BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

REPORT ON WATER TURBINE MANUFACTURING

SUBMITTED BY

SHUBHAM RAI

ACKNOWLEDGEMENT

I am greatly thankful to B.H.E.L for providing me vital and much needed practical experience in the field of machines and manufacturing. I express my gratitude to Human Resource and Development department for giving me a chance to feel the industrial environment. I am also thankful to the B.H.E.L engineers and the technical staff for giving their precious time for helping me in understanding various aspects of machine manufacturing and their assembly.

SHUBHAM RAIBBD NITM, LUCKNOW

MECHANICAL DEPARTMENT

INDEX Bharat Heavy Electrical Plant Brief Quality Policies Research and Development WTM Block

Bay 1 Bay 2 Governor Assembly Bay 3 Bay 4 Bay 5 Bay 6 Bay 7 Bay 8

Hydro Turbines Classification of Impulse and Reaction Turbine Francis Turbine Pelton Turbine Kaplan Turbine Hydro Turbine Governor Spiral case and Stay Ring Wicket Gate and Operating Mechanism Construction of Runner Hub and Blade Power of Water Turbine Design and Application Parts manufactured for current projects Conclusion

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

BHELBhopal manufactures Hydro, Steam, Marine & Nuclear Turbines; Heat Exchangers; Hydro & Turbo Generators; Transformers; Switchgears; Control gears; Transportation Equipment; Capacitor; Bushings; Electric Motors andRectifiers.

BHELBhopal has its own Laboratories for material testing and instrument calibration which are accredited with ISO 17025 by NABL. The Hydro Laboratory, Ultra High Voltage laboratory and Centre for Electric Transportation are the only laboratories of its kind in this part of the world.Bharat Heavy Electricals Limited is country’s ‘Navratna’ company and has earned its place among very prestigious national and international companies. It finds place among the top class companies of the world for manufacture of electrical equipment. BHEL caters to core sectors of the Indian Economy viz., Power Generation's &Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense, etc.The Company today enjoys national and international presence featuring in the “Fortune International-500” and is ranked among the top 10 companies in the world, manufacturing power generation equipment. BHEL is the only PSU among the 12 Indian companies to figure in “Forbes Asia Fabulous 50” list.BHEL has:-· Installed equipment for over 100000 MW of power generation--- for utilities captive and industrial users.· Supplied over 225000 MVA transformer capacity and other equipment operating in transmission and distribution network up to 400 kV (AC & DC).· Supplied over 25000 motors with drive control systems to power projects, petrochemicals, refineries, steel, aluminum, fertilizers, cement plants etc.· Supplied Traction electrics and AC/DC locos to power over 12000 km railway network. Supplied over one million valves to power plants and other Industries

QUALITY POLICIES

Towards meeting its Quality Policy, BHEL is using the vehicle of Quality Management Systems, which are certified to ISO 9001:2000 series of Standards by Internationally acclaimed certifying agency, BVQI. Corporate Quality and Unit level Quality structure enables requisite planning, control and implementation of Companywide Quality Policy and Objectives which are linked to the Company's Vision statement. Corporate Quality derives strength from direct reporting to Chairman and Managing Director of the Company.

Other than traditional Quality functions, today the focus is on:-

· Propagating Quality Management Systems and Total Quality Management.

· Formulating, implementing and monitoring, "Improvement Plans" with focus on internal and external Customer Satisfaction.

· Investigations and preventive actions on Critical Quality Issues.

Calibration and testing laboratories of BHEL are accredited under the National Accreditation Board for Calibration and Testing Laboratories (NABL) scheme of Laboratory Accreditation, which has got mutual recognition with Asia Pacific Laboratory Accreditation Conference and International Laboratory Accreditation Conference. As a result of its thrust on quality and technology, BHEL enjoys national and international recognition in the form of Product Certification by International Bodies like ASME, API and Plant Approvals by agencies like Lloyds Register of Shipping, U.K., Chief Controller of Explosives India, TUV Germany etc.

