A PROJECT REPORT ON HYDRO TURBINE ANDRITZ HYDRO PVT. LTD.

PALWAL(HR)

SUBMITTED BY: NAME: HARVEER BRANCH: MECHANICAL

Guru Jambheshwar University Of Science & Technology,Hisar(HR)

ACKNOWLEDGEMENT
To express my opinion in words is extremely difficult, though the present project apparently speaks out names .The real credit goes to the organization which gave me this lifetime opportunity to work & learn in this much systematic and professional environment. Now I would like to thank Mr. Lars, Mr. S.Rao, Mr. Pankaj Aggarwal, Mr. Ram perkash and Mr. Ravi Kalra, Mr. Satish Kumar, Mr. G.N Singh, Mr. Ravinder Kumar and Mr. Amit Kumar who provided me constant guidance, inspiration and help whenever and however required. Last but not the least I would like to thank those numerous employees of the company whose clarity of concepts and ability to solve problems is proverbial. Their unflinching encouragement shall ever remain as a treasure in my memory.

CONTENTS
S.NO.
1

Chapter Name
Introduction to hydro turbines

Machine shop

Fabrication shop

Assembly shop

Grinding Shop

Maintenance

Quality control

Stores

PROFILE
ANDRITZ HYDRO is a global supplier of turnkey electromechanical equipment and services ("Water to Wire") for hydropower plants with a leading position in the growing market of plant refurbishment

Member of the ANDRITZ Group since June 2006 Core activities: LARGE HYDRO: Turnkey construction, supply and installation of hydropower plants including: turbines, digital speed governors, shut-off valves, generators, control&automation, protection, excitation & synchronisation, site management, installation, commissioning, testing, training.

HYDRO SERVICE: Integrated solutions enhancing the profitability and long-term value of existing hydro assets: Rehabilitation, Modernization, Automation, Monitoring & Diagnosis systems, Management information systems, Operation & Maintenance services, Spare parts management, Energy management system.

COMPACT HYDRO: Solutions for small and medium hydropower projects with unit sizes up to 15 MW of Kaplan-, Francis- and Pelton COMPACT turbines including systems Water to Wire (W2W) for environmentally friendly applications.

GENERATOR TURBO Supply of air- and hydrogen-cooled turbo generators. The output range covers 50 to 350 MVA mainly for applications in combined cycle and fossil fired thermal power plants.

HISTORY

With the acquisition of VA TECH Hydro by Andritz in June 2006, the Hydro Power Business Area of ANDRITZ has become one of the world's largest suppliers of hydro power equipment with a global presence. As of 1 January 2009 the company has been renamed into ANDRITZ HYDRO GmbH.

ANDRITZ HYDRO has more than 170 years of experience and expertise in hydraulic power generation.

In 2000 the hydro business units of the companies SULZER HYDRO, VA TECH VOEST MCE and VA TECH ELIN were merged to create VA TECH HYDRO, which was purchased by the International ANDRITZ GROUP in 2006.

HYDRO TURBINES
A hydro turbine uses the potential and kinetic energy of water and converts it into usable mechanical energy. The fluid energy is available in the natural or artificial high level water reservoirs, which are created by constructing dam at appropriate places in the flow path of rivers. When water from the reservoir is taken to the turbine, transfer of energy takes place in the blade passages of the unit .the mechanical energy made available at the turbine shaft is used to run an electric generator, which is directly couple to the turbine shaft. The power generated by utilizing the potential and kinetic energy of water has the advantages of high efficiency, operational flexibility, low wear and tear, and ease of maintenance.

Classification of turbine Turbines are of two types:

Impulse Turbine: Wherein the available hydraulic energy is first converted into kinetic energy
by means of an efficient nozzle. The high velocity jet issuing from the nozzle then strikes a series of suitably shaped buckets fixed around the rim of a wheel .The buckets change direction of jet without changing its pressure .The resulting change in momentum sets bucket and wheel into rotary motion and energy. An impulse turbine operator under atmospheric pressure, there is no change of static pressure across turbine runner and the unit is often referred to as free jet turbine. Important impulse turbines are: pelton wheel, turgo-impulse wheel, girad turbine, bunki turbine and jonval turbine etc.

