Hydro turbines(datas)

A

PRATICAL TRAINING REPORT

ON

HYDRO TURBINES

AT

ANDRITZ HYDRO LTD.

(DURATION-18 JUNE TO 18 JULY)Submitted in partial fulfillment of Bachelor of Technology of Rajasthan

Technical University, KOTA

(2011-2012)

Submitted To: Submitted By :Mr. D.N. NARESH ABHISHEK TANWAR (HEAD) B.TECH MECH ENGG. HEAD OF DEPARTMENT 4TH YEAR [VII SEM.] ME08002

DEPARTMENT OF MECHANICAL ENGINEERINGJAIPUR ENGINEERING COLLEGE

KUKAS, JAIPUR (RAJ.)

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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. D. N. NARESH (HOD) 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 specially Mr. Kuldeep Kumar (D. Manager)whose clarity of concepts and ability to solve problems is proverbial. Their unflinching encouragement shall ever remain as a treasure in my memory.

ABHISHEK TANWAR

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PREFACE

Engineer student gain their theoretical knowledge only through their books. Only theoretical knowledge is not sufficient for absolute mastery in any field.theoritical given in our books is not much use without knowing its practical implementation, it has been experienced that theoretical knowledge is volatile in nature, however practical knowledge make solid foundation of our mind.

To accomplish this aspect, RTU, KOTA has included a SUMMER TRAINING programme for the student of B.Tech. in summer vacation.

I took training in “ANDRITZ HYDRO” at Faridabad from 18 June to 18 July 2011. Successding chapter give detail about what I have learned in this prestigious organization.

ABHIHEK TANWAR

CONTENTS

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Chapter Name Page 1 Company Profile 5

2 History 7

3 Introduction to hydro 10 Turbines 4 Machine shop 16

5 Fabrication shop 24

6 Assembly shop 30

7 Grinding Shop 33

8 Maintenance 35

9 Quality control 36

10 Stores 37

11 Planning 43

12 Machines & components 44

13 Conclusion 50

CHAPTER-1

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Company Profile

Global Activities

The ANDRITZ GROUP is a global market leader for customized plant, systems and services for hydropower, the pulp and paper, steel and other specialized industries (solid/liquid separation, feed and biofuel).

The Group is headquartered in Graz, Austria and has a staff of approx. 16,100 employees worldwide. It develops and makes its high-tech systems at production, service and sales sites all around the world.

Five business areas

The Group focuses on five business areas:

HYDRO

PULP & PAPER

METALS

ENVIRONMENT & PROCESS

FEED & BIOFUEL

The ANDRITZ HYDRO business area is a global supplier of turnkey electromechanical equipment and services for hydro power plants; the product range also covers pumps for the pulp and paper industries, and space technology components (e.g. for the European ARIANE rocket launcher program).

PULP & PAPER provides technology and services that enable the industry to produce practically all grades of pulp for the manufacture of paper, board and fibreboard, and also specialized machines for tissue production.

ANDRITZ METALS develops, manufactures and installs plants for the production of cold-rolled and hot-rolled, surface-finished carbon steel, high-grade steel and non-ferrous metal strip. This includes plants for the regeneration of pickling acids and for

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metal oxides.  In addition, the Business Area builds plants for punching and metal forming.

ENVIRONMENT & PROCESS covers a comprehensive range of technologies, products and services for mechanical and thermal solid/liquid separation for municipalities and major industries (mining, steel).

The FEED & BIOFUEL business area supplies systems and machines for industrial production of conventional mixed animal feed and high-quality, special animal feed.  In addition, the Business Area holds a leading position in equipment for wood pelleting.

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CHAPTER-2

History

ANDRITZ: From small iron foundryto globally leading machinery and plant engineering company

Milestones in the history of ANDRITZ:

1852-1900 Beginnings as an iron foundry

ANDRITZ AG has its origins in an iron foundry that was established in 1852 by the Hungarian entrepreneur Josef Körösi in Andritz, a suburb of the city of Graz. Soon after its foundation, the company’s production program was extended to include large capital goods, such as cranes, pumps, water turbines, and later also bridges, steam boilers and engines, as well as mining equipment.

In 1900, ANDRITZ became a stock corporation.

1900-1946 World Wars and the Great Depression

At the end of the First and Second World Wars and during the Great Depression in the early 1930s, ANDRITZ’s production came to a standstill, but committed management and employees succeeded each time in making a new start.

