Case Study By

Mr. Pradeep Kumar Verma

Asst. Engineer, Grade-II
&
Mr. B Thimmaiah
Artisan, Grade-II

HEAVY MACHINE SHOP
ELECTRICAL MACHINES DIVISION
BHEL-HYDERABAD


EM Division of BHEL Hyderabad manufactures
Turbogenerators from 5MW to 150MW air cooled and
270MW hydrogen cooled machines.
Heavy Machine Shop of EM Division does Rotor
machining operation ( Turning, Slotting, Drilling, Boring
& Tapping operation), machining of turbine
casings(steam and gas from 30MW to 250MW) and
generator stator frames.
Critical machines in Heavy Machine Shop consists of
Rotor Slot Milling machine (HELLER-Germany), CNC
Horizontal boring Machine (PAMA-Italy), CNC Center
Lathe (TACCHI-Italy).
BHEL- Hyderabad
HEAVY MACHINE SHOP
EM DIVISION-BHEL HYDERABAD
AN INTRODUCTION

MACHINE DESCRIPTION
CNC Horizontal Boring Machine (PAMA-Italy)
SPEEDRAM 6
SPINDLE HEADSTOCK
Boring spindle diameter mm 225
Boring spindle axial travel (W) mm 1600
Ram section mm 600 x 725
Ram axial travel (Z) mm 1600
Total axial travel (W+Z) mm 3200
SPINDLE SPEED
Speed range rpm 5 - 1150
POWERS
Main motor kW 130
TRAVELS
Max. headstock vertical traverse (Y) mm 5000
Column longitudinal travel (X) mm 15000
TABLE
Table Longitudinal Travel (V) mm 2500
Table Size mm 4500 x 5000
Table Rotation (B) 360
0

Table Capacity Kgs 70,000

MACHINE APPLICATION
BHEL- Hyderabad
Machining of Steam Turbine & Gas Turbine Casings:
Parting Plane & Connecting Flange-Milling, Drilling, Boring, Reaming
Tapping & Butter Threading.
Machining of Turbo-generator Stator Frames & End
Shield: Bearing Seating, End Shield Seating, End Shield Parting Plane &
Connecting Flange Holes.
CNC Horizontal Boring Machine PAMA is multi-skill machine
with wide applications and used for critical machining
operations. E.g.- Stator Frames, End Shield, Turbine casings.

MACHINE APPLICATION
BHEL- Hyderabad
GAS TURBINE CASING
STEAM TURBINE CASING
TURBO-GENERATOR
STATOR FRAME
GAS TURBINE CASING
TURBO-GENERATOR
END-SHIELD
PARTING PLANE HOLES
PARTING PLANE HOLES
CONNECTING FLANGE HOLES
STATOR FRAME
GAS TURBINE
OUTER CASING
PARTING PLANE HOLES
CONNECTING FLANGE HOLES
CONNECTING FLANGE HOLES

BHEL- Hyderabad
PROBLEM DESCRIPTION
Machine was supplied with ISO60 spindle taper and
ISO60/BT50 reducer sleeves with pull stud
arrangement. Because of this only BT50 holder has to be
used.
PAMA CNC horizontal boring machine did not have the
facility of pull-stud locking for heavy duty ISO-60 tool
holder.
Hence machining was to be carried out at very less
cutting parameters, so heavy cuts are not possible.

PROBLEM DESCRIPTION
BT-50 TOOL HOLDER ISO-60/BT-50 REDUCER SPINDLE TAPER (ISO-60)
MACHINE SPINDLE

BHEL- Hyderabad
Because of this tool holding system limitation of PAMA CNC Boring Machine:

Only BT-50 holders can be used and heavy cuts are not possible.
Maximum 250 cutters can be used, but the application requires heavy
cuts.
Tool holders getting broken when heavy cuts are given .
Machine capacity is under-utilized due to poor cutting parameters and tool
holding system.
PROBLEM DESCRIPTION-MILLING
BROKEN HOLDER
BT-50 HOLDER

Drilling of holes are done in many
steps for larger diameter holes
(More than 32 mm holes) by
changing drills (32, 48, 60).
Maximum 60mm drills can be
used for drilling, for holes more
than 60mm boring operation is
used.

BHEL- Hyderabad
PROBLEM DESCRIPTION-DRILLING

BHEL- Hyderabad
SUGGESTION
After studying the
construction features of the
machine spindle, ISO60
holder clamping and
unclamping system, one
new pull stud was designed
and got it machined
(manufactured) in shop.

BHEL- Hyderabad
DESIGN OF NEW PULL-STUD
New Pull-Stud should have automatic locking &
unlocking (Hydraulic) facility for ISO60 holders with
internal coolant arrangement.
NEW PULL-STUD
ISO 60 HOLDER
NEW PULL STUD
ISO-60 HOLDER

BHEL- Hyderabad
DESIGN OF NEW PULL STUD

M
3
0

BHEL- Hyderabad
DESIGN OF NEW PULL STUD

BHEL- Hyderabad
DESIGN OF NEW PULL STUD

BHEL- Hyderabad
PULL STUD SUPPLIED WITH MACHINE PULL STUD MANUFACTURED IN SHOP
NEW PULL STUD

EXISTING METHOD
IMPROVED METHOD

ISO60 holders like heavy duty boring heads, the
latest U drill holders ISO60/ABS100 were mounted
on to the (with modified pull stud) machine spindle
and tested successfully.
107mm holes were drilled directly and even boring
operation carried out (with modified pull stud) for
250mm and 680mm bores.
All the cutters, shoulder mills, side and face cutters
and face mill cutters for 63mm to 550mm were
mounted (with modified pull stud) for different
operations.
BHEL- Hyderabad
IMPLEMENTATION

