BHEL - Haridwar VOCATIONAL TRAINING REPORT

Balancing of turbine !aft b" O#BT

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Bac!elor of Tec!nolog" $Production engg*) COLLEGE O+ TECHNOLOG,- PANTNAGAR

Pro.ect Guide/ 1r* Alo2 #!u2la $#3G1)

#ub0itted b"/ Adit"a Puri $I3/ 455&6)

Turbine
A tea0 turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in !!". It has almost completely replaced the reciprocating piston steam engine #invented by $homas %ewcomen and greatly improved by &ames 'att( primarily because of its greater thermal efficiency and higher power)to)weight ratio. *ecause the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator + about !,- of all electricity generation in the world is by use of steam turbines. $he steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process.

Par on turbine from the Polish destroyer ORP Wicher II

T"7e
Steam turbines are made in a variety of sizes ranging from small hp #,../ 0'( units #rare( used as mechanical drives for pumps, compressors and other shaft driven e1uipment, to 2,,,,,,,, hp # ,/,,,,,, 0'( turbines used to generate electricity. $here are several classifications for modern steam turbines.

#tea0 #u77l" and E8!au t Condition

$hese types include condensing, non)condensing, reheat, extraction and induction. %on)condensing or bac0pressure turbines are most widely used for process steam applications. $he exhaust pressure is controlled by a regulating valve to suit the needs of the process steam

pressure. $hese are commonly found at refineries, district heating units, pulp and paper plants, and desalination facilities where large amounts of low pressure process steam are available. Condensing turbines are most commonly found in electrical power plants. $hese turbines exhaust steam in a partially condensed state, typically of a 1uality near 3,-, at a pressure well below atmospheric to a condenser. 4eheat turbines are also used almost exclusively in electrical power plants. In a reheat turbine, steam flow exits from a high pressure section of the turbine and is returned to the boiler where additional superheat is added. $he steam then goes bac0 into an intermediate pressure section of the turbine and continues its expansion.

Ca ing or #!aft Arrange0ent

$hese arrangements include single casing, tandem compound and cross compound turbines. Single casing units are the most basic style where a single casing and shaft are coupled to a generator. $andem compound are used where two or more casings are directly coupled together to drive a single generator. A cross compound turbine arrangement features two or more shafts not in line driving two or more generators that often operate at different speeds. A cross compound turbine is typically used for many large applications.

Princi7le of O7eration and 3e ign

An ideal steam turbine is considered to be an isentropic process, or constant entropy process, in which the entropy of the steam entering the turbine is e1ual to the entropy of the steam leaving the turbine. %o steam turbine is truly 5isentropic6, however, with typical isentropic efficiencies ranging from 2,-)3,- based on the application of the turbine. $he interior of a turbine comprises several sets of blades, or 5buc0ets6 as they are more commonly referred to. 7ne set of stationary blades is connected to the casing and one set of rotating blades is connected to the shaft. $he sets intermesh with certain minimum clearances, with the size and configuration of sets varying to efficiently exploit the expansion of steam at each stage.

Turbine Efficienc"
$o maximize turbine efficiency, the steam is expanded, generating wor0, in a number of stages. $hese stages are characterized by how the energy is extracted from them and are 0nown as impulse or reaction turbines. 8ost modern steam turbines are a combination of the reaction and impulse design. $ypically, higher pressure sections are impulse type and lower pressure stages are reaction type. I07ul e Turbine An i07ul e turbine has fixed nozzles that orient the steam flow into high speed 9ets. $hese 9ets contain significant 0inetic energy, which the rotor blades, shaped li0e buc0ets, convert into shaft rotation as the steam 9et changes direction. A pressure drop occurs across only the stationary blades, with a net increase in steam velocity across the stage.

Reaction Turbine In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles. $his type of turbine ma0es use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a 9et that fills the entire circumference of the rotor. $he steam then changes direction and increases its speed relative to the speed of the blades. A pressure drop occurs across both the stator and the rotor, with steam accelerating through the stator and decelerating through the rotor, with no net change in steam velocity across the stage but with a decrease in both pressure and temperature, reflecting the wor0 performed in the driving of the rotor.

GA# T9RBINE

A ga turbine, also called a co0bu tion turbine, is a rotary engine that extracts energy from a flow of combustion gas. It has an upstream compressor coupled to a downstream turbine, and a combustion chamber in)between. #Ga turbine may also refer to 9ust the turbine element.( :nergy is added to the gas stream in the combustor, where air is mixed with fuel and ignited. Combustion increases the temperature, velocity and volume of the gas flow. $his is directed through a nozzle over the turbine;s blades, spinning the turbine and powering the compressor.

