national competence in marine gas turbine …ficci.in/events/22716/isp/cdr-chv-sudhakar-navy.pdf ·...
TRANSCRIPT
ON THE ANVIL
INTRODUCTION
CHALLENGES – DESIGN, METALLURGY & MANUFACTURING PROCESSES
CURRENT INDIGENOUS COMPETENCE
WAY AHEAD
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INTRODUCTION
• THREE MAJOR COMPONENTS
• DESIGN OF EACH COMPONENT VERY COMPLEX
• R & D AND INNOVATION
• NEW MATERIALS & COATINGS
• IMPROVED ENGINEERING AND MANUFACTURING
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COMPRESSOR
CC
TURBINE
DESIGN CHALLENGES
HIGHLY SOPHISTICATED AERODYNAMICS
ABILITY TO MANAGE STALL
INLET GUIDE VANES AND BLEEDING AIR FROM COMPRESSOR
STAGES
COMPRESSOR
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DESIGN CHALLENGES
• COMBUSTION AT HIGHTEMPERATURES WITH AMINIMUM PRESSUREDROP AND EMISSION
• COOLING TECHNOLOGY
• MATERIALS TOWITHSTAND HIGHTEMPERATURES
CC
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TURBINE
METALLURGICAL CHALLENGES
* HIGH STRENGTH TO WEIGHT RATIO
* TITANIUM ALLOYS
* HT CREEP RUPTURE STRENGTH
* OXIDATION RESISTANCE
* EMISSION CONTROL
* NICKEL BASE SUPERALLOYS
* HIGHER FIRING TEMP & HOT CORROSION
* NI BASE SAs WITH SPECIAL PROCESSING
* TBCs
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COMPRESSOR
COMBUSTION CHAMBER
TURBINE
MANUFACTURING CHALLENGES
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• CASTING FOR STATICCOMPONENTS
• FORGING FOR ROTATINGCOMPONENTS
• POWDER METALLURGY
• EQUIAXED INVESTMENT CASTING
• DIRECTIONALLY SOLIDIFIEDCASTING
• SINGLE CRYSTAL CASTING
GAS TURBINE DESIGN
• CONCERTED EFFORTS OVER THE LAST 50 YRS PUT INTODESIGNING A GAS TURBINE
• PREMIER ORGANISATIONS - GTRE, HAL AND BHEL
• SUCCESSFUL DESIGNS INCLUDE GTX37-14U AFTER-BURNING TURBOJET AND TURBOFAN DERIVATIVE,GTX37-14UB
• ‘KAVERI’ GAS TURBINE (GTX-35VS) FOR TEJAS & KMGT
GTRE
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KAVERI GAS TURBINE
•INDIGENOUS GAS TURBINE ENGINEFOR LCA OR TEJAS FIGHTER
•INTEGRATED WITH IL-76 AIRCRAFTAT GROMOV FLIGHT RESEARCHINSTITUTE (GFRI), RUSSIA
•82 KN THRUST ACHIEVED AGAINSTDESIRED THRUST OF 90 – 95 KN
LACK OF TECHNICALLY SPECIALISED MANPOWER, NON-AVAILABILITY OFTEST FACILITIES, DENIAL OF TECHNOLOGIES BY FOEMs ANDTECHNOLOGICAL COMPLEXITIES
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KAVERI MARINE GAS TURBINE (KMGT)
•CLOSEST TO PRODUCE A MARINE GT
•CORE OF THE KAVERI ENGINEAUGMENTED WITH LP SPOOL AND PT
•TESTED AT VISAKHAPATNAM UPTO12 MW SUITABLE FOR SNFs
•ACHIEVED RATED POWER BUT COULDNOT SUSTAIN
SHORTCOMINGS ON METALLURGY OF HOT SECTION COMPONENTSAND COOLING TECHNOLOGY
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GAS TURBINE DESIGN
• AERO ENGINE RESEARCH & DESIGN CENTRE (AERDC).SUCCESSFULLY DESIGNED & DEVELOPED AEROENGINES
• PTAE-7 ENGINE FOR LAKSHYA AIRCRAFT, GTSU-110STARTER ENGINE FOR LCA (TEJAS) & 25 kN HTFE
HAL
• HUGE CLIENTELE IN INDUSTRIAL GTs IN POWER ANDPROCESS SECTORS
• 100 MACHINES AND ACCUMULATED EXPERIENCE OFOVER FOUR MILLION FIRED HOURS
BHEL