1946-1980 Growth and new products

         In 1949, ANDRITZ began a lasting cooperation with the Escher Wyss

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Group of Switzerland, initially in the water turbines sector. ANDRITZ’s product portfolio was revised: Production of steam engines and air compressors ceased, and the focus was placed on water turbines, centrifugal pumps, cranes, and steel structures. In 1951, ANDRITZ embarked on production of complete paper machines in cooperation with Escher Wyss.

In 1950, Creditanstalt-Bankverein of Vienna acquired a majority interest in ANDRITZ.

During the 1960s and 1970s, ANDRITZ continued to grow. The production shops were extended, new machines purchased, and R&D activities intensified. Electrochemical and metallurgical equipment was added to the production program.

1980s Crisis and recovery

The second global oil crisis and worldwide economic stagnation in the early 1980s caused a drop in ANDRITZ’s order intake and the company was operating at a loss, but Austrian government subsidies and drastic rationalization measures enabled the company to survive.

In 1987, AGIV AG, a Frankfurt-based investment company, purchased the ANDRITZ share majority. ANDRITZ began to change its strategic direction, from being a licensee of other equipment manufacturers to become a leading international supplier of its own high-tech production systems.

Since 1990 Growth through acquisitions

In 1990, the acquisition of Sprout-Bauer, a US company supplying equipment for mechanical pulp and animal feed production, marked the beginning of the ANDRITZ GROUP’s successful expansion policy through acquisitions. Complementary acquisitions, in addition to research and development, have been an important driver of company growth ever since.

Since 1990, ANDRITZ has acquired and integrated more than 60 companies, pursuing its policy of complementary acquisitions. The largest transactions in terms of sales were the acquisition of Ahlstrom Machinery Group in 2000/2001 (making ANDRITZ a globally leading supplier of pulp production systems) and VA TECH HYDRO’s hydropower section in 2006 (advancing ANDRITZ to a globally leading supplier of hydropower plants).

1999 Change of ownership

        AGIV AG sold its shareholding in ANDRITZ to a consortium of

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investment companies (The Carlyle Group, GE Capital, Unternehmensinvest AG, Deutsche Beteiligungs AG) and the Custos private foundation (established by ANDRITZ President and CEO, Wolfgang Leitner).

2001/2003 Going public

In 2001, ANDRITZ went public on the Vienna Stock Exchange. Two million newly issued shares were placed successfully with national and international investors.

2003 saw the Secondary Placing of ANDRITZ shares on the Vienna stock exchange. The financial investors sold the entirety of their shareholding in ANDRITZ, which resulted in a rise in free float to over 70%.

TODAY ANDRITZ today

The ANDRITZ GROUP is a globally leading supplier of plants and services for the hydropower, pulp and paper, metals, and other specialized industries (solid/liquid separation, feed and biofuel). The Group is headquartered in Graz, Austria, and operates over 120 production sites, service and sales companies all around the world.

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CHAPTER-3

HYDRO TURBINES

What are hydro turbines? ANS: 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:

A. 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.

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Important impulse turbines are: pelton wheel, turgo-impulse wheel, girad turbine, bunki turbine and jonval turbine etc.

B. 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:

I. Direction of water flow through runner:Turbine

1.Tangential flow Axial or parallel flow Mixed: radial and axial(Pelton wheel) (Kapaln turbine) (Modern Francis turbine)

Flow path in different types of runner has been illustrated in following figure.

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.

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II. Available head and discharge

High head turbines, which operate under high head (above 250 m) and require relatively small rates or flow. Pelton wheel is a high head turbine.

Medium head turbines, which operates under medium heads (60 m to 250 m) and require medium flow rates. Modern Francis turbine belongs to this category.

Low head turbines, which operate under heads, up to 30m and require very large volumetric rates of flow. Units of axial flow turbine (Propellor and Kaplan) are examples of low head turbines.

III. On the basis of speed

For Pelton wheel: Ns = 9-17 for a slow runner =17-25 for a normal runner

=25-30 for fast runner=40 for a double jet

Francis turbine: Ns = 50-100 for a slow runner =100-500 for a normal runner =150-200 for a fast runner

Kaplan turbine: Ns =250-850

IV. Disposition of shaft Impulse turbines have usually a horizontal shaft and vertical runner arrangement. Reaction turbine may be either of vertical or horizontal shaft type.

