A Pratical Training Report ON Hydro Turbines AT Andritz Hydro Ltd. (Duration-18 June To 18 July)
A Pratical Training Report ON Hydro Turbines AT Andritz Hydro Ltd. (Duration-18 June To 18 July)
A Pratical Training Report ON Hydro Turbines AT Andritz Hydro Ltd. (Duration-18 June To 18 July)
ON
HYDRO TURBINES
AT
(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
1
me this lifetime opportunity to work & learn in this much systematic and
professional environment. Now I would like to thank Mr. D. N. NARESH (HOD)
who provided me constant guidance, inspiration and help whenever and however
required. Last but not the least I would like to thank those numerous employees of
the company specially Mr. Kuldeep Kumar (D. Manager)whose clarity of
concepts and ability to solve problems is proverbial. Their unflinching
encouragement shall ever remain as a treasure in my memory.
ABHISHEK TANWAR
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
2
in our books is not much use without knowing its practical implementation, it has been
experienced that theoretical knowledge is volatile in nature, however practical knowledge
make solid foundation of our mind.
ABHIHEK TANWAR
CONTENTS
3
2 History 7
3 Introduction to hydro 10
Turbines
4 Machine shop 16
5 Fabrication shop 24
6 Assembly shop 30
7 Grinding Shop 33
8 Maintenance 35
9 Quality control 36
10 Stores 37
11 Planning 43
13 Conclusion 50
CHAPTER-1
4
C
o
m
p
a
n
y
P
ro
fil
e
Global Activities
The ANDRITZ GROUP is a global market leader for customized plant, systems and
services for hydropower, the pulp and paper, steel and other specialized industries
(solid/liquid separation, feed and biofuel).
The Group is headquartered in Graz, Austria and has a staff of approx. 16,100
employees worldwide. It develops and makes its high-tech systems at production,
service and sales sites all around the world
5
CHAPTER-2
H
ist
or
y
6
ANDRITZ: From small iron foundry
to globally leading machinery and plant engineering company
Milestones in the history of ANDRITZ:
all around
the world.
7
CHAPTER-3
HYDRO TURBINES
8
• What are hydro turbines?
ANS: A hydro turbine uses the potential and kinetic energy of water and converts it
into usable mechanical energy. The fluid energy is available in the natural or artificial
high level water reservoirs, which are created by constructing dam at appropriate places
in the flow path of rivers. When water from the reservoir is taken to the turbine, transfer
of energy takes place in the blade passages of the unit .the mechanical energy made
available at the turbine shaft is used to run an electric generator, which is directly couple
to the turbine shaft. The power generated by utilizing the potential and kinetic energy of
water has the advantages of high efficiency, operational flexibility, low wear and tear,
and ease of maintenance.
• Classification of turbine
9
1.
Tangential flow Axial or parallel flow Mixed: radial and axial
(Pelton wheel) (Kapaln turbine) (Modern Francis turbine)
Flow path in different types of runner has been illustrated in following figure.
STATOR
ROTOR
BLADE
Pelton wheel is the tangential flow turbine; here the centerline of jet is
tangential to the path of rotation of the runner.
Propellor and Kaplan turbines are axial flow turbines; here water enters
and leaves the runner along a direction parallel to the axis of the shaft.
Mixed flow turbines where water enters the runner at the outer periphery
in the radial direction and leaves it at the center in the direction parallel
to the axis of rotation of the runner. Modern Francis turbine is a mixed
flow machine.
High head turbines, which operate under high head (above 250 m) and
require relatively small rates or flow. Pelton wheel is a high head turbine.
Medium head turbines, which operates under medium heads (60 m to 250
m) and require medium flow rates. Modern Francis turbine belongs to this
category.
Low head turbines, which operate under heads, up to 30m and require
very large volumetric rates of flow. Units of axial flow turbine (Propellor
and Kaplan) are examples of low head turbines.
