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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 ENGINEERING

JAIPUR ENGINEERING COLLEGE

KUKAS, JAIPUR (RAJ.)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

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me this lifetime opportunity to work & learn in this much systematic and

professional environment. Now I would like to thankMr. 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 unflinchingencouragement shall ever remain as a treasure in my memory.

ABHISHEK TANWAR

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

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our books is not much use without knowing its practical implementation, it has been

experienced that theoretical knowledge is volatile in nature, however practical knowledgemake 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

Chapter Name Page1 Company Profile 5

2 History 7

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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

Company Profile

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Global Activities

The ANDRITZ GROUP is a global market leader for customized plant, systems andservices 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 EuropeanARIANE rocket launcher program).

PULP & PAPERprovides technology and services that enable the industry to produce

practically all grades of pulp for the manufacture of paper, board and fibreboard, and alsospecialized 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-ferrousmetal strip. This includes plants for the regeneration of pickling acids and for 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

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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. Inaddition, the Business Area holds a leading position in equipment for wood pelleting.

CHAPTER-2

History

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ANDRITZ: From small iron foundry

to globally leading machinery and plant engineering company

Milestones in the history of ANDRITZ:

1852-1900Beginnings as an iron foundry

ANDRITZ AG has its origins in an iron foundry that was established in

1852 by the Hungarian entrepreneurJosef Krsi in Andritz, a suburb of

the city of Graz. Soon after its foundation, the companys 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.

1900-1946World Wars and the Great Depression

At the end of the First and Second World Wars and during the Great

Depression in the early 1930s, ANDRITZs production came to a standstill,

but committed management and employees succeeded each time in making a

new start.

1946-1980Growth and new products

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

Group of Switzerland, initially in the water turbines sector. ANDRITZsproduct portfolio was revised: Production of steam engines and air

compressors ceased, and the focus was placed on water turbines, centrifugalpumps, cranes, and steel structures. In 1951, ANDRITZ embarked on

production ofcomplete 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 theproduction program.

1980s Crisis and recovery

The second global oil crisis and worldwide economic stagnation in the early

1980s caused a drop in ANDRITZs order intake and the company was

operating at a loss, but Austrian government subsidies and drastic

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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 strategicdirection, from being a licensee of other equipment manufacturers to

become a leading international supplier of its own high-tech productionsystems.

Since 1990 Growth through acquisitions

In 1990, the acquisition of Sprout-Bauer, a US company supplyingequipment for mechanical pulp and animal feed production, marked the

beginning of the ANDRITZ GROUPs successful expansion policythrough acquisitions. Complementary acquisitions, in addition to researchand 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 pulpproduction systems) and VA TECH HYDROs 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 investment

companies (The Carlyle Group, GE Capital, Unternehmensinvest AG,

Deutsche Beteiligungs AG) and the Custos private foundation (establishedby 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 andinternational investors.

2003 saw the Secondary Placing of ANDRITZ shares on the Vienna stockexchange. The financial investors sold the entirety of their shareholding in

ANDRITZ, which resulted in a rise in free float to over 70%.

TODAYANDRITZ today

The ANDRITZ GROUP is a globally leading supplier of plants andservices for the hydropower, pulp and paper, metals, and other specializedindustries (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?

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ANS: A hydro turbine uses the potential and kinetic energy of water and converts itinto 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 theturbine 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 easeof 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 jetissuing 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 underatmospheric pressure, there is no change of static pressure across turbine

runner and the unit is often referred to as free jet turbine. Important impulse

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

B. Reaction Turbine: Wherein the part of the total available hydraulic energyis 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 turbinesare: Fourneyron, Thompson, Francis, Kaplan and propellor turbines.

Hydraulic turbines further classified into various kinds according to:

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)

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

BLADE

ROTOR

STATOR

(a)AXIAL FLOW(b)RADIAL FLOW (c)MIXEDFLOW

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 entersand 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 flowmachine.

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 250m) 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.

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

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Kaplan turbine: Ns =250-850

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) Static1) Turbine housing

2) Disposition

3) Distribution Pipe4) Inlet Pipe

b) Dynamic1) Nozzle Assembly

2) Deflection Assembly

3) Runner Assembly4) Distributor Assembly

5) Oil Head

6) Cooling Water

c) Governing

1) Governor

2) 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 areprovided 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 orforward thereby controlling flow area either by governing mechanism or by hand wheel.