:nergy is extracted in the form of shaft power, compressed air and thrust, in any combination, and used to power aircraft, trains, ships, generators, and even tan0s.

T!eor" of o7eration
<as turbines are described thermodynamically by the *rayton cycle, in which air is compressed isentropically, combustion occurs at constant pressure, and expansion over the turbine occurs isentropically bac0 to the starting pressure. In practice, friction and turbulence cause=
. %on)isentropic compression= for a given overall pressure ratio, the compressor delivery temperature is higher than ideal. 2. %on)isentropic expansion= although the turbine temperature drop necessary to drive the compressor is unaffected, the associated pressure ratio is greater, which decreases the expansion available to provide useful wor0. >. Pressure losses in the air inta0e, combustor and exhaust= reduces the expansion available to provide useful wor0.

As with all cyclic heat engines, higher combustion temperature means greater efficiency. $he limiting factor is the ability of the steel, nic0el, ceramic, or other materials that ma0e up the engine to withstand heat and pressure. Considerable engineering goes into 0eeping the turbine parts cool. 8ost turbines also try to recover exhaust heat, which otherwise is wasted energy. 4ecuperators are heat exchangers that pass exhaust heat to the compressed air, prior to combustion. Combined cycle designs pass waste heat to steam turbine systems. And combined heat and power #co)generation( uses waste heat for hot water production. 8echanically, gas turbines can be considerably less complex than internal combustion piston engines. Simple turbines might have one moving part= the shaft?compressor?turbine?alternative) rotor assembly #see image above(, not counting the fuel system. 8ore sophisticated turbines #such as those found in modern 9et engines( may have multiple shafts #spools(, hundreds of turbine blades, movable stator blades, and a vast system of complex piping, combustors and heat exchangers. As a general rule, the smaller the engine the higher the rotation rate of the shaft#s( needs to be to maintain top speed. $urbine blade top speed determines the maximum pressure that can be gained@ this produces the maximum power possible independent of the size of the engine. &et engines operate around ,,,,, rpm and micro turbines around ,,,,,, rpm.

T"7e of ga turbine
Aero deri:ati:e and .et engine

Aiagram of a gas turbine 9et engine

Air breathing 9et engines are gas turbines optimized to produce thrust from the exhaust gases, or from ducted fans connected to the gas turbines. &et engines that produce thrust primarily from the direct impulse of exhaust gases are often called turbo9ets, whereas those that generate most of their thrust from the action of a ducted fan are often called turbofans or #rarely( fan)9ets. <as turbines are also used in many li1uid propellant roc0ets, the gas turbines are used to power a turbo pump to permit the use of lightweight, low pressure tan0s, which saves considerable dry mass.

Aiagram of a high)pressure turbine blade

A0ateur ga turbine
Increasing numbers of gas turbines are being used or even constructed by amateurs. In its most straightforward form, these are commercial turbines ac1uired through military surplus or scrap yard sales, then operated for display as part of the hobby of engine collecting. In its most extreme form, amateurs have even rebuilt engines beyond professional repair and then used them to compete for the Band Speed 4ecord. $he simplest form of self)constructed gas turbine employs an automotive turbocharger as the core component. A combustion chamber is fabricated and plumbed between the compressor and turbine sections. 8ore sophisticated turbo9ets are also built, where their thrust and light weight are sufficient to power large model aircraft. $he Schrec0ling design constructs the entire engine

from raw materials, including the fabrication of a centrifugal compressor wheel from plywood, epoxy and wrapped carbon fiber strands. Bi0e many technology based hobbies, they tend to give rise to manufacturing businesses over time. Several small companies now manufacture small turbines and parts for the amateur. 8ost turbo9et)powered model aircraft are now using these commercial and semi)commercial micro turbines, rather than a Schrec0ling)li0e home)build.

Au8iliar" 7ower unit

Auxiliary power units #APCs( are small gas turbines designed for auxiliary power of larger machines, such as those inside an aircraft. $hey supply compressed air for aircraft ventilation #with an appropriate compressor design(, start)up power for larger 9et engines, and electrical and hydraulic power.

Indu trial ga turbine for electrical generation

<: D series power generation gas turbine. $his "!,)megawatt unit has a rated thermal efficiency of E,in combined cycle configurations.