BHEL- Hyderabad
IMPLEMENTATION
(Steam Turbine Casing)
PARTING PLANE HOLES

IMPLEMENTATION
(125 MW IOCL PARADEEP, Steam Turbine Casing-Parting Plane)

BHEL- Hyderabad
125 MW IOCL PARADEEP, Steam Turbine Casing
Parting Plane holes(94, 107)

BHEL- Hyderabad
IMPROVEMENT IN TOOLING
IOCL PARADEEP (125MW), STEAM TURBINE CASING, PARTING PLANE HOLES DRILLING (UPPER HALF)
OPERATION
EXISTING PRACTICE IMPROVED METHOD
TOOLS USED
No. of
Tools
Drilling
Time
(min)
Setting
Time
(min)
TOOLS USED
Drilling
Time
(min)
Setting
Time
(min)
94x328mm Deep x14
Holes
Drills-32, 48, 60
7
765.33 30.00 Drill- 94
1
153.07 10
Boring- 60 to 94 (70, 80, 90, 94) 3061.33 40.00 Boring not required 0 0
107 x 278 mm Deep x2
Holes
Drills-32, 48, 60
8
92.67 30.00 Drill- 107
1
22.24 10
Boring- 60 to 107 (70, 80, 90, 100,
107)
500.40 50.00 Boring not required 0 0
84 x 175mm Deep x
8Holes
Drills-32, 48, 60
6
233.33 30.00 Drill -84
1
46.67 10
Boring -60 to 84 (70, 80, 84) 700.00 30.00 Boring not required 0 0
68 x 125mm Deep x 2
Holes
Drills-32, 48, 60
5
41.67 30.00 Drill- 68
1
7.81 10
Boring- 60 to 68 83.33 20.00 Boring not required 0 0
32 x 278mm deep,
M100 x 6 x 122mm deep,
CB-107mm x 65mm
deep x 4 Holes
Drills-32, 48, 60
7
148.93 30.00 Drill- 94, 32
4
49.92 20
Boring- 60 to 94 (70, 80, 90, 94) 512.00 40.00
Boring-94 to 107 (104,
107)
52 20
28 x 175mm deep,
M80 x 6 x 127mm Deep,
CB-84 x 25mm deep x
10Holes
Drills-28, 48, 60
7
255.83 30.00 Drill- 74, 28
4
77 20
Boring- 60 to 74 (70, 74)
CB-74 to 84
523.33 30.00 CB- 74 to 84 100 20
Sub Total
40
6918.17 390.00
12
508.71 120
Total
7308.17

628.71

EXISTING IMPROVED METHOD
Drill Size Speed (RPM) Feed (mm/Min) Drill Size Speed (RPM) Feed (mm/Min)
Drilling
32 200 20 68 500-800 25-35
48 160 20 84 500-800 25-30
60 120 15 94 500-800 25-30
107 500-600 25-30
Boring
70 120 6
80 120 6
90 120 6
100 100 5
107 100 5
BHEL- Hyderabad
IMPROVEMENT IN MACHINING PARAMETERS

BHEL- Hyderabad
BENEFITS (TANGIBLE)
= (. )
Machine Hourly Rate =Rs. 8571.09 (Taken From Process Planning Dept.)
No. of Gas-Turbine & Steam Turbine casing Machined in year 2012-13 = 5 no.
Earlier Improved Method Saving
Machining Time for each casing 243.61 Hrs. 20.96 Hrs. 222.65 Hrs.
Machining Cost for each casing Rs. 20.88 Lac Rs. 1.80 Lac Rs. 19.08 Lac
Total Machining cost for 4 casing ( In
Year 2012-13)
Rs. 83.52 Lac Rs. 7.18 Lac Rs. 76.33 Lac

BHEL- Hyderabad
Steam Turbine Casing
Parting Plane Machining
0
50
100
150
200
250
MACHINING
TIME (Hrs.)
243.61
20.96
EARLIER
IMPROVED METHOD
0
5
10
15
20
25
MACHINING
COST Rs. (in lacs)
20.88
1.8
EARLIER
IMPROVED METHOD

This Project was implemented for:
250MW Pipavav 9-FA, Gas Turbine Casings (1
st
250MW Gas Turbine
Supplied by BHEL Corporation).
125 MW IOCL Paradeep & 150 MW Hindalco Aditya Steam Turbine
Casing.
270 MW Turbo-Generator Stator Frame Machining. (Manufactured for
first time in BHEL Hyderabad)
EASINESS: Mechanical Clamping not required because it provides
Hydraulic Clamping.
WIDE APPLICATION : All type of holders can be mounted and heavy
cutters can be used. Also, now ISO60/BT50 reducers sleeves and ISO60
holder can be mounted directly on spindle.
CYCLE TIME REDUCTION: Cycle time reduced by means of better
parameters.
LESS MANUFACTURING LEAD TIME

BHEL- Hyderabad
BENEFITS (INTANGIBLE)

BHEL- Hyderabad