The turbine rotor, called the runner is acicular disk carrying a number ofcup 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 ofthe large hydro turbine or large runner size the buckets are bolt mounted to the runners

disc. The runner is generally mounted on a horizontal shaft support in a small thrust

bearing and is casted integrally; they are made up of stainless steel. The inner surface of hebuckets 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

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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 90to 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 asafeguard 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 thecentrifugal 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 thespear to a position, which increases the annular area of the nozzle. Quantum of water

striking the buckets is then increased and the normal turbine speed is restored. Conversely

happen when we have to reduce the load.

Main assemblies and operation of Francis turbines

ASSEMBLIES


a) Static1) Turbine housing

2) Disposition

3) Stay Ring

4) Spiral

b) DynamicDistribution

Runner

Oil Seal

Shaft Seal Cooling water

Guide Bearing

c) Governing

1) Governor2) Skada

Working Of Francis turbine

Penstock is a large size conduit, which conveys water from the high levelreservoir 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

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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 flowdirection 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 toguide 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 withits 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 crownand shroud in one direction and two consecutives blades on the other. There is about 16 to

24 number of blades in runner. These passages take water in at the outer periphery it in a

direction parallel to the axis of rotor. The driving force is both due to the impulse andreaction 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 racethrough 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

ASSEMBLIES


d) Static1) Turbine housing

2) Disposition

3) Stay Ring4) Spiral

e) Dynamic

DistributionRunner

Oil Seal

Shaft SealCooling water

Guide Bearing

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f) Governing

1) Governor

2) 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 bossare 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 frominside of the hollow shaft of turbine runner and the movement of piston is employed to the

twist blades through suitable linkages.

CHAPTER-4

MACHINE SHOP

Vertical Turret Lathe-1

Machine Maker FroriepMachine No. VTL 1

Job Undergoing Discharge ring lower part

Project Undergoing Karcham WangtooOperation Undergoing Boring

Tool Used Boring Tool or an Insert tool

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Maximum Diameter 7100 mm

Maximum Height 4200 mm

Digital Control PanelNo. 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 2Job Undergoing Runner Hub

Project Undergoing SomanamardiOperation Undergoing Boring

Tool Used DJNL (name of an single point insert)

Maximum Diameter of Job 1600 mm

Maximum Height 1000 mmNo. Of RAM 2

No. Of Turret or Tool Index 5

Speed: 180 RPMFeed: 0.044 4 mm per minute

Digital Control Panel

Vertical Turret lathe-3

Machine Maker FroriepMachine Number VTL-3

Max. Diameter 1200mmMax. Height 500mm

Job undergoing Servomotor cover

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Project - BabehalliTool Used DNMG (name of an insert)

Operation Undergoing: TurningNo. of Tool RAM 2

Tool Index / Turret 5

Max. Speed 180 RPMFeed 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. Scrapproduced 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 themachine 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.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 thepresent dimension will work or not.

Precaution

Read the drawing carefully.

Check the accuracy of tool and calculate the error if there is any.

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 mmb. Sleeve Diameter: 400 mm

c. Distance Sleeve to Spindle: 350 2150 mm

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d. Spindle Traverse Distance, Base to Spindle: 380- 1645 mme. 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

h. Minimum Feed: 0.125 mm per mini. Range Of Speeds:

Standard: 40 1800 RPMOptional: 50 2240 RPM

j. Machine Weight 4560 kg

Project Undergoing Somanamardi

Operation Undergoing Reaming

Job Undergoing Sealing SupportTool Used Taper Shunk socket Reamer

Drilling Machine

Machine Maker CsepelMachine No. 06 RD 1

Maximum Height: 10 11 feet

Job Undergoing Rotating Sump BottomProject Undergoing Somanamardi

Tool Used Drill Tool (Maximum 100 mm)

Operation Drilling

Speed 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 automaticand 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.

6. Shrinkage in Stainless steel7. Tool Setting

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Precautions

1. Metal plate should be used to prevent bending of

both tool and work piece.

