Professional Documents
Culture Documents
I AMAN DWIVEDI student of B.Tech student Mechanical Engineering from Dr. KNMIET,
Modinagar, U.P hereby declare that the training report entitled MANUFACTURING OF
COMPRESSOR BLADE is an original work and the same has not been submitted to any other
institute.
AMAN DWIVEDI
Roll No. 1207740015
ACKNOWLEDGEMENT
It gives me immense pleasure to present my Project Report before you. I thankfully acknowledge
the staff of Bharat Pumps and Compressor Ltd, Allahabad for giving me so much co-operation
and taught lots of new things to me, which I am sure will help me in my war future.
A special thanks to Mr. Rachit Singhal for his support during my Industrial Training. I pay my
sincere regards to him. Without his support I was not able to accomplish my training. I also
thanks to all the working staff of fabrication block for their helpful guidance and support during
the period.
AMAN DWIVEDI
II
TABLE OF CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
1
9
10
11
15
17
19
21
22
III
LIST OF FIGURE
Fig-1: Main view of the company
11
12
13
16
17
19
IV
Centrifugal Pumps (as per latest edition of API 610) for Refinery and Petroleum Industry.
Centrifugal Pumps for Nuclear Power plants.
Reciprocating Pistons and Plunger Pumps as per API 674 latest edition.
Reciprocating Fueling Machine Supply Pumps for Nuclear Power Plants
High pressure liquid Ammonia Reactor Feed Pump
High pressure seamless industrial cylinders. As per IS: 7285:BS970
High pressure compressed natural gas (CNG) cylinders for on-board applications.
Compressed Natural gas (CNG) cascades
Reciprocating compressors as per API-618
NUCLEAR POWER
PRODUCT PROFILE
1. RECIPROCATING COMPRESSORS PROFILE
BPCL design and manufacture custom-built reciprocating compressors for a wide range of
application and gases such as ammonia synthesis (N2 + 3H2), Carbon dioxide ethylene, natural
gas. Hydrocarbon mixtures, Ammonia, Oxygen, air etc. The maximum power rating is 25000KW
and the discharge pressure is up to 450 Pascal. BPC enjoys the unique privilege of having shared
with its ex collaborator M/s. Nuovo Pignone, Italy a world giant having vast experience in this
field for more than three-quarters of a century. Some of the major applications areas covered by
reciprocating compressors designed and manufactured by BPCL include the following:
FERTILIZERS
REFINERIES
PETROCHEMICALS
OTHERS
RECIPROCATING PUMPS
BPCL design and manufacture custom built reciprocating pumps for wide range of applications
for handling variety of liquids, such as, petroleum, crude oil, Ammonia, carbamate, cementing
slurry, DM-water condensate, Sulphodizing chemical fatty acids, etc. The product range includes
mud pumps, plunger pumps, ammonia pumps, etc. The pumps cater to a maximum of 1700 hp
(1260 Kw) power rating and maximum pressure of 1000 Pascal. Some of the major application
areas covered by reciprocating pump designed and manufactured by BPCL include the
following:
Wash pump
Carbamate feed pumps
REFINERIES
In this report, we will discuss conventional techniques in producing jet compressor blades such
as investment casting, single crystal growing process, thermal barrier coating and a few testing
method to look for defects in newly made blades.
RAW MATERIAL:
The raw material is the main source for the manufacturing of Compressor blade
The raw material used in the manufacturing of Compressor blade is stainless steel.
Specifications:
The raw material cross-section is of
Width= 170mm
Height= 90mm
MAIN PROCESS INVOLED:
The hardness and strength of the material is very high or the material is too brittle.
The work piece is too flexible, slender, or delicate to withstand the cutting or grinding
forces, or the parts are difficult to fixture that is, to clamp in work holding devices.
The shape of the part is complex, including such features as internal and external profiles
or small diameter holes in fuel injection nozzles.
Surface finish and dimensional tolerance requirements are more rigorous than those
obtained by other processes.
Temperature rise and residual stresses in the work piece are not desirable or acceptable.
10
MANUFACTURING PROCESS:
1. Raw Material
2. Cutting
3. Milling
4. Surface Grinding
5. CNC Machining
6. Operations and Tools
7. Quality Control
8. Polishing
11
The work piece required to obtain blade profile is of the following dimensions.
Length= 265mm
Width = 150mm
Height= 90mm
After hacksaw cutting operation
HACKSAW CUTTING MACHINE:
The hacksaw cutting machine is used for cutting the raw material, The work piece is held on the
hacksaw machine with the help of chain pulley supported by three vertical members.
Power Axe
Material
Length
24inch
Thickness
1.9mm
Motor RPM
90
Spindle Power :
3HP
Operation Time:
12
MILLING:
A milling machine is a machine tool used to machine solid materials. Milling machines are often
classed in two basic forms
Vertical milling machine, which refers to the orientation of the main spindle.