Main assemblies and operation of Pelton turbines

ASSEMBLIES Assemblies mainly classified into three categories:-

a) Static 1) Turbine housing2) Disposition3) Distribution Pipe4) Inlet Pipe

b) Dynamic1) Nozzle Assembly2) Deflection Assembly3) Runner Assembly4) Distributor Assembly5) Oil Head6) Cooling Water

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c) Governing1) Governor2) 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 runner’s 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

ASSEMBLIESAssemblies mainly classified into three categories:-

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a) Static 1) Turbine housing2) Disposition3) Stay Ring4) Spiral

b) Dynamic1) Distribution 2) Runner3) Oil Seal4) Shaft Seal5) Cooling water6) Guide Bearing

c) Governing1) Governor2) 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

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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. After passing through the runner, the water is discharged to the tail race through a gradually expanding tube called the draft tube .the free end of the tube is submerged deep into the tail race.

Main assemblies and operation of Kaplan turbines ASSEMBLIESAssemblies mainly classified into three categories:-

d) Static 1) Turbine housing2) Disposition3) Stay Ring4) Spiral

e) Dynamic1) Distribution 2) Runner3) Oil Seal4) Shaft Seal5) Cooling water6) Guide Bearing

f) Governing1) Governor2) 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.

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CHAPTER-4

MACHINE SHOP

Vertical Turret Lathe-1Machine Maker – FroriepMachine No. – VTL 1Job Undergoing – Discharge ring lower partProject Undergoing – Karcham WangtooOperation Undergoing – BoringTool Used – Boring Tool or an Insert toolMaximum Diameter – 7100 mm

Maximum Height – 4200 mm Digital Control Panel

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No. Of RAM – 3Speed: 0.5 – 56 RPMFeed: 0.05- 10 mm per minute

Vertical Turret Lathe-2Machine Maker – DorriesMachine No. – VTL 2Job Undergoing – Runner HubProject Undergoing – SomanamardiOperation Undergoing – BoringTool Used – DJNL (name of an single point insert)Maximum Diameter of Job – 1600 mmMaximum Height – 1000 mm No. Of RAM – 2No. Of Turret or Tool Index – 5Speed: 180 RPMFeed: 0.044 – 4 mm per minuteDigital 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.

Errors in VTL1. Misinterpretation of drawing and getting machined wrong dimensions.2. Measuring instrument errors.3. Sometimes machining of hot job causes shrinkage when the job cools.

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4. When doing vertical boring more than 100 mm sometimes taper occur at the bottom.

Remedy1. When shrinkage occurs extra material is welded to it and later on machining is again done.2. Also job is examined by the design and planning department whether the present dimension will work or not.

Precaution1. Read the drawing carefully.2. Check the accuracy of tool and calculate the error if there is any.3. Use proper coolant like cutting oil.4. For avoiding taper at the bottom during vertical boring, slide should be

straight.

Radial Drilling Machine (RM 65)

Machine Maker - HMTWorking Range:a. Drilling Radius: 550 – 2350 mmb. Sleeve Diameter: 400 mmc. Distance Sleeve to Spindle: 350 – 2150 mmd. Spindle Traverse Distance, Base to Spindle: 380- 1645 mme. Working Surface Of Base: Length 2330 mm

Width 1000 mmf. Standard Box Table (L*B*H): 600*500*500 mmg. Maximum Feed: 1.25 mm per minh. Minimum Feed: 0.125 mm per mini. Range Of Speeds:

Standard: 40 – 1800 RPMOptional: 50 – 2240 RPM

j. Machine Weight 4560 kg

Project Undergoing – SomanamardiOperation Undergoing – ReamingJob Undergoing – Sealing SupportTool Used – Taper Shunk socket Reamer

Drilling Machine

Machine Maker – Csepel

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Machine No. – 06 RD 1Maximum Height: 10 – 11 feetJob Undergoing – Rotating Sump BottomProject Undergoing – SomanamardiTool Used – Drill Tool (Maximum 100 mm)Operation – DrillingSpeed – 1800 RPMFeed 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.