Reaction Turbine: Wherein the part of the total available hydraulic energy is transformed into
kinetic energy before the water is taken to the turbine runner. A substantial part remains in the form pressure energy. Subsequently both the velocity and pressure change simultaneously as water bleeds along the turbine runner. The flow from inlet to outlet of the turbine is under pressure and, therefore, blades of reaction turbine are closed passages sealed from atmospheric conditions. Important reaction turbines are: Fourneyron, Thompson, Francis, Kaplan and propellor turbines.

Hydraulic turbines further classified into various kinds according to:

Direction of water flow through runner: Turbine

Tangential flow (Pelton wheel)

Axial or parallel flow (Kapaln turbine)

Mixed: radial and axial (Modern Francis turbine)

Pelton wheel is the tangential flow turbine; here the centerline of jet is tangential to the path of rotation of the runner. Propellor and Kaplan turbines are axial flow turbines; here water enters and leaves the runner along a direction parallel to the axis of the shaft. Mixed flow turbines where water enters the runner at the outer periphery in the radial direction and leaves it at the center in the direction parallel to the axis of rotation of the runner. Modern Francis turbine is a mixed flow machine.

Main assemblies and operation of Pelton turbines

ASSEMBLIES

Assemblies mainly classified into three categories: Static a) Turbine housing b) Disposition c) Distribution Pipe d) Inlet Pipe

Dynamic a) Nozzle Assembly b) Deflection Assembly c) Runner Assembly d) Distributor Assembly e) Oil Head f) Cooling Water Governing a) Governor b) Skada

Working Of Pelton turbine

Penstock is a large size conduit, which conveys water from the high level reservoir to the turbine. Depending upon head it is made up of mild steel, concrete, or wood .It is provided with control valves like butterfly valve, also screens and trashrack are provided at the inlet of the penstock prevent entries of debris. At its downstream end, penstock fitted with an efficient nozzle that converts the whole of hydraulic energy into a high-speed jet. To regulate water flow a spear is provide which moves backward or forward thereby controlling flow area either by governing mechanism or by hand wheel. The turbine rotor, called the runner is acicular disk carrying a number of cup shaped buckets, which are arranged equidistantly around the periphery of the disk. In case of mini hydro turbine the buckets are the integral part of the runner while in case of the large hydro turbine or large runner

size the buckets are bolt mounted to the runners disc. The runner is generally mounted on a horizontal shaft support in a small thrust bearing and is casted integrally; they are made up of stainless steel. The inner surface of he buckets is polished to reduce frictional resistance to the water jet. Each bucket has a ridge or splitter, which distributes the striking jet equally into two halves of the hemispherical bucket. Again there is a cut (notch) in the outer rim of each bucket this make the jet face the bucket only when they are at 90( to each other. The angular deflection of jet in the bucket is limited to about 165-170 degree. The arrangement has advantage that bearings supporting the wheel shaft are not subjected to any axial or end thrust. A casing is provided around the runner to prevent splashing of water and to guide the water to the tail race. It has no hydraulic function to perform apart it act as a safeguard against accidents. Speed of turbine runner is maintained so that generator coupled directly to the turbine shaft runs at constant speed under varying load conditions. Governing mechanism by regulating water supply does this above function. With increase in load, the runner speed falls and consequently balls of the centrifugal governor move inwards. Through suitable linkages, the resulting downward movement of the governor sleeve is transmitted to a relay, which admits oil under pressure to servomotor .The oil exerts a force on the piston of the servomotor, and that pushes the spear to a position, which increases the annular area of the nozzle. Quantum of water striking the buckets is then increased and the normal turbine speed is restored. Conversely happen when we have to reduce the load.