10
=150-200 for a fast runner
ASSEMBLIES
Assemblies mainly classified into three categories:-
a) Static
1) Turbine housing
2) Disposition
3) Distribution Pipe
4) Inlet Pipe
b) Dynamic
1) Nozzle Assembly
2) Deflection Assembly
3) Runner Assembly
4) Distributor Assembly
5) Oil Head
6) Cooling Water
c) Governing
1) Governor
2) Skada
11
bucket has a ridge or splitter, which distributes the striking jet equally into two halves of
the hemispherical bucket. Again there is a cut (notch) in the outer rim of each bucket this
make the jet face the bucket only when they are at 90° to each other. The angular
deflection of jet in the bucket is limited to about 165-170 degree. The arrangement has
advantage that bearings supporting the wheel shaft are not subjected to any axial or end
thrust.
A casing is provided around the runner to prevent splashing of water and to
guide the water to the tail race. It has no hydraulic function to perform apart it act as a
safeguard against accidents.
Speed of turbine runner is maintained so that generator coupled directly to the
turbine shaft runs at constant speed under varying load conditions. Governing
mechanism by regulating water supply does this above function.
With increase in load, the runner speed falls and consequently balls of the
centrifugal governor move inwards. Through suitable linkages, the resulting downward
movement of the governor sleeve is transmitted to a relay, which admits oil under
pressure to servomotor .The oil exerts a force on the piston of the servomotor, and that
pushes the spear to a position, which increases the annular area of the nozzle. Quantum
of water striking the buckets is then increased and the normal turbine speed is restored.
Conversely happen when we have to reduce the load.
ASSEMBLIES
Assemblies mainly classified into three categories:-
a) Static
1) Turbine housing
2) Disposition
3) Stay Ring
4) Spiral
b) Dynamic
1) Distribution
2) Runner
3) Oil Seal
4) Shaft Seal
5) Cooling water
6) Guide Bearing
c) Governing
1) Governor
2) Skada
12
Penstock is a large size conduit, which conveys water from the high
level reservoir to the turbine. Depending upon head it is made up of mild steel, concrete,
or wood .It is provided with control valves like butterfly valve, also screens and trashrack
are provided at the inlet of the penstock prevent entries of debris. At its downstream end,
penstock fitted with an efficient nozzle that converts the whole of hydraulic energy into a
high-speed jet. To regulate water flow a spear is provide which moves backward or
forward thereby controlling flow area either by governing mechanism or by hand wheel.
Penstock is connected to and feeds water directly into the spiral casing. Casing
constitutes a closed passage whose cross section area gradually decreases along the flow
direction area are maximum at inlet and very less at exit. The casing is made up of mild
steel or concrete. Stay vanes are usually provided to direct the water from the casing to
guide vanes.
Guide vanes or wicket gates are series of airfoil shaped vanes, which are arranged
inside casing to form a number of flow passages between the casing and the runner
blades. They guide the water onto the runner as per design. They swing around their own
axes that change the flow area between two consecutive runner blades. The motion is
given by means of governor.
The system consists of a centrifugal governing mechanism, linkages servomotor
with its oil pressure governor and the guide wheel. The water flow and its direction
remain same at all the passages between any two consecutive guide vanes.
Runner of the Francis turbine is a rotor and has passages formed between
crown and shroud in one direction and two consecutives blades on the other. There is
about 16 to 24 number of blades in runner. These passages take water in at the outer
periphery it in a direction parallel to the axis of rotor. The driving force is both due to the
impulse and reaction force. The runner blades are usually is made up of stainless steel.
The runner is keyed to the shaft, which may be of vertical or horizontal disposition.
After passing through the runner, the water is discharged to the tail race
through a gradually expanding tube called the draft tube .the free end of the tube is
submerged deep into the tail race.
d) Static
1) Turbine housing
2) Disposition
3) Stay Ring
4) Spiral
e) Dynamic
1) Distribution
2) Runner
3) Oil Seal
4) Shaft Seal
13
5) Cooling water
6) Guide Bearing
f) Governing
1) Governor
2) Skada
CHAPTER-4
MACHINE SHOP
14
Tool Used – Boring Tool or an Insert tool
Maximum Diameter – 7100 mm
15
Job undergoing – Servomotor cover
Project - Babehalli
Tool Used – DNMG (name of an insert)
Operation Undergoing: Turning
No. of Tool RAM – 2
Tool Index / Turret – 5
Max. Speed – 180 RPM
Feed – 0.07 to 5 mm per min
Digital Control Panel
In vertical turret lathe while working tool remain fixed and job rotates. Various
operations carried on VTL are facing, turning, boring, grooving etc. Feed is automatic.
