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

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.

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 Page

1 Company Profile 5

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

12 Machines & components 44

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

Five business areas

The Group focuses on

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

Turbines are of two types:

A. Impulse Turbine: Wherein the available hydraulic energy is first

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

B. Reaction Turbine: Wherein the part of the total available hydraulic

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

Hydraulic turbines further classified into various kinds according to:

I. Direction of water flow through runner:

Turbine

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

(b)RADIAL FLOW (c)MIXED FLOW

(a)AXIAL FLOW

 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.

II. Available head and discharge

 High head turbines, which operate under high head (above 250 m) and
require relatively small rates or flow. Pelton wheel is a high head turbine.
 Medium head turbines, which operates under medium heads (60 m to 250
m) and require medium flow rates. Modern Francis turbine belongs to this
category.
 Low head turbines, which operate under heads, up to 30m and require
very large volumetric rates of flow. Units of axial flow turbine (Propellor
and Kaplan) are examples of low head turbines.

III. On the basis of speed

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

=17-25 for a normal runner
=25-30 for fast runner
=40 for a double jet

 Francis turbine: Ns = 50-100 for a slow runner

=100-500 for a normal runner

10
 =150-200 for a fast runner

 Kaplan turbine: Ns =250-850

IV. Disposition of shaft

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

• Main assemblies and operation of Pelton turbines

 ASSEMBLIES
Assemblies mainly classified into three categories:-
a) Static
1) Turbine 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

 Working Of Pelton turbine

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

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.

• Main assemblies and operation of Francis turbines

 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

 Working Of Francis turbine

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.

• Main assemblies and operation of Kaplan turbines

 ASSEMBLIES
Assemblies mainly classified into three categories:-

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

 Working Of Kaplan turbine

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

CHAPTER-4

MACHINE SHOP

• Vertical Turret Lathe-1

Machine Maker – Froriep
Machine No. – VTL 1
Job Undergoing – Discharge ring lower part
Project Undergoing – Karcham Wangtoo
Operation Undergoing – Boring

14
 Tool Used – Boring Tool or an Insert tool
Maximum Diameter – 7100 mm

Maximum Height – 4200 mm

Digital Control Panel
No. Of RAM – 3
Speed: 0.5 – 56 RPM
Feed: 0.05- 10 mm per minute

• Vertical Turret Lathe-2

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

• Vertical Turret lathe-3

Machine Maker – Froriep
Machine Number – VTL-3
Max. Diameter – 1200mm
Max. Height – 500mm

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.

• Radial Drilling Machine (RM 65)

Machine Maker - HMT

Working Range:
a. Drilling Radius: 550 – 2350 mm
b. Sleeve Diameter: 400 mm
c. Distance Sleeve to Spindle: 350 – 2150 mm

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

Project Undergoing – Somanamardi

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

• Drilling Machine

Machine Maker – Csepel

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

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

 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 steel
7. Tool Setting

 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.

 Remedy is similar to that of VTL

• Horizontal Boring Machine (Large)

Machine Maker – Skoda

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

• Horizontal Boring Machine (Small)

Machine Maker – Pama

Machine No. – AL 127(15 HB 2)
Job Undergoing – Runner Blade
Operation Undergoing – Facing
Project Undergoing – Karcham Wangtoo
Tool Used – Cutter
Speed Range: 8 – 950 RPM
Maximum Feed – 3 mm per revolution
Minimum Feed – 0.025 mm per revolution
Maximum Length – 1500 mm * 1500 mm
Maximum Height – 1000mm

Job is fixed and tool rotates. For cutting purpose tool moves in clockwise
direction and for boring in any direction. It can move in X, Y, Z directions. For hard
material the speed of spindle is kept low i.e. in first gear. For soft material we use high

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

 Error in drilling machine

1. Over size of bore, drill and length i.e. crossing the tolerance provided in
the drawing.
2. Shrinkage, which generally occurs when job gets heat up and after cooling
it contracts.

 Precautions
1. Coolant should be used.
2. Measuring instruments should be checked for errors.
3. While working with long drill lubricating oil or cutting oil must be used.

 Remedy is similar to that of VTL.