Main assemblies and operation of Francis turbines

ASSEMBLIES
Assemblies mainly classified into three categories: Static a) Turbine housing b) Disposition c) Stay Ring d) Spiral Dynamic a) Distribution b) Runner c) Oil Seal d) Shaft Seal e) Cooling water f) Guide Bearing Governing a) Governor b) Skada

Working Of Francis turbine

Penstock is a large size conduit, which conveys water from the high level reservoir to the turbine. Depending upon head it is made up of mild steel, concrete, or wood .It is provided with control valves like butterfly valve, also screens and trashrack are provided at the inlet of the penstock prevent entries of debris. At its downstream end, penstock fitted with an efficient nozzle that converts the whole of hydraulic energy into a high-speed jet. To regulate water flow a spear is provide which moves backward or forward thereby controlling flow area either by governing mechanism or by hand wheel. Penstock is connected to and feeds water directly into the spiral casing. Casing constitutes a closed passage whose cross section area gradually decreases along the flow direction area are maximum at inlet and very less at exit. The casing is made up of mild steel or concrete. Stay vanes are usually provided to direct the water from the casing to guide vanes. Guide vanes or wicket gates are series of airfoil shaped vanes, which are arranged inside casing to form a number of flow passages between the casing and the runner blades. They guide the water onto the runner as per design. They swing around their own axes that change the flow area between two consecutive runner blades. The motion is given by means of governor. The system consists of a centrifugal governing mechanism, linkages servomotor with its oil pressure governor and the guide wheel. The water flow and its direction remain same at all the passages between any two consecutive guide vanes. Runner of the Francis turbine is a rotor and has passages formed between crown and shroud in one direction and two consecutives blades on the other. There is about 16 to 24 number of blades in runner. These passages take water in at the outer periphery it in a direction parallel to the axis of rotor. The driving force is both due to the impulse and reaction force. The runner blades are usually is made up of stainless steel. The runner is keyed to the shaft, which may be of vertical or horizontal disposition.

Main assemblies and operation of Kaplan turbines

ASSEMBLIES
Assemblies mainly classified into three categories: Static a) Turbine housing b) Disposition c) Stay Ring d) Spiral Dynamic a) Distribution b) Runner c) Oil Seal d) Shaft Seal e) Cooling water f) Guide Bearing Governing a) Governor b) Skada

Working Of Kaplan turbine

Except the runner, all other parts such as spiral casing, stay ring and stay vanes, guide mechanism and the draft tube are similar to those of Francis turbine. Between the guide vanes and the runner water turns through right angle and subsequently flows parallel to the shaft. The runner is in the form of boss, on the periphery of the boss are mounted equidistantly 3 to 6 vanes made of stainless steel. Hence it has less friction resistance as runner blades are directly attached to the runner hub and also there are fewer blades as compared to Francis turbines. The Kaplan has a double regulation, which comprises the movement of guide vanes and runner vanes. The runner employs two servomotors; one control the guide vanes and the second operates on the runner vanes .the governing is done by the governor from inside of the hollow shaft of turbine runner and the movement of piston is employed to the twist blades through suitable linkages.

SUMMARISED INFORMATION ABOUT HEAVY MACHINE SHOP Vertical Turret Lathe-1

Machine Maker Froriep Machine No. VTL 1 Job Undergoing Discharge ring lower part Project Undergoing Babehalli Operation Undergoing Boring Tool Used Boring Tool or an Insert tool Maximum Diameter 3313 mm Maximum Height 2500 mm Digital Control Panel No. Of RAM 3 Speed: 0.5 56 RPM Feed: 0.05- 10 mm per minute

Vertical Turret Lathe-2

Machine Maker Dorries Machine No. VTL 2 Job Undergoing Runner Hub Project Undergoing Somanamardi Operation Undergoing Boring Tool Used DJNL (name of an single point insert) Maximum Diameter of Job 1600 mm Maximum Height 1000 mm No. Of RAM 2 No. Of Turret or Tool Index 5 Speed: 180 RPM Feed: 0.044 4 mm per minute Digital Control Panel

 Vertical Turret lathe-3

Machine Maker Froriep Machine Number VTL-3 Max. Diameter 1200mm Max. Height 500mm Job undergoing Servomotor cover Project - Babehalli Tool Used DNMG (name of an insert) Operation Undergoing: Turning No. of Tool RAM 2 Tool Index / Turret 5 Max. Speed 180 RPM Feed 0.07 to 5 mm per min Digital Control Panel

In vertical turret lathe while working tool remain fixed and job rotates. Various operations carried on VTL are facing, turning, boring, grooving etc. Feed is automatic. Scrap produced are spring like ribbon chips. RPM should always be low while working on profile. For good finishing the RPM should be high and feed should be low. But final cut is always small to maintain the desired accuracy and surface finish. Job is set on table. Dial indicator is used to see whether it is uniformly attached to the machine always checks its position.