Coolant should be used.Waste material should be removed bye brush.

Measuring instrument should be checked for error.Drawing should be studied properly.

Remedy is similar to that of VTL

Horizontal Boring Machine (Large)

Machine Maker SkodaMachine No. 14 HB-1

Job Undergoing Head Cover

Project Undergoing Karcham WangtooProcess Boring

Tool Used Boring Tool

Maximum Height 3800 mmMaximum Length 10,740 mm

Spindle Taper ISO 60

Table Length 3500 mm * 3500 mm

Maximum RPM 600Feed two types: 1/1 and 1/10

Maximum and minimum feed: 6.32 1250 mm per minute

X Direction Reciprocating Motion.

Y Direction Upward and Downward Motion.Z Direction Inward and Outward Motion.

Horizontal Boring Machine (Small)

Machine Maker Pama

Machine No. AL 127(15 HB 2)Job Undergoing Runner Blade

Operation Undergoing Facing

Project Undergoing Karcham WangtooTool Used Cutter

Speed Range: 8 950 RPMMaximum Feed 3 mm per revolution

Minimum Feed 0.025 mm per revolutionMaximum 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

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material the speed of spindle is kept low i.e. in first gear. For soft material we use highspindle speed i.e. fourth gear. It is used for making slots, t- slots, boring, and turning,

facing and drilling etc. Tool used areboring 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 factor1. 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 thedrawing.

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

it contracts.

Precautions

Coolant should be used.

Measuring instruments should be checked for errors.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

Job Undergoing Dummy Discharge RingProject Undergoing Somanamardi

Tool Used Turning Tool i.e. an insert PDJNL

Operation Undergoing Ding turning proof machiningChuck: Swing over bed 2000 mm.

Bed Length 6000 mm

Maximum 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.

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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

Lathe Machine

Machine Maker- HMTMachine no. NH-26 (No. 6)

Bed Length 6 feet/ 3000 mm

Gap Bed 290 mm

Holding Capacity of Chuck 480 mm diameterSwing Over Centroid 300 mm diameter

RPM: 40 240Project Undergoing Baglihar

Job Undergoing Centering Bushing

Operation Boring

Tool Used CNMP 4000 (an insert)Coolant Used Soluble Oil

Lathe Machine L2

Machine Maker HMTMachine no. NH-32

Bed Length 3000 mmHolding Capacity Of Chuck 480 mm diameter

RPM 40- 230

Swing over Bed 640 mmJob Undergoing - Guide Vanes


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Operation Run Out CheckTool Used TNMP (an insert)

Shaper Machine No. 1

Machine Maker Sagar

Machine no. - SH-1Stroke 26-inch/550 mmRPM 72

Job Undergoing Pointer


Operation TaperTool Used High Speed Steel cutting tool

Milling Machine

Mainly used to make boresMachine Maker HMTMachine no. - UM-1

RPM 35-1800

Coolant Used Cutting OilVertical Height 400 mm

Operation Undergoing Boring

Instructions Ensure proper clamping of the cutter, work piece and fixture beforestarting the machine.

Universal Tool & Cutter Grinder

Machine Maker HMT

Machine no. - TCG 1Length Of Magnetic chuck size 200 mm * 375 mm

Table can rotate at 45 Deg.

Tool Head 25 Deg. Both ways

The chuck can be attached to it to hold the job of bigger diameter.Universal vise is used for holding job.

Common lifting machines

Fork lifter

Capacity 3 tones

Make Godrej

Cylinder 4

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Fuel DieselFuel 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.

CHAPTER -5

FABRICATION DEPARTMENT

Welding Equipments

TIG (Tungsten Inert Gas)

Machine Make: Frronius and Triodyn.

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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 3500C. Inert environment is provided by argon gas.

Hands supply filler metal manually.TIG has better penetration as comparison to otherwelding 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 2.4mm (Make is ESAB, kobelco and bohler). Copper cable is used to connect

Electrode holder and D.C. Flow meter are generally attached to the argon

cylinder.