• Computerized Numerically Controlled Lathe Machine

Machine Maker – Ravens burg

Machine No. – 01 L1
Job Undergoing – Dummy Discharge Ring
Project Undergoing – Somanamardi
Tool Used – Turning Tool i.e. an insert PDJNL
Operation Undergoing – Ding turning proof machining
Chuck: Swing over bed 2000 mm.
Bed Length – 6000 mm
Maximum Speed – 125 RPM
Feed range: 0.037 – 3.15 RPM

Here is job is set in the chuck. Here alignment of the job with respect to chuck is
checked with the help of dial indicator fitted with stand.

 Errors are similar to above said machine.

 Precautions and remedy are also similar.

The selection of tool depends upon following criteria.

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.

Similarly the feed depends upon

1. Proof cut or finish cut.

2. Type of material.

LIGHT MACHINE SHOP

• Lathe Machine

Machine Maker- HMT

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

• Lathe Machine – L2

Machine Maker – HMT

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

20
• Shaper Machine No. 1

Machine Maker – Sagar

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

• Milling Machine

Mainly used to make bores

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

• Universal Tool & Cutter Grinder

Machine Maker – HMT

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

Common lifting machines

• 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

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.

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.

 MIG (Metal Inert Gas)

Machine Make: Frronius and Triodyn.

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

between electrode and job. But here electrode is filler metal wire. Electrode is
consumable. Here filler metal wire speed is 5 mm per revolution. Argon and
carbon-di-oxide gases provide the inner environment. Color code for argon and
carbon-di-oxide cylinder is green. The Mild steel wire diameter ranges are 1.2
mm, 2 mm, and 4 mm (Make is ESAB). Sometimes S.S coating is provided over
M.S for water resistant coating.
In MIG welding, spatter is prevented by applying spatter gel is
applied on the torch so that spatter doesn’t stick to the torch. Spatter core is the
area where spatter can reach.
Welding fixture for M.S comes along with wire but for a S.S a separate fixture is
used.

 SAW (Submerged Arc Welding)

Machine Make: Frronius and Triodyn.

It is an automatic welding process. Electrode is consumable. Here

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

 SMAW (Shield Metal Arc Welding)

Machine Make: Frronius and Triodyn.

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”.

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. 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

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 4.5
4. A basic coated alloyed core wire electrode design for both joint and
build up welding of similar stainless Cr steels and cast steels.
Especially suited for water turbine, compressor and pumps. The
Maker: D&H
It yields a weld deposit of 25 % Cr, 12 % Ni austenitic deposit
gives high resistance against cavitations.
Both AC and DC (+) can be applied to it.

Electrode: Cranitherne 25/12stainless steel suitable for welding. Its uses are as
follows:-
a) Welding stainless steel of similar composition.
b) Joining 18% Cr, 8% Ni from stainless steel to mild steel.
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

5. Electrode: Eutectic CPS 006

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

 Safety Equipments used are

1) Welding curtain
2) Leather Hand gloves
3) Welding Respirator
4) Leg Guard
5) Fire Retardant Cap
6) Welding glasses with side safety
7) Welding head screen
8) Helmet

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

1. Dye Penetration Test:

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

2. Magnetic Penetration Test:

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

3. Ultrasonic Test
In these test ultrasonic sound waves comes. The device used in UT test
is known as transducer or search unit .It contains piezoelectric material which
transmits desired frequency of sound .For normal casting defects zero degree
angles is used & for bevel weld joint angled transducer is used like 60 degree, 45
degree. The defects are shown on the cathode ray oscilloscope. Before testing

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

 Computerized Numerically Controlled Gas Cutting Machine

Machine maker: Sato
Table length: 8400 mm * 3200 mm.
Oxygen/Acetylene & Oxygen/LPG is used for cutting. Mainly LPG is used because
it is cheap. Piercing pressure comes from Oxygen. Job is not heated to the melting point
but to the temperature where it can be plastically deformed. Gas cutting equipment uses
air pressure to produce arc. Cutting pressure ranges from 9-kg/sq. cm to 16-kgf/sq.cm up
to thickness of 50 mm of Mild Steel. Nozzle cutting speed or piercing pressure depends on
the thickness of the plate. Working pressure for oxygen and acetylene is 9-10 kg/sq. cm.
The pressure in cylinder for oxygen and acetylene is 15-kg/sq. cm. While ratio between
oxygen/acetylene and is Oxygen/LPG 1:2.In CNC gas cutting machine first it check
whether the required shape is possible or not. Nozzle, cutting speed, pressure, Pre-
heating time, pre-heating pressure, piercing pressure and curf are all according to
thickness of plate. Line in and out also causes changes in piercing time for different
shape.