In its movement towards Business Excellence and with the objective of achieving International level of Quality, BHEL has adopted European Foundation for Quality Management (EFQM) model for Business Excellence. Through this model and annual self-assessment exercise, BHEL is institutionalizing continuousimprovement in all its operations.

RESEARCH AND DEVELOPMENT

To remain competitive and meet customers' expectations, BHEL lays great emphasis on the continuous improvement of products and related technologies, and development of new products. BHEL's commitment to advancement of technology is reflected in its involvement in the development of futuristic technologies like fuel cells and superconducting generators.

BHEL's investment in R&D is amongst the largest in the corporate sector in India. During the year 2010-11, BHEL invested Rs.10050 Million on R&D efforts- 21% higher than the previous year. R&D and technology development are of strategic importance to BHEL as it operates in a competitive environment where technology is a key driver. Technology development efforts undertaken by BHEL have led to the filing of patents and copyrights at the rate of nearly one a day, significantly enhancing the company's intellectual capital. In 2010-11, BHEL filed 303 patents and copyrights, enhancing the company's intellectual capital to 1,438 patents and copyrights filed, which are in productive use in the company's business. The year saw a massive growth in grant of patents and copyrights. A total of 91 patents and copyrights were granted during the year.Currently, 532 patents & copyrights are in force. Notably, BHEL has been ranked as the Number One Company in India in terms of filing of patents by the Economic Times Intelligence Group. Significantly, BHEL is one of the only four Indian companies and the only Indian Public Sector Enterprise figuring in 'The Global Innovation 1000' of Booz & Co., a list of 1,000 publicly-tradedcompanies which are the biggest spenders on R&D in the world.BHEL has also won the coveted CII-Thompson Reuters Innovation Award 2010 in the 'Hi-tech Corporate' category. The award recognizes BHEL's innovation and entrepreneurship in India based on number of patents and efficiency and impact of innovation as measured by patent citations.The company's Corporate R&D division at Hyderabad leads BHEL's research efforts in a number of areas of importance to BHEL's product range. Research and Product Development (RPD) centers at all its manufacturing divisions play a complementary role. BHEL has introduced,

in the recent past, several state of the art products. Commercialization of products and systems developed by way of in-house Research andDevelopment contributed Rs.77, 580 Million corresponding to around 18% to the company's total turnover in 2010-11. In keeping with the National commitment to a clean environment, BHEL has developed the technology for Integrated Gasification Combined Cycle (IGCC) power plants and is pursuing the development of Advance Ultra Supercritical Thermal Power Plants in the country. BHEL is also actively working on a number of projects in futuristic areas like Clean Coal Technology, Nano Technology, Fuel Cells, Superconductivity and thin film solar cells, etc. to advance the development of technologies for power and industry sector. The engineering and technology character of the organization will be further enhanced with increased focus on innovation and R&D.

WTM BLOCK

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

The entire block is divided into different bays.

BAY-1

It houses the following machines:

Deep drilling machine - Used to drill holes in the shaft.

CNC lathe– Computer Numerically Controlled Lathes

Planing machine-uses linear relative motion between the work piece and a single-point cutting tool to machine a linear tool path.

Horizontal floor boring machine-bores holes in horizontal direction.

Vertical boring machine- work piece rotates around a vertical axis.

CNC vertical boring machine- Computer Numerically Controlled vertical boring machine.

Radial drilling machines-are known for their precision, accuracy and efficiency. These are designed to meet the most exacting requirements of engineering and allied operations and utility. They ensure smooth rotation of column and avoid angular deflection of spindle axis.

Slotting machine- for perfect slotting and planning of materials.