Error in drilling machine1. Misinterpretation of drawing and getting machined wrong

dimensions.2. Measuring instrument errors.3. If tapping tool breaks then it get stuck inside the hole. 4. Improper clamping of job causing slip of job.5. RPM improper arrangement.6. Shrinkage in Stainless steel7. Tool Setting

Precautions1. Metal plate should be used to prevent bending of both tool and

work piece.2. Coolant should be used.3. Waste material should be removed bye brush.4. Measuring instrument should be checked for error.5. Drawing should be studied properly.

Remedy is similar to that of VTL

Horizontal Boring Machine (Large)

Machine Maker – SkodaMachine No. – 14 HB-1Job Undergoing – Head CoverProject Undergoing – Karcham WangtooProcess – BoringTool Used – Boring Tool Maximum Height – 3800 mmMaximum Length – 10,740 mm

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Spindle Taper – ISO 60Table Length – 3500 mm * 3500 mmMaximum RPM – 600Feed two types: 1/1 and 1/10Maximum and minimum feed: 6.32 – 1250 mm per minuteX 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 – Karcham Wangtoo 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.RPM is decided on following factor

1. Type of material i.e. hard or soft2. Diameter of the job3. Tool used

Error in drilling machine1. Over size of bore, drill and length i.e. crossing the tolerance provided in

the drawing.2. Shrinkage, which generally occurs when job gets heat up and after cooling

it contracts.

Precautions1. Coolant should be used.2. Measuring instruments should be checked for errors.

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3. While working with long drill lubricating oil or cutting oil must be used.

Remedy is similar to that of VTL.

Computerized Numerically Controlled Lathe Machine

Machine Maker – Ravens burgMachine No. – 01 L1Job Undergoing – Dummy Discharge Ring Project Undergoing – Somanamardi Tool Used – Turning Tool i.e. an insert PDJNLOperation Undergoing – Ding turning proof machiningChuck: Swing over bed 2000 mm.Bed Length – 6000 mmMaximum Speed – 125 RPMFeed 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.

Errors are similar to above said machine.

Precautions and remedy are also similar.

The selection of tool depends upon following criteria.

1. Operation to be performed.2. Size of the job e.g. how large is the diameter of the hole to be made.3. Vibrations in the job.4. Finishing required.5. Thickness of the job.6. Type of material.

Similarly the feed depends upon

1. Proof cut or finish cut.2. Type of material.

LIGHT MACHINE SHOP

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Lathe Machine

Machine Maker- HMTMachine no. – NH-26 (No. 6)Bed Length – 6 feet/ 3000 mmGap Bed – 290 mmHolding Capacity of Chuck – 480 mm diameterSwing Over Centroid – 300 mm diameterRPM: 40 – 240 Project Undergoing – BagliharJob Undergoing – Centering BushingOperation – BoringTool Used – CNMP 4000 (an insert)Coolant Used – Soluble Oil

Lathe Machine – L2

Machine Maker – HMTMachine no. – NH-32Bed Length – 3000 mm Holding Capacity Of Chuck – 480 mm diameterRPM – 40- 230Swing over Bed – 640 mmJob Undergoing - Guide VanesProject Undergoing – SomanamardiOperation – Run Out CheckTool Used – TNMP (an insert) Shaper Machine No. 1

Machine Maker – Sagar Machine no. - SH-1Stroke – 26-inch/550 mmRPM – 72Job Undergoing – PointerProject Undergoing – SomanamardiOperation – TaperTool Used – High Speed Steel cutting tool

Milling Machine Mainly used to make bores

Machine Maker – HMTMachine no. - UM-1RPM – 35-1800Coolant Used – Cutting Oil

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Vertical Height – 400 mmOperation Undergoing – BoringInstructions – 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 mmTable can rotate at 45 Deg.Tool Head 25 Deg. Both waysThe chuck can be attached to it to hold the job of bigger diameter.Universal vise is used for holding job.

Common lifting machines

Fork lifter

Capacity – 3 tones Make – Godrej Cylinder – 4 Fuel – Diesel Fuel tank – 40 liter

Automatic transmission i.e. only two gears reverse and forward. Jaws can go up to a height of 3m. Power steering is also provided.

Cranes

Make – WMI Cranes ltd. and Grip. Capacity : 1- 40 tones. There are 4 such cranes in the workshop. Mainly nylon sling and wire sling are used to carry load with the help of attachments like S clamp, C clamp, Eye bolt, Swivel Threads, manual hoist and D circle.

Even this nylon sling and wire sling varies from 1 tone capacity to 40 tones capacity.

