutting stroke) Broaching Speed (return stroke) Drive power rating

: 135 KW

Broaching slide movement : Electro-mechanical Maximum noise level : < 80 Dbs : 2300 mm

Max. dia of the disc (mountable) Max. weight of the job

: 3000 Kgs

Indexing & rotating tables : 1500 mm, 1000 mm Indexing accuracy Plan No. : +/- 3 Arc sec. : 2-485

14. CREEP FEED GRINDING M/C Make Model CNC System Work-piece diameter : ELB CHLIFE, GERMANY : ELTAC SFR 200 CNC : SINUMERIC 3 GG : 200 2000 mm

CNC BROACHING MACHINE

Work height : 2400 mm

Rotary & indexing table dia. : 2050 mm Indexing accuracy Max. load capacity : +/- 1 ARC SEC : 20000 KG

Y-axis (grinding head movement) Vert. Traverse : 750 mm

Z- axis (grinding head support) Movement on cross rail) Horizontal traverse Traverse feed rate : 2400 mm : 02 1200 mm /min

Grinding head main support Drive motor : 34 KW

Grinding wheel max. Dia. : 500 mm Max. Width Bore Surface speed Plan No. : 100 mm : 203.2 mm : 16-35 M/Sec. : 2-49

NON-CNC MACHINE TOOLS

PRECISION HEAVY DUTY LATHE Manufacturer: Karamatorsk Heavy Machine Tool Works (USSR); Model KS-1614 Specifications 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 . Maximum Swing Maximum Diameter of work piece over the Saddle Maximum Distance between Centres Diameter of Spindle bore Maximum Taper when machining by the method of Combined Feeds Maximum Length between Centres when machining by the method of Combined Freeds Maximum Weight of work piece Maximum Length of Machine over the Saddle Maximum Summary Effort of Cutting Limit Dimension of Thread Cut: 2000mm 1500 mm 8000mm 80 mm 0.15 mm 1200 mm 20000 kg 8000 kg 10,000 kg

BALANCING MACHINE Manufacturer: SCHENK (West Germany) Model: Dj 90 Specifications 1. 2. 3. 4. 5. 6. 7. 8. Weight of rotor Minimum weight without considerable loss of measuring sensitivity, provided the berings can accommodate such small rotors. Maximum weight for one bearing pedestal Height of rotor axis above machine bed Rotor diameter (free swing over machine bed) not considering the funnel Diameter of journal Diameter of journal, with special sleeve bearing cups made from high grade material. Minimum distance between bearings for less than 10 tons 10,000 to 80,000 kg 5000 kg 45,000 kg 1600 mm 4000 mm Max. 540 mm Max. 600 mm 1500 mm

9. 10 . 11 .

rotor Minimum distance between bearings for more than 10 tons rotor Maximum distance between coupling plague and center of the scond bearing pedestals Rotational Speeds (a) For rotors from 5 to 10 tons (b) For rotors from 10 to 20 tons (c) For rotors from 20 to 80 tons Maximum test speed and overspeeds (a) For rotors upto 50 tons

1900 mm 13500 mm Min. 800 rpm Max. 4000 rpm Min. 700 rpm Max. 3600 rpm Min. 600 rpm Max. 3600 rpm 4500 rpm 3600 rpm 50,000 Kg 0.3 to 3 micron

12 .

13 . 14 .

(b) For rotors upto 50 to 80 tons Maximum centrifugal force admissible on each bearing pedestals for short period of time Balancing accuracy to be obtained depending on Selling Weight

SPECIAL DRILLING & BORING MACHINE Manufacturer: Machine Tool Works, Ryazan (USSR) Model: PT 182 H5 SPECIFICATIONS: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 . 11 . Swing over bed Drilling dia Boring dia Swing of job in rest Swing of job in Headstock chuck Maximum length of job Maximum weight of job Number of spindles Spindle location Distance to spindle axis: Head stock Spindle speed 800 mm 40-80 mm 80-250 mm 300 mm 110 mm 300 110 mm 3000 mm 2000 Kg 1 1 Horizontal 400 mm 1100 mm 750 r.p.m.

Max Min Max. Min. Headstock Stemstock From bed wasy From floor Max

CONCLUSIONS
The Vocational training at BHEL Hardwar helped me in improving my practical knowledge and awareness regarding telephone exchanges to a large extent. Here I came to know about the technology and material used in telecommunication. Besides this, I also visualized the parts involved or equipments used in the fault detection. Here I learnt about how different techniques used to tackle the various problems under different circumstances. At least I could say that the training at BHEL Hardwar is great experience for me and it really helped me in making or developing my knowledge about telecommunication.

BIBLIOGRAPHY
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