Radial Drilling Machine (RM 65)

Machine Maker - HMT Working Range: a) Drilling Radius: 550 2350 mm b) Sleeve Diameter: 400 mm

c) Distance Sleeve to Spindle: 350 2150 mm d) Spindle Traverse Distance, Base to Spindle: 380- 1645 mm e) Working Surface Of Base: Length 2330 mm f) Width 1000 mm g) Standard Box Table (L*B*H): 600*500*500 mm h) Maximum Feed: 1.25 mm per min i) Minimum Feed: 0.125 mm per min j) Range Of Speeds: k) Standard: 40 1800 RPM l) Optional: 50 2240 RPM m) Machine Weight 4560 kg

Project Undergoing Somanamardi Operation Undergoing Reaming Job Undergoing Sealing Support Tool Used Taper Shunk socket Reamer

Drilling Machine
Machine Maker Csepel Machine No. 06 RD 1 Maximum Height: 10 11 feet Job Undergoing Rotating Sump Bottom Project Undergoing Somanamardi Tool Used Drill Tool (Maximum 100 mm) Operation Drilling Speed 1800 RPM Feed range: 0.3 2 mm per min

Job is fixed and tool moves and rotates. It is used for drilling, reaming and tapping, spot facing etc. Tools are adjusted and fixed by clamp. The waste material produced is continuous long helical spring. Tool used are twist drill, extra long drill, core drill, taper shrunk socket reamer etc. It has both automatic and manual feed.

Horizontal Boring Machine (Large)

Machine Maker Skoda Machine No. 14 HB-1 Job Undergoing Head Cover Project Undergoing Babehalli Process Boring Tool Used Boring Tool Maximum Height 3800 mm Maximum Length 10,740 mm Spindle Taper ISO 60 Table Length 3500 mm * 3500 mm Maximum RPM 600 Feed two types: 1/1 and 1/10 Maximum and minimum feed: 6.32 1250 mm per minute X Direction Reciprocating Motion. Y Direction Upward and Downward Motion. Z Direction Inward and Outward Motion.

Horizontal Boring Machine (Small)

Machine Maker Pama Machine No. AL 127(15 HB 2) Job Undergoing Runner Blade Operation Undergoing Facing Project Undergoing Babehalli

Tool Used Cutter Speed Range: 8 950 RPM Maximum Feed 3 mm per revolution Minimum Feed 0.025 mm per revolution Maximum Length 1500 mm * 1500 mm Maximum Height 1000mm

Job is fixed and tool rotates. For cutting purpose tool moves in clockwise direction and for boring in any direction. It can move in X, Y, Z directions. For hard material the speed of spindle is kept low i.e. in first gear. For soft material we use high spindle speed i.e. fourth gear. It is used for making slots, t- slots, boring, and turning, facing and drilling etc. Tool used are boring tool,

radius slot cutter, facing cutter, turning tool and all drilling tool etc. Sometimes a special drilling tool is also used depending upon the job. This tool automatically uses coolant and has drill diameter of 120mm and 150 mm. It has a digital read out (DRO). For holding job we have v block, clamp, strut and nut bolt. Waste materials produced are spiral shaped chips.

Computerized Numerically Controlled Lathe Machine

Machine Maker Ravens burg Machine No. 01 L1 Job Undergoing Dummy Discharge Ring Project Undergoing Somanamardi Tool Used Turning Tool i.e. an insert PDJNL Operation Undergoing Ding turning proof machining Chuck: Swing over bed 2000 mm. Bed Length 6000 mm Maximum Speed 125 RPM Feed range: 0.037 3.15 RPM Here is job is set in the chuck. Here alignment of the job with respect to chuck is checked with the help of dial indicator fitted with stand.