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CHAPTER -5

FABRICATION DEPARTMENT

Welding Equipments

TIG (Tungsten Inert Gas)

Machine Make: Frronius and Triodyn. 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) Machine Make: Frronius and Triodyn. 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

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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 doesn’t 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)

Machine Make: Frronius and Triodyn. 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 300C for 2 hours .The make of flux is either ESAB or Ador. It is generally used for heavy thickness.

SMAW (Shield Metal Arc Welding)

Machine Make: Frronius and Triodyn. It is used for welding pipe section like spiral. Butt joint can be weld up to thickness 15 – 20 mm. Here arc is struck between electrode and the job. Electrode can be of various types depending upon job material and the thickness of the job. Always the positive terminal of the dc source is connected to the electrode i.e. 1/3 to the electrode and 2/3 to the job. The distance between the job and the electrode depends upon thickness of the electrode at most it could be 3 mm. Electrodes are generally heated in the electronic furnace at a temperature about 100c to 120c before use so that it has no moisture and it gives you a continuous weld. Hoses are made us of rubber. Reverse polarity is applied in SMAW. According to American Standards, E 6013 means ‘E’ stands for Electrode. 60 stand for “tensile strength”. 1 stands for “Welding Position”. 3 stand for “flux coating or covering”.

Welding job: Spiral Casing

Various electrodes used are: -

1. Electrode: 7018

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Used for MS (Mild Steel). Heavy coated low hydrogen iron powder electrode for high quality welds in restrained joints in MS. Radiographic Quality Weld. Metal recovery minimum 110%. Ready electrode at 300 Deg. Celsius per hour.Manufacturer: D & H

Use AC 70 or DC + Diameter in mm Current (Amperes)2.0 50 – 70 2.5 70 - 1003.15 100 - 1504.0 150 - 1905.0 200 - 2566.30 270 - 320

2. Electrode: 309LUsed for stainless steel. Electrode deposits a stainless steel weld metal of 25%Cr – 12%Ni with extra low carbon. The weld deposit displays excellent resistance to cracking even in restrained joints. The electrode is highly suitable for welding mild steel to stainless steel. The electrode possesses pleasing performance characteristics.Manufacturer: D&H

Use AC or DC (+)Diameter (mm) Current (ampere)

2 40-502.5 60-803.15 80-100 4 110-140 5 150-180

3. Electrode: Bohler Fox (CN 13/4 Supra) Maker – Bohler ThyssenType – C 0.03, Si 0.3, Mn 0.6, Cr 12.5, Mo 0.5, Ni 4.5

4. A basic coated alloyed core wire electrode design for both joint and build up welding of similar stainless Cr steels and cast steels. Especially suited for water turbine, compressor and pumps. The

Maker: D&H It yields a weld deposit of 25 % Cr, 12 % Ni austenitic deposit gives high resistance against cavitations.Both AC and DC (+) can be applied to it.

Electrode: Cranitherne 25/12stainless steel suitable for welding. Its uses are as follows:-

a) Welding stainless steel of similar composition.b) Joining 18% Cr, 8% Ni from stainless steel to mild steel.

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c) Applying sheet linings of12% Cr steel to mild steel. Both AC and DC (+) can be use Diameter (mm) Current (ampere)

2 40-502.5 60-803.15 80-100 4 110-140 5 150-180

5. Electrode: Eutectic CPS 006 Maker: L&T It is an all position electrode, design to yield low carbon weld metal with superior corrosion resistance properties. Use for welding S.S.Welding may produce fumes and gases, which are hazardous to health. Avoid breathing this. Use adequate ventilations.

Safety Equipments used are1) Welding curtain2) Leather Hand gloves3) Welding Respirator4) Leg Guard5) Fire Retardant Cap6) Welding glasses with side safety7) Welding head screen8) Helmet

NOTE: In other to prevent the bending while doing welding spiders are generally attached to the large hollow job. These spiders are removed by gas cutting equipments.

Defects in Welding:

1. External

I. Blow HolesII. Slag Trap

III. ImpurityIV. Surface CrackV. Under Cuts

VI. Spatter

2. Internal

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I. Blow HolesII. Pin Holes

III. PorosityIV. Insufficient FusionV. Internal Cracks

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. After these if cracks are found there then these cracks are removed by gauging rod then grinding is done and after that it is again checked for cracks. For best results in gauging following steps need to be followed:

1) Air pressure should be between 5 kg/ sq. cm and 8 kg/ sq. cm2) The angle of rod should 45 to the work piece.3) Air jet should be switched on before striking of an arc.