Components machined:-

ShaftLog for leverSleeveBush housingGuide bent stockHexagonal screw headGuiding pieceBush housing

BAY-2

It houses the following machines:Vertical boring machineTable planing machineLathe machineCNC end milling machineCNC horizontal table borer

Make-CravenBoring spindle diameter-130mmMaximum load capacity-12 tons

Horizontal boring machineSpindle diameter-88.9mmSwiveling table size-1067*1067mmSliding table size-1676*1067mmMaximum facing head mill face-1219mm

CNC lathe machineComponents machined:

Rubber seal clamping ringBottom cover plateBushGuide vaneExtension tubeDeflector

GOVERNOR ASSEMBLY-Bay 2 also houses the governor assembly area.

Governor Assembly WTM

Components Manufactured: Guide Bearing

MIV Servo Motor

Nozzle Assembly- Nozzle tip

Anti-Vacuum Valve

Pressure Receiver

By pass valve

BAY-3

It houses the following machines:

Vertical boring machineTable diameter-6705mmMaximum job diameter-7696mmMaximum capacity-90 tons

CNC vertical boring machine

Runner blade turning machineMaximum length of work-8000mmMaximum diameter that can be turned-4000mmLength of job that can be done-7200mm

Column boring machineTable diameter-5523mmMaximum external diameter that can be machined-9000mmStroke of RAM-3353mmMaximum capacity-100 tons

Components machined:

· Top cover· Inner turbine housing· Spacer flange· Pivoted ring cover· Sealing flange· Stay ring· Runner blade

BAY-4

It houses the following machines:Lathe machineCNC lathe machineTable planing machineEnd milling machine

Distance between columns-4242mmMaximum underbridge movement-3276mmMaximum length of machines-9144mmMaximum height upto vertical head-3200mmMaximum capacity-100 tons

Horizontal boring and milling machineSpindle diameter-203mmTraverse X-8992mm, Y-4500mm, Z-1981mmMinimum height of spindle center to bed-760mm

Break lathe machineSliding bed and center height-1422mmBase plate and center height-2108mmSaddles rotation over sliding bed-2286mmDistance between centre-7621mmLength of sliding bed-9905mm

Diameter of face plate-2438mmWeight capacity-50 tons

Vertical milling machineHeight between spindle nose and table-660mmSpindle to face column-559mm

Slotting machineMaximum stroke -530mmMinimum stroke -190mm

Radial drilling machineVertical boring machine

CNC horizontal floor borerBoring spindle diameter-200mmColumn guide way-1050mmHeadstock vertical movement-5000mmSpindle / rack movement-2000/1600mmRotary table size-3150*3150mm

Components machined:TrunnionSleeve screwBottom sleeveTop cover

FABRICATION SHOP

BAY-5

It is the place where degreasing and fabrication work takes place. It houses the following machines:

Electro slag welding machineJob completed in one passfor job of thickness 40-110mm single nose is usedfor job of thickness greater than 110mm double nose is usedlesser defects as compared to manual arc welding

Ovenheatingfuel-LPGMaximum heating temperature-150 degree CelsiusMaximum size-W-5250mmTransformer tank assembly-H-5000mm

Components fabricated:DistributorPivot ringTransformer tank

BAY-6

It houses the following machines and equipment:Manual arc welding

Manual grinding

Submerged arc welding

BAY-7

It houses the following machines:Submerged arc weldingRobotic arm welding

Shot blast plant-Used for treating corroded partsPaint shop-Used to paint shot blasted components

Components fabricated:Transformer tankSpacer flange

Bay-8

It houses the heat exchanger and cooler assembly. Following machines are situated in this bay:Lahar deep gun drilling machineRadial drilling machineArboga CNC drilling machineMulti-spindle drilling machine

Traverse x-7000mm y-8500mm z-350mmNo. of spindles-8Min. pitch-100mmMax.pitch-200mmper spindle drilling capacity-40mmSpindle speed-71-1400 RPMSpindle feed-10-1000 mm/minNo. of drilling motors-2

Lathe machine

Components machined:

BuffelTube plateSleeve

PRODUCT INFORMATION

HYDRO TURBINES:-

1. HYDROELECTRIC POWER PLANT:

The purpose of a hydro-electric power plant is to harness power from

water. As such it incorporates a no. of waterdriven prime movers known as water turbines. The water or hydraulicTurbine converts the kinetic and potential energies possessed by water into mechanical power. The hydraulic turbine whencoupled to a generator produces electric power.