13
SURFACE GRINDING:
Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely Used abrasive
machining process in which a spinning wheel covered in rough particles (grinding wheel) cuts
chips of metallic or non-metallic substance from a work piece, making a face of it flat or smooth.
CNC MACHINING:
(COMPUTERISED NUMERICAL CONTROLLED MACHINE)
CNC refers to the automation of machine tools that are operated
by
pre
programmed
14
It is used to measure the height of the specimen from the datum surface and to measure
the groove and slots. To check the depth of the slot and the height of the slot by this
measuring gauge. The readings of the height are shown digitally on the display arranged
on the gauge.
MAGNETIC V-BLOCK:
The specimen is placed on the V-block and then required measurements are taken, marking the
specimen is also done in this process
BLADE MEASURING GAUGE:
This apparatus is used to measure the final shape of the blade profile.
CLEANING AND PACKING:
After the completion of the final inspection, the Compressor blade is proceeded into the next
stage of cleaning. In cleaning the blade is rinsed with the water and the water is wiped with the
cotton cloth.
15
increases creep effect in the material. Also, there exists the diffusion of atoms along the grain
boundaries (Coble creep) which causes changes in grain shapes.
Therefore, compressor blades are made using metal with directionally solidified crystal structure
to limit the weakness at grain boundaries. Compressor blade which has columnar crystals with
grain boundaries parallel to its axis can limit or eliminate shear stress caused by tensile load
while rotating.
16
COATING:
4.1) Introduction:
Another improvement that can be made to the compressor blade is adding the thermal barrier
coatings (TBCs). TBCs are complex defected thick film made of zirconia-based refractory
ceramics oxides. The technology allows compressor blades to work at higher temperature and
thus can increase engines power as well as the blades service life.
Thanks to the development of advanced deposition technologies, TBCs production and
application is now more widespread. TBCs materials nature with extremely high melting point
(for instance, yttria partially stabilized zirconia has melting temperature about 3000K) requires
ultrahigh temperature processing capability. Thus, thermal plasma and electron beam sources
have become the method of choice to create TBCs. Both of those methods can also further
reduce the thermal conductivities of the materials used due to structure defects in the TBC layer.
4.2) Atmospheric Plasma Spray (APS):
17
substrate surface is usually roughen by an abrasive process such as grit blasting. The molten
particles settle on the destined surface quickly solidify and create a wall of splats of typically
100-150 microns in diameter and a few micrometers in thickness. Each splat is attached to the
substrate surface because of physical interlocking of the splat and irregularities on the surface.
Internal passages and cooling holes cannot be coated by plasma spray.
Since the solidification of each particle happens quickly and independently, the structure formed
as a result consists of splats interfaces and unfilled regions which creates porosity in the coating.
Therefore, the TBC has low thermal conductivity and non-linear stress-strain behavior.
As we can see, the processing parameters decide much of the characteristic of the deposited
microstructure. Such parameters include the characteristic of the spray stream (particles
trajectory, kinetic and thermal state and degree of melting); location and state of substrate
(roughness, temperature, position, geometry and movement); and speed of torch and part. To sum
up, properties of both the powder and torch play significant roles in determining the
characteristic of the TBC (porosity, interface, grain size, cracking, phase evolution, stability).
18
shadowing. Thus, the microstructure pattern can be adjust in the coating process to meet the
compressor blade property requirements.
To sum up, the EBPVD coating technique has the advantage of being able to produce coating
with columnar structure with strain tolerance and pseudo-plasticity. Compared to Plasma Spray
TBCs, TBC using EBPVD has better corrosion resistance and smoother surface, which creates
better aerodynamics properties for the compressor blades. Furthermore, the cooling channels will
stay open throughout the coating process. Nevertheless, the method still has certain
disadvantages in terms of limited material choice (due to vapor pressure problem), higher cost
and thermal conductivity and low utility rate of raw material.
TESTING:
Before the compressor blade can be used, it must go through tests for defects in the material and
the blade structure itself.
19
Also, the interior of the blade can be inspected using fiber optic method. Before being put to use,
the blade will be put through an engine running test which they will be put into a real working
condition in a jet engine test.
20
CONCLUSION
With advances in manufacturing methods, compressor blades are now made with higher quality
than ever before. By using Investment casting, we are able to create intricate compressor blade
designs with internal cooling passages and holes. Moreover, the compressor material processing
techniques also enable us to from compressor blades of single crystal structure which have better
capability to work in extremely high temperature of the jet engine. Thermal Barrier Coating
(TBC) is another improvement to the quality of the compressor blade. The use of TBCs can help
protect the compressor blade from the extreme heat of the engine and corrosion.
21
REFERENCES:
Sanjay Sampath, Uwe Schulz , Maria Ophelia Jarligo , and Seiji Kuroda, 2012
22