BHEL AN OVERVIEW BHEL is the largest engineering and manufacturing enterprise in India in the energy related infrastructure sector

r 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, Defense, etc. The wide network of BHEL's 14 manufacturing division, four power Sector regional centre, over 150 project sites, eight service centre 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. Custom made hydro sets of Francis;Pelton and Kapian 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 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 modernization and uprating of a variety of power plant equipment besides specialized 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). P resently 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, petrochemicals, 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. INDUSTRIES BHEL is a major contributor of equipment and systems to industries, cement, sugar, fertilizer, refinances, petrochemicals, paper, oil and gas, metallurgical and other process industries. The range of system & equipment supplied includes: captive power plants, co-generation plants DG power plants, industrial steam turbines, industrial boilers and auxiliaries. Wate 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. The Company is a major producer of large-size thruster devices. It also supplies digital distributed control systems for process industries, and control & instrumentation s ystems for power plant and industrial applications. BHEL is the only company in India with the capability to make simulators for power plants, defense and other applications. The Company has commenced manufacture of large desalination plants to help augmen the t 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 equipmen cars, Special well t 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. 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 requiremen viz extended ts 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 Organizations 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 up gradation 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. 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 centers 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 commercialization. Some of the on-going development & demonstration projects include: Smant 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 centers 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 engende red 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 endeavor 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: ENVIRONMENTAL POLICY
y Compliance with applicable Environmental Legislation/Regulation; y Continual Improvement in Environment Management Systems to protect our natural environment and Control Pollution; y Promotion of activities for conservation of resources by Environmental Management; y 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

y y

Compliance with applicable Legislation and Regulations; Setting objectives and targets to eliminate/control/minimize risks due to Occupational and Safety Hazards;

y y y y

Appropriate structured training of employees on Occupational Health and Safety (OH&S) aspects; Formulation and maintenance of OH&S Management programs 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. 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.

Labour Standards 3. Business should uphold the freedom of association and the effective recognition of the right to collective bargaining; 4. 5. 6. The elimination of all form of forces and compulsory labour. The effective abolition of child labour, and Eliminate discrimination.

Environment 7. 8. 9. Businesses should support a precautionary approach to environmental challenges; Undertake initiatives to promote greater environmental responsibility and 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.

ACTIVITY PROFILE PRODUCTS Power Generation & Transmission - Steam Turbine-Generator Sets & Auxiliaries - Boiler and Boiler Auxiliaries - Once-through Boilers - Nuclear Power Generation Equipment - Hydro Turbine-Generator Sets & Auxiliaries - Mini/Micro Hydro Generator Sets - Gas Turbine-Generator Sets - Waste Heat Recovery Boilers - Heat Exchangers - Condensers - Bowi Mills and Tube Mills - Gravimetric Feeders - Regenerative Air Pre-Heaters - Electrostatic Precipitators - Bag Filters - Valves - Pumps - Electrical Machines - Piping Systems -Power,Distribution&InstrumentTransformers - Reactors - Synchronous Condensers - Switchgear - Control gear - Distributed Digital Control for Power Stations - Bus Ducts - Rectifiers - Porcelain Insulators - Ceralin

- Industrial Fans - Seamless steel Tubes - Fabric Filters - AC DC Motors, Variable speed - AC Drive - Electronic Control Gear & Automation - Equipment - DDC for Process Industry - Thruster Equipment - Power Devices - Energy Meters - Transformer - Switch gear - Insulator - Capacitors - Broad Gauge AC, AC/DC Loco motives - Diesel-Electric Shunting Locomotives - Traction Motors & Control Equipment - Electric Trolley Buses - AC/DC Electric Multiple Units - Drives and Controls for Metro Systems - Battery-Operated Passengers Vans - X-Mas Trees and Well Heads - Cathodic Protection Equipment - Digital Switching Systems - Rural Automatic Exchange - Simulators Wind Electric Generators Solar Powered Water Pumps Solar Water Heating Systems Photo Votaic Systems Defense Equipment Reverse Osmoses Desalination Plants

INDUSTRIES/TRANSPORTATION/OIL & GAS/ TELECOMMUNICATION/RENEWABLE ENERGY - Steam Turbine-Generator Sets - Gas Turbine-Generator Sets - Diesel Engine-Based Generators - Industrial Steam Generators - Heat Recovery Steam Generators - Fluidised Bed Combustion Boilers Drive Turbine Manne Turbines Industrial Heat Exchangers Centrifugal Compressor

SYSTEMS & SERVICES

- Industrial Valves - Reactors - Columns - Pressure Vessels - Pumps

- Turkey Utility Power Stations/ EPC - Contracts - Captive Power Plants - Co-generation Systems - Combined Cycle Power Plants - Modernisation& Renovation of Power Stations and FLA Studies - Switch yards and Substations - HVDC Transmission Systems - Shorts sines condensation Systems - Power system analysis - Electron comissionly and operation - Consultancy services - Consultancy Services

THERMAL

SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS CORE SECTORS Power Generation RATING (MW) NO. OF SETS 500 30 250 9 210/200 138 120/125/130 20 195 1 110 38 100 6 70/67.5 6 60 14 30 5 TOTAL 267 (THERMAL)

TOTAL CAPACITY (MW) 15000 2250 28570 2420 195 4180 600 410 840 150 54615

GAS

FRAME SIZE/ SCOPE 9 6 5 3 V 94.2 6FA STG GEN TOTAL (GAS)

NO. OF SETS 5 17 13 6 2 3 24 4 74

TOTAL CAPACITY (MW) 730 580 309 48 286 207 1190 87 3437

NUCLEAR

RATING (MW)

500 220 TOTAL (NUCLEAR)

NO. OF SETS 2 10 12

TOTAL CAPACITY (MW) 1000 2200 3200

TOTAL (THERMAL+GAS+NUCLEAR) HYDRO GRAND TOTAL

353 402 755

61252 18735 79987

SUMMARY OF BHEL'S CONTRIBUTION TO VARIOUS CORE SECTORS

POWER TRANSMISSION & DISTRIBUTION
In the T&D sector, BHEL is both a leading equipment -manufacturer and a systemintegrator. BHEL-manufactured T&D products have a proven track record in India and abroad. In the area of T&D systems, BHEL provides turnkey solutions to utilities. Substations and shunt compensation installations set up by BHEL are in operation all over the country. EHV level series compensation schemes have been installed in KSEB, MSEB, SMPSEB and POWERGRID networks. Complete HVDC systems can be delivered by BHEL. The technology for state-of-theart Flexible AC Transmission Systems (FACTS) is being developed. INDUSTRIES Since inception in 1982, the Industry Sector business has grown at an impressive rate and, today, contributes significantly of BHEL's turnover.