Scrap produced are spring like ribbon chips. RPM should always be low while working
on profile. For good finishing the RPM should be high and feed should be low. But final
cut is always small to maintain the desired accuracy and surface finish.
Job is set on table. Dial indicator is used to see whether it is uniformly attached to the
machine always checks its position.
Errors in 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 the
present dimension will work or not.
Precaution
1. Read the drawing carefully.
2. Check the accuracy of tool and calculate the error if there is any.
3. Use proper coolant like cutting oil.
4. For avoiding taper at the bottom during vertical boring, slide should be
straight.
16
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
h. Minimum Feed: 0.125 mm per min
i. Range Of Speeds:
Standard: 40 – 1800 RPM
Optional: 50 – 2240 RPM
j. Machine Weight 4560 kg
• Drilling Machine
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.
Precautions
17
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 bye brush.
4. Measuring instrument should be checked for error.
5. Drawing should be studied properly.
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
18
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
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.
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.
19
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.
• Lathe Machine
• Lathe Machine – L2
20
• Shaper Machine No. 1
• Milling Machine
• Fork lifter
Capacity – 3 tones
Make – Godrej
Cylinder – 4
Fuel – Diesel
Fuel tank – 40 liter
21
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
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
22
It is a semiautomatic welding process. Here arc is struck
between electrode and job. Electrode is non-consumable. There is ceramic
coating over tungsten electrode tip. Ceramic coating is used because it has a
very high melting point of 3500° C. Inert environment is provided by argon
gas. Hands supply filler metal manually.
TIG has better penetration as comparison to other
welding operations. It has no backfire. It is specially used for giving a coating
of stainless steel over a job when it is over machined or over grinded. Also
some times for balancing purpose metal are added through TIG. The filler
metal comes in various range of thickness from 1.2 mm, 1.6 mm, 2 mm and 2.4
mm (Make is ESAB, kobelco and bohler). Copper cable is used to connect
Electrode holder and D.C. Flow meter are generally attached to the argon
cylinder.
23
It is used for welding pipe section like spiral. Butt joint can be weld up to thickness 15 –
20 mm. Here arc is struck between electrode and the job. Electrode can be of various
types depending upon job material and the thickness of the job. Always the positive
terminal of the dc source is connected to the electrode i.e. 1/3 to the electrode and 2/3 to
the job. The distance between the job and the electrode depends upon thickness of the
electrode at most it could be 3 mm. Electrodes are generally heated in the electronic
furnace at a temperature about 100°c to 120°c 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”.
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. Metal
recovery minimum 110%. Ready electrode at 300 Deg. Celsius per hour.
Manufacturer: D & H
Use AC 70 or DC +
Diameter in mm Current (Amperes)
2.0 50 – 70
2.5 70 - 100
3.15 100 - 150
4.0 150 - 190
5.0 200 - 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
mild steel to stainless steel.
The electrode possesses pleasing performance characteristics.
Manufacturer: D&H
Use AC or DC (+)
Diameter (mm) Current (ampere)
2 40-50
2.5 60-80
3.15 80-100
4 110-140
24
5 150-180
Electrode: Cranitherne 25/12stainless steel suitable for welding. Its uses are as
follows:-
a) Welding stainless steel of similar composition.
b) Joining 18% Cr, 8% Ni from stainless steel to mild steel.
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 80-100
4 110-140
5 150-180
25
NOTE: In other to prevent the bending while doing welding spiders are generally
attached to the large hollow job. These spiders are removed by gas cutting equipments.
