SVKM’s Narsee Monjee Institute of Management Studies

PROJECT REPORT
Report On Hydro Turbine Manufacturing
Process And Identify Potential Improvement.

DISTRIBUTION LIST:
 PROF Rajendra Shimpi, NMIMS ( Faculty supervisor)
 Mr. Deepak Kumar, BHEL Bhopal ( Industry mentor)

MUKESH PATEL SCHOOL OF TECHNOLOGY

MANAGEMENT AND ENGINEERING

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 BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL
PROJECT
STUDY OF WATER TURBINE MANUFACTURING
AND IDENTIFY POTENTIAL IMPROVEMENT

PREPARED BY:
HEMANK JOSHI (k216)
MBA (TECH) MECH
PERMIT NO: - VT-2019/95

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 Mukesh Patel School of Technology Management & Engineering

Vile Parle (W), Mumbai - 400 056.

TECHNICAL INTERNSHIP REPORT Semester VII – MBA (TECH)

Submitted in Partial Fulfillment of the requirements for Technical Project/Training for

VIISemester MBA – (Tech).

Name of the Student: HEMANK JOSHI

Roll No.: &Batch: K216 & 2016-21

Academic Year: 2019-20

Name of the Discipline: MECHANICAL

Name and Address of the Company: BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

Training Period: From : 2ND MAY 2019 To: 26TH JUNE 2019

THIS IS TO CERTIFY THAT

MR. HEMANK JOSHI

1. Exam Seat No. K216 has satisfactorily completed his/her Training/Project

Work, submitted the training report and appeared for the Presentation & Viva
as required.

External Examiner Internal Examiner Head of Dept. Chairperson/Dean

Date:

Place:

Seal of the University

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 Completion Certificate

This is certify that Shri/Smt./Kum HEMANK JOSHI Roll No K216 has completed the training &
project as a part of Technical Internship Programmed in our company as mentioned below and
the report is also submitted.

Project Title: STUDY OF WATER TURBINE MANUFACTURING AND IDENTIFY POTENTIAL

IMPROVEMENT

Date of Joining: 2ND MAY 2019

Date of Completion: 26TH JUNE 2019

In partial fulfillment of VII Semester Technical Internship Programme for MBA(Tech) program
of Mukesh Patel School of Technology Management & Engineering, Narsee Monjee Institute of
Management Studies (NMIMS ) ( Deemed-to-be University), Mumbai.

…………………….

Under guidance of: - DEEPAK KUMAR Submitted to: - Er. S.P.

SHUKLA

(DY. MANAGER CIM DIVISON) (Sr.

ENGINEER HRDC)

(INDUSTRY MENTOR)

Date: 26-06-19

Place: BHOPAL

Company Seal:

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 ACKNOWLEDGEMENT
I am greatly thankful to B.H.E.L for providing me vital and much needed practical
experience in the field of machines and manufacturing. I express my gratitude to Human
Resource and Development department for giving me a chance to feel the industrial
environment. I am also thankful to the B.H.E.L engineers and the technical staff for
giving their precious time for helping me in understanding various aspects of machine
manufacturing and their assembly.
It is my foremost duty to express my deep sense of gratitude and respect to Mr. DEEPAK
KUMAR (DY MANAGER) for his valuable guidance as well as uplifting tendency and
inspiring me for taking up training and completion it successfully.
I express my sincere gratitude to Mr. S.P. SHUKLA worthily principal of VT section
HRDC. For providing me an opportunity to undergo vocational training at BHEL,
BHOPAL
Prof. RAJENDRA SHIMPI MPSTME, NMIMS Shirpur (faculty guide) always being a
best guidance being in the campus or being out of project. I would also show gratitude
towards him for the all time support, guidance, and help during my project and to attend
me whenever I need him. I would also thank Dr. k.k. Gupta, HOD, Mechanical Dept. to
support me with my regular work. I feel myself lucky to persue my studies under
MECHANICAL DEPARTMENT, MPSTME, NMIMS.

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 ABSTRACT

In hydro power plant we use gravitational force of fluid water to run the turbine which is
coupled with electric generator to produce electricity. This power plant plays an important
role to protect our fossil fuel which is limited, because the generated electricity in hydro
power station is the use of water which is renewable source of energy and available in
lots of amount without any cost. The big advantage of hydro power is the water which the
main stuff to produce electricity in hydro power plant is free, it not contain any type of
pollution and after generated electricity the price of electricity is average not too much
high.

Hydropower is the cheapest way to generate electricity today. That's because once a dam
has been built and the equipment installed, the energy source—flowing water—is free.
It's a clean fuel source that is renewable yearly by snow and rainfall.

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 TABLE OF CONTENTS
ACKNOWLEDGMENT………………………………………………………………………

ABSTRACT………………………………………………………………………………………

1. INTRODUCTION
1.1 COMPANY PROFILE…………………………………
1.2 HYDRO POWER PLANT……………………………
1.3 HYDRAULIC MACHINES…………………………..

2. CLASSIFICATION OF TURBINE………………………………………………………..

3. IMPULSE AND REACTION TURBINE………………………………………………..

3.1 REACTION TURBINE………………………………..

3.1.1 AXIAL FLOW REACTION TURBINE….
3.1.2 RADIAL FLOW REACTION TURBINE….
3.1.3 DIAGONAL FLOW REACTION TURBINE.
3.2 IMPULSE TURBINE……………………………………

4. CHOICE OF TURBINE………………………………………………………………………

5. WTM BLOCK…………………………………………………………………………………..

5.1 VERTICAL TURRENT LATHE1…………………..

5.2 VERTICAL TURRENT LATHE 2…………………..
5.3 VERTICAL TURRENT LATHE 3……………………..
5.4 RADIAL DRILLING MACHINE………………………
5.5 DRILLING MACHINE…………………………………..
5.6 HORIZANTAL BORING MACHINE (LARGE)….
5.7 HORIZANTAL BORING MACHINE(SMALL)……
5.8 CNC LATHE MACHINE…………………………

6. VACCUM BREAKING VALVE………………………………………………….

6.1 PROBLEM STATEMENT…………………………..

6.2 OBJECTIVE……………………………………………..
6.3 OLD SOLUTION………………………………………….
6.4 NEW PREFERED SOLUTION…………………………

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 6.5 IMPROVEMENT………………………………………….
6.6 COMPONENTS AND FUNCTION………………….
6.7 ASSEMBLY…………………………………………………
6.8 TESTING……………………………………………………..