BHEL, today, supplies all major equipment for the industries: AC/DC machines, alternators, centrifugal compressors, special reactor column, heat exchangers, pressure vessels, gas turbine based captive co-generation and combined-cycle power plants, DG power plants, steam turbines and turbo-generators, complete range of steam generators for process industries, diesel engine based power plants, solar water heating systems, photovoltaic systems, electrostatic precipitators, fabric filters, etc. The industries which BHEL serves include: Steel, Aluminum, Fertilizer, Refinery, Petrochemicals, Chemicals, Automobiles, Cement, Sugar, Paper, Mining, Textile etc. TRANSPORTATION In the transportation filed, product range covers: AC locomotives, AC/DC dual-voltage locomotives, diesel-electric shunting locomotives, traction motors and transformers, traction elections and controls for AC, DC and dual voltage EMUs, diesel-electric multiple units, diesel power car and diesel electric locomotives, battery-powered vehicles. A high percentage of the trains operated by Indian Railways are equipped with traction equipment and controls manufactured and supplied by BHEL. B. HEEP: AN OVER VIEW 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 Centers and 4 Power Sectors Regional Centers 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 providing total business solutions. MISSION The leading Indian engineering enterprise providing quality products system and services in the s fields of energy, transportation, infrastructure and other potential areas. VALUES y Meeting commitments made to external and internal customers. y Foster learning creativity and speed of response. y Respect for dignity and potential of individuals. y Loyality and pride in the company. y Team playing. y 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 the construction machinery woke up Shivalik Hills during early 60s and sowed the seeds of one of the g reatest 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 2oC in Winter (December to January) to 45oC in Summer (April-June); Relative humidity 20% during dry season to 95-96% during rainy season. Longitude 78o3' East, Latitude 29 o55'5" North. 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 (0133) 427350-59, 423050-423954 FAX : (0091) (133) 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 U Grid (132 KV / 11KV / 6.6 KV) P (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. 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 center 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). 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) * CONTROL PANELS (For Thermal / Hydro sets and Industrial Drives) LARGE SIZE GAS TURBINES (Unit Rating : 60-200 MW) LIGHT AIRCRAFT DEFENSE PRODUCTS HEEP: FACILITIES AND INFRASTRUCTURE

* * 10.

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 196472, 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 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 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 centers 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-ofthe-art in manufacturing processes and can be utilized for a variety of products' manufacture. TURBINE BLOCK Steam turbine Power plantmarket requirements have changed in recent years. The tendency for highly flexible and efficient power plants with long revision intervals, life times 200 000h as well as low

investment costs have resulted in an increased effort in the improvement of design and materials. One possible way to meet high efficiency requirements is to install sub-critical steam power plants with live steam temperatures of T 565C and an optimized steam cycle path. As a result, new challenges have arisen for the design of a two cylinder steam turbine line for a capacity up to700 MW. In addition, the realization of critical turbine components need improved design andmaterials, which offer all possibilities for a cost effective and flexible service. At the same time,the combined cycle power plant market demands constantly high performance, reliability andoperating flexibility at moderate prices for competitive life cycle costs. For this power range, twocylinder designs are also typically applied for the steam turbine.This paper outlines the different aspects of a modular design concept. The authors company hasbeen following this concept in recent years with an aim to accurately fulfilling marketrequirements. It has already been applied to various aspects of the two double-casingconfigurations for both single and double-flow low pressure turbines. This paper providesexamples on how the concept has been realized within various design aspects and features, allwith an underlying target to produce steam turbines that meet all named market requirements atcompetitive prices. INTRODUCTION The worlds power generation markets have been deregulated to a large extent over the past fewyears, and this process is still ongoing. In order to remain competitive, power plants need to have Features that match with the requirements of the changing market. With the focus on costefficient production of electricity, the most important requirements of today are low overall lifecyclecosts, high reliability, availability and operating flexibility. Additionally, specific customerAnd local site requirements need to be met by the suppliers of power plants and components. Atthe same time, the market demands continuously decreasing turbine delivery times and prices.Thus, one of the primary requirements of all steam turbine manufacturers is to standardize theirproducts in order to meet the cost and delivery time targets while at the same time providinga high level of flexibility to their customers. This also helps to obtain optimum performancelevels and product quality. For steam turbines, the main design parameters are the power output, the steam conditions, theambient temperature and the power plant configuration. In combined cycle power plants (CCPP)these are strongly related to the number and type of the installed gas turbines. In single shaftunits a gas turbine and a steam turbine commonly drive a single generator. For start up and shutdownoperations, this configuration requires a switch gear to separate the steam turbine from the shaft train. Multi-shaft configurations use independent gas turbine-generator and steam turbinegeneratorsets. Commonly, one or two gas turbines power a heat recovery steam generator(HRSG), which drives the steam turbine-generator set. Within a given CCPP configuration, the steam conditions depend on the power output and temperature level of the applied gas turbine. Hence, as a re sult of the ongoing gas turbine development, steam temperatures and mass flows are increasing continuously. Typically, thecurrent generation of CCPPs (e.g. [8]) are designed for main steam conditions of 157 bar and 565C, and reheat temperatures of 565C. However, due to the numerous gas turbines in the market, steam turbines need to be able to cover a wide pow range for CCPP. This range er mayalso be considerably increased if duct-firing is applied.

For sub-critical steam power plants (SPP) the market requires main steam temperatures up to 600Cat main steam pressures of 177 bar. Additionally, steam turbines for SPP need to featuresteam extractions as well as an overload injection to support an optimum steam cycle design.In recent years the steam turbine division of the Siemens Power Generation Group has focusedon the development of two-cylinder designs to cover the complete range of applications in CCPPand SPP up to a steam turbine power output of 700MW. The HE series, with a single flow LP, isapplied for lower power range and high back pressures, whereas the KN series covers the upperpower range and applications with large LP flows. For both product lines, particular effort hasbeen made to fulfill the market requirements with respect to performance, availability, start-up times and delivery times. Due to challenging price levels in the market, this could only be achieved with a modular design concept. The concept allows for high flexibility in the design phase, in order to deliver customer specific designs using standardized modules as a basis. This paper will provide an overview of the two product lines, and give details on the application of the modular concept within different aspects of steam turbine design.