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4) Always use reverse polarity. Sometimes dousing is also done. It is done generally during heavy thickness

and internal crack. Carbon electrode and rectifier sets with heavy current do dousing.

After welding jobs are generally given a heat treatment in furnace. There are two furnaces:

a) Electric Furnace: 2800 mm * 2000 mm * 2000 mm, 440 volts.b) Diesel Furnace: 9400 mm * 4400 mm * 2000 mm, With 6 burners.

IN S.R furnace first there is mild steel then there is a coating of brick, then glass wool or asbestos wool and lastly mild steel grill. In Stress relieving furnace gloves made of asbestos are used.

Gas Cutting Equipments

Computerized Numerically Controlled Gas Cutting Machine Machine maker: SatoTable length: 8400 mm * 3200 mm.

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.

Plasma Cutting Machine Machine maker: Hypertherm powermax (1100 watts)

In these machines air pressure is used to produce arc and also used for cutting with pressure ranging from 9-kg/ sq. cm to 16-kg/ sq. cm up to thickness of 50 mm of stainless steel. Here the arc produced is plasma arc .The electrode is made up of brass.

Also carbon electrode can be attached to the SMAW for cutting purpose for stainless steel for more than 50 mm thickness.

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CHAPTER-6

ASSEMBLY SECTION

Project Undergoing – SomanamardiJob Undergoing Assembly – Wicket Gate Assembly or Distributor Assembly

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.

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.

Inner head or inner distributor is fit into the center of wicket gate assembly and through it the shaft is passed.

Through guide bearing housing shaft is passed. Guide Vanes – It consists of two side’s 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.

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.

Filler gauge – It is used to check the gap between two mating parts given as per drawing.

Axial play is done through dial indicator and dial stand. After the fitting of head cover dew surface washers having the

property of self-lubrication are placed on the upper surface of the

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guide veins. Their main use is to reduce friction & provide lubrication. Without their application the working of shaft will be affected.

After fitting of dew surface washers we place the track ring which remain fixed on the guide vanes.

In Francis and Kaplan turbine regulating wheel is used to provide clockwise and anticlockwise rotation to guide vanes.

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.

Water attacks on the pressure side of the guide vanes and flow away from the suction side.

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.

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.

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.

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.

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.

There are two types of balancing – static & dynamic. Static balancing is mainly done in Pelton turbine. It is mainly done to check weight

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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.

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.

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.

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.

SILT Tanks is used for cleaning purpose to prevent sand coming into the turbine. Although trash racks are provided in the penstock but they can’t stop sand. They can control only stop big wood blocks sought of thing.

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CHAPTER-7

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 Maker: Chicago.

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 Maker: NORTON

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

Maker: NORTON

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Stone wheel 50 mm in diameter. is used for removing carbon. Flat wheel or Amri Wheel:

Maker: Split Fire 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.

Mounting Wheel or Mounted Tip:Maker: NORTON

Mounted tip is used in pneumatic air tool. It is used for finishing & polishing. It is of following two types: -

1) Conical T3: It is used for sharp edges and is conical in shape. It is made up of tungsten.

2) Round B4: It is used for round edges or making cylindrical radius. It is also made up of tungsten.

Amri Disc: Maker: Alkon Gold

It is used for surface finishing & mainly for light work. Grit size varies from 20, 36, 60, 80 and 80. Its compositions are diamond dust, zirconium and silicon carbide. General order for finishing in grit size is 20, 36, 60, and 80 and 120 depending upon the surface finishes required.

Swing Grinder wheel Make: Norton. Its size is 300*40*38.1.

In grinding section manufacturing of runner, stay vanes, runner blades, and guide vanes is done. Sometimes job comes for step merging also. Manual Grinding is done to obtain special hydraulic contours. Grinding is done according to the requirements mention in the drawing using various templates for various contours or profiles. Some places need rough grinding and some need finish grinding depending upon the part. Safety Equipments Used is goggles, earplug, and gloves. When mounting job in the fixture it should be covered by tape so that no scratches occur. Punching is done to have proper thickness and proper hydro dynamically contour. It is done from both sides i.e. x and y direction. Grinding is done in Z direction. Tolerances for Pelton wheel are +0.5 or –0.5, for runner profile in Francis turbine is +1 or –1; for thickness of runner is +0.3 and – 0.3 and for guide vanes and runner blades is +0.5 to –0.5. Moving trolley has trips the meter when earthing doesn’t work then it get trip. Templates are made through CNC wire cutting machine. These are made up off SS, MS, spring steels and gunmetal.