7. ASSEMBLY OF TURBINE……………………………………………………………

7.1 MAJOR COMPONENTS MANUFACTURED…..

7.2 STEPS OF ASSEMBLY…………………………………

8. TESTING AND QUALITY CHECK………………………………………………..

8.1 MAIN INLET VALVE TEST……………………………

8.2 RUNNER BALANCING…………………………………
8.3 GUIDE APPARATUS……………………………………
8.4 GUISE BEARING…………………………………………

9. CONCLUSION…………………………………………………………………………………..

10. REFERENCES……………………………………………………………………………

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 INTRODUCTION
 Company Profile :-
 Bharat Heavy Electrical Plant It is the largest engineering and manufacturing enterprise
in India, both in energy and infrastructure. It is located at about 7 km from Bhopal railway
station and about 18 km from Airport. With technical assistance from Associated
Electricals (India) Ltd, a UK based company it came into existence on 29 th of August,
1956. Pt. Jawaharlal Nehru dedicated this plant to the nation on 6 th November 1960.

 BHELBhopal manufactures Hydro, Steam, Marine & Nuclear Turbines; Heat

Exchangers; Hydro & Turbo Generators; Transformers; Switchgears; Control gears;
Transportation Equipment; Capacitor; Bushings; Electric Motors and Rectifiers.

 BHEL Bhopal has its own Laboratories for material testing and instrument calibration
which are accredited with ISO 17025 by NABL. The Hydro Laboratory, Ultra High
Voltage laboratory and Centre for Electric Transportation are the only laboratories of its
kind in this part of the world. Bharat Heavy Electricals Limited is country’s ‘Navratna’
company and has earned its place among very prestigious national and international
companies. It finds place among the top class companies of the world for manufacture of
electrical equipment. BHEL caters to core sectors of the Indian Economy viz., Power
Generation's &Transmission, Industry, Transportation, Telecommunication, Renewable
Energy, Defense, etc. The Company today enjoys national and international presence
featuring in the “Fortune International-500” and is ranked among the top 10 companies in
the world, manufacturing power generation equipment. BHEL is the only PSU among the
12 Indian companies to figure in “Forbes Asia Fabulous 50” list.

 BHEL has:-
1. Installed equipment for over 100000 MW of power generation--- for utilities captive
and industrial users.
2. Supplied over 225000 MVA transformer capacity and other equipment operating in
transmission and distribution network up to 400 kV (AC & DC).
3. Supplied over 25000 motors with drive control systems to power projects,
petrochemicals, refineries, steel, aluminum, fertilizers, cement plants etc.
4. Supplied Traction electrics and AC/DC locos to power over 12000 km railway
network. Supplied over one million valves to power plants and other Industries.

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  Hydro power plant
Hydropower is electricity generated using the energy of moving water. Rain or melted snow, usually
originating in hills and mountains, create streams and rivers that eventually run to the ocean. The
energy of that moving water can be substantial, as anyone who has been whitewater rafting knows.
This energy has been exploited for centuries. Farmers since the ancient Greeks have used water wheels
to grind wheat into flour. Placed in a river, a water wheel picks up flowing water in buckets located
around the wheel. The kinetic energy of the flowing river turns the wheel and is converted into
mechanical energy that runs the mill.

In the late 19th century, hydropower became a source for generating electricity. The first hydroelectric
power plant was built at Niagara Falls in 1879. In 1881, street lamps in the city of Niagara Falls were
powered by hydropower. In 1882 the world’s first hydroelectric power plant began operating in the
United States in Appleton, Wisconsin.

A typical hydro plant is a system with three parts: an electric plant where the electricity is produced;
a dam that can be opened or closed to control water flow; and a reservoir where water can be stored.
The water behind the dam flows through an intake and pushes against blades in a turbine, causing
them to turn. The turbine spins a generator to produce electricity. The amount of electricity that can
be generated depends on how far the water drops and how much water moves through the system. The
electricity can be transported over long-distance electric lines to homes, factories, and business .Power
system mainly contains three parts namely generation, transmission and distribution. Generation
means how to generate electricity from the available source and there are various methods to generate
electricity but in this project we only focused on generation of electricity by the means of hydro or
water (hydro power plant). As we know that the power plant is defined as the place where power is
generated from a given source, so here the source is hydro that’s why we called it hydro power plant.

Hydropower is a renewable, non-polluting and environment friendly source of energy.

Oldest energy technique known to mankind for conversion of mechanical energy into electrical
energy.
Contributes around 22% of the world electricity supply generated.

Maximum benefits in minimum time.

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 Offers the fastest economical means to enhance power supply, improve living standards,
stimulate industrial growth and enhance agriculture with the least environmental impact and
without heavy transmission losses.
Due to less transmission losses there is a reduction in distribution cost as well.

 Hydraulic Machine (Turbine):-

Hydraulic turbines are highest efficiency prime movers used for power production which utilizes the
energy of water ways.