TWO CYLINDER DESIGNS UP TO 700MW For the power range from 100MW to 700 MW, Siemens provides two optimized twocylindersteam turbine designs with single and double flow low pressure sections. Forapplications with lower power output or high back pressures, the HE product line with single flow LP is used. The flat floor mounted HE steam turbine set consists of a high pressure turbinemodule (H) and a single flow combined intermediate/low pressure module (E) with axialexhaust. The H-turbine is a single-flow, full-arc admission machine. The steam enters through one combined control and stop valve. The H-turbine casing uses the proven barrel-type design, whichdoes not have horizontal flanges at the outer casing to ensure a homogenous distribution of theforces regarding main steam pressure and thermal load. Additionally, the design improves the

TWO CYLINDER DESIGNS UP TO 700MW For the power range from 100MW to 700 MW, Siemens provides two optimized two-cylinder steam turbine designs with single and double flow low pressure sections. (Fig. 1). Forapplications with lower power output or high back pressures, the HE product line with singleflow LP is used. The flat floor mounted HE steam turbine set consists of a high pressure turbine module (H) and a single flow combined intermediate/low pressure module (E) with axialexhaust.The H-turbine is a single-flow, full-arc admission machine. The steam enters through onecombined control and stop valve. The H-turbine casing uses the proven barrel-type design, which does not have horizontal flanges at the outer casing to ensure a homogenous distribution of theforces regarding main steam pressure and thermal load. Additionally, the design improves the TWO CYLINDER DESIGNS UP TO 700MW For the power range from 100MW to 700 MW, Siemens provides two optimized two-cylinder steam turbine designs with single and double flow low pressure sections. (Fig. 1). For applications with lower power output or high back pressures, the HE product line with single flow LP is used. The flat floor mounted HE steam turbine set consists of a high pressure turbine module (H) and a single flow combined intermediate/low pressure module (E) with axial exhaust. The H-turbine is a single-flow, full-arc admission machine. The steam enters through one combined control and stop valve. The H-turbine casing uses the proven barrel-type design, which does not have horizontal flanges at the outer casing to ensure a homogenous distribution of the forces regarding main steam pressure and thermal load. Additionally, the design improves the Turbine Modules For the K-Turbine, the full application range from 100-700 MW (for 60Hz) is covered with four module sizes (Fig. 2). All modules are based on the same design philosophy in order to apply similar proven design features to all turbines. The latest design incorporates the Kturbine experience of the past 30 years from both Siemens andWestinghouse.The scaling factor between the different turbine modules have been regard to turbine efficiency. As a result, the K-turbine family covers the complete applicationrange with a constantly high performance. Additionally, the modular design yields further cost and delivery-time benefits to the customer. Firstly, developmental efforts for new K-turbine types is considerably reduced and contractspecific design work is minimized, while at the same time the high level of reliability ismaintained. Secondly, the long lead time items are standardized for 50Hz and 60 Hz applicationsin order to reduce the delivery times. As an example, identical casing patterns can be used for50Hz and 60Hz as well as for CCPP and SPP applications. Due to the design of the patterns,required extractions and overload admission can be added by means of separate parts. Sub-Modules The turbine modules are furthermore divided into sub-modules of different sizes, which may be combined as required. This approach has been especially favourable for the E-turbine, since size of the IP part is mainly linked to the main steam flow, whereas the size of the LP part alsostrongly depends on the ambient temperature. Therefore the modular concept consists of astandardized axial separation plane between the IP and LP casings and of a welded rotor module. The modular concept yields an optimum number ofrequired components to cover a wide rang of e applications for both CCPP and SPP. For the latter, anadditional set of casing components is available withsteam extractions. Again, the main benefits from themodular concept are reduced prices and delivery timesdue to the standardized long lead time items while atthe same time a very high performance level ismaintained.

Valves The HP, IP and LP admission valves comprise stop andcontrol valves arranged at right angles to each other andcombined in a single casing (Fig. 4). For both the E andthe K turbines, the valve assembly is provided with a flange connection at the bottom of the outercasing of the turbine. The modular valve concept consists of a standardized connection to the turbine casings fordifferent sizes. Thus different valve sizes can be assembled to a single turbine size, and a single valve fits to different turbine types. Hence an optimum valve arrangement with respect to flow velocities can always be applied to achieve maximum element efficiency. Bearings The HE and the KN steam turbine arrangements both consist of three bearings. All three bearing pedestals are separated from the turbine casings and are supported directly on the foundation. Only one bearing is located between the turbine sections tomi imize the effect of foundation n deformation on loads to bearingsand shaft journals. Axial thermalexpansion of the entire rotor trainstarts at the combined journal andthrust bearing as the fixed point. Ifrequired, the bearing pedestal canonly one bearing is locatedbetween the turbine sections tominimize the effect of foundationdeformation on loads to bearingsand shaft journals. Axial thermalexpansion of the entire rotor trainstarts at the combined journal andthrust bearing as the fixed point. Ifrequired, the bearing pedestal candesign with optimumefficiencies is delivered to thecustomer. Different to the other elementsof the steam turbine, theprimary goal of standardizationwith regard to HP/IP bladinghas been to standardize theway to the product instead ofthe product itself. The basis isa strictly modular concept ofblade path construction from standard and proven elements (e.g. air foils, roots, grooves, shrouds,extractions, locking devices). As an example (Fig. 7), the composition of a single blade fromroot, shroud and air foil is demonstrated. For each element, different types exist for the variousapplications, each type having its own advantages and disadvantages with respect toperformance, mechanics and costs. Within the modular concept all these different types may becombined freely to give an optimum blade for the specific design boundary conditions such asaerodynamics, forces, materials and temperatures. Hence, cylindrical, twisted or bowed airfoilscan be assembled with any of the roots or shrouds. Details on the concept applied for HP/IPblading are given in MODULAR CONCEPT TO FULFILL TEMPERATURE AND PRESSURE REQUIREMENTS Besides the main stream flow, the second major design parameters are the main steam conditions.Main steam temperatures are continuously increasing to optimize the overall performance ofSPPs, and as in gas turbine development, also for CCPPs. At the same time high temperaturesrequire expensive material to withstand the associated optimum pressure levels. In order to keepprice increase moderate for such advanced steam cycles, one focus of the modular concept is toreduce the amount of required high-temperature material to a minimum. The basic designelements of the concept are: y To apply identical designs for the main components at different temperature levels (e.g. 565Cand 600C) and thereby only to change material.