Industrial gas turbines differ from aero derivative in that the frames, bearings, and blades are of heavier construction. Industrial gas turbines range in size from truc0)mounted mobile plants to enormous, complex systems. $hey can be particularly efficientFup to E,-Fwhen waste heat from the gas turbine is recovered by a heat recovery steam generator to power a conventional steam turbine in a combined cycle configuration. $hey can also be run in a cogeneration configuration= the exhaust is used for space or water heating, or drives an absorption chiller for cooling or refrigeration. A cogeneration configuration can be over 3,- efficient. $he power turbines in the largest industrial gas turbines operate at >,,,, or >,E,, rpm to match the AC power grid fre1uency and to avoid the need for a reduction gearbox. Such engines re1uire a dedicated enclosure, both to protect the engine from the elements and the operators from the noise.

Radial ga turbine
8ain article= 4adial turbine

In 3E>, &an 8owill initiated the development at Gongsberg HIpenfabri00 in %orway. Harious successors have made good progress in the refinement of this mechanism. 7wing to a

configuration that 0eeps heat away from certain bearings the durability of the machine is improved while the radial turbine is well matched in speed re1uirement.

Ad:ance in tec!nolog"
<as turbine technology has steadily advanced since its inception and continues to evolve@ research is active in producing ever smaller gas turbines. Computer design, specifically CJA and finite element analysis along with material advances, has allowed higher compression ratios and temperatures, more efficient combustion and better cooling of engine parts. 7n the emissions side, the challenge in technology is increasing turbine inlet temperature while reducing pea0 flame temperature to achieve lower %7x emissions to cope with the latest regulations. Additionally, compliant foil bearings were commercially introduced to gas turbines in the 33,s. $hey can withstand over a hundred thousand start?stop cycles and eliminated the need for an oil system.

Ad:antage and di ad:antage of ga turbine engine

Ad:antage of ga turbine engine

Hery high power)to)weight ratio, compared to reciprocating engines@ Smaller than most reciprocating engines of the same power rating. 8oves in one direction only, with far less vibration than a reciprocating engine. Jewer moving parts than reciprocating engines. Bow operating pressures. Digh operation speeds. Bow lubricating oil cost and consumption.

3i ad:antage of ga turbine engine

Cost is much greater than for a similar)sized reciprocating engine since the materials must be stronger and more heat resistant. 8achining operations are also more complex@ Csually less efficient than reciprocating engines, especially at idle. Aelayed response to changes in power settings.

$hese disadvantages explain why road vehicles, which are smaller, cheaper and follow a less regular pattern of use than tan0s, helicopters, large boats and so on, do not use gas turbine engines, regardless of the size and power advantages imminently available.

SPECIFICATIONS OF MACHINES AVAILABLE IN BLOCK-III:

Vertical Boring 1ac!ine /
8ax diameter of wor0 piece accommodated 8ax height of wor0 piece Aiameter of table 8ax travel of vertical tool head 4A8 slides 8ax travel of vertical tool heads from centre of $able 8ax weight of wor0 piece Jor %KLErpm@ ,,$ for any speed Aiameter of boring spindle of combined head $ravel of boring spindle $aper hole of boring spindle = E,mm = 2/,mm = ,,metric =/2/,mm =2,, $ = ,,,,mm to 2/,,mm =/,,,mm =!./,mm =>2,,mm

Centre Lat!e /$ Bigge t of all BHEL)

8ax diameter over bed 8ax diameter over saddle Bength between centers 8ax weight of wor0 piece Spindle bore =>2,,mm =2/,,mm = Em = ,, $ =3Emm

CNC Lat!e/

8anufacturer= Safop, Italy Swing over carriage Centre distance 'eight capacity Spindle power :xternal chuc0ing range Dydrostat steady range 8ax spindle rpm C%C system =>/,,mm =3,,,mm = 2, $ = 3EG' =2/,)2,,,mm =2,,) 2/,mm =2,, =SI%C8:4IG !",A

CNC Indicating tand /

8anufacturer= Deinrich <eorg, <ermany $urning diameter $urning length 'eight capacity =/.>m = /m = E, $

CNC Vertical Borer /

8anufacturer = 8?S Pietro Carnaghi, Italy 8achine model $able diameter 8ax turning diameter 8in boring diameter 8ax height for turning and milling $able Speed =AP !,$8)E/,, =E/,,mm =!,,,mm =EE,mm =.,,,mm =,.2)/, rpm

$able load capacity 8illing spindle speed Spindle taper C%C system

=2,, $ =>.")>,,, rpm at ",G' =*$ /, =SI%C8:4IG !",A

CNC +acing Lat!e / ;H-%&&-CNC

Swing over bed Swing over carriage 8ax distance between faced plate and carriage 8ax weight of 9ob held in chuc0 Jace plate diameter Spindle speed 8ain spindle drive =2>,,mm = !,,mm =2,,,mm =E,,,0g = !,,mm = .")",,rpm =3/./G'