The hydraulic energy contained in the stream is converted by to mechanical power.

The mechanical energy used in running the electric generator which is directly coupled to shaft of the
turbine

The shaft is connected to the rotor of generator, as rotor rotates with the help of shaft an EMF is
induced in conductor and electricity is produced.

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 Classification of turbines:-
Hydraulic turbines are classified according to the type of energy available at the inlet of the turbine,
direction of flow through vanes, head at inlet of the turbine and the specific seed of turbine. Thus the
following are the main classification of turbine.

 According to the type of energy at inlet :

 Impulse turbine
 Reaction turbine
 According to direction of flow through runner:
 Tangential flow turbine
 Radial flow turbine
 Axial flow turbine
 Mixed flow turbine
 According to the head at inlet of turbine:
 High head turbine
 Medium head turbine
 Low head turbine
 According to the specific speed of turbine:
 Low specific speed
 Medium specific speed
 High specific speed

If at the inlet of turbine the energy available is only kinetic, the turbine is known as impulse turbine
.In a reaction turbine the water supplied to the runner possesses energy which is partly kinetic and
partly pressure. Both types of energies are converted into work in the runner which results in a drop
of pressure and absolute velocity of water.

As the water flows through runner, the water is under pressure and the pressure energy goes on
changing into kinetic energy. The runner is completely enclosed in air tight casing and the runner and
casing is full of water.

If the water flows along the tangent of the runner the turbine is known as tangential flow turbine. If
the water flows along radial direction through the runner the turbine is known as radial flow turbine.
If the water flows from outwards to inwards, radially, the turbine is known as inward radial flow
turbine. On the other hand if the water flows from inwards to outwards, radially, the turbine is known
outward radial flow turbine. If the water flows through runner along the direction parallel to the axis
of rotation of runner, the turbine is known as axial flow turbine. . If the water flows through runner in
the radial direction and leaves in the direction parallel to the axis of rotation of runner, the turbine is
called mixed flow turbine.

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 Impulse & Reaction Turbine
Each turbine has a water passageway which incorporates a turbine casing, stay vanes for support,
wicket gates for flow control, a runner that rotates the generator, and a draft tube or the exit channel
downstream of the turbine.

Figure1 shows the typical positioning of a reaction and impulse turbines with respect to the incoming
water conducting system and the draft tube, which is the exiting duct of the flowing water.

For or the reaction type of turbine, (Figure 1a), the turbine section is assumed to begin at the entrance
to the turbine case (section A-A in the figure) and end at the exit from the draft tube (section B-B). It
may be noted that this setting for a reaction turbine ensures the following characteristics:

1. The wheel passage remains completely filled with water

2. The water acting on the wheel vanes is under pressure greater than atmospheric
3. The water enters all round the periphery of the wheel through the scroll case
4. Energy in the form of both pressure and kinetic is utilized by the wheel

In the Figure1, Ht is the head of water on the turbine and is the difference in water specific energy
between beginning and end of the turbine section.

For the impulse type turbine (Figure1b), the following characteristics of the turbine setting
differentiates it from the impulse type of turbines:

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1. The wheel passages are not completely filled with water since a jet emanating from the
penstock nozzle strikes the buckets of the runner
2. The water acting on the vanes or buckets located at the wheel periphery is under atmospheric
pressure
3. The water impacts on the runner at one point or at a few discrete points, depending upon the
number of nozzles

4. Energy applied to the wheel is completely kinetic

The components of the different types of turbines are discussed in the following paragraphs.

 Reaction turbine
Turbine has stationary as well as rotating members. The stationary components of a reaction turbine
with vertical axis are shown in Figure 2.

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The purpose of each part is as follows:

1. Stay ring, which forms the outer support of a turbine case. It resists heavy loads imposed by
the equipment and the concrete of the power house structure. It consists of an upper and lower circular
plates joined by 10 to 16 stay vanes of streamline shape. The stay rings of some turbines may have no
lower plate.

2. Wicket gates, which are provided inside the stay rings regulate the discharge and direct the
water flow towards the runner by their angle. Also, the wicket gates serve to start up and shutdown
the turbine and to control its power output and rotational speed. Wicket gates also have an upper and
lower rings resting in recesses provided in the circular plates of the stay ring. The rings of the wicket
gate are joined together by 20 to 32 blades (or gates) of streamline shape.

3. Operating ring, to which the gates are connected by slotted guides and levers rigidly fastened
to their top pins. The function of the operating ring is to open or close the gates which can rotate about
their axes.
4. Turbine cover, the operating ring is installed in a recess provided in the turbine cover which,
in turn, rests in a recess made in the upper ring of the wicket gates. The turbine cover gives support to
the turbine bearing and separates the water passageway through the turbine from the dry turbine pit.

The rotating or movable parts of a reaction turbine comprises of the runner and the shaft.

The shape of such part differs for different types of reaction turbines, as described below:

 Axial flow reaction turbines :-

Figure 3 shows the Kaplan type of adjustable blade axial flow turbine, where the stream of water flows
in the direction of the axis of the turbine.

The axial flow turbine resembles the propeller of a ship and hence is also termed as the propeller
turbine. The runner of such a turbine has three to eight blades, cantilever-mounted on a spherical or
cylindrical hub equipped with a cone (Figure 3c). In a fixed blade propeller turbine, the blades are
rigidly fastened to the hub at a permanent angle. In the adjustable-blade propeller (or Kaplan) turbine,
the blade angles can be adjusted by a hydraulic operated piston located within the hub (Figure 3d).
The advantage of having an adjustable-blade for a propeller turbine, as for the Kaplan turbine, is that
the fixed blade wheels show peak efficiency at only a small range of load. If load is slightly higher or
smaller than this range, its efficiency drastically decreases. On the other hand, the blade adjustable
turbines can be operated in such a way that their efficiency remains high over a very large range of
load.