y y y y

To weld main components in order to minimize the amount of high-temperature material. To shield components against the hot steam. To cool affected areas. The application of the concept to HEand KN product lines will be outlinedbelow. K-Turbine Material Concept forTemperatures up to 600C

The combined HP/IP turbine (KTurbine,Fig. 8) consists of a top and abottom half of inner and outer casingswith horizontal flanges. The thermalload due to the high main steam andreheat steam temperatures andpressures is completely carried by the inner casing. For this reason, the material of the innercasing is selected according to the specific application temperatures. Similarly, the rotor materialis chosen depending on the size of the K -turbine, the application temperature and the rotationalspeed (50 or 60 Hz).Steam TemperatureMain / Reheat SteamVariant 1540C / 540C Variant 2566C / 566C Variant 3600C / 600C Future600C / 620C Rotor(50Hz or 60Hz) low alloyed low alloyed orhigh alloyedhigh alloyed high alloyedInner Casing low alloyed low alloyed high alloyed high alloyedOuter Casing globular castironglobular castironglobular castironglobular castironValve Casingslow alloyedor high alloyed low alloyedorhigh alloyedhigh alloyed high alloyed Table 2: K-Turbine and Valve Materials

The design consists of special features which shield the outer casing from the hot main steam and reheat steam temperatures. The valve is connected to the inner casing via a flexible L-ring and a thermo sleeve that guides the hot steam directly into the inner casing and the HP or IP blading respectively. As a result, the outer casing only needs to withstand the IP-exhaust pressure andtemperature. Therefore the outer casing material for all applications is globular cast iron, which yields considerable cost reductions. Similarly, the valve casing materials are cost optimized for different design pressure and temperature regimes. As an example of the modular material concept, an overview of the K -turbine material combinations applied for different main steam and reheat steam temperatures. Welded Rotor Design A welded design has been applied to the rotor of the new E-turbine. The required material properties for the hot IP section with smaller blades and the cold LP section with large centrifugal

forces are completely different. Therefore, only a welded rotor design enables the use of optimal materials for both the hot IP section and the cold LP section. The combination of two materials for the rotor yields an optimum of mechanical properties over a wide reheat temperature range: up to 565C 2%-Cr-steel is utilized for the IP rotor block and the inner casing. Up to 600C, the rotor and inner casing material is substituted by a 10%-Cr-steel. The LP rotor block consists of a 3.5%-Ni-steel. The rotor welding seam is positioned behind the LP front stages. This offers the advantage to implement a cost effective welding seam at the low diameter of the IP drum.

Cooling of Dummy Piston To achieve maximum thermodynamic efficiencies, a straight-flow design was chosen for the new E-turbine. In contrast to a reverse-flow concept, the chosen straight-flow design requires a large IP piston diameter for sufficient axial thrust compensation. Due to the mechanical impact of this large piston diameter at reheat temperatures, a forced rotor cooling has been developed for the IP piston to ensure high life cycles. Cooling steam (350C) from the cold reheat is blown into a special mixing space in front of the IP piston and mixed with hot reheat steam (between 565C and 600C) from the IP inlet to achieve an optimum temperature of 450C. At this temperature, two advantages for both the IP rotor and the IP piston are combined: optimum rotor life cycles and minimum clearances at the IP piston seal. Thereby 2%-Cr-steel can be used for the IP rotor up to temperatures of 565. Thus, performance and reliability remain at a high level without increasing material costs. The cooling system has successfully been tested in E-turbines with high temperature capability in the USmarket. MODULAR CONCEPT FOR OPTIMUM LP ENDS FOR A WIDE RANGE OF CONDENSER PRESSURES The third major design parameter with respect to modularity is the volume flow through the LP end stages, which is directly connected to the mass flow and the condenser pressure. The performance of the last stages and the exhaust diffuser is strongly related to the mean axial velocity in this area. A number of different LP sizes are therefore required to cover the range of condenser pressures without compromising the performance of the LP section. In this case, the focus of the modular concept is to achieve an optimum balance between maximum LP performance and moderate costs. Therefore, the main targets where set to define an optimum set of LP standard stages to cover the required range of volume flows. to enable cost effective connections of all required combinations of LP and IP components and thereby to maintain optimum performance. Thereby, a large condenser pressure range of 20 to 200mbar is being considered.

LP Blading Since the axial velocity after the last blade is primarily related to the exit area (and not to length of the last blade), a homogenous distribution of exit areas has been chosen for the Siemens family of LP standard stages . For each of the given exit areas, a Free Standing LP End Blades In general, the last two rows of LP moving blades are designed as free-standing blades with curved fir-tree roots for a homogenous stress distribution. The highly-efficient three-dimensional airfoil design consists of super-sonic tip section for the large end blades (Fig. 10). The inlet edge is flame or laser hardened, respectively, to prevent from droplet erosion. Additional erosion protection measures are applicable to the last stationary blades. They are designed as hollow blades that either consist of drainage slots (Fig. 11) to remove moisture from the blade surface or can be heated with steam. An advanced three-dimensional airfoil design is applied in order to increase stage reaction at the blade hub and hence improve performance at lowloadIn order to allow for larger axial movement due to thermal expansion, non-interlocking labyrinth seals are applied within the LP section of the turbine. The seal design provides an optimum sealing efficiency within a relatively short seal length. LP Exhaust Casing for Single Flow ETurbine The modular concept of the E-turbine provides only three different LP exhaust casings to cover the complete exit area range specified in table 1. The six related sets of standard LP stages are

installed by means of standardizedinterfaces. Also, the axial joint betweenthe LP exhaust casing and the IP outer casing is a standard interface that allows any combination