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CHAPTER-8

MAINTENANCE DEPARTMENT

Maintenance is of two types:1. Planned

I. 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.

II. Preventive:In these MTBF (mean time between failures) and MTTR (mean time to repair) should be same.

III. Predictive Maintenance It is like you can predict the time to failure. It requires control

over frequency of checking.

IV. 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.

2. UnplannedI. Breakdown Maintenance

II. 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, synchronization thru PLC. Maintenance also assembled new machinery.

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CHAPTER –9

QUALITY CONTROL

There are four stages of quality control:

1. Incoming Stage

2. Process

3. Final Machining

4. Assembly

a) Standard of quality is achieved in accordance to customer needs.b) QAP stands for Quality Assurance Planc) Casting test is done at the foundry shop witnessed by VA TECH

Officials.d) NCR means Non Confirmation Report is made for the faulty

product.e) Various test conducted under quality control are Hardness Test,

Elongation Test, Tensile Strength Test, Dimensioning and heat treatment.

f) In process test Penetration Test, Ultrasonic Test, Magnetic Test and Accuracy Test, Radiography test is done.

g) In final machining dimensioning and penetration test are conducted.

h) In assembly dimensioning test are conducted.

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CHAPTER-10

STORES DEPARTMENT

In two ways the material is given:

Consumables (electrodes, grinding wheel) These tools once you give don’t 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.

How to maintain the stock levels?1. Identify all major regular items with monthly average consumption.2. Fix the maximum, minimum and ordering level of these items in SAP.3. Review the stock levels and raise MPR when stock reaches ordering level

(material purchase requisition).4. Consider the current lead-time while raising MPR.5. Purchase MPR if the level is going down.6. Review the consumption trend periodically.7. Based on the consumption trend review the list of stock items and their

stock levels with the users and update the same.

MRV stands for material receive voucher.Store is divided into following sections: Special Erection Tools

Used when machines are plotted or fixed.

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.

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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 doesn’t allow it to flow back. It ha various dies 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

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Allen key

Ring spanner

Lifting Tools

Manual hoist is lifting equipment.

CALIBRATED & MEASURING INSTRUMENTS

Electronic Surface finish tester is used to measure the surface finish. It gives you RA um. A conversion sheet is provided to convert finishing N6,

N7 etc to corresponding RA um

Vernier bevel protector is used to measure angles from 5’-360.

Radius gauge is used to measure radius of a section. You can measure both outside and inside radius. Its range is from 1mm to 25 mm.

Combination set is used to find center of round shape objects from o-180. It has two main parts center head and 45 head.

Pistol caliper is used to measure thickness of a job where micrometer can’t reach. Its least count is 0 .1 mm. Its range is from 0.1 to 100mm.

Depth micrometer is used to measure depth. Its least count is 0.1 mm. Its range is from 0 to 300 mm.

Filler gauge use to find out facial gap .It has a standard thickness plate. Its range is from 0.5 to 1mm.

Dial gauge indicator is used to measure run outs, finding center and parallel also used to check whether job is aligned with machine or not its least count is 0.01 mm. Its range is from 0.01mm to 10 mm.

Bore gauge is used to measure diameter of a bore. Its least count is according to dial gauge. But generally is 0.01 mm. Its range is from 6 to 450. Its main parts are dial indicator, holder (grip), outer sleeve, measuring, contact point, guide, interchangeable rod, limited hand, and bezel.

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Bore gauge

Flange type micrometer is used to measure small gap like parting area. Its least count is 0.01 mm. Its range is from 1 to 25 mm.

Height gauge is used to find height of a job. It has carbide, which can be use for marking. Its main parts are base, vernier scale, and scriber locking screw, adjusting screw. Its least count is 0.02 mm. Its range is from 0.1 mm to 600 mm. Its main part are base, reference surface of base, column, slider, main beam, main scale, vernier scale, clamp screw, fine feed screw, scriber and magnifying glass.