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  Radial flow reaction turbines

Figure 4 shows the runner of a Francis turbine, where the flow of water from the stationary part into
the turbine runner is in a radial direction.

Once inside the runners, the flow direction changes and gets directed downward. The runners of
Francis turbine are attached at their upper ends to a conical crown and the lower ends to a circular
band. The shrouded buckets make an angle with the radial planesand bend at the bottom. The number
of blades usually ranges from 14 to 19 (Figure 4c). As with the propeller turbine, the runner shape
depends upon the head, as shown in Figure 4d.

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  Diagonal flow reaction turbines

Figure 5 shows the runner of a Deriaz turbine, which is the adjustable-blade modification of a diagonal
turbine

Here, the flow of water against the turbine blades is neither axial nor radial, but at an angle. The angle
θ made by the blade axes with the main shaft decreases with increasing head and ranges between 30 0
and 600. As with Kaplan turbines, the mechanism for adjusting the blade angles is located within the
hub.

Reaction turbines with the turbo-generator axis placed vertically, as described before, causes the
stream of water to change by 90 0 from the point where it leaves the stationary part and the water enters
the turbine runner. Again, the water turns by 900 as it leaves the runner and enters the draft tube before
finally joining the tail water. This turning of flow twice – results in a loss of energy. Another
inconvenience is that vertical turbo generators require extra head room in low-head power plants and
thus becomes inconvenient to place there. Under these circumstances, a horizontal axial-flow
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(propeller type) arrangement of reaction turbine has been often adopted like the bulb type turbine
(Figure 6). It has the generator in series with the turbine runner at a submerged elevation and enclosed
in a streamlined water tight housing located in the water passageway on either upstream or downstream
side of the runner.

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The S-type tubular turbine (coupled to an open-air generator) is also favored for very low head range
and designed as a low capacity unit (Figure

7). the blades of the turbine can be fixed (propeller) or movable (Kaplan).

 Impulse turbines

As mentioned above, the Pelton turbine is an impulse turbine that is used commonly in hydro power
projects worldwide for very high head installations. The runner of a Pelton turbine (Figure 8) consists
of a disk with buckets attached around its periphery. The buckets can be integrally cast with the disk
or welded or bolted to the wheel centre. The buckets may vary in details of their construction but in
general they are bowl-shaped and have a central dividing wall, or splitter, extending radially outward
from the shaft. The runner is enclosed in housing and is mounted on the same shaft with the rotor of
the water-wheel generator, placed either vertically or, more frequently, horizontally. The water is
supplied from the upper pool through penstocks which end with one or several tapering nozzles. The
water jet escaping from the nozzles hit the dividing wall which splits it into two streams, and the bowl-
shaped portions of the buckets turn the water back, imparting the full effect of the jet to the runner.
The quantity of water through the nozzle is controlled with the help of a spear-valve. The used water
flows down a conduit into the lower pool.

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  Choice of a turbine
The water power designer has to make a choice on the type of turbine that can be adopted for a
particular project. After the range of head to be handled by a turbine has been evaluated by stream
flow analysis and the installed capacity determined from the analysis of the power-generating
capacity of the proposed plant, the task of the designer is to choose an optimum turbine type and
series, the number of power generating units, the runner diameter, rotational speed, and runner
axis elevation. Knowing the total installation at the power station, the number of units can be
decided. The capacity of the plant should be fixed as high as possible with adequate care on
efficient running and low initial costs, and available transport and shipping facilities.

The following Bureau of Indian Standard Codes of practices may be referred to for the detailed
design of hydraulic turbines and their selections:

1. IS:12837-1989 “Hydraulic turbines for medium and large power houses - guidelines for
selection”
2. IS: 12800-1993 “ Guidelines for selection of turbines, preliminary dimensioning and layout of
surface hydro-electric power houses”:
Part 1: Medium and large power houses

Part 2: Pumped storage power houses

Part 3: Small, mini and micro hydroelectric power houses

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One of the important parameters of a turbine is the Specific Speed denoted as n s, which and defined
as the speed in r.p.m. at which a turbine of homologous design would operate, if the runner were
to reduce to a size which would develop one metric horse power under one meter head. It is given
by the following relation:

= n P ×1.358
n
s H5 /4

where
ns = Specific speed of turbine in revolutions per minute(r.p.m.)
n = Rated speed of turbine in revolutions per minute

P = turbine output in kW, and

H = Rated head in meters.

Once the specific speed (ns) is determined, the chart given in IS: 12837-1989 and reproduced in
Figure 9 may be used to determine the type of turbine that may be adopted for the particular project.

The type of turbine selected also depends upon techno-economic considerations of the generating
equipment, power house cast and relative benefits of power generation. The factors given in the
following table determine the type of turbine to be used depending upon site conditions.

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 Type of Head Load variation Specific Peak
Machine Variation Percent of speed Efficiency in

percent of rated outlet (m-mhp) percent

Rated head

(m)

Pelton 120 to 80 50 to 100 15 to 65 90

Francis 125 to 65 50 to 100 60 to 400 93

Deriaz 125 to 65 50 to 100 200 to400 92

Kaplan 125 to 65 40 to 100 300 to 800 92

Propeller 110 to 90 90 to 100 300 to 800 92

Bulb 125 to 65 40 to 100 600 to 1200 92

The following points may additionally be noted:

1. The performance of a turbine is ideal at the design head. Fall of efficiency in case of Pelton,
Kaplan and Bulb turbines is much less in comparison to Francis-and Propeller types. Therefore in
overlapping head ranges selection of type of turbine should consider the head variation existing at
site.