MIG (Metal Inert Gas)


It is also semi automatic welding process. Here arc is also struck

between electrode and job. But here electrode is filler metal wire. Electrode isconsumable. Here filler metal wire speed is 5 mm per revolution. Argon and

carbon-di-oxide gases provide the inner environment. Color code for argon and

carbon-di-oxide cylinder is green. The Mild steel wire diameter ranges are 1.2 mm,2 mm, and 4 mm (Make is ESAB). Sometimes S.S coating is provided over M.S for

water resistant coating.

In MIG welding, spatter is prevented by applying spatter gel is applied

on the torch so that spatter doesnt stick to the torch. Spatter core is the area wherespatter can reach.

Welding fixture for M.S comes along with wire but for a S.S a separate fixture is

used.

SAW (Submerged Arc Welding)


It is an automatic welding process. Electrode is consumable. Herearc 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 of6kg/cm^2. Flux come and covers the welded zone. Grain size of flux varies from 0.2 mm to1.6 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)

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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. Thedistance 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

Used for MS (Mild Steel). Heavy coated low hydrogen iron powder electrode for

high quality welds in restrained joints in MS. Radiographic Quality Weld. Metalrecovery 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 - 150

4.0 150 - 1905.0 200 - 256

6.30 270 - 320

2. Electrode: 309L

Used 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 mildsteel to stainless steel.

The electrode possesses pleasing performance characteristics.

Manufacturer: D&H

Use AC or DC (+)

Diameter (mm) Current (ampere)

2 40-502.5 60-80

3.15 80-100

4 110-140

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5 150-180

3. Electrode: Bohler Fox (CN 13/4 Supra)

Maker Bohler Thyssen

Type C 0.03, Si 0.3, Mn 0.6, Cr 12.5, Mo 0.5, Ni 4.54. A basic coated alloyed core wire electrode design for both joint and

build up welding of similar stainless Cr steels and cast steels. Especiallysuited for water turbine, compressor and pumps. The

Maker: D&H

It yields a weld deposit of 25 % Cr, 12 % Ni austenitic deposit giveshigh resistance against cavitations.

Both AC and DC (+) can be applied to it.

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

a) Welding stainless steel of similar composition.

b) Joining 18% Cr, 8% Ni from stainless steel to mild steel.c) Applying sheet linings of12% Cr steel to mild steel.

Both AC and DC (+) can be use

Diameter (mm) Current (ampere)2 40-50

2.5 60-80

3.15 80-1004 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 metalwith 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 are

1) Welding curtain

2) Leather Hand gloves

3) Welding Respirator4) Leg Guard

5) Fire Retardant Cap

6) Welding glasses with side safety

7) Welding head screen8) Helmet

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

Defects in Welding:

1. External

I. Blow Holes

II. Slag Trap

III. ImpurityIV. Surface Crack

V. Under Cuts

VI. Spatter

2. Internal

I. Blow HolesPin Holes

II. Porosity

III. Insufficient FusionIV. 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 isapplied 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 surfacedefects 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 powderstarts 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 whichtransmits 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

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coupling should be applied. More the smoothness of the job more clearly thetransducer 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 avery 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 ascompared 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 bygauging 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. cm

2) The angle of rod should 45to the work piece.

3) Air jet should be switched on before striking of an arc.

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 orasbestos 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 airpressure 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. Thepressure 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 checkwhether the required shape is possible or not. Nozzle, cutting speed, pressure, Pre-heatingtime, 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.

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Generally single regulator is used for LPG, acetylene and oxygen. In winter seasonelectronic 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 withpressure 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.

CHAPTER-6

ASSEMBLY SECTION


Job Undergoing Assembly Wicket Gate Assembly or Distributor Assembly

Dummy discharge ring is placed at the bottom and is known as bottomhead. 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 placelevers 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 areplaced. 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.

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Through guide bearing housing shaft is passed.

Guide Vanes It consists of two sides i.e. thick end and thin side. The

thick side is called flat side and the thin side is called chamfer side. The

water strikes at the thick side and passes away from the thin side. The

distance between the thick ends of the guide vein is called facial gap.

Ceiling Gap The distance between two corresponding faces of guidevanes. 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 partsgiven as per drawing.

Axial play is done through dial indicator and dial stand.