#te7 boring 1ac!ine/

8ax boring diameter 8in boring diameter $able 8ax weight of 9ob Deadstoc0 travel =2/,,mm =E2/mm =",,,mmx",,,mm = ,, $ =",,,mm

3ouble Colu0n Vertical Borer/

$able diameter 8ax traverse of cross rail 8ax weight of wor0 piece =",,,mm ="2/,mm ="2,,mm

8ax weight of 9ob

=/, $

CNC #2oda Hori<ontal Borer/

Spindle diameter $aper spindle 4A8 size 4A8 length Spindle length Deadstoc0 $able C%C system &ob =2,,mm =*$ /, ="/,x"/,mm = E,,mm =2,,,mm =/,,,mm =",,,x>/,,mm =SI8:%S !/,mm = I.P. 7uter

Hori<ontal Borer/ L#TG '&&5

Spindle diameter Deight of machining bed 8ax boring depth with spindle 8ax extension of 4A8 'idth of bed guide ways Actual length of headstoc0 with vertical lift Actual length of column horizontal feed Bowest position of spindle axis upon bed guide ways 8achine weight with electrical e1uipments Deight of machine =2/,mm =E,,mm =2,,,mm = E,,mm =2/,,mm =2 /,mm = /,,,mm = "./mm = ", $ = ,.>m

CNC Lat!e/ (-(%&

8anufacturer= 4avensburg 8ain spindle bore Aistance between centers $urning diameter over bed cover $urning diameter over carriage 'or0 piece weight unsupported 'or0 piece weight between centers = 2m = ",,mm = ,,mm =",,,0g =2, $ = /,mm

Centre Lat!e/ (-%4

8anufacturer= G>$C, CSS4 8ax diameter over bed 8ax diameter over saddle Bength between centers 8ax weight of wor0 piece Spindle bore 8achine wattage = 2/,mm =3,,mm =E>,,mm =2/ $ =!,mm =//G'

Hori<ontal Boring 1ac!ine/ (-%'

Aiameter of spindle 'or0ing surface of table 8ax travel of table 8ax vertical travel of headstoc0 = /,mm =22/,x 2/,mm = 2,,mm =2,,,mm

Hori<ontal Boring 1ac!ine /

*oring spindle taper *oring spindle diameter =*$/, = E,mm

Deadstoc0 vertical travel Bongitudinal 4A8 travel Bongitudinal spindle travel Column cross travel 4otary table travel $able load

=>,,,mm =.,,mm = ,,,mm = ,m =>,,,mm =", $

Hori<ontal Boring 1ac!ine/ (-((

*oring spindle internal taper material *oring spindle diameter 8ax spindle travel Hertical head travel $ransverse column travel 8ax longitudinal column travel 8achine wattage =2,, =>2,mm =2/,,mm =E,,,mm =E,,,mm =!,,mm =3,G'

3ouble Colu0n Rotar" Table Vertical Borer/

8ax diameter of wor0 piece accommodated 8ax height of wor0 piece accommodated Aiameter of table 8ax travel of vertical tool head 4A8 slides 8ax travel of vertical tool head from centre of table =/.2/m 8ax weight of wor0 piece =2,,$ for %KL!rpm @ ,,$ for any speed Aiameter of boring spindle of combined head = E,mm = ,m? 2./m =/m =!../m =>.2m

$ravel of boring spindle $aper hole of boring spindle

= 2/,mm = ,, metric

Hori<ontal borer/ (-%

Spindle diameter 'or0ing surface 8ax vertical travel 8ax transverse travel of column 8ax longitudinal travel of column 8ax longitudinal travel of spindle =22,mm =! ,, x /,,,mm =>mm =Em =Em = .!m

CNC Lat!e/ %-45&

8anufacturer= Doesch 8ax load 8ax length between centers Swing over bed =>2, $ = !m =>.2m

Hori<ontal Borer/ %-(6'

Spindle diameter 8ax vertical travel 8ax transverse travel of column 8ax longitudinal travel of column 8ax longitudinal travel of spindle 'or0ing surface =22,mm =>m =Em =Em = .!m = !,,x/,,mm

Cree7 +eed Grinding 1ac!ine /

Aiameter of 9ob &ob height $able rpm $able diameter Swing diameter C%C control =2m =2."m = ,rpm#max( =2,/,mm =2/,,mm =SI:8:%S)><<

Broac!ing 1ac!ine/
*roaching capacity *roaching stro0e *roaching slide width *roaching specific cutting stro0e *roaching specific return stro0e 8ax diameter of disc 8ax move of table Delix angle?s0ew angle setting Cone angle =>2 $ = ,.>m = /,,mm = .2/m?min =E,m?min =2>,,mm =E,,mm =M"/?)"/ =,)2,