 Manual Gas cutting machine

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.

 Plasma Cutting Machine

Machine maker: Hypertherm powermax (1100 watts)
In these machines air pressure is used to produce arc and also used for cutting
with pressure ranging from 9-kg/ sq. cm to 16-kg/ sq. cm up to thickness of 50 mm
of stainless steel. Here the arc produced is plasma arc .The electrode is made up
of brass.

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

CHAPTER-6

ASSEMBLY SECTION
Project Undergoing – Somanamardi
Job Undergoing Assembly – Wicket Gate Assembly or Distributor Assembly

• Dummy discharge ring is placed at the bottom and is known as bottom

head. On this ring we place the 24 guide vanes and on these guide
vanes we place bushes along with the top head. On this top head we
place levers whose one end is attached to the guide vane and other to
the link. This link is attached to the regulating wheel. With the help of
servomotor we get reciprocating motion, which is of guide vanes.
• In upper head there are 24 bores and in these bores 24 bushes are
placed. In these bushes similar number of guide vanes is also placed.

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

 Single-phase 50hz angle grinder

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

 Pneumatic air grinder

Maker: Chicago.
Pressure in pneumatic air grinder is 6.2 bars. RPM in pneumatic air
grinder is 13000.
 Sendor

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.

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 diameter
ranges from 25 mm, 40 mm and 50 mm. Its grit size ranges from 36, 60, 80 and 120.
 Mounting Wheel or Mounted Tip:
Maker: NORTON
Mounted tip is used in pneumatic air tool. It is used for finishing & polishing. It
is of following two types: -
1) Conical T3: It is used for sharp edges and is conical in shape. It is made
up of tungsten.
2) Round B4: It is used for round edges or making cylindrical radius. It is
also made up of tungsten.
 Amri Disc:
Maker: Alkon Gold
It is used for surface finishing & mainly for light work. Grit size varies from 20,
36, 60, 80 and 80. Its compositions are diamond dust, zirconium and silicon carbide.
General order for finishing in grit size is 20, 36, 60, and 80 and 120 depending upon the
surface finishes required.

 Swing Grinder wheel

Make: Norton.
Its size is 300*40*38.1.

In grinding section manufacturing of runner, stay vanes, runner blades,

and guide vanes is done. Sometimes job comes for step merging also. Manual Grinding is
done to obtain special hydraulic contours. Grinding is done according to the
requirements mention in the drawing using various templates for various contours or
profiles. Some places need rough grinding and some need finish grinding depending upon
the part. Safety Equipments Used is goggles, earplug, and gloves. When mounting job in
the fixture it should be covered by tape so that no scratches occur.

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

Maintenance is of two types:

1. Planned
I. Autonomous: 3M 3S (Japanese Method)
3M 3S stands for 3 minute 3 services that mean daily to daily
checking of machine cleanliness, hydraulic pressure and oiling or
lubrication.

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

III. Predictive Maintenance

It is like you can predict the time to failure. It requires control
over frequency of checking.

IV. Conditioning Maintenance:

It is monitory very close before sometime of predictable
failure date i.e. 10 days before so that if it fails first we can replace it or if
it works for some more days then it prevents some money for organization.
Different tests carried on condition monitoring like vibration test and
hydraulic check etc.

2. Unplanned
I. Breakdown Maintenance
II. Corrective Maintenance

Maintenance mainly involves infrastructure details along with the machine

profile and all computer related things.

Here in VA Tech total production management is followed. Maintenance department also

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

34
 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.

35
 CHAPTER-10

STORES DEPARTMENT

In two ways the material is given:

• Consumables (electrodes, grinding wheel)

These tools once you give don’t return back. Consumables are always enter the SAP.

• Non-Consumables (instrument, tools)

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

• How to maintain the stock levels?

1. Identify all major regular items with monthly average consumption.
2. Fix the maximum, minimum and ordering level of these items in SAP.
3. Review the stock levels and raise MPR when stock reaches ordering level
(material purchase requisition).
4. Consider the current lead-time while raising MPR.
5. Purchase MPR if the level is going down.
6. Review the consumption trend periodically.
7. Based on the consumption trend review the list of stock items and their
stock levels with the users and update the same.