2. Turbine efficiency varies with load. Fall of efficiency at part load for Francis and Propeller is
much steeper in comparison to that for Kaplan and Pelton turbines. Therefore, necessity of
operating turbines at part loads for longer time influences the choice of turbines in the overlapping
head ranges. Thus in the head ranges where both Kaplan and Francis are suitable. The requirement
of large pressure head and electrical load variation dictates, Kaplan turbine to be superior to Francis
turbine from considerations of higher power generation on account of better overall efficiency.
Similarly, in the overlapping head ranges where both Francis and Pelton could be used, Pelton has
advantages over Francis in overall performance level when variation of load and head is higher.
3. Highest specific speed of turbine resulting in higher speed of rotation for generator with
consequent reduction in cost of generator. This criteria is very important for selecting-type of
turbine from cost consideration in the overlapping head ranges.

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 WTM BLOCK
Water turbine manufacturing block (block-1) is one of the biggest blocks in the BHEL complex.
Hydro turbine and its associated components are machined and manufactured here.

 Vertical Turret Lathe-1

Machine Maker – Froriep

Machine No. – VTL 1

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

Operation Undergoing – Boring

Tool Used – DJNL (name of a single point insert)

Maximum Diameter of Job – 1600 mm

Maximum Height – 1000 mm

No. Of RAM – 2

No. Of Turret or Tool Index – 5

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 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

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 VTL
1. 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.

 Remedy
1. 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.

 Precaution
1. Read the drawing carefully.
2. Check the accuracy of tool and calculate the error .
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 - 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
Width 1000 mm

f. Standard Box Table (L*B*H): 600*500*500 mm

g. Maximum Feed: 1.25 mm per min

Operation Undergoing – Reaming

Tool Used – Taper Shunk socket Reamer

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 Drilling Machine

Machine Maker – Csepel

Machine No. – 06 RD 1

Maximum Height: 10 – 11 feet

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.

 Error in drilling machine

1. 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.

 Precautions
1. 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 by brush.
4. Measuring instrument should be checked for error.
5. Drawing should be studied properly.

 Remedy is similar to that of VTL

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 Horizontal Boring Machine (Large)

Machine Maker – Skoda

Machine No. – 14 HB-1

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

 Horizontal Boring Machine (Small)

Machine Maker – Pama

Machine No. – AL 127(15 HB 2)

Job Undergoing – Runner Blade

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

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 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 soft

2. Diameter of the job
3. Tool used

 Error in drilling machine

1. 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.

 Precautions
1. Coolant should be used.
2. Measuring instruments should be checked for errors.
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 burg
Machine No. – 01 L1
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

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 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.

 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.

Vacuum breaking valve:-

What is vacuum breaking valve??

As the name suggest, it is one of the important component in turbine which is used to remove
vacuum from it.

Where it is used in hydro power?

It is fitted at the top of the inlet pipe of turbine. Water from source flows from inlet pipe to the
penstock from where it goes to outlet pipe. The outlet pipe is connected to turbine through spiral
casing.

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What are the reasons for using it?? (Functions)

It is used to remove vacuum from inlet pipe. When we withdraw water from inlet pipe, there are
chances of formation of vacuum in turbine. Now this vacuum will start putting pressure on
components inside the turbine,

There are possibilities of breakage of components so to prevent components from breakage

vacuum breaking valve is used.

Once opened, it will quickly allow the air to pass through it and will remove the vacuum in this
way.

 Problem statement:-

As this vacuum breaking valve is fitted at top of inlet pipe, its lower part is always dipped inside
the water of inlet pipe. To avoid any chance of leakage it takes two to three days for manufacturing.

 Objective:-

The aim is to find out better way of manufacturing of vacuum breaking valve in minimum time
and then assemble its components. Finally testing of valve by different methods so to ensure that
there is no chance of leakage.

 effect of leakage :-
Due to the leakage from top of the inlet pipe through valve, there is problem in working
there; the whole workplace is covered by water. In 15 min 1000ltr of water flows from the
leakage, it is not possible for the labor to work in such conditions.

Also the company (BHEL) claims no leakage from the valve so any problem regarding
leakage of water must be solved by BHEL only. For example these valves were used on
site in Jammu, leakage came into the picture, to remove the water from workplace they
used motors and the whole expense of removing water is given by BHEL BHOPAL.

 Solution:-

Old way:-
None of the process is ideal so while manufacturing valve components according to the
engineering drawing these were completely finished according to the drawing. But the
dimensions of the components were not accurate. This is due to lack of accuracy of

32
 machines, worker or by human errors. During assembly due to improper dimensions of
components, problems arise like improper fittings between components, leakage, also
difference in their central axis. To remove such problems they have to disassemble the
valve and have to rework on it (lapping process). Hit and trial methods are applied for
perfect fittings. Due to this whole process of disassembling and rework on components
individually extra time is needed. Maximum two to three days was required at that time.
Extra machining hours were required; usage of machine was much more, further finishing
was required. They have to further look up to the dimensions of components.

Sr. Observed Processes Time in Hours

No. (approx.)

1 Finishing of components 19

2 Assembly of components 6

3 Actual Mating of components 1

4 Center axis alignment 1

5 Dis-assemble 3

6 Dimension Analysis (Rework) 2

7 Lapping 36

8 Re-assemble 4

TOTAL TIME (A) 72 HOURS

New preferred way:-

Now what we are doing is that we just do not finish the components (copper ring) of the
valve first. Some layers of the material are remained on the components for finishing.
Before finishing these materials assembly is done. Now whatever problem arises during
assembly these components will accommodate that problems (problems like matching of
central axis of whole valve, fittings) and based on that finishing of material is done
whatever it requires. The finishing is now done manually only; the copper plate is put on
another flat plate which has blue paste on it. Now wherever the blue paste is seen on the
copper plate that means it has more material there, this material is removed manually by
lapping process. In which the worker rubs a paper against the extra metal on it. This metal
is removed in two to three shifts of working and no leakage condition is obtained in
minimum time.