2. Advantages of hydraulic electric power:

a. Cheap and immune to inflationb. inexhaustiblec. This can be developed wherever water continuously

flowing under

pressure.d. robust, reliable, lest maintenance.e. Operate in high efficiency level.f. Quick loading and off-loading flexibilities.g. Ideal peaking partner of base load thermal/nuclear.h. Multipurpose benefitsi. No pollution to environment.

3. INTRODUCTION:

Hydraulic turbines are highest efficiency prime movers used for

power production which utilize the energy of water ways. Thehydraulic energy contained in the stream is converted by to mechanical power.

Basically these are of two types:a. Impulse turbinesb. Reaction turbines

In an impulse turbine the water possessing kinetic energy is supplied to the runner at Atmosphericpressure. The flow through

the runner is entirely at atmospheric pressure, the force exerted by the water being due to the impulse of the jet.

In a reaction turbine the water supplied to the runner possesses energy which is partly kinetic and partly pressure. Both types of energies are converted into work in the runner which results in a drop of pressure and absolute velocity of water.

FURTHER CLASSIFICATION OF IMPULSE AND REACTIONTURBINES:

Impulse turbine:- pelton turbine

Reaction turbine:- Francis turbine- Kaplan and Propeller turbinePropeller turbines are mainly Kaplan turbines but Moody, nagler and Bell turbines may be found in market. The main difference between Kaplan and other type of propeller turbines is that the former has adjusted runner blades.

FRANCIS TURBINE-

These are inward flow reaction turbine. Used when operating head is in the range of 30-500m. These are medium pressure turbine. Total machines -190 Megawatt capacity-5-165 MW Runner radius-1050-5250mm

FRANCIS TURBINES

The Francis turbine is a type of water turbine that was developed by James B. Francis in Lowell, Massachusetts. It is an inward-flow reaction turbine that combines radial and axial flow concepts.

The Francis turbine is a reaction turbine, which means that the working fluid changes pressure as it moves through the turbine, giving up its energy. A casement is needed to contain the water flow. The turbine is located between the high-pressure water source and the low-pressure water exit, usually at the base of a dam.

The inlet is spiral shaped. Guide vanes direct the water tangentially to the turbine wheel, known as a runner. This radial flow acts on the runner's vanes, causing the runner to spin. The guide vanes (or wicket gate) may be adjustable to allow efficient turbine operation for a range of water flow conditions.

As the water moves through the runner, it’s spinning radius decreases, further acting on the runner. For an analogy, imagine swinging a ball on a string around in a circle; if the string is pulled short, the ball spins faster due to theconservation of angular momentum. This property, in addition to the water's pressure, helps Francis and other inward-flow turbines harness water energy efficiently.At the exit, water acts on cup-shaped runner features, leaving with no swirl and very little kinetic or potential energy. The turbine's exit tube is shaped to help decelerate the water flow and recover the pressure.

MAIN COMPONENTS OF FRANCIS TURBINE:

1. SPIRAL CASING: in order to distribute the water around the guide ring evenly the scroll casing is designed with a cross sectional area reducing uniformly around the circumference, maximum at the entrance and nearly zero at tip. This gives spiral shape and hence is named as spiral casing. These are also provided with inspection holes and also with pressure gauge connection.

2. GUIDE MECHANISM: these have a cross sectional area of aero foil section. This particular cross section allows water to pass over them without forming eddies and with minimum frictional losses. It is mounted on a ring which is connected to generator shaft by means of a regulating shaft depending upon load, speed of turbine is controlled by a governor which basically deals with the guide vane opening.