Defects in Welding:
1. External
I. Blow Holes
II. Slag Trap
III. Impurity
IV. Surface Crack
V. Under Cuts
VI. Spatter
2. Internal
I. Blow Holes
Pin Holes
II. Porosity
III. Insufficient Fusion
IV. Internal Cracks
Types of Test
3. Ultrasonic Test
In these test ultrasonic sound waves comes. The device used in UT test
is known as transducer or search unit .It contains piezoelectric material which
transmits desired frequency of sound .For normal casting defects zero degree
angles is used & for bevel weld joint angled transducer is used like 60 degree, 45
degree. The defects are shown on the cathode ray oscilloscope. Before testing
26
coupling should be applied. More the smoothness of the job more clearly the
transducer detects the defect & more clear the graph is plotted.
4. Radiography Test
In these test x-rays are made to fall on the job piece and deflections are
noted in the form of graph and by studying them we can find out internal defects. It is a
very dangerous test as these rays are very harmful to human beings. So when these test
are carried nobody should be around a radius of 50 meter. These are a very accurate test
as compared to other test. For X-ray test cobalt-92 and Ra-162 are used.
After these if cracks are found there then these cracks are removed by
gauging rod then grinding is done and after that it is again checked for cracks. For best
results in gauging following steps need to be followed:
1) Air pressure should be between 5 kg/ sq. cm and 8 kg/ sq. cm
2) The angle of rod should 45° to 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 or
asbestos wool and lastly mild steel grill. In Stress relieving furnace gloves made of
asbestos are used.
• Gas Cutting Equipments
27
In these machines there are two cylinders each of oxygen and acetylene or oxygen
and LPG connected two torches through hoses. The torch is made up of gunmetal.
Generally single regulator is used for LPG, acetylene and oxygen. In winter
season electronic pre-heater is used when to temperature falls very low. It is fitted
between the regulator and the cylinder.
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
Project Undergoing – Somanamardi
Job Undergoing Assembly – Wicket Gate Assembly or Distributor Assembly
28
• Inner head or inner distributor is fit into the center of wicket gate
assembly and through it the shaft is passed.
• Through guide bearing housing shaft is passed.
• Guide Vanes – It consists of two side’s i.e. thick end and thin side. The
thick side is called flat side and the thin side is called chamfer side.
The water strikes at the thick side and passes away from the thin side.
The distance between the thick ends of the guide vein is called facial
gap.
• Ceiling Gap – The distance between two corresponding faces of guide
vanes. If ceiling gap is more than we have to file to make it less.
• Filler gauge – It is used to check the gap between two mating parts
given as per drawing.
• Axial play is done through dial indicator and dial stand.
• After the fitting of head cover dew surface washers having the property
of self-lubrication are placed on the upper surface of the guide veins.
Their main use is to reduce friction & provide lubrication. Without
their application the working of shaft will be affected.
• After fitting of dew surface washers we place the track ring which
remain fixed on the guide vanes.
• In Francis and Kaplan turbine regulating wheel is used to provide
clockwise and anticlockwise rotation to guide vanes.
• Tripping Relay Device – It is a safety device used in turbines. It
consists of arrangement of lever, spring and cam. An electronic speed-
measuring device is placed on the shaft to calculate its speed. As the
speed of shaft increases tension in the spring increases and it begin to
move and a stage comes when it outer face collides with the trip of
tripping device because of which the trip cuts off and the supply of oil
to the shaft stops which causes shaft to switch off. It is mainly due to
the cut off of servomotor. Maximum pressure in servomotor is 60kg/cm
square& maximum stroke of servomotor is 172.
• Water attacks on the pressure side of the guide vanes and flow away
from the suction side.
• Shot blasting is done before painting so that paints stick hard on the
surface. The pressure in shot blasting is 6-kg/sq. cm. In shot blasting
chips of either S.S or M.S are used of size varying from 0.2 mm to 0.5
mm diameter. Shot blasting is carried out in a closed room having 2
mm thick rubber walls. The operator operating shot blasting has to
wear a special dress, which covers all his body.