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Sr. Observed Processes Time in Hours
No. (approx.)

1 Assembly of unfinished components 6

2 Actual Mating of components 1

3 Dis-assemble 3

4 Dimension Analysis (Rework) 1

5 Lapping and finishing 3

6 Re-assemble 4

TOTAL TIME (B) 18 HOURS

 Improvements :-

By accepting this way of manufacturing, the consumption of machine and man power is
utilized more preciously. Now further rework (lapping) and machining on components is
no longer required. Due to which the life of machines is also increased, the cost of rework
is also saved. This process also saves time, by eliminating rework and further finishing of
components. This process actually saves 48 to 64 hrs in manufacturing. Last but not the
least this is full proof process regarding leakage. This process ensures complete and
accurate fitting between the components and provides zero leakage condition.

 components and their functions :-

1. Lower cone: - starting from below, it is lowest part of valve. It is in the shape of cone due
to aerodynamics reasons. It is supposed to move downside during vacuum conditions; the
conical shape will allow the air to enter into inlet pipe more easily.

2. Upper cone: - it is the other half of the cone mounted on the base plate. The upper and
lower cone both together makes the shape of barbarism. This will allow air to flow easily
in inlet pipe.

3. Base plate: - as the name suggest, it provide base for fitting of two halves of cone. It is
situated in between the two halves of cone. It moves along with the cones during vacuum.
Basically it id for the support.

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4. Body:- it part at the middle of the valve on which the upper part will be mounted like
resting of the spring and cylinder. It also has windows in it which will provide air during
working of valve.

5. Rod:- it is connected through base plate and will pass through cylinder to the upper most
part of the valve. It will move with the cones during vacuum and parts attach to it will also
move simultaneously.

6. Cylinder: - it comprises of many other components of valve like spring, sleeve, nut and
rod. It is acting as a shell in which oil is poured and stored.

7. Spring: - when the conical part moves downward due to suction, there is a spring inside
the cylinder which will be compressed and this generated spring force will help in
backward stroke of cylinder. It is situated inside the cylinder and rested upon body.

8. Piston: - it is situated inside the cylinder on the top of the spring. This will help in
compression of spring during forward stroke.

9. Sleeve:- it is placed on the top of piston actually it is attached to the rod when the rod
moves down it will go with it a d in this way it will push the piston due to which the piston
will move and able to compress the spring.

10. Nut: - these are also mounted on the cylinder and these will act as a stopper. Their distance
from the piston will decide the length of stroke. As the piston compresses the spring during
suction force these will stop the compression by restricting the movement of piston after a
certain point which is sufficient length of opening stroke.

11. Throttle:- these will regulate the flow of oil from upper chamber of cylinder to the lower
chamber of cylinder. The opening of throttle will decide the speed of strokes. With the
larger opening of throttle the speed of opening and closing strokes will be greater. It is
necessary to provide sufficient time for air to remove the vacuum in the inlet pipe.

12. Top cover:- it is fitted on the top part on the cylinder as to cover it and make sure the oil
does not get out from the top.

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  Assembly:-
Step by step assembly of vacuum breaking valve is give as follows:-

1. Assembly starts from the lower part of the cone to upper part. Firstly the base
plate and the rod are fixed, join together. This arrangement is placed on a stand.

2. After the above step, the upper part of the cone is introduced and this will bolted
with the base plate. In between the upper cone and base plate the seal is provided
as to ensure the stoppage of leakage of water between them.

3. After addition of upper half, the lower half of cone is bolted in same way as
upper half. This time the gas cut is fixed between the lower half and base plate
as to ensure no leakage and proper fitting of lower half.

4. Now the middle part that is body of valve comes in contact with the periphery
of base plate by putting on it from the hole from which rod will pass. The body
has further a main part connected to it i.e. copper ring which will comes in
contact to the periphery of base plate to make sure that there is no leakage of
water otherwise the water comes outside of inlet pipe and there is requirement
of extra motor to add on water in it.

5. Now the upper cylindrical part is bolted upon body and further the rod will pass
through the center of cylinder.

6. Spring with high tension is inserted inside the cylinder and this will be rested
upon the body of valve.

7. Further nut is fitted around the lower part of rod in the cylinder. The nut will
decide the length of stroke.

8. Further piston is introduced in the upper part of the rod in the cylinder. The
distance between the piston and nut is the stroke length.

9. Throttle is introduced in the picture and it is mounted on the cylinder.

10. Now the oil is poured from the top of cylinder and top cover is bolted on it.

36
  Testing:-

It contains three major sequential testing, these testing are given as follows:-

 Gravity test:- In this first test after the completion of assembly of vacuum breaking valve
, water is poured from outside of valve through body’s windows to make sure that there is
no leakage of water between the copper ring and base plate when the valve is in closed
condition. This test is done for up to 120min and after that it is checked for the leakage. If
any leakage is found lapping process is done on the copper ring. For lapping they first
spread ink on the base plate and then the copper ring is place upon the base plate. Area
where the metal is in excess in copper ring, the ink comes on that part and that part is
removed by hands. The lapping process can take one hour to one day depending upon the
accuracy of the labor.