3. DRAFT TUBE: It is a conduit which connects the runner exit to theTailrace. A tube should be drowned approx. below the lowest tail race level. It basically increases the workable

head of turbine by anamount equal to the height of the runner outlet, thus making it

possible to install the turbine above the tail race level without loss of head.

APPLICATION OF FRANCIS TURBINES

Francis turbines may be designed for a wide range of heads and flows. This, along with their high efficiency, has made them the most widely used turbine in the world. Francis type units cover a head range from 20 to 700 meters, and their output power varies from just a few kilowatts up to one Gigawatt. Large Francis turbines are individually designed for each site to operate at the highest possible efficiency, typically over 90%.In addition to electrical production, they may also be used for pumped storage, where a reservoir is filled by the turbine (acting as a pump) during low power demand, and then reversed and used to generate power during peak demand.

Construction of spherical valve

Valve disc of spherical valveSpherical valve with dismantling joint

Spherical valve under pressure testConstruction of spherical valve

PELTON TURBINE

These are impulse turbines which extract energy fromthe impulse(momentum)of moving water.

These are high pressure turbines Total machines-46 Head limit-245-1025m Megawatt limit-1.5-200 MW

The Pelton wheel is an impulse turbine which is among the most efficient types of water turbines. It was invented by Lester Allan Pelton in the 1870s. The Pelton wheel extracts energy from the impulse (momentum) of moving water, as opposed to its weight like traditional overshot water wheel.  Pelton's paddle geometry was designed so that when the rim runs at ½ the speed of the water jet, the water leaves the wheel with very little speed, extracting almost all of its energy, and allowing for a very efficient turbine.

The water flows along the tangent to the path of the runner. Nozzles direct forceful streams of water against a series of spoon-shaped buckets mounted around the edge of a wheel. As water flows into the bucket, the direction of the water velocity changes to follow the contour of the bucket. When the water-jet contacts the bucket, the water exerts pressure on the bucket and the water is decelerated as it does a "U-turn" and flows out the other side of the bucket at low velocity. In the process, the water's momentum is transferred to the turbine. This "impulse" does work on the turbine. For maximum power and efficiency, the turbine system is designed such that the water-jet velocity is twice the velocity of the bucket. A very small percentage of the water's original kinetic energy will still remain in the water; however, this allows the bucket to be emptied at the same rate it is filled, (see conservation of mass), thus allowing the water flow to continue uninterrupted. Often two buckets are mounted side-by-side, thus splitting the water jet in half (see photo). This balances the side-load forces on the wheel, and helps to ensure smooth, efficient momentum transfer of the fluid jet to the turbine wheel.

Because water and most liquids are nearly incompressible, almost all of the available energy is extracted in the first stage of the hydraulic turbine. Therefore, Pelton wheels have only one turbine stage, unlike gas turbines that operate with compressible fluid.

PARTS OF PELTON TURBINE:

1. Guide mechanism: this mechanism controls the quality of water passing through the nozzle and striking the bucket thus meeting the variable demand of power. It maintains the speed constant of wheel, when head varies.

2. Bucket and runner: Each bucket is divided vertically into two parts by splitter, which is the sharp edge at center giving the shape of double hemispherical cup (in BHEL, the edgeof splitter is cut to increase efficiency and to reduce the impact force of the impinging jet which otherwise will decrease the life of bucket).

3. Casing: it does not have any hydraulic function toperform. It is necessary only to prevent splashing and tolead the water to tail race, and also further safe guardagainst accidents.

4. Hydraulic brakes: After shutting down the inlet valve ofturbine, the large capacity of runner will go on revolvingor a considerable period, due to inertia. This has necessitated the development of brakes to bring the turbine to a standstill in a shortest possible time.