SUMMARISED INFORMATION ABOUT LIGHT MACHINE SHOP Lathe Machine

Machine Maker- HMT Machine no. NH-26 (No. 6) Bed Length 6 feet/ 3000 mm Gap Bed 290 mm Holding Capacity of Chuck 480 mm diameter Swing Over Centroid 300 mm diameter RPM: 40 240 Project Undergoing Baglihar Job Undergoing Centering Bushing Operation Boring Tool Used CNMP 4000 (an insert) Coolant Used Soluble Oil

Lathe Machine L2
Machine Maker HMT Machine no. NH-32 Bed Length 3000 mm Holding Capacity Of Chuck 480 mm diameter RPM 40- 230 Swing over Bed 640 mm Job Undergoing - Guide Vanes Project Undergoing Somanamardi Operation Run Out Check Tool Used TNMP (an insert)

 Shaper Machine No
Machine Maker Sagar Machine no. - SH-1 Stroke 26-inch/550 mm RPM 72 Job Undergoing Pointer Project Undergoing Somanamardi Operation Taper Tool Used High Speed Steel cutting tool

Milling Machine
Mainly used to make bores Machine Maker HMT Machine no. - UM-1 RPM 35-1800 Coolant Used Cutting Oil Vertical Height 400 mm Operation Undergoing Boring Instructions Ensure proper clamping of the cutter, work piece and fixture before starting the machine.

Universal Tool & Cutter Grinder

Machine Maker HMT Machine no. - TCG 1 Length Of Magnetic chuck size 200 mm * 375 mm Table can rotate at 45 Deg. Tool Head 25 Deg. Both ways The chuck can be attached to it to hold the job of bigger diameter. Universal vise is used for holding job.

SUMMARISED INFORMATION ABOUT FABRICATION DEPARTMENT

Welding Equipments TIG (Tungsten Inert Gas)

It is a semiautomatic welding process. Here arc is struck between electrode and job. Electrode is non-consumable. There is ceramic coating over tungsten electrode tip. Ceramic coating is used because it has a very high melting point of 3500( C. Inert environment is provided by argon gas. Hands supply filler metal manually. TIG has better penetration as comparison to other welding operations. It has no backfire. It is specially used for giving a coating of stainless steel over a job when it is over machined or over grinded. Also some times for balancing purpose metal are added through TIG. The filler metal comes in various range of thickness from 1.2 mm, 1.6 mm, 2 mm and 2.4 mm (Make is ESAB, kobelco and bohler). Copper cable is used to connect Electrode holder and D.C. Flow meter are generally attached to the argon cylinder.

MIG (Metal Inert Gas)

It is also semi automatic welding process. Here arc is also struck between electrode and job. But here electrode is filler metal wire. Electrode is consumable. Here filler metal wire speed is 5 mm

per revolution. Argon and carbon-di-oxide gases provide the inner environment. Color code for argon and carbon-di-oxide cylinder is green. The Mild steel wire diameter ranges are 1.2 mm, 2 mm, and 4 mm (Make is ESAB). Sometimes S.S coating is provided over M.S for water resistant coating. In MIG welding, spatter is prevented by applying spatter gel is applied on the torch so that spatter doesnt stick to the torch. Spatter core is the area where spatter can reach. Welding fixture for M.S comes along with wire but for a S.S a separate fixture is used.

SAW (Submerged Arc Welding)

It is an automatic welding process. Electrode is consumable. Here arc is struck between the electrode i.e. filler metal wire and the job. Filler metal wire act as an electrode. Here shielding is done by flux. Flux is kept inside a cylinder at a pressure of 6kg/cm^2. Flux come and covers the welded zone. Grain size of flux varies from 0.2 mm to 1.6 mm. Its basicity index is 1.4. Before filling cylinder with flux, flux has to be heated at a temperature of 300(C for 2 hours .The make of flux is either ESAB or Ador. It is generally used for heavy thickness.

Types of Test
1. Dye Penetration Test:
In this test firstly the surface to be tested is cleaned by thinner & then red penetrant is applied on it & then again it is cleaned. After this developer is applied on it. After drying all surface impurities like crack are visible to eye & this can be removed by the use of gauging. It is used for examining external cracks. The developer stays there for about a minute so examiner had to note the entire surface defects very quickly.

2. Magnetic Penetration Test:

In this test magnetic powder is spread on the welded part & then through magnetic jaws the magnetic field is applied & where the crack exist this powder starts to jump-up or starts to attract towards the crack that depends on the development of south-north pole i.e. on the polarity. It is used for examining the internal cracks.