of sizes of the two casings. Fig. 12 shows the LP exhaust casing module for the 12.5m2 exhaust section. Exhaust Geometry Optimization Detailed computational fluid analyses are performed in the design phase, in order to optimize the geometry of the LP turbine exhaust as well as the transition region to the condenser. In conjunction with measurements on models and on turbines in the field, effort is focused on increasing exhaust pressure recovery and hence improving the overall steam turbine performance. As an example, Fig. 13 shows the results of an exhaust analysis with flow lines for a classic turbine deck arrangement with the condensers mounted below the turbine. The steam flow downstream of the last turbine stage passing into the exhaust hood shows considerable vortices, which were also observed in the flow in the exhaust casing itself. As vortices cause energy loss in the flow, guide vanes have been installed to improve flow and thereby reduce pressure losses. SUMMARY For a power range from 100MW up to 700MW Siemens provides the HE and KN steam turbine product lines for both CCPP and SPP. Both turbo sets consist of a two casing design. The HE is applied where a single flow LP section is sufficient to take the steam flow at optimum velocities. For large power output and low condenser pressures the KN product line with a double flow LP turbine is applied. Both designs are based on a modular design concept. Details have been given in the paper on how the concept is applied to compensate for the effects of the major design parameters power output, temperature and condenser pressure. Thereby, the main targets are to reduce the

number of variants of major components and to minimize the material cost impact of high temperatures.

The concept has successfully been applied within the HE and KN product lines and is seen a fundamental basis to fulfill the challenging requirements in todays steam turbine market. The reduced number of major components ensures short delivery times and low costs. At the same time the concept stands for reliability due to the application of proven Siemens technology and similar designs through-out each set of module sizes. Special design features such as the welded E-turbine rotor contribute to short start-up times and operational flexibility. All configurations consist of Siemens latest LP standard stage designs. In the HP and IP sections a highperformance fully three-dimensional reaction blading is applied, which is designed on a contract specific basis to provide maximum blade path efficiency. Hence, Siemens two casing designs have been optimized to fulfill the markets most important requirements of low overall life cycle costs, high reliability, availability and operating flexibility in order to support the customer focus on cost efficient production of electricity.

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. 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 M height to facilitate access to different stages of Rotor. This is installed in Bay-I assembly area. b) 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. c) 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. d) 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 hold the gas turbine rotor discs to form a composite turbine rotor. f) 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. 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. 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. h)

e)

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. Then the assembly is machined as per requirement. 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/Cm2. 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.

BROAD SPECIFICATION OF MAJOR/IMPORTANT MACHINE TOOLS & MACHINES CNC MACHINE TOOLS CNC HORIZONTAL BORERS: 1. Item Description Model Supplier CNC Control System : Spindle Dia. Table Max. Load on Table : Travers : Ram traverse Ram size Power Rating : Weight of the m/c ATC Capacity : Plan No. 2. Item Description Model Supplier CNC Control System Boring Dai Table Headstock Travel Spindle Speed Power Rating Max. Load Capacity Weight of the m/c Plan No. Item Description Model Supplier CNC Control System Spindle Dia. Traverse : CNC Horz. Borer : RAPID 6C : WOTN, GERMANY FANUC 12M : 200mm : 4000 x 4000 mm 100 T X=20000, Y=5000, X=1400mm : W = 1000 mm : 400 x 400 mm 90 KW : 111 T 60 Nos. : 1-227 (Block-I) : CNC Stub Borer : DW 1800 : HEYLIGENSTAEDT, GERMANY 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

: : :

3.

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.

6.

Item Description : CNC Centre Lathe Mode : D-2300 NYFS-1 Supplier : HOESCH MFC, GERMANY CNC Control System : SINUMERIK 7T Centre Distance : 18000 mm Swing Over Carriage : 2300 mm Swing Over Bed : 2900 mm Spindle Speed : 5 125 RPM Power Rating : 110 KW Weight of the job : 320 TON Weight of the m/c : 216 TON Plan No. : 2-360 (Block-III) Item Description : CNC Centre Lathe Model : KV2-1100 CNC Supplier : RANVENSBURG, GERMANY CNC Control System : SINUMERIK 820 T Centre Distance : 12000 mm Centre Height : 900 mm Swing Over Carriage : 1100 mm Swing Over Bed : 1400 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 Plan No. : 1-120 (Block-III)

CNC MILLING MACHINES

7.

Item Description Model Supplier CNC Control System : Table Traverse

Spindle Speed Power Rating Max. Load Capacity Weight of the m/c Plan No. III:TBM) 8.

: : :

: CNC Horz. Milling M/c (6 Nos.) : BFH-15 : BATLIBOI, INDIA SINUMERIK 810 M : 1500 x 400 mm : X=1170 mm Y=420 mm Z=420 mm 45 to 2000 RPM 11 KW 630 Kg : 4200 Kg : 2-449, 2-453, 2-454, 2-459, 2-460 (Block-

Item Description Model Supplier CNC Control System : Table Traverse

Spindle Speed Power Rating Max. Load Capacity Weight of the m/c Plan No. 9.

: : :

: Universal Milling M/cs (2Nos.) : BFK-15 : BATLIBOI, INDIA SINUMERIK 810 M : 1500 x 400 mm : X=1170 mm Y=420 mm Z=420 mm 45-2000 RPM 11 KW 630 Kg : 4200 Kg : 2-463, 2-466 (Block-III: TBM) : CNC Bed Type Milling M/c : FSQ 80 CNC : TOSKURIM, CZECH SINUMERIK 810 M : 3000 x 800 mm TEE SLOT 28H7 : X= 3000 mm Y= 870 mm Z= 850 mm H 2500 RPM 18 KW continuous 22 KW intermittent : 620 x 500 incldg ram 543 x 420 encldg ram 24 Nos. : 2500 Kg : 2-484 (Block-III)

Item Description Model Supplier CNC Control System : Table Traverse

Spindle Speed Range : Spindle Drive Power : Spindle Head Size ATC Capacity Table Load Plan No. :

CNC MACHINING CENTRES 10. Item Description (2nos.) Supplier CNC Control System : Indexing Table : Indexing Position Plan No. 11. Item Description Model Supplier CNC Control System : Table Traverse : SPL. Purpose 6 Station T-Root Machining Centre

: MIH, JAPAN FANUC 7M 1900 mm dia : 6 Nos. : 2-356, 2-41 (Block-III: TBM) : SPL Purpose FIR Tree Root M/cingCenre : NTH 200 : RIGID, SWITZERLAND SINUMERIK 7M : 1400 x 1400 mm : X= 1950 mm Y= 900 mm Z= 600 mm 30600 RPM 4 22 KW 2-354 (Block-III TBM)

Spindle Speed No of Spindle Power Rating Plan No.