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MATERIALS
• DEDICATED METALLURGY R & DCENTRES
• MIDHANI DEVELOPED OVER 100GRADES OF SPECIAL ALLOYS FORSTRATEGIC AND COMMERCIALSECTORS
• TITANIUM ALLOYS BT 14, TI 15 FORCOMPRESSOR
• NICKEL BASED SUPERALLOYSHASTELLOY X, NIMONIC 263,NIMONIC 90 & INCONEL 601 FORHOT SECTION COMPONENTS
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MANUFACTURING PROCESSES
• CASTING
• FORGING
• POWDER METALLURGY
• EQUIAXED INVESTMENT CASTING
• DIRECTIONALLY SOLIDIFIED CASTING
• SINGLE CRYSTAL CASTING
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LESSON FROM HISTORY
RESTRUCTURE OF THE POWER SECTOR
REDUCE THE NOxEMISSIONS
ABUNDANCE OF NATURAL
GAS FOR POWER
GENERATION
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RESEARCH & DEVELOPMENT
• CONSISTENT EFFORTS IN R&D OFSUPERALLOYS AND TBCs WHICH CANWITHSTAND HIGHER TEMPERATURES
• UNSTINTED SUPPORT FROM GOVTBOTH IN TERMS OF MONEY & TIME
• TIME TESTED CONCEPT OF‘BUILDING BLOCK’ APPROACH
• COMPRESSOR, COMBUSTOR &TURBINE AS INDIVIDUAL UNITS
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JOINT VENTURES
• COLLABORATIONBETWEEN FOEMs &PSUs ALREADYINVOLVED IN GASTURBINES
• COLLABORATIONBETWEEN FOEMs WITHINDIAN PRIVATEINDUSTRY
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INDUSTRY - ACADEMIA
• TECHNOLOGICAL SHORTCOMINGS AREBEYOND THE REACH OF INDIVIDUALORGANISATIONS
• CONSORTIUM TO PROVIDE IMPETUS INSPECIALISED AREAS OF GT TECHNOLOGY
• PARTICIPATION FROM IITs/ TECHUNIVERSITIES, PSUs & POTENTIALCANDIDATES FROM PVT INDUSTRY
• STEERED BY THE INDIAN NAVY
• BREAKDOWN MULTI-DISCIPLINARYPROBLEM INTO KEY RESEARCH AREAS
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ROLE OF GOVERNMENT
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• INDUSTRY OF CIVIL AVIATION –THE MOST LUCRATIVE MARKET
• ENCOURAGING BUSINESSMODEL FOR THE ENTHUSIASTICFIRMS
ROLE OF GOVERNMENT
POWER
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• EXTREME SHORTAGE OF COAL &NATURAL GAS RESERVES
• MIGRATION FROM COAL BASEDTHERMAL POWER PLANTS TONATURAL GAS BASED GT POWERPLANTS
• TAP THE TALENT AT AN EARLYSTAGE
• THRUST NEEDS TO BE GIVEN ONGAS TURBINE TECHNOLOGY ATUG/ PG LEVEL
TECHNICAL EDUCATION
*BE A FACILITATOR IN ALLCOLLABORATIONS
*SOTRs, SELECTING PROSPECTIVE OEMs &STARTING THE VENTURE
OVERSEEING TEAMS DURING THE PROCESSOF DEVELOPMENT AND MANUFACTURING
ROLE OF INDIAN NAVY
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AUGMENT EXISTING TEST FACILITY &ENHANCE INTO AN UNIVERSAL MARINE GASTURBINE TEST BED
TO CO-ORDINATE & DEVELOP INDIGENOUSSOLUTIONS, SET UP NAVAL RESEARCHORGANIZATION (NRO)
ROLE OF INDIAN NAVY
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CONCLUSION
• R & D ON ADVANCED MATERIALS
• JOINT VENTURES WITH ToT
• ENCOURAGING BUSINESS ATMOSPHERE
• ORIENTATION TOWARDS GT TECHNOLOGY AT HIGHER TECHNICAL EDUCATION LEVEL
• SETTING UP OF A NAVAL RESEARCH ORGANISATION
• LEVERAGE EXPERTISE FROM NUCLEAR & SPACE SPHERES
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