3. Ultrasonic Test
In these test ultrasonic sound waves comes. The device used in UT test is known as transducer or search unit .It contains piezoelectric material which transmits desired frequency of sound .For normal casting defects zero degree angles is used & for bevel weld joint angled transducer is used

like 60 degree, 45 degree. The defects are shown on the cathode ray oscilloscope. Before testing coupling should be applied. More the smoothness of the job more clearly the transducer detects the defect & more clear the graph is plotted.

4. Radiography Test
In these test x-rays are made to fall on the job piece and deflections are noted in the form of graph and by studying them we can find out internal defects. It is a very dangerous test as these rays are very harmful to human beings. So when these test are carried nobody should be around a radius of 50 meter. These are a very accurate test as compared to other test. For X-ray test cobalt-92 and Ra-162 are used.

Gas Cutting Equipments

Computerized Numerically Controlled Gas Cutting Machine

Oxygen/Acetylene & Oxygen/LPG is used for cutting. Mainly LPG is used because it is cheap. Piercing pressure comes from Oxygen. Job is not heated to the melting point but to the temperature where it can be plastically deformed. Gas cutting equipment uses air pressure to produce arc. Cutting pressure ranges from 9-kg/sq. cm to 16-kgf/sq.cm up to thickness of 50 mm of Mild Steel. Nozzle cutting speed or piercing pressure depends on the thickness of the plate. Working pressure for oxygen and acetylene is 9-10 kg/sq. cm. The pressure in cylinder for oxygen and acetylene is 15-kg/sq. cm. While ratio between oxygen/acetylene and is Oxygen/LPG 1:2.In CNC gas cutting machine first it check whether the required shape is possible or not. Nozzle, cutting speed, pressure, Pre-heating time, pre-heating pressure, piercing pressure and curf are all according to

thickness of plate. Line in and out also causes changes in piercing time for different shape.

Manual Gas cutting machine

In these machines there are two cylinders each of oxygen and acetylene or oxygen and LPG connected two torches through hoses. The torch is made up of gunmetal. Generally single regulator is used for LPG, acetylene and oxygen. In winter season electronic pre-heater is used when to temperature falls very low. It is fitted between the regulator and the cylinder.

SUMMARISED INFORMATION ABOUT ASSEMBLY SECTION

a) Dummy discharge ring is placed at the bottom and is known as bottom head. On this ring we place the 24 guide vanes and on these guide vanes we place bushes along with the top head. On this top head we place levers whose one end is attached to the guide vane and other to the link. This link is attached to the regulating wheel. With the help of servomotor we get reciprocating motion, which is of guide vanes. b) In upper head there are 24 bores and in these bores 24 bushes are placed. In these bushes similar number of guide vanes is also placed. c) Inner head or inner distributor is fit into the center of wicket gate assembly and through it the shaft is passed. d) Through guide bearing housing shaft is passed. e) Guide Vanes It consists of two sides i.e. thick end and thin side. The thick side is called flat side and the thin side is called chamfer side. The water strikes at the thick side and passes away from the thin side. The distance between the thick ends of the guide vein is called facial gap. f) Ceiling Gap The distance between two corresponding faces of guide vanes. If ceiling gap is more than we have to file to make it less. g) Filler gauge It is used to check the gap between two mating parts given as per drawing. h) Axial play is done through dial indicator and dial stand. i) After the fitting of head cover dew surface washers having the property of self-lubrication are placed on the upper surface of the guide veins. Their main use is to reduce friction & provide lubrication. Without their application the working of shaft will be affected. j) After fitting of dew surface washers we place the track ring which remain fixed on the guide vanes. k) In Francis and Kaplan turbine regulating wheel is used to provide clockwise and anticlockwise rotation to guide vanes. l) Tripping Relay Device It is a safety device used in turbines. It consists of arrangement of lever, spring and cam. An electronic speed-measuring device is placed on the shaft to calculate its speed. As the speed of shaft increases tension in the spring increases and it begin to move and a stage comes when it outer face collides with the trip of tripping device because of which the trip cuts off and the supply of oil to the shaft stops which causes shaft