CNC Lat!e/
8anufacturer= Innse *erardi, Italy Swing over carriage Swing over bed Capacity Cost = /,,mm =2,,,mm =>, $ = E crore

C%C system

=SI%C8:4IG !",A

O:er #7eed Balancing of Turbine /

1ain feature / $ype of pedestals 4otor weight 4otor diameter 4otor 9ournal diameter *earing centre distance *alancing speed 8in vibration limit 8ax vacuum =AD 3,?AD 2 =8in " 8$, 8ax >2, 8$ =8ax E3,,mm =8in 2/,mm,8ax 3/,mm =8in >,,,mm,8ax /.,,mm = !,)>E,,rpm = micron = torr

Tunnel +eature / $unnel length $unnel diameter 8ax thic0ness of tunnel Steel plate thic0ness Cost of balancing e1uipment#J:( $otal cost of balancing tunnel = 3,,,mm =E3,,mm =2/,,mm =>2mm =""" la0hs =.., la0hs

1ain +eature of 3ri:e/ Arive motors #2 no.( $otal drive power =3/,H AC, /,,rpm,>./ 8' each =. 8'#2x>./(

1G et of 3ri:e/ Synchronous motors = GH,38',/,Dz,/,,rpm

AC <enerator #2 no.(

=3/,H,/,,rpm,>.!8' each

HOW IT WORKS

#TEA1 +LO= THRO9GH #TEA1 T9RBINE

1oderni<ation of +acilitie /
C%C Bathe for BP 4otor from SAJ7P, I$ABN C%C Dorizontal *oring machine for machining of casing from PA8A, I$ABN C%C Indicating Stand for BP 4otor *lade machining from <:74<, <:48A%N C%C Jir $ree 4oot 8illing machine C%C <antry 8illing machine

1a.or +acilitie for New Turbine #!o7/

C%C H *orer)$able diameter)./,,mm C%C H *orer)$able diameter)",,,mm C%C D *orer Spindle Aiameter)2,,mm, E,mm C%C Bathe capacity) 2, $,!,$ C%C Jir $ree 4oot 8illing machine C%C <antry 8illing machine

Hig!lig!t /
I07orted #ub titution /
Dybrid burner for gas turbine : ring for gas turbine Aeep hole drilling in DP outer casing supplied by 8achine Shop, CJJP

Proce

I07ro:e0ent /

Slitting of casing, thrust rings, <$ rings on *and Saw milling machine, thus saving the time on critical machines such as 4am *orers Csing G78:$ drilling systems, the productivity in 9oint plane drilling of casing and BP 4otors has increased Seeing the congestion on G77P milling machine, a new wor0 center machine called 4A8*D74 machine#%o. 2".>

Tool Brand /
'idia Sandwic0 Seco Isear Addisson <uhring Indian tools 8itutoyo

Tool In tru0ent /
Aie ring spanner Dac0 saw frame *urr cutter Solid tap #carbide( Dand tap

Grinding Cutter /
Combination cutter) ",x",mm Jillet cutter) E,x>2mm

Dand mill cutter :nd mill cutter Internal profile cutter Shell end mill cutter)E>x!,mm *all nose Slab mill

500 MW Steam Turbi e:

HP Turbine/
8odule Steam Pressure Steam temperature 4eheating temperature 'eight Bength of 4otor Deight =D>,) ,,)2 = .,Gg?s1.cm =/>. deg.cel =/>. deg.cel =!E",, Gg =".E m =2. /m

LP Turbine/
8odule 'eight Bength of 4otor 'idth Deight =%>,)2x ,s1.m =>./ $ =!..m = ,..m =".Em

 IP Turbine/
Bength 'idth Deight Steam pressure Steam temperature ="."2/m =/m =".!m =" Gg?s1.cm =/>. deg.cel

!a" Turbi e V #$%&:

IS7 /38' =2,, $ = ,m =2./m = ,E, deg.cel =Dybrid *urner 'eight Bength *readth $emperature of hot gas in turbine $ype of burner

1illing Cutter /
( Side end face milling cutter 2( Interloc0ing side and face milling cutter >( Shell end mill cutter "( 8etal slitting saw /( Single angle milling cutter E( Aouble une1ual angle milling cutter .( Aouble e1ual angle milling cutter !( Geyway milling cutter 3( 8illing cutter for chain wheels ,( Single corner rounding milling cutter