: : :

CNC VERTICAL BORERS 12. Item Description Model Supplier CNC Control System : Table dia Turning dia Turning Height : Spindle Speed : No. of Ram Power Rating : Max. Load Capacity : Machine Weight Max. Ram Travel (Vertical) Plan No. : CNC Vertical Borer : TMD 40 / 50 : OSAKA MACHINES, JAPAN FANUC 6TB, 3TC : 4000 mm : 5000 mm 4200 mm 0.23-30 RPM : 2 75 KW 70T : 100 T : 2200 mm : 2-422 (Block-III)

13.

Item Description : CNC Vertical Borer (2 Nos.) Model : 40 DZ Supplier : SCHIESS, GERMANY 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 Power Rating : 71 KW Table Load Carrying Capacity:80 T ATC Capacity : 12 Nos. Plan No. : 1-235 (Block-I), 2-472 (Block-III) Item Description : CNC Vertical Borer Model : 32 DS 250 Supplier : SCHIESS, GERMANY CNC Control System : SINUMERIK 850T 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 Power Rating : 56 KW ATC Capacity : 12 Nos. Plan No. : 2-483 (Block-III)

14.

OTHER SPECIAL PURPOSE CNC MACHINES 15. CNC SURFACE BROACHING M/C Make Model CNC System Broaching capacity (pulling force) Broaching slide stroke Broaching slide width Max tool length (continuous /row) Broaching Speed (cutting stroke) Broaching Speed (return stroke) Drive power rating Broaching slide movement Maximum noise level Max. dia of the disc (mountable)

: : : : : : : : : : : : :

MarbaixLapointe, UK Champion 32 /10, 300 SINUMERIC 850 M 320 KN 10.3 mm 1500 mm 9650 mm 1-25 M/min 60 M/min 135 KW Electro-mechanical < 80 Dbs 2300 mm

Max. weight of the job Indexing & rotating tables J Indexing accuracy Plan No. 16. CREEP FEED GRINDING M/C Make Model CNC System Work-piece diameter Work height Rotary & indexing table dia. Indexing accuracy Max. load capacity Y-axis (grinding head movement) Vert. Traverse Z- axis (grinding head support) Movement on cross rail) Horizontal traverse Traverse feed rate Grinding head main support Drive motor Grinding wheel max. dia. Max. width Bore Surface speed Plan No. BROACH SHARPENING M/C Make CNC System Work-piece diameter Work Length Plan No.

: : : :

3000 Kgs 1500 mm, 1000 mm +/- 3 Arc sec. 2-485

: : : : : : : : :

ELB CHLIFE, GERMANY ELTAC SFR 200 CNC SINUMERIC 3 GG 200 2000 mm 2400 mm 2050 mm +/- 1 ARC SEC 20000 KG 750 mm

: : : : : : : :

2400 mm 02 1200 mm /min 34 KW 500 mm 100 mm 203.2 mm 16-35 M/Sec. 2-491

17.

: : : : :

LANDRIANI, ITALY SELCA Upto 250 mm 200 mm 2-487

BROAD SPECIFICATIONS OF MAJOR / IMPORTANT MACHINE TOOLS & MACHINES B: NON-CNC MACHINE TOOLS

(1)

PRECISION HEAVY DUTY LATHE Manufacturer :Karamatorsk Heavy Machine Tool Works (USSR); Model KS-1614

Specifications 1. 2. 3. 4. 5. 6. 7. 8. 9. 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 2000mm 1500 mm 8000mm 80 mm 0.15 mm

Maximum Length between Centres when machining by the method of 1200 mm Combined Freeds Maximum Weight of work piece Maximum Length of Machine over the Saddle Maximum Summary Effort of Cutting 20000 kg 8000 kg 10,000 kg

10. Limit Dimension of Thread Cut:

Thread Pitch

Max Length of Thread, Min Max 96 20 3/8 mm 6300 6300

Metric Threade Pitch (in mm) 1 British Trhread Pitch (Per inch)

Name of Part

Power

Displacement in mm

One Division Of Dial

Rapid Traverse M/min 2.02

Manual Carriage Transverse Slide Longitudinal Slide 1130 600 1130 600

Per Rev. of Dial

Represent

8 6

0.1 mm 0.1 mm

1.03 0.48

Tool Slide Rotary Part

150 90o

6 5o

0.1 mm 0.5 260 mm 17 mm Available Available

Maximum Displacement of the Tailstock Spindle Maximum Transverse Displacement of the Tailstock Rotating Built in Centre Power Extraction of the Tailstock Spindle Rapid Traverse of the Tailstock 12. Overall Dimension: Length 13900 mm 13. Width 3845 mm

3.44 M/min

Height 2865 mm

Plant No. 2-182 (Block-III)

UNIVERSAL VERTICAL TURNING & BORING MACHINE Manufacturer :Kolomna Machine Tool Works (USSR) Model KY 152 Specifications 1. 2. 3. 4. Maximum Dia. of workpiece accommodated Dia. of central table Maximum travel of vertical Tool Heads from center of table 5250 mm Maximum weight of workpiece accommodated on central table (a) With table speed limited to n (n e 6) r.pm. (b) At any speed 200 T 100 T 10000/12500 mm 8750 mm

5. Maximum cutting force with different length of tool over-hang (L) from head face R.H. Head 16000 Kg with Le 1500 mm 7500 Kg with L e 2000 mm 2000 Kg with L e 3000 mm 1200 Kg with L e 3700 mm L.H. Head 12500 Kg with Le 1500 mm 7500 Kg with L e 2000 mm 2000 Kg with L e 3000 mm 1200 Kg with L e 3700 mm 6. Rated cutting dia on central table 6300 mm

7. 8.

Maximum cutting torque on central table Speed range of central table rotation

80000 Kg.M Minimum = 0.112 r p.m. Maximum 11.2 r.p.m.

9. 10.

Travel rate of column assembly Plan No.