to switch off. It is mainly due to the cut off of servomotor. Maximum pressure in servomotor is 60kg/cm square& maximum stroke of servomotor is 172. m) Water attacks on the pressure side of the guide vanes and flow away from the suction side. n) Shot blasting is done before painting so that paints stick hard on the surface. The pressure in shot blasting is 6-kg/sq. cm. In shot blasting chips of either S.S or M.S are used of size varying from 0.2 mm to 0.5 mm diameter. Shot blasting is carried out in a closed room having 2 mm thick rubber walls. The operator operating shot blasting has to wear a special dress, which covers all his body. o) Firstly Red oxide (epoxy-71) is used for coating the surface. Afterwards the epoxy paint coatings are done at the end of the job. These paints are of Epoxy 72 and are high quality abrasion resistant and water resistant. Sometimes synthetic paint is also used over S.S just to give a good look to the turbine and to hide the scratches. p) Red oxide coating ensures good surface texture and smoothening. It also avoids scratching to the job made by applying the blue and black color directly to the job. q) In hydro turbines black paint is used to coat that part of the job, which is placed inside the water. Single red coating is applied at that place which comes in direct contact with oil. Yellow and blue are mainly used for outer surfaces, which come in contact with the air. r) In spiral casing water is mainly given the view to flow and also a force is exerting on it. The water enters the spiral casing gets divided by the help of internal fixed blades. This water then strikes the pressure side of the guide vanes, which is thick and then goes to suction side, which is thin. After passing from the guide vanes water strikes the runner placed inside the spiral casing and then it starts to rotate the shaft. Due to this rotation the hydro energy is converted into mechanical energy of the rotation of shaft and this mechanical energy is converted into electrical energy by use of generator. s) There are two types of balancing static & dynamic. Static balancing is mainly done in Pelton turbine. It is mainly done to check weight irregularity. In the runner of Pelton turbine we always place weight during static balancing for the balancing of job. But in case of Francis weight removal is done from Francis runner. t) Jobs accuracy is measured or checked by means of templates. The templates drawings are sending by the designer to the assembly department where the help of these drawings makes the required templates of brass. For making this we use flat files, half round files,

needle files, rounded files and tools. u) In runner hub we use the inner bush of brass (non-ferrous) because if the ferrous part is made in contact with the ferrous part for the rotation purpose then both these SS parts produce friction between them and cause scratching of each other and our purpose of rotation is not fulfilled. Therefore we use ferrous and non-ferrous combination to avoid friction. Also in these brass bushes small slots are made for the purpose of lubrication. v) Tungsten carbide is used for the coating of the turbine face because due to high pressure water consisting of sand particles the turbine face is affected very much and their exists some holes in it. Due to this reason turbines life is reduced. To increase its life we use tungsten carbide. w) SILT Tanks is used for cleaning purpose to prevent sand coming into the turbine. Although trash racks are provided in the penstock but they cant stop sand. They can control only stop big wood blocks sought of thing.

SUMMARISED IMFORMATION ABOUT THE GRINDING SECTION

Different Types Of Grinders Single-phase 50hz angle grinder Three-phase 300hz angle grinder
Three-phase high frequency angle grinder can be used for longer time & does not get heat up as compare to single-phase grinder. It requires less maintenance than other grinder.

Pneumatic air grinder

Pressure in pneumatic air grinder is 6.2 bars. RPM in pneumatic air grinder is 13000.

Sendor
It is also single-phase 50hz. Support pad is used in sender for supporting amri disc. Generally two-amri disc are also used for support.

Swing Grinder
It is used for rough grinding. It is very helpful in removing material in large scale.

BOSCH manufactures all die grinders stated above.

TOOLS USED Grinding Wheel

It is used for rough or proof machining or material removing. Its diameter ranges from 7 inch, 9 inch and 125 mm. They all have different RPM.

Stone Wheel
Stone wheel 50 mm in diameter. is used for removing carbon. Flat wheel or Amri Wheel It is used for polishing and finishing e.g. Pelton wheel runner etc. Its diameter ranges from 25 mm, 40 mm and 50 mm. Its grit size ranges from 36, 60, 80 and 120.