• Firstly Red oxide (epoxy-71) is used for coating the surface.
Afterwards the epoxy paint coatings are done at the end of the job.
These paints are of Epoxy 72 and are high quality abrasion resistant
and water resistant. Sometimes synthetic paint is also used over S.S
just to give a good look to the turbine and to hide the scratches.
• Red oxide coating ensures good surface texture and smoothening. It
also avoids scratching to the job made by applying the blue and black
color directly to the job.
29
• In hydro turbines black paint is used to coat that part of the job, which
is placed inside the water. Single red coating is applied at that place
which comes in direct contact with oil. Yellow and blue are mainly
used for outer surfaces, which come in contact with the air.
• In spiral casing water is mainly given the view to flow and also a force
is exerting on it. The water enters the spiral casing gets divided by the
help of internal fixed blades. This water then strikes the pressure side
of the guide vanes, which is thick and then goes to suction side, which
is thin. After passing from the guide vanes water strikes the runner
placed inside the spiral casing and then it starts to rotate the shaft.
Due to this rotation the hydro energy is converted into mechanical
energy of the rotation of shaft and this mechanical energy is converted
into electrical energy by use of generator.
• There are two types of balancing – static & dynamic. Static balancing
is mainly done in Pelton turbine. It is mainly done to check weight
irregularity. In the runner of Pelton turbine we always place weight
during static balancing for the balancing of job. But in case of Francis
weight removal is done from Francis runner.
• Jobs accuracy is measured or checked by means of templates. The
templates drawings are sending by the designer to the assembly
department where the help of these drawings makes the required
templates of brass. For making this we use flat files, half round files,
needle files, rounded files and tools.
• In runner hub we use the inner bush of brass (non-ferrous) because if
the ferrous part is made in contact with the ferrous part for the
rotation purpose then both these SS parts produce friction between
them and cause scratching of each other and our purpose of rotation is
not fulfilled. Therefore we use ferrous and non-ferrous combination to
avoid friction. Also in these brass bushes small slots are made for the
purpose of lubrication.
• Tungsten carbide is used for the coating of the turbine face because
due to high pressure water consisting of sand particles the turbine face
is affected very much and their exists some holes in it. Due to this
reason turbines life is reduced. To increase its life we use tungsten
carbide.
• SILT Tanks is used for cleaning purpose to prevent sand coming into
the turbine. Although trash racks are provided in the penstock but they
can’t stop sand. They can control only stop big wood blocks sought of
thing.
30
CHAPTER-7
GRINDING SECTION
• Different Types Of Grinders
31
It is also single-phase 50hz. Support pad is used in sender for
supporting amri disc. Generally two-amri disc are also used for support.
Swing Grinder
It is used for rough grinding. It is very helpful in removing material in large scale.
• 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 diameter
ranges from 25 mm, 40 mm and 50 mm. Its grit size ranges from 36, 60, 80 and 120.
Mounting Wheel or Mounted Tip:
Maker: NORTON
Mounted tip is used in pneumatic air tool. It is used for finishing & polishing. It
is of following two types: -
1) Conical T3: It is used for sharp edges and is conical in shape. It is made
up of tungsten.
2) Round B4: It is used for round edges or making cylindrical radius. It is
also made up of tungsten.
Amri Disc:
Maker: Alkon Gold
It is used for surface finishing & mainly for light work. Grit size varies from 20,
36, 60, 80 and 80. Its compositions are diamond dust, zirconium and silicon carbide.
General order for finishing in grit size is 20, 36, 60, and 80 and 120 depending upon the
surface finishes required.
32
Punching is done to have proper thickness and proper hydro dynamically
contour. It is done from both sides i.e. x and y direction. Grinding is done in Z direction.
Tolerances for Pelton wheel are +0.5 or –0.5, for runner profile in Francis
turbine is +1 or –1; for thickness of runner is +0.3 and – 0.3 and for guide vanes and
runner blades is +0.5 to –0.5.
Moving trolley has trips the meter when earthing doesn’t work then it get trip.