APPLICATION OF PELTON WHEELPelton wheels are the preferred turbine for hydro-power, when the available water source has relatively high hydraulic head at low flow rates. Pelton wheels are made in all sizes. There exist multi-ton Pelton wheels mounted on vertical oil pad bearings inhydroelectric plants. The largest units can be up to 200 megawatts. The smallest Pelton wheels are only a few inches across, and can be used to tap power from mountain streams having flows

of a few gallons per minute. Some of these systems utilize household plumbing fixtures for water delivery. These small units are recommended for use with thirty meters or more of head, in order to generate significant power levels. Depending on water flow and design, Pelton wheels operate best with heads from 15 meters to 1,800 meters, although there is no theoretical limit.The Pelton wheel is most efficient in high head applications (see the "Design Rules" section). Thus, more power can be extracted from a water source with high-pressure and low-flow than from a source with low-pressure and high-flow, even when the two flows theoretically contain the same power. Also a comparable amount of pipe material is required for each of the two sources, one requiring a long thin pipe, and the other a short wide pipe.

KAPLAN TURBINE-

The Kaplan turbine is a propeller-type waterturbine which hasadjustable blades.

These are reaction turbines The head ranges from 10-70 meters Output from 5 to 120 MW Runner diameters are between 2 and 8 meters Used in high-flow, low-head power production

The Kaplan turbine is a propeller-type water turbine which has adjustable blades. It was developed in 1913 by the Austrian professor Viktor Kaplan, who combined automatically adjusted propeller blades with automatically adjusted wicket gates to achieve efficiency over a wide range of flow and water level.

 Its invention allowed efficient power production in low-headapplications that was not possible with Francis turbines. The head ranges from 10-70 meters and the output from 5 to 120 MW. Runner diameters are between 2 and 8 meters. The range of the turbine is from 79 to 429 rpm. Kaplan turbines are now widely used throughout the world in high-flow, low-head power production.

THEORY OF OPERATION

The Kaplan turbine is an inward flow reaction turbine, which means that the working fluid changes pressure as it moves through the turbine and gives up its energy. Power is recovered from both the hydrostatic head and from the kinetic energy of the flowing water. The design combines features of radial and axial turbines.The inlet is a scroll-shaped tube that wraps around the turbine's wicket gate. Water is directed tangentially through the wicket gate and spirals on to a propeller shaped runner, causing it to spin.The outlet is a specially shaped draft tube that helps decelerate the water and recover kinetic energy.

The turbine does not need to be at the lowest point of water flow as long as the draft tube remains full of water. A higher turbine location, however, increases the suction that is imparted on the turbine blades by the draft tube. The resulting pressure drop may lead to cavitation.

APPLICATION OF KAPLANKaplan turbines are widely used throughout the world for electrical power production. They cover the lowest head hydro sites and are especially suited for high flow conditions.

HYDRO TURBINE GOVERNOR

Used to govern the speed of rotation of the runner such that the frequency of power generated is 50 Hz.

This is done by controlling the opening of guide vanes.

SPIRAL CASE AND STAY RING

Spiral case for turbine with 411m head Stay ring for turbine with 146m head

WICKET GATES AND OPERATING MECHANISM

Wicket gates for a low head turbine Wicket gates for a high head turbine

Wicket gates operating linkage Self-lubricated bearing for wicket gate stem

CONSTRUCTION OF RUNNER HUB AND BLADE

The runner blades are operated to smoothly adjust their blade angles by a link mechanism. Their mechanism is installed inside the runner hub, containing the runner blade and stem, the link crosshead and so on. A high quality lubricating oil is filled inside the runner hub to lubricate the mechanism interior.

Shop assembly of runner Runner blade under machining

MAIN SHAFT

The main shaft for the turbine is made of high-grade forged carbon steel. When the size of the main shaft exceeds the limitation of forging capacity or transportation or it is economical, the main shaft is formed by welding steel plates or a combination of forged steel and steel plates.The main shaft is connected to the generator shaft or the intermediate shaft by a flange coupling. The shaft surface passing through the shaft seal is protected with a stainless steel shaft sleeve to prevent the main shaftfrom wearing.