After the fitting of head cover dew surface washers having the propertyof self-lubrication are placed on the upper surface of the guide veins.

Their main use is to reduce friction & provide lubrication. Without their

application the working of shaft will be affected.

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 provideclockwise 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-measuringdevice 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 devicebecause 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 awayfrom the suction side.

Shot blasting is done before painting so that paints stick hard on thesurface. 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 mmthick 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 areof 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

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which comes in direct contact with oil. Yellow and blue are mainly usedfor 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 thehelp 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 isthin. After passing from the guide vanes water strikes the runner placedinside 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

irregularity. In the runner of Pelton turbine we always place weightduring 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. Thetemplates 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 andcause 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 isaffected 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 theycant 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 grinderMaker: 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.

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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

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 diameterranges 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 isof 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 GoldIt 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 isdone to obtain special hydraulic contours. Grinding is done according to the requirementsmention 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 itshould 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.

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Tolerances for Pelton wheel are +0.5 or 0.5, for runner profile in Francisturbine 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 doesnt 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 (meantime to repair) should be same.

III. Predictive MaintenanceIt 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 checketc.

2. Unplanned

I. Breakdown Maintenance

II. Corrective Maintenance

Maintenance mainly involves infrastructure details along with the machineprofile and all computer related things.

Here in VA Tech total production management is followed. Maintenance department alsohandles 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 andphase 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 Plan

c) 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 dont return back. Consumables are always enter the SAP.

Non-Consumables (instrument, tools)

These tools are return back to the customer after there use. Non- consumables are

manually maintained in the register.

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 theirstock 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 usedspecially for foundation purpose or packing purpose. It is a portable

machine.

Pipe bending hydraulic machine fitted with oil seal is used to bend pipe.

Pumping is done by hand. Oil seal doesnt allow it to flow back. It ha

various dies of different shape. Also pipe holder can hold pipes ofdifferent 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 HZPower: 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 isprovided to convert finishing N6,N7etc 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 from1mm 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

45head.

Pistol caliper is used to measure thickness ofa job where micrometer cant 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 alignedwith machine or not its least count is 0.01 mm. Its range is from 0.01mmto 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),

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outer sleeve, measuring, contact point, guide, interchangeable rod, limitedhand, and bezel.

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 1to 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 Assembly

c) Height Gauge

d) Adaptor Assemblye) Universal clamp Assembly

f) Spanner

g) Calibration

Slip gauge is small blocks which stick to each

other when they are rub against each other due to better surface finishhence 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.

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Inside micrometer is used to measure insidediameter. 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 amasterpiece, which is used to check error. Each division is of 10 microns

or 0.01 mm. Spindle, frame, anvil, inner sleeve, outer sleeve, adjustmentnut, 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 ringgauge (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

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accuracy on nut while plug gauge is used to measure the accuracy ofthread in holes. Its range starts from M6.

Digital Vernier micrometer gives thereadings digitally .It is very accurate machine. It gives readings up to

microns. Its range is from 1 micron to 25 mm.

Digital height gauge is also a very accuratemeasuring 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) Technology

c) Subcontracting

d) 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, sothat 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 ofplanning are:

a) Raising sub contracting purchase requisition

b) Preparation of purchase requisitionc) Handling proof machined items

d) Amending purchase requisition

e) Booking material and hoursf) Booking hours for PPC (production planning control).

g) Ordering and inspection of hardware

h) External processing of customer supplied goodsi) Control of plate material

j) Regularization of materials lying in project stockk) Closing subcontracting orders

l) Closing of projectsm) Closing of P.O

n) Making checklist for P.O

o) Preparation of MIS reportsp) Logging of man hours

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CHAPTER-12

Machines & Components

FRANCIS STAY RING

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SKODA HB-1

PANCHEEL HILL RUNNER ASSEMBLY

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FINAL GRINDING OF KAPLAN RUNNER

ASSEMBLY OF SPIRAL CASING

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FINAL GRINDING FRANCIS RUNNER

KAPLAN RUNNER

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HEAVY ROLLING MACHINE

PELTON TURBINE

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DRAFT TUBE

FRANCIS TURBINE

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LAYOUT OF KAPLAN TURBINE

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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Documents

Hydro Datas