Templates are made through CNC wire cutting machine. These are made up off SS, MS,
spring steels and gunmetal.
33
CHAPTER-8
MAINTENANCE DEPARTMENT
II. Preventive:
In these MTBF (mean time between failures) and MTTR
(mean time to repair) should be same.
2. Unplanned
I. Breakdown Maintenance
II. Corrective Maintenance
34
CHAPTER –9
QUALITY CONTROL
There are four stages of quality control:
1. Incoming Stage
2. Process
3. Final Machining
4. Assembly
35
CHAPTER-10
STORES DEPARTMENT
• 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.
36
Special purpose drilling machine both magnetic and vaccum used
specially for foundation purpose or packing purpose. It is a portable
machine.
Pipe bending hydraulic machine fitted with oil seal is used to bend
pipe. Pumping is done by hand. Oil seal doesn’t allow it to flow back. It
ha various dies of different shape. Also pipe holder can hold pipes of
different shape.
• Electrical Instruments
BS-60 electric paint spray gun mainly used for painting, disinfecting,
corrosion-removal & cleaning. It has .5 mm round spray nozzle.
Specifications:
Power supply: 230V, 50 HZ
Power: 60 Watts
Maximum pressure (app.): 140 bars
• General Instruments
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.
Die spanner
37
Allen key
Ring spanner
• Lifting Tools
Depth micrometer is used to measure depth. Its least count is 0.1 mm. Its
range is from 0 to 300 mm.
Filler gauge use to find out facial gap .It has a standard thickness plate.
Its range is from 0.5 to 1mm.
Dial gauge indicator is used to measure run outs, finding center and
parallel also used to check whether job is aligned with machine or not
its least count is 0.01 mm. Its range is from 0.01mm to 10 mm.
38
Bore gauge
Flange type micrometer is used to measure small gap like parting area.
Its least count is 0.01 mm. Its range is from 1 to 25 mm.
Height gauge is used to find height of a job. It has carbide, which can be
use for marking. Its main parts are base, vernier scale, and scriber
locking screw, adjusting screw. Its least count is 0.02 mm. Its range is
from 0.1 mm to 600 mm. Its main part are base, reference surface of
base, column, slider, main beam, main scale, vernier scale, clamp screw,
fine feed screw, scriber and magnifying glass.
Lever type dial gauge or Puppy dial is used to find center of a bore or
hole. Its main part are as follows:
a) Stylish
b) Dovetail Spigot Assembly
c) Height Gauge
d) Adaptor Assembly
e) 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 finish hence they create a
vacuum. It is use to measure Height .It is made up of high carbon steel.
Its range is from 0.5 mm to 100 mm.
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check error. Each division is of 10 microns or 0.01 mm. Spindle, frame,
anvil, inner sleeve, outer sleeve, adjustment nut, ratchet stop, ratchet
screw, clamp, frame cover, carbide tip and thimble are its important
part.
Inside dial caliper is used to measure inside diameter. It has least count
of 0.025 mm. Its range is from 10 – 70 mm.
Ring gauge are of two types thread ring gauge (male threads) and
thread plug gauge (female gauge). These are of go and no go types.
Thread ring gauge is used to measure the thread accuracy on nut while
plug gauge is used to measure the accuracy of thread in holes. Its range
starts from M6.
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Digital height gauge is also a very accurate measuring instrument. It
has a digital display. It gives readings up to microns and can measure
up to 600 mm.
Master level or spirit level is used to check the level of machine during
foundation.
Laser range meter is use to measure the distances with the help of laser
light. It has a very wide range and is very accurate instrument.
• Cutting tool
• 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 planning
b) Technology
c) Subcontracting
d) Loading and scheduling
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CHAPTER-12
SKODA HB-1
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PANCHEEL HILL RUNNER ASSEMBLY
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ASSEMBLY OF SPIRAL CASING
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KAPLAN RUNNER
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PELTON TURBINE
DRAFT TUBE
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FRANCIS TURBINE
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CHAPTER-13
CONCLUSION
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.
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