SUMMARISED INFORMATION ABOUT MAINTENANCE DEPARTMENT

Maintenance is of two types: a) Planned
1. Autonomous: 3M 3S (Japanese Method) 3M, 3S stands for 3 minute 3 services that mean daily to daily

checking of machine cleanliness, hydraulic pressure and oiling or lubrication. 2. Preventive: In these MTBF (mean time between failures) and MTTR (mean time to repair) should be same. 3. Predictive Maintenance It is like you can predict the time to failure. It requires control over frequency of checking. 4. Conditioning Maintenance: It is monitory very close before sometime of predictable failure date i.e. 10 days before so that if it fails first we can replace it or if it works for some more days then it prevents some money for organization. Different tests carried on condition monitoring like vibration test and hydraulic check etc.

b) Unplanned
1. Breakdown Maintenance 2. Corrective Maintenance Maintenance mainly involves infrastructure details along with the machine profile and all computer related things.

Here in VA Tech total production management is followed. Maintenance department also handles computer network wiring and generators. For computer networking VA TECH use Cat-7 technology in which 20,000 meters long wires are laid down. Proportional Logic Controller Synchronization is used in generators which synchronies voltage, frequency and phase angle. Maintenance involves external power generation, internal power generation in case of power cut off, and synchronization thru PLC. Maintenance also assembled new machinery.

SUMMARISED INFORMATION ABOUT QUALITY CONTROL

There are four stages of quality control:
a) Incoming Stage

b) Process

c) Final Machining

d) Assembly

1. Standard of quality is achieved in accordance to customer needs. 2. QAP stands for Quality Assurance Plan 3. Casting test is done at the foundry shop witnessed by VA TECH Officials. 4. NCR means Non Confirmation Report is made for the faulty product. 5. Various test conducted under quality control are Hardness Test, Elongation Test, Tensile Strength Test, Dimensioning and heat treatment. 6. In process test Penetration Test, Ultrasonic Test, Magnetic Test and Accuracy Test, Radiography test is done. 7. In final machining dimensioning and penetration test are conducted. 8. In assembly dimensioning test are conducted.

SUMMARIZED INFORMATION ON STORES DEPARTMENT

In two ways the material is given: Consumables (electrodes, grinding wheel)
These tools once you give dont return back. Consumables are always enter the SAP.

Non-Consumables (instrument, tools)

These tools are return back to the customer after there use. Non- consumables are manually maintained in the register.

Store is divided into following sections:

Special Erection Tools Welding Equipments Grinding Equipments Safety Equipments Heavy Sections

Hydraulic jacks are used to uplift the heavy loads. Using a cycle chain like arrangement uses roller spadder to move heavy jobs from one place to another. Its ranges from 1 tons to 20 tons. Oil pump pumps the oil to the hydraulic machine. It has a dial showing how much weight lifted. Special purpose drilling machine both magnetic and vaccum used specially for foundation purpose or packing purpose. It is a portable machine. Pipe bending hydraulic machine fitted with oil seal is used to bend pipe. Pumping is done by hand. Oil seal doesnt allow it to flow back. It ha various die of different shape. Also pipe holder can hold pipes of different shape.

Electrical Instruments
BS-60 electric paint spray gun mainly used for painting, disinfecting, corrosion-removal &

cleaning. It has .5 mm round spray nozzle.

Specifications: Power supply: 230V, 50 HZ Power: 60 Watts Maximum pressure (app.): 140 bars HILTI PD-10 mainly used to measure the distance during erection. These include torches, Meqquer, Electronic Label maker, C.R.O, and Switchboard. In these devices some are current measuring devices & some are used for the purpose of amplification

General Instruments
Center head (dead center) revolving whole. Revolving head only tip port. Drill chuck

General Tools
BOX SPANNER: They are used for tightening purposes. Handle, which is fitted inside the box spanner & is working like lever & rotates to produce tightening. (6 mm to 110 mm diameter) Vice are used to hold the job. Letter punch, Number punch are used to print numbers & letters on the job. Hammer spanner (30 mm to 125 mm diameter) Hammer ring spanner (50 mm, 55 mm, 125 mm) Die spanner Allen key Ring spanner