 Hydraulic test:- The valve is lifted through cranes and put on a water chamber which has
a lever which is bolted with the body. The chamber contains water under pressure. There
is a sealing in between body and water so as to prevent leakage of water from the chamber
when the pressure is applied. Pressure of 30 to 40 kg of water is applied for one hour to
check the leakage between body and base plate when the valve is closed. Further to remove
if any leakage appears lapping process is done on the copper ring.

 Load test:- After above two test if those two are cleared then final hydraulic test is done
on valve. This test is further classified on the basis of direction of load, these are as follows.
o Upper load test: - In this case the load is applied from the top of the valve to ensure
the proper opening of the valve. The opening stroke is measured and the timing of
closing stroke is measure by stop watch. The timing must be in between five to six
seconds if it is not proper then the flow of oil is regulated by throttle valve which
is responsible for the speed of stroke.
o Lower load test: - in this case the load is applied from the downward ward side of
the valve. A particular amount of load is applied according to the demand of
costumer generally in between 270 to 320 kg to check the opening time of the valve
generally it must be up to 3 sec , to adjust its timing the flow is regulated with the
help of throttle valve.

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 Assembly of turbine:-
 Various components of hydro power plant manufactured:-

 Main inlet valve:-

The conduits in all water power plants except large low head plants are ordinarily provided with
shut off devices. Generally these components are valves. They exist in different types and designs
depending on function and requirements.

In any power plant valves of different purposes are usually needed. Normally it is a shut off valve
just in front of turbine. In this way the turbine may be emptied without emptying the shaft or
penstokes. In addition the guide vane cascade is depressurized so that the leakage flow is avoided.

With a long head race tunnel and surge chamber it is normal to have a shut off valve just
downstream to the surge chamber. In this way the shaft or penstokes may be emptied without
emptying the tunnel.

To prevent large damage to a eventual rupture of penstock, a pipe line break valve is normally
installed in a pipe just downstream of the shut off valve. This valve closes automatically when the
water velocity exceeds a certain set valve. The most relevant type of valves manufactured in BHEL
are:-

 Spherical valve:-

These valves are applied mostly as shut off valve in front of high head water turbines. They are
however, used as pipe break valve as well. Spherical valves are presently covering a pressure range
of 160 to 1250m water head. These consist of valve housing with flanges, valve rotors, bearings
and seals. The valve housing has a spherical shape. It may either be axially split permanently in
two halves and bolted together with heavy flanges, or these two halves may be welded together
after the rotor has been installed. The opening and closing operation of valve is carried out by one
or two servomotors.

 Butterfly valve:-

These valves are normally applied in front of low and medium head water turbine that is heads up
to 200m. For high head power plants the butterfly valve is from time to time used as closing device
in inlet tunnels and alternative as emergency closure valves.

The butter fly valve shall be able to open and close under equalized water pressure on the disc
sides as well as to close at full turbine discharge. In addition emergency closure valves shall close
automatically in the case penstock rupture.

38
  Stay ring:-

It consists of upper and lower ring to which the stay vanes are welded. The stay vanes are given a
favorable hydraulic shape to conduct the water towards the guide vanes with minimal losses. The
stay vanes also carry the axial forces inside the scroll casing. The vanes in the stay conduct the
water towards the guide vanes. In addition the hydraulic forces are transferred through the stay
ring and the stay vanes which are anchored to the concrete with large pre stressed stay bolts.

 REGULATING RING:-

The guide of blades of a Francis turbine are pivoted and connected by levers and link to the
regulating ring. The regulating ring is regulating ring is in turn connected with regulating shift,
which is operated by the piston of servomotor,

When load on turbine increases, regulating ring is moved in reverse direction to increase the
passage between the guide blades thus allowing more water to meet the increase load demand.
Similar is the function and connection in case of Kaplan turbine except that servomotors are
connected to turbine blade also to give the required motion, hence this system is known as
“Double Regulation” and gives higher efficiency.

 RUNNER:-

It is basically a rotating part of the turbine on which blades are either casted or bolted and then it
is mounted on the shaft which transmits energy. Runners of Pelton wheel consist of circular disc
mounted on a horizontal shaft, on the periphery of the runner, a numbers of bucket are fitted
uniformly. The pelton runner may be design either for casting the disc and buckets in one piece
or the disc and each of the buckets are casted in separate pieces and the bolted together. The first
method mentioned is preferred and common for the pelton turbines in modern power plants
where the turbine units are of the high power and bigger sizes.

Runner of the Francis is a circular wheel on which a series of radial curved vans are fixed. The
runner may be either casted or fabricated. For a large unit, Cast steel or stainless steel may be
used and for small unit, cast iron. The surface of the runner is made smooth to reduce the losses.
The runner is so shaped that the water flow through the runner in combination of radial and
tangential flow and leaves runner without shock.

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Kaplan consists of an axial flow runner usually with four to six blade of aerofoil shape. In consist
of a slot in which blades can be bolted and can be rotated with the help for servomotors
according to the load.

Runners for Pelton, Francis and Kaplan for projects like Parbarti ill, Srinagar, Pulichintala,
Rampur had been manufactured in BHEL Bhopal. Other than this guide vanes are finished here,
drilling of blades of Kaplan is also done here.

 TOP COVER AND PIVOT RING:-

There are circular ring with seat or projection provided on dam to accumulate the guide wind. Top
cover is provided on the top of the guide ring in which top of the guide ring is connected which is
connected with the lever to the arm which is bolted on regulating ring

As the regulating rotates with the help of servomotor the arm rotates, rotating the lever to the guide
ring and hence flow of water is regulated

Pivot ring is provided to the base of guide ring which act as supporting or pivot to the guide ring.
It is also circular shape. For Kaplan the runner starts from the pivot ring while in francis it starts
from the guide vanes.