MRV stands for material receive voucher.

Store is divided into following sections:
• Special Erection Tools
Used when machines are plotted or fixed.

• Welding Equipments

• Grinding Equipments

• Safety Equipments

• Heavy Sections

 Hydraulic jacks are used to uplift the heavy loads. Using a cycle chain
like arrangement uses roller spadder to move heavy jobs from one
place to another. Its ranges from 1 tons to 20 tons.
 Oil pump pumps the oil to the hydraulic machine. It has a dial showing
how much weight lifted.

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

 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

37
 Allen key

 Ring spanner

• Lifting Tools

 Manual hoist is lifting equipment.

• CALIBRATED & MEASURING INSTRUMENTS

 Electronic Surface finish tester is used to measure the surface finish. It

gives you RA um. A conversion sheet is provided to convert finishing N6,
N7 etc to corresponding RA um

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

 Radius gauge is used to measure radius of a section. You can measure

both outside and inside radius. Its range is from 1mm to 25 mm.

 Combination set is used to find center of round shape objects from

o°-180°. It has two main parts center head and 45° head.

 Pistol caliper is used to measure thickness of a job where micrometer

can’t reach. Its least count is 0 .1 mm. Its range is from 0.1 to 100mm.

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

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

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

 Bore gauge is used to measure diameter of a bore. Its least count is

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

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.

 Inside micrometer is used to measure inside diameter. It has micrometer

in which you can add rod of required length to measure the diameter. Its
range is from 50 mm to 5 m.

 Outside micrometer used to measure the outside diameter of the job in

the range of 0 mm to 1100 mm. It has a masterpiece, which is used to

39
 check error. Each division is of 10 microns or 0.01 mm. Spindle, frame,
anvil, inner sleeve, outer sleeve, adjustment nut, ratchet stop, ratchet
screw, clamp, frame cover, carbide tip and thimble are its important
part.

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

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

 Digital Vernier micrometer gives the readings digitally .It is very

accurate machine. It gives readings up to microns. Its range is from 1
micron to 25 mm.

40
  Digital height gauge is also a very accurate measuring instrument. It
has a digital display. It gives readings up to microns and can measure
up to 600 mm.

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

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

• Cutting tool

 Twist drill is made up of HSS. Its range is from 3 mm to 80 mm.

 Extra long twist drill is made up of HSS.
 Core drill is made up of HSS.
 Taper shank socket reamer made up of HSS. Its range is from 5 mm to
60 mm.
 Cutter is also made up of HSS.
 Brazing tool is made of carbide tip.
 Flat drill is also made up of HSS.
 Taps are available from M1 to M 80.

• Stationary

41
 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

Basically it handles the manufacturing process in workshop and subcontracting.

First it prepares a job card, which has all the operation to be performed. Every time
each process is over the supervisor has to enter the time taken by each operation in
SAP, so that planning can monitor over the progress over job.
It has an important part called subcontracting which look after the jobs which
have to be machined from outside. Planning you can say is completely done and
controlled with the help of SAP (system application product). Various important
functions of planning are:
a) Raising sub contracting purchase requisition
b) Preparation of purchase requisition
c) Handling proof machined items
d) Amending purchase requisition
e) Booking material and hours
f) Booking hours for PPC (production planning control).
g) Ordering and inspection of hardware
h) External processing of customer supplied goods
i) Control of plate material
j) Regularization of materials lying in project stock
k) Closing subcontracting orders
l) Closing of projects
m) Closing of P.O
n) Making checklist for P.O
o) Preparation of MIS reports
p) Logging of man hours

42
 CHAPTER-12

Machines & Components

FRANCIS STAY RING

SKODA HB-1

43
PANCHEEL HILL RUNNER ASSEMBLY

FINAL GRINDING OF KAPLAN RUNNER

44
ASSEMBLY OF SPIRAL CASING

FINAL GRINDING FRANCIS RUNNER

45
KAPLAN RUNNER

HEAVY ROLLING MACHINE

46
PELTON TURBINE

DRAFT TUBE

47
FRANCIS TURBINE

LAYOUT OF KAPLAN TURBINE

48
 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.

49