Lever type dial gauge or Puppy dial is used to find center of a bore or hole. Its main part are as follows:

a) Stylishb) Dovetail Spigot Assemblyc) Height Gauged) Adaptor Assemblye) Universal clamp Assemblyf) Spannerg) Calibration

Slip gauge is small blocks which stick to each other when they are rub against each other due to better surface finish hence they create a vacuum. It is use to measure Height .It is made up of high carbon steel. Its range is from 0.5 mm to 100 mm.

Inside micrometer is used to measure inside diameter. It has micrometer in which you can add rod of required length to measure the diameter. Its range is from 50 mm to 5 m.

Outside micrometer used to measure the outside diameter of the job in the range of 0 mm to 1100 mm. It has a masterpiece, which is used to

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check error. Each division is of 10 microns or 0.01 mm. Spindle, frame, anvil, inner sleeve, outer sleeve, adjustment nut, ratchet stop, ratchet screw, clamp, frame cover, carbide tip and thimble are its important part.

Inside dial caliper is used to measure inside diameter. It has least count of 0.025 mm. Its range is from 10 – 70 mm.

Ring gauge are of two types thread ring gauge (male threads) and thread plug gauge (female gauge). These are of go and no go types. Thread ring gauge is used to measure the thread accuracy on nut while plug gauge is used to measure the accuracy of thread in holes. Its range starts from M6.

Digital Vernier micrometer gives the readings digitally .It is very accurate machine. It gives readings up to microns. Its range is from 1 micron to 25 mm.

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Digital height gauge is also a very accurate measuring instrument. It has a digital display. It gives readings up to microns and can measure up to 600 mm.

Master level or spirit level is used to check the level of machine during foundation.

Laser range meter is use to measure the distances with the help of laser light. It has a very wide range and is very accurate instrument.

Cutting tool

Twist drill is made up of HSS. Its range is from 3 mm to 80 mm. Extra long twist drill is made up of HSS. Core drill is made up of HSS. Taper shank socket reamer made up of HSS. Its range is from 5 mm to

60 mm. Cutter is also made up of HSS. Brazing tool is made of carbide tip. Flat drill is also made up of HSS. Taps are available from M1 to M 80.

Stationary

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CHAPTER-11

PLANNING

After release of drawing from design department it comes to planning department. It has following three parts:

a) Action planningb) Technologyc) Subcontractingd) Loading and scheduling

Basically it handles the manufacturing process in workshop and subcontracting. First it prepares a job card, which has all the operation to be performed. Every time each process is over the supervisor has to enter the time taken by each operation in SAP, so that planning can monitor over the progress over job. It has an important part called subcontracting which look after the jobs which have to be machined from outside. Planning you can say is completely done and controlled with the help of SAP (system application product). Various important functions of planning are:

a) Raising sub contracting purchase requisitionb) Preparation of purchase requisitionc) Handling proof machined itemsd) Amending purchase requisitione) Booking material and hoursf) Booking hours for PPC (production planning control).g) Ordering and inspection of hardwareh) External processing of customer supplied goodsi) Control of plate materialj) Regularization of materials lying in project stockk) Closing subcontracting ordersl) Closing of projects m) Closing of P.On) Making checklist for P.Oo) Preparation of MIS reportsp) Logging of man hours

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CHAPTER-12

Machines & Components

FRANCIS STAY RING

SKODA HB-1

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PANCHEEL HILL RUNNER ASSEMBLY

FINAL GRINDING OF KAPLAN RUNNER

45

ASSEMBLY OF SPIRAL CASING

FINAL GRINDING FRANCIS RUNNER

46

KAPLAN RUNNER

HEAVY ROLLING MACHINE

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PELTON TURBINE

DRAFT TUBE

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FRANCIS TURBINE

LAYOUT OF KAPLAN TURBINE

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CHAPTER-13

CONCLUSION

ANDRITZ HYDRO LTD is one of the global leading company in HYDRO POWER PLANT, which manufacture , design & overhaul of a variety of hydro products from small to large hydro projects.

Since its inception in 1852, the company has grown into a giant hrdro complex spread worldwide, the advancement of new technology using SCADA(supervisory control & data acquisition) for automation.The divisions competence is based on more than 225,000 MW of installed hydro capacity worldwide with turbine of all type.

Thus increasing the business on commercial lines in a climate of growing professional competence. And finally training has proved to be quite fruitful.

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