Forged shaft Fabricated shaft

Power of Water TurbineThe poweravailable in a stream of water is;

where:

P = power (J/s or watts)

η = turbine efficiency ρ = density of water (kg/m³) g = acceleration of gravity (9.81 m/s²) h = head (m). For still water, this is the difference in height between the inlet and outlet surfaces.

Moving water has an additional component added to account for the kinetic energy of the flow. The total head equals the pressure head plus velocity head.

= flow rate (m³/s)

DESIGN AND APPLICATIONTurbine selection is based mostly on the available water head, and less so on the available flow rate. In general, impulse turbines are used for high head sites, and reaction turbines are used for low head sites. Kaplan turbines with adjustable blade pitch are well-adapted to wide ranges of flow or head conditions, since their peak efficiency can be achieved over a wide range of flow conditions.

Small turbines (mostly fewer than 10 MW) may have horizontal shafts and even fairly large bulb-type turbines up to 100 MW or so may be horizontal. Very large Francis and Kaplan machines usually have vertical shafts because this makes best use of the available head, and makes installation of a generator more economical. Pelton wheels may be either vertical or horizontal shaft machines because the size of the machine is so much less than the available head. Some impulse turbines use multiple water jets per runner to increase specific speed and balance shaft thrust.

Typical range of heads• Hydraulic wheel turbine• Archimedes' screw turbine• Kaplan• Francis• Pelton• Turgo

0.2 < H < 4   

1 < H < 102 < H < 4010 < H < 35050 < H < 130050 < H < 250

Specific speedThe specific speed ns of a turbine characterize the turbine's shape in a way that is not related to its size. This allows a new turbine design to be scaled from an existing design of known performance. The specific speed is also the main criteria for matching a specific hydro site with the correct turbine type.

The specific speed is the speed with which the turbine turns for a particular discharge Q, with unit head and thereby is able to produce unit power.

Affinity lawsAffinity Laws allow the output of a turbine to be predicted based on model tests. A miniature replica of a proposed design, about one foot (0.3 m) in diameter, can be tested and the laboratory measurements applied to the final application with high confidence. Affinity laws are derived by requiringsimilitudebetween the test model and the application. Flow through the turbine is controlled either by a large valve or by wicket gates arranged around the outside of the turbine runner. Differential head and flow can be plotted for a number of different values of gate opening, producing a hill diagram used to show the efficiency of the turbine at varying conditions.

Runaway speedThe runaway speed of a water turbine is its speed at full flow, and no shaft load. The turbine will be designed to survive the mechanical forces of this speed. The manufacturer will supply the runaway speed rating.

Parts manufactured for Current Projects:

Part manufactured Forged RunnerProject AD Hydro Power Ltd.Wt. of the Part 9200kgNo. of Cups 20

Part manufactured Main InjectorProject Tapovan Vishnugad HEPWt. of the part 4900kg

Part manufactured Runner HubProject Pulichintala ProjectWt. of Part 9240kg

Part manufactured Door (Francis Turbine)Project Parbati HEP Stage 3Wt. of part 32000kg

Part manufactured Runner BladeProject Pulinchintala ProjectWt. of Part 3779kg

CONLUSION

The Vocational training at BHEL Bhopal helped me in improving my practical knowledge and understanding of Hydro turbine, its manufacturing and types to a large extent. Here I came to know about the technology and material used in manufacturing of hydro turbine. Besides this, I also visualized the parts involved and equipment that were used during the manufacturing process of these turbines. In all it was a truly learning experience for me. As a mechanical engineering student I hope that the training I got here would help me in coming future. I hereby thank all theauthorities at BHEL for their kind cooperation and guidance.