( Convex milling cutter 2( Concave milling cutter >( $ slot milling cutter with plane parallel shan0 "( $ slot milling cutter with 8orse taper shan0 having tapered end /( Cylindrical milling cutter E( Slot milling cutter with parallel shan0 .( :nd mill with parallel shan0 !( *all nosed end mill with parallel shan0 3( Jlat end tapered die sin0ing cutter with plane parallel shan0 2,( *all nosed taper die sin0ing cutter with plane parallel shan0 2 ( Slot milling cutter with 8orse tapered shan0 having tanged end 22( :nd mill with 8orse tapered shan0 having tanged end 2>( *all nosed end mill with 8orse tapered shan0 having tanged end 2"( Jlat end tapered die sin0ing cutter with 8orse tapered shan0 having tapped end 2/( *all nosed tapered die sin0ing cutter with 8orse tapered shan0 having tapped end 2E( Slot milling cutter with 8orse tapered shan0 having tapped end 2.( :nd mill 8orse tapered shan0 having tapped end 2!( *all nosed mill 8orse tapered shan0 having tapped end 23( 4oughing end mill with parallel shan0 finishing type >,( 4oughing end mill with parallel shan0 roughing type > ( Slot milling cutter with .?2" taper shan0 >2( :nd mill with .?2" taper shan0 >>( *all nosed end mill with .?2" taper shan0 >"( 'oodruff 0ey slot milling cutter with parallel shan0 >/( Screwed shan0 slot drill

Ma'(r C(m)( e t" (* Steam Turbi e:

BP 4otor BP Inner Casing Cpper Dalf BP Inner Casing Bower Dalf BP 7uter Casing Cpper Dalf BP 7uter Casing Bower Dalf IP 4otor IP Inner Casing Cpper Dalf IP Inner Casing Bower Dalf IP 7uter Casing Cpper Dalf IP 7uter Casing Bower Dalf DP 4otor DP Inner Casing Cpper Dalf DP Inner Casing Bower Dalf DP 7uter Casing Cpper Dalf DP 7uter Casing Bower Dalf Aiffuser <*C #<uide *lade Carrier( IHCH #Intercept Halve Control Halve( :SHCH #:mergency Stop Halve Control Halve(

Au8iliar" Part of #tea0 Turbine/

( Halve Seal 2( C)4ing

>( Piston 4od "( *ase Plate /( Sealing 4ing E( Biner .( <uide 4ing !( Halve Cover 3( <uide *lades = ,( Support ( *earing 2( *earing Shell >( Angle 4ing "( Sleeve /( Pin $aper #2/x ",( E( &ournal *earing Shell .( Casing !( <uide bush 3( Piston #/,,8'( 2,( Halve Cone 2 ( No0e 22( 8andrel 2>( Support 4ing 2"( $hrust 4ing 2/( Ad9usting 4ing Jixed *lades 8oving *lades

2E( Shaft Sealing Cover

Au8iliar" Part of Ga Turbine/

( Spacer 4ing 2( 7il <uard 4ing H 3".2 >( 7il Pro9ecting 4ing "( Plate /( Coupling *olt E( Inlet Shell

T+)e" (* B,a-e":
$2 blades $" blades $O blades >AS blades J) blades <$)Compress blades *razed blades 4ussian design blades P)Shroud blades Compressor blades #Sermental coated( BP 8oving blade /,,8'

Ne. B,a-e S/():

 +ir t Generation Blade /

$2 Profile *lades Cylindrical Profile *lades # 3.,(

#econd Generation Blade /

$" Profile *lades Cylindrical Profile *lades # late 3!,( - <ain in Stage :fficiency over $2 Profile *lades

T> Profile Blade

Cylindrical Profile *lades # late 33,(

Gain /
4educes Profile Bosses ,.2- <ain in Stage :fficiency over $" Profile *lades

A77lication /
8iddle Stage 7f D.P. and I.P $urbine Initial Stage of B.P. $urbine

43# Blade /

Gain /
4educes Secondary Jlow Bosses ,./ + .,- <ain in Stage :fficiency over $O Profile *lades

A77lication /

 Initial Stage of D.P. and I.P $urbine

+- Blade Gain /
4educes Indirect Jlow Bosses ,./ + .,- <ain in Stage :fficiency over $O Profile *lades

A77lication /
4ear Stage of D.P. and I.P $urbine 8iddle Stage of B.P. $urbine

#e?uential o7eration for 0ac!ining of T> blade / O7eration

( *lan0ing 2( 4homboid machining >( 4emoval of tech allowance?parting off "( 4oot machining /( Profile and expansion angle#internal and external( E( Shroud copying .( $aper grinding !( <rinding and polishing 3( Jinal fitting of blades ,( Hibro finishing of blades ( Jinal inspection