190 mm /minute 1-13 (Block-I) 1-24 (Block-III)

BALANCING MACHINE Manufacturer: SCHENK (West Germany) Model :Dj 90 Specifications 1. Weight of rotor 10,000 to 80,000 kg

2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Minimum weight without considerable loss of measuring sensitivity, 5000 kg provided the berings can accommodate such small rotors. Maximum weight for one bearing pedestal Height of rotor axis above machine bed 45,000 kg 1600 mm

Rotor diameter (free swing over machine bed) not considering the 4000 mm funnel Diameter of journal Max. 540 mm

Diameter of journal, with special sleeve bearing cups made from high Max. 600 mm grade material. Minimum distance between bearings for less than 10 tons rotor Minimum distance between bearings for more than 10 tons rotor 1500 mm 1900 mm

Maximum distance between coupling plague and center of the scond 13500 mm bearing pedestals Rotational Speeds (a) For rotors from 5 to 10 tons Min. 800 rpm Max. 4000 rpm Min. 700 rpm (b) For rotors from 10 to 20 tons Max. 3600 rpm Min. 600 rpm

(c) For rotors from 20 to 80 tons 12. Maximum test speed and overspeeds (a) For rotors upto 50 tons (b) For rotors upto 50 to 80 tons 13. 14. 15. 16. 17.

Max. 3600 rpm

4500 rpm 3600 rpm

Maximum centrifugal force admissible on each bearing pedestals for 50,000 Kg short period of time Balancing accuracy to be obtained depending on Selling Weight 0.3 to 3 micron

Sensitivity of indication depending on rotor weight, speed and selling 0.1-8 div/micron weight Accuracy of the angle indication 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).
s 1 o 2o

SPECIAL DRILLING & BORING MACHINE Manufacturer: Machine Tool Works, Ryazan (USSR) Model: PT 182 H5 SPECIFICATIONS: 1. 2. 3. 4. Swing over bed Drilling dia Boring dia Swing of job in rest Max Min 5. Swing of job in Headstock chuck 6. 7. Maximum length of job Maximum weight of job Max. Min. 800 mm 40-80 mm 80-250 mm 300 mm 110 mm 300 110 mm 3000 mm 2000 Kg

8.

Number of spindles

Headstock Stemstock

1 1 Horizontal

9. 10.

Spindle location Distance to spindle axis: From bed wasy From floor

400 mm 1100 mm 750 r.p.m. 71. r.p.m. 24 Available

11.

Head stock Spindle speed

Max Min.

Number of steps of spindle speed Spindle braking 12. Stemstock Spindle speeds Max. Min. Number of steps of spindle speed Stemstock feed Max. Min. Number of feed steps 13. Overall dimensions Length Width Height Weight 14. Plan No

730 r.p.m. 123 r.p.m. 6 1680 mm / min 168 mm / min Stepless

13500 mm 2300 mm 1700 mm 23844 Kg. 1-105 III) (Block-

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 560 mm 600 Kg 1100 mm

2. 3. 4. 5.

Maximum length of grinding (with maximum hole diameter) Maximum weight of work Distance from spindle axis to floor level Distance from spindle axis to table (a) Maximum (b) Minimum

300 mm 100 mm

6.

Cantilever vertical travel (a) Per one revolution of handwheel (b) Speed of rapid vertical traverse (from motor) (c) Per dial graduation 0.133 mm 190 mm / min. 0.01 mm 500 x 1200 mm

7. 8.

Table working surface dimensions Table cross-traverse (a) To operator from intermediate (zero) position (b) From operator from intermediate (zero) position (c) Total (d) For one revolution of hand wheel (e) For one dial graduation (f) Speed of rapid traverse (from motor)

200 mm 200 mm 400 mm 0.2 mm 0.01 mm 280 mm / min

UNIVERSAL THREAD GRINDING MACHINE Manufacturer: Moscow Jig Boring Machine Plant (USSR) Model : 5822B3 SPECIFICATIONS 1. 2. Maximum diameter of work admitter Nominal diameter of thread being ground Min Max 160 mm 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 (b) By multiple ribbed wheel 75 mm 55 mm 1o 47' 24" or 1:16

5.

Maximum taper of thread:

6.

Table Maximum longitudinal table traverse, (a) By hand (b) By power Table rapid withdrawal speed 425 mm 415 mm (variable: maximum about m/min) 1.2

7.

Taper (a) Headstock spindle (b) Tailstock spindle MT 4 MT 5

8.

Grinding Wheelhead Maximum cross feed (a) By hand (b) By power Movement per dial division Movement per dial revolution 125 mm 50 mm 0.005 mm 1 mm

PLANER Manufacturer : The Yefemov Plant TIAZHSTANKOGIDRO-PRESS (USSR) Model : 7A288-T SPECIFICATIONS 1. Max. width of planning 4000 mm

2. 3. 4.

Max. height under cross rail Distance between housings Max. travel of slides below cross rail and inside housing (a) for vertical tool heads (b) for side tool heads

4000 mm 4250 mm

700 mm 700 mm 100 T 40000 Kg.

5. 6.

Max. allowable weight of workpiece Max. cutting force Arrangement for mechanizing and automating the machine operation is available

7.

Table Dimension of working surface of table, (a) Width (b) Length Table Stroke, Max. Min. Safety devices disengaging. to stop table after worm 3600 mm 12000 mm 12000 mm 3000 mm Available.

8.

Tool Heads Number of tool heads (a) Vert. (b) Side Travel of tool heads, mm. V.Tool Side Tool Heads Heads R.H. 3750 700 L.H. 3750 700 2 2

(i) (ii) (iii)

Max. vertical travel Max. horizontal travel Travel per turn of hand-wheel lever, (in mm) Vertical travel Horizontal travel

700 5000

1.14 0.52

4.25 1.14

4.25 1.14

(iv)

Dial division value Vertical 0.1 0.2 0.2

Horizontal (v) Rapid travel Speed mm Vertical Horizontal

0.2

0.1

0.1

1.25 2.5

2.5 1.25

2.5 1.25

9. (i)

Cutter Head: Max. dimension of tool holder Vertical Tool head (a) Width (b) Height 120 mm 120 mm Side Tool head 120 mm 120 mm

(ii)

Max. angle of slide Swiveling (a) To the right (b) To the left 60 o 60 o 10
s 10 o

45o 45o 10
s 10 o

(iii) (iv) (v)

Dial division value Swiveling of cutter head plate

Cutter head automatic lifting during return stroke Available of table Cross Rail: Maximum travel Rapid travel speed Time of cross rail automatic fixing Main drive motor 4000 mm

Available

10.