 GUIDE VANES:

The basic purpose of the guide vanes or stay vanes is to convert a part of pressure energy of a fluid
at its entrance to the kinetic energy and then to direct the fluids on to the runner blades at the angle
appropriate to the design. Moreover, the guide vanes are pivoted and can be turned by a suitable
governing mechanism to regulate the flow while the load changes. The guide vanes are also known
as the wicket gates.

The guide vanes imparts a tangential velocity and hence an angular momentum to the water before
its entry to the runner. The flow in the runner of francis turbine is not purely radial but a
combination of radial and tangential. The flow is inward, that is from the periphery towards the
centre. The height of the runner depends upon the specific speed. The height increases with
increase in specific speed the main direction of flow change as water passes through the runner
and is finally turned into the axial direction while entering the draft tube.

40
  SPIRAL CASING:

These are connecting leads between penstock and stay rings. These are gradually decreasing
conduct around the circumference of the wheel (maximum at the entrance and minimum at the
top) these carry water from penstock and supply to the runner. These are made of decreasing cross
section because the losses occur during the flow can be avoided.

 Steps of assembly
Turbine takes at least takes two weeks if all the things are perfect as per drawing. Steps for
assembly of turbine is given as follows

1. Pivot ring :-

These are also known base ring. As the name suggest, These act as supporting or pivot to
the guide vanes.

2. Guide vanes:-

After placing of pivot ring guide vane are placed. These are fitted from the tunion part of
the guide vanes. The upper half is still open.The basic purpose guide vanes or stay vanes
is to convert a part of pressure energy of the fluid to its entrance to the kinetic energy and
then and direct fluid on to the runner blades at an angle appropriate to the design.

3. Top cover :-

As the name suggest, Top cover is fitted on the top of the guide vane in which hub of the
guide vanes are connected. These are used for proper holding of vanes.

4. Lever:-

These are connected to the guide vanes from one side and from the other side these are
connected to regulating ring with the help of link. These are used for the sole purpose of
connecting guide vanes from regulating ring.

5. Regulating ring:-

When the load on the turbine increases, torque is generated due to which regulating ring
is moved in reversed direction to increase the passage between guide blades and thus
allowing more water to meet the increased load demand. The regulating ring movement is
controlled by motors which are connect to ring in opposites direction.

41
 6. Runner:-

It is basically rotating part of turbine on which blades are either casted or bolted and then
it is mounted on the shaft which transmits mechanical energy to the rotor of generator. Due
to movement of rotor EMF is induced which is responsible for the generation of electricity.
Runners are classified on the basis of type working head

7. Main inlet Valve:-

It is present between inlet and outlet pipe of turbine. The function of these components is
to regulate the flow of water in turbine.
The are classified on the basis of working pressure, these valves are as follows:-

o Spherical valve: these are used for high pressure heads ranging from 160m to
1250m.

o Butterfly valve: these are used for low pressure heads, up to 200m.

8. Stay ring:-

The stay ring consists of upper and lower ring to which stay vanes are welded. The stay
vanes are given favorable hydraulic shape to conduct the water towards guide vanes with
minimal losses.

Testing and checking of turbine:-

Main inlet valve testing:-

In this test, the pressurized water is supplied to the valve to check the leakage when the valve is in
fully closed condition. There is seal in the valve which is responsible for the stopping of water , if
there is any leakage found the valve is further machined.

42
In the case of pelton turbine there is nozzle which is responsible for regulating the flow in turbine.
As above explained it is done is the same way. The water is passed through nozzle when it closed
to see the leakage.

 Runner balancing:-
In the process of runner balancing, the runner is centrally kept on a pole and then it is rotated up
to a certain rpm as per requirement to check the unbalancing part in it. The machine on which it is
rotated identifies the unbalancing part in it. The machine is perfectly divided in the degrees,
positive reading in the machine means excess amount of metal in the runner and negative means
some amount of metal to be added in the machine. In this way the runner is balanced about an axis.

 Guide apparatus inspection or checking:-

In this case the guide apparatus assembly is perfectly checked according to the drawing and
dimensions given in it. The main focused part during the checking is throat opening. The throat
opening in turbine is responsible for the discharge in it. If the discharge is less than the guide vanes
are grinded for the required discharge. In this way the required discharge is met.

 Guide bearing assembly checking:-

These are fixed around the turbine shaft as to maintain its temperature and prevent from heating.
The done by the oil filled in the guide bearing. During the assembly of guide bearing the alignment
of holes, fitting and spacing is measured and compared as per given in drawing for accurate
assembly.

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 CONCLUSION

The Vocational training at BHEL Bhopal helped me in improving my practical knowledge and
understanding of Hydro turbine, its manufacturing and types to a large extent. Here I came to know
about the technology and material used in manufacturing of hydro turbine. Besides this, I also
visualized the parts involved and equipment that were used during the manufacturing process of
these turbines.

Hence the objective was satisfactorily achieved by me during the course of this project. The
objectives achieved are as follows:-

a. Study of manufacturing of turbine

b. Assembly of turbine
c. Testing of turbine
d. Study of vacuum breaking valve
e. Assembly of vacuum breaking valve
f. Various testing processes to ensure no leakage
g. From the tables (on page no. 40&41) the time difference can be seen A-B is 48 to 54 hours
(approx.) is saved in the overall process.

In all it was a truly learning experience for me. As a mechanical engineering student I hope that
the training I got here would help me in coming future.

44
 REFRENCES

 https://www.energy.gov/eere/water/types-hydropower-turbines

 http://www.bhel.com/

 https://easyengineering.net/a-textbook-of-fluid-mechanics-and-and-hydraulic-machines-
bansal/

 https://www.bhel.com/index.php/history

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