1ac!ine
*and saw C%C rhomboid machine cell band saw C%C high speed root machining C%C heavy?light duty machine or C%C profile and fillet machining center C%C heavy?light duty machine C%C creep feed grinding machine Polishing machine ) Hibro finishing e1uipment )

#e?uential o7eration for 0ac!ining of 43# and + blade / O7eration

( *lan0ing 2( Preparation of technological ends for wor0 piece holding >( Complete blade machining#with normal shroud?P shroud( "( Inspection /( milling off technological ends at root and shroud radius machining E( Jitting .( vibro finishing for surface finishing improvement !( Inspection *and saw C%C machining center C%C / axis machining centre >A C88 C%C machining centre ) Hibro finishing e1uipment )

1ac!ine

Nu0ber of ad:ance de ign blade / Blade

$O Profile blade J and >AS blade Jree standing blade

%@&1=
,>3, > ,, 22"

@&&1=
E!2, 2!/2 2/2

O:er #7eed Balancing of Turbine /

1ain feature / $ype of pedestals =AD 3,?AD 2

4otor weight 4otor diameter 4otor 9ournal diameter *earing centre distance *alancing speed 8in vibration limit 8ax vacuum

=8in " 8$, 8ax >2, 8$ =8ax E3,,mm =8in 2/,mm,8ax 3/,mm =8in >,,,mm,8ax /.,,mm = !,)>E,,rpm = micron = torr

Tunnel +eature / $unnel length $unnel diameter 8ax thic0ness of tunnel Steel plate thic0ness Cost of balancing e1uipment#J:( $otal cost of balancing tunnel = 3,,,mm =E3,,mm =2/,,mm =>2mm =""" la0hs =.., la0hs

1ain +eature of 3ri:e/ Arive motors #2 no.( $otal drive power =3/,H AC, /,,rpm,>./ 8' each =. 8'#2x>./(

1G et of 3ri:e/ Synchronous motors AC <enerator #2 no.( = GH,38',/,Dz,/,,rpm

=3/,H,/,,rpm,>.!8' each

Rigid Rotor = 4igid rotors are those rotors when it can be corrected in any two #arbitrary selected( planes and after these correction, its unbalance does not significantly exceed the balancing tolerance #relative to the shaft axis( to any speed upto maximum service speed when running under conditions approximately close of the final supporting system.

+le8ible Rotor = $he rotor is not specifically define due to static deflection.

Pro:i ion for correction 7lane/ $he exact number of axial location along the rotor that are needed depends some extent on the particular balancing procedure. If the operating speed of the rotor exceeds the nth critical speed at least #nM2( corrected planes #transverse to the rotor axis( are li0ely to be needed along the rotor.

GENERAL= IS7 says balancing is a procedure by which the mass distribution of a rotor is chec0ed and if necessary, ad9usted in order to ensure that the vibrations on the supporting bearing at a fre1uency corresponding to the operations are within specified limits. $his is done to avoid damage to bearings, housing and foundations and to minimize the fatigue stresses on the rotor. In the existing facility it is carried out on hard bearing balancing machine type AD3,?AD 2 on completely assembled, rotors installed in technological bearing on rotor 9ournals or using a stub shaft, if necessary technological bearing are also of antifriction #sleeve type( and incorporate of many features of original bearing. *earing is carried out by consecutive compensation below and above critical speed and its rated speed to bring down the vibrations within the specified limits.

Brief La"out
$he rotors are assembled on the bogle pedestal and it is then driven into the overspeed and the balancing tunnel which can be evacuated to a high degree of vaccum upto 2 torr. Hibration are pic0ed up through electro)magnetic pic0 up mounted on the pedestal and the readings are displayed on the instrument installed in the control room. $he intelligence about the various parameters e.g. vibrations bearing temperature, tunnel temperature etc. are carried out to the instrument mounted in the control room trough cable passing through special vaccum penetration system located in the rear wall of the tunnels. $he rotors is driven through a drive system consisting of 2 A.C. motors of >./ 8' each connected in tendem a ?"./?!.3 step gear box and a intermediate shaft. $he drive system is coupled to the rotor through a universal 9oint cardon shaft. $he speed of the motor can be regulated from about 2 rpm to /,, rpm and of or rotor from , rpm to ""/, rpm.