Not less than 0.3 M/min 20 to 30 sec. 2 x 130 KW 2-189 (Block-III)

11.

Plan No.

MATERIALS SPECIFICATION X20 Cr 13 A. 13% Cr. Stainless Steel Bars (Hardened & Tempered) 1. General bars of grade X20 Cr. 13 2. Application Turbine. : : This specification governs the quality of stainless steel For machining of moving and guide blades of steam

3. Condition of Delivery : Hot rolled / Forged & hardened and tempered. The bars shall be straight and free from waviness. 4. 5. Complete with standards: There is no Indian standard covering this material. 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 per table. 5.1. Hot Rolled Bars below : : : The tolerance on cross sectional dimensions shall be as Tolerance on hot rolled flat bars shall be as specified

s
"b" width across flates mm Up to 35 Over 35 and Upto 75 Over 75 Allowable deviation on "s" thickness mm Allowable devi. on "b" mm 'S' mm b + 1.5 +2 +3 Up to 20 +1

Over 20 and + 2 Upto 40 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 ignot (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 10300C and the tempering temperature shall not be below 6500C 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 300C 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. 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 9.3 Repair of surface flaws by welding in not permitted The edges of bars shall be cut square by swaing or shearing.

10.CHEMICAL COMPOSITION : The chemical composition of material shall be as follows (table analysis in %)

Element Carbon Silicon Manganese Chromium Nickel

Min. 0.17 0.10 0.30 12.50 0.30

Max. 0.22 0.50 0.80 14.00 0.80

Sulphur Phosphorus 11.

---

0.020 0.030

SELECTION OF TEST SAMPLES : 11.1 Chemical analysis shall be reported on each heat basis.. 11.2 For Mechanical Test

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, all the 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 which ever 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/MM2 Min Tensile strength % Elongation on 5.65 % reduction in area Impact (mean of 3.1S0 V sample) Hardness (HB-30) * The smallest value shall be at least 14 J. 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.
S0

: : : : :

800 950 N/mm2 15 min. 50 min. * 20 J min.

e 280

13.1 UT of the prematerial 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 D3 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 D2. 13.2.2 13.2.3 13.2.4 a)
y y

Mix up test (verification test) of all bars. Visual inspection of all bars Acceptance Criteria

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 are unacceptable.

Defect indication observed during MT, can be removed by grinding (dressing up) b with in ut 1mm depth. b) Ultrasonic Test : Quality class 2b with following modification that individual indication > 2mm EFB (KSR) and back wall losses > 3dB are unacceptable. X2 CrMoV1 21 B. 600 N/MM2 minimum 0.2% Proof stress Heat resistant steel bars for steam turbine blades 1. General 21. 2. Application blades for steam turbines. 3. Dimension & Tolerance : : : Hot rolled and forged bars of steel grades X22 CrMoV1 Bars are required for machining of guide and moving

b
"b" width across flates mm Up to 35 & Over 35 Upto 75 Over 75 Allowable deviation on "s" "b" mm mm 1.5 +2 +3 thickness Allowable devi. on 'S' s mm

Up to 20 & Over +1 20 Upto 40 Over 40 +2 +3

4. Chemical Composition : Element % min. % max.

Carbon Silicon Manganese Chromium Malybeonum Vanadium Nickel Sulphur Phosphorous 5. MECHANICAL PROPERTIES : 0.2 % proof stress Tensile Strength % Elongation % Reduction in area Notch Impact Value

0.18 0.10 0.30 11.00 0.80 0.25 0.30 ---

0.24 0.50 0.80 12.50 1.20 0.35 0.80 0.020 0.030

: : : : :

600 N/mm2 min. 800-950 N/MM2 14 Min. 40% Min. 27 J * Min. * Average of 3 IS0 V Samples.

C. 600 N/MM2 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: per ordering drawing accompanying the order. The dimension and tolerances shall be as

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 6500 C. The minimum residual are to be aimed through sufficient duration of the tempering treatment and the slow cooling rate from 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 6100C followed by slow cooling. 7. Freedom from Defects : Blades shall be free from folds due to forging ; cracks, tearing and other material defects, elonganed non-metallic and jusions, seams etc. any blade blade containing such defects shall be rejected. 8. Surface finish : The blade shall be supplied in a desoaled and deburred condition. The surface finish shall comply with the requirements specified on the drawing. In the surface is ground prior to blasting the 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 H/2 and ground areas shall be blended over a length of LP/2. However H Shall not be exceeded. H pressure side. LP to trailing edge. : : Allowable profile deviation on the

Profile length measured from leading edge The chemical analysis of the material shall % min. 0.17 0.10 0.30 12.50 0.30 --% max. 0.22 0.50 0.80 14.00 0.80 0.020 0.030

9. Chemical Composition : confirm to the following : Element Carbon Silicon Manganese Chromium Nickel Sulphur Phosphorous

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 Tensile Strength % Elongation % Reduction in area Impact Value (Average of 3, ISO V Sample) Brinell hardness HB 30 11.2 confirm to the gauge length. : : 20 J Min. 280 Max. The tensile test piece shall : : : :
u 600 N/mm2

800-950 N/MM2 15 Min. 50 Min.

Tensile Test :

L0 ! 5.65 S0
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 : Blade shall only be manufactured from

12.1 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. Dimenional Checks for Acceptance : The supplier shall check 100% of the forgings Dimensions parameters to be checked for

13.1 w.r.t. to all parameters. 13.2 acceptance.

y 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 o From tolerance for suction side o From tolerance for Inlet edge

= = =

H R, max difference R H

o Twist Tolerance = y y y y y y y y

( H, R) max. = D Max. / D/ D1

Profile thickness of each section. 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
y

Procedure for dimensional checks :

Check of inlet edge : The profile of inlet edge shall be checked by using split profile gauges.

y Check of Profile : All the dimensional parameters mentioned at (13.2) shall be checked using a vertical measuring stand. y y

Drilling of BHEL Centre holes Checking of BHEL Centres.