$he power to the motor is fed through an 8< set consisting of a 3 8' synchronous motor and 2 A.C. generators of " 8' each. $here are two lubrication system, atmospheric oil system providing oil to 8< set and drive system and the vacuum oil system providing oil to the rotor bearing house in balancing pedestal in the tunnel and oil in water cooled*

Balancing Procedure
A e0bl" of Rotor/ $he distance of the boggle pedestal is ad9usted as the supporting
9ournals to the 9ournal center line distance of the rotor. $he continuity of the 4$AQs of bearing should be chec0ed by a R.C. before these are mounted on the pedestal. $he rotor is then placed in the balancing machine pedestal with the help of special lifting tac0le and the assembly is done as per drawing. $he oil gaps between the rotor 9ournal and the side?top of the bearing shall be as per drawing. $he side gap of the bearing, alignments of pedestal and fitting of oil catcher should be chec0ed before placing the upper half of the bearing bodies care must be ta0en to ensure that the dowel pin of the top cover of both the bearing is set in the right position. $he re1uired no. of correct balancing weights #approx.>,- of the total periphery of each groove( should be fixed by assembly with section in the grooves provided in the rotor for balancing to avoid any mismatching of these weights at a later stage@ rotor will then be handed over by in charge assembly section to 7.S.*.$. in charge. $he balancing pedestal along with the rotor will be driven into the balancing tunnel by means of a hydraulic electric boggle mechanism. $he balancing pedestals are placed in a suitable position near the rear wall of the tunnel and the boggle is driven out. $he rotor shall be aligned with a main drive by tightening the special pre)ad9usted wedges provided on sides of each pedestal. 4otor is mounted to the drive using a cardon shaft of suitable tor1ue value. $o ease the coupling of the rotor to the cardon shaft, the intermediate shaft can be moved forward or reverse upto maximum distance of 2, mm from its mean position. Pedestals are secured to the machine bases in the tunnel in horizontal as well as vertical direction by means of a bolt provide for this purpose.

Pre7aration for Balancing

After securing of the pedestal and connection of the rotor with the drive system the lubricating oil pipes, 9ac0ing oil pipes and drain oil pipes should be connected. Bubricating oil should be started to the pedestal bearings and flushing main be carried out for couple of hours. Auring flushing the rotor may be 9ac0ed a few times and the rotor lifts at both the pedestal are to be chec0ed by means of a dial gauge.

$he rotor then can be run at a about /, rpm for a few minutes #without any vacuum( and observed visually. It should be chec0ed that there is no abnormal sound and no lea0age of oil etc. after these close the rear wall and ensured that no loose things. $he lights of the tunnel and the power supply to tunnel hoist and 9ib crane. $he tunnel evacuation now started by vacuum pump sets first for the pedestal oil system and there after the main tunnel vacuum pump sets and then for the intermediate shafts. After attaining vacuum in the tunnel the rotor can be run unto a suitable speed below first critical speed at which vibrations do not become excessive #normally a vibration velocity of ,) 2 mm?sec( may not be exceeded during the process of entire balancing. Critical speed range where ever it is appearing should be crossed over 1uic0ly. 4eading of correction weights are to be noted down and rotor may be stopped. After stopping the rotor the correction planes shown in correction planes in low rpm#",,)/,, rpm( in a b)c mode are put directly in two side correction planes at re1uired angle as indicated by measuring instruments, either in polar form or in co)ordinate form. After correction of unbalance for the first critical speed, it should be impossible the rotor speed beyond the first critical speed without sub9ected to rotor to any excessive level of vibration at the first critical speed. 4otor should now be run at second balancing speed. Cnbalance correction should be done using a Scouple weightQ a pair of weight one in each plane of rotor and with an angular displacement of !,,. $his process is to be continued till we get a low value of vibration at >,,, rpm. After achieving sufficiently low vibrations at the rated speed the rotor can now be over)speeded. *efore the over)speeding run, the rotor should be chec0ed that no part in the rotor show any sign of looseness, there is no excessive lea0age of oil and temperature is within limits. %ow rotor over)speed #>>E,?>E,,rpm max >./,( and retained there for two minutes or as specified. After over)speeding the rotor is stopped and thoroughly chec0ed for any part of the rotor having become loose specially the loc0ing blades. After achieving the vibration within the specified limits a couple of runs will be carried out to improve the balance 1uality. After the balancing is over the position of the weights placed in different correction planes will be noted with reference to the cloc0ed punched on the rotor?rotor coupling hole. 4otor should be disconnected from the drive system and the lubricating pipes, 9ac0ing oil pipes etc. will be disconnected from pedestal. E:aluation of 9nbalance= All rotors in 7S*$ are balanced at the rated speed and the evaluation of unbalance is by means of vibration measurement at rated speed. Jollowing information are ta0en)

a. Hibration level at operating speed. b. Position of correction weights with respect to the cloc0ed punched on the rotor shaft. c. 4pm and duration of over)speed test.