VACATIONAL TRAINING REPORT

2021

Under the Guidance of-

Sh. Ajay Kumar
BHEL, BHOPAL

Gauraang Singh Baghel

MAULANA AZAD NATIONAL INSTITUTE OF

TECHNOLOGY ,BHOPAL
BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

VACATIONAL TRAINING REPORT

Duration: 14 DAYS (28 June, 2021 to 12 July, 2021)

Under the Guidance of

Sh. Ajay Kumar

Sr. Manager

BHEL, BHOPAL

Submitted By:
Gauraang S. Baghel

VT-2021/105
MANIT, BHOPAL
1
 CERTIFICATE

This is to certify that “Gauraang Singh Baghel” student of 6th semester

of Mechanical Engineering branch has successfully completed his Major
Training in BHEL, BHOPAL. This training is vocational training required to
be submitted as a part of syllabus of Semester in MAULANA AZAD
NATIONAL INSTITUTE OF TECHNOLOGY, BHOPAL.

DATE: 26 -July- 2021 PLACE: BHOPAL

 DECLARATION

I, Gauraang Singh Baghel pursuing Bachelor of Technology from

Maulana Azad National Institute of Technology, Bhopal, hereby

declare that the work presented in this report is outcome of my

work carried out at BHEL from 28/06/2021 to 12/07/2021 is

bonafide, correct to the best of my knowledge and this work has

been carried out taking care of Engineering Ethics. I worked under

the rules and regulations of BHEL, BHOPAL. And the work presented

does not infringe any patented work.

Date: 02 August 2021 Gauraang Singh Baghel

 ACKNOWLEDGEMENT
“It is not possible to prepare a project report without the assistance &
encouragement of other people. This one is certainly no exception.”

On the very outset of this report, I would like to extend my sincere and
heartfelt obligation towards all the personages including the following
instructor, technical staff and supervisor of various sections who helped me in
this endeavor. Without their active guidance, help, cooperation and
encouragement, I would not have made head way in the project.

I would like to express my sincere gratitude to my project guide or better to

say mentor, S h . Ajay Kumar , (Sr. Manager) who gave his valuable time to me
to utilize my time to fullest during industrial training . I was privileged to
experience a sustained enthusiastic and involved interest from his side in
BHEL, Bhopal.

Thanking You,
Gauraang Singh
Baghel
MANIT BHOPAL
INTRODUCTION

Bharat Heavy Electricals Limited (BHEL) owned and founded by the

Government of India, is an engineering and manufacturing company
based in New Delhi. Established in 1964, BHEL is India's largest power
generation equipment manufacturer.

Government of India (Ministry of Heavy Industries and Public

enterprises) has granted the status of MAHARATNA to Bharat Heavy
Electricals Limited on 1st Feb 2013.

BHEL is engaged in the design, engineering, manufacturing,

construction, testing, commissioning and servicing of a wide range of
products, systems and services for the core sectors of the economy,
viz. power, transmission, industry, transportation, renewable energy,
oil & gas and defense.

It has a network of 17 manufacturing units, 2 repair units, 4 regional

offices, 8 service centres , 8 overseas offices, 15 regional centres, 7
joint ventures, and infrastructure allowing it to execute more than
150 projects at sites across India and abroad. The company has
established the capability to deliver 20,000 MW p.a. of power
equipment to address the growing demand for power generation
equipment
BHEL, BHOPAL: “Centre of Excellence for Hydro Machines”

BHEL BHOPAL has :-

 Added more than 124000 MW to the country's installed power generating

capacity so far.
 Supplied over 25000 Motors with Drive Control System to power
projects, Petrochemicals Refineries, Steel, Aluminium, Fertilizer, Cement
plant, etc.
 Supplied Traction electrics and AC/DC locos over 12000 kms Railway
network.
 Supplied over one million Values to Power Plants and other Industries.
 BHEL has retained its market leadership position during 2013-14 with
72% market share in the Power Sector, even while operating in a difficult
business environment.
PRODUCTS OF BHEL, BHOPAL
 AC Motors and Alternators
 Transportation Equipment’s
 Hydro Generator
 Excitation Control Equipment
 Turbine
 Oil Rings
 Transformer
 Switch gear
 Control and Relay Panel
Industry Profile: -

Heavy industry sector is one of the core sectors of Indian economy. Therefore,
its fund requirements are inverse keeping in view the scale and size of the industrial
units in the sector, the financial requirements are also huge. The heavy engineering
sector is driving primarily by technology. This, coupled with the fact that the initial
investment required for heavy engineering or capital goods manufacturing facilities is
relatively high, creates relatively high entry barriers. Any business enterprises viability
eventually boils down to cost – return trade off. Cost of funds is undoubtly, the most
important determined of the viability. This becomes more crucial in heavy engineering
sectors.
The development of the Indian heavy electrical machinery industry is directly linked
to the Performance of the Power sector in India. With India’s development, the need
for more and Better Power supply has become essential for industries to grow. Thus,
with increasing focus on capacity expansion in the Power sector, the heavy electrical
machinery manufacturing industry is expanding vigorously.
BACKGROUND: -
Heavy Electrical Industry covers power generation, transmission and
distribution and utilization equipment’s. These include turbo generators, boilers,
various types of turbines, transformers, steam turbines and other allied items. Majority
of the products manufactured by heavy electrical industry in the country, which
includes items like transformers, steam turbines etc. are used by all sectors of the
Indian economy. Some major areas where these are used are the multi core projects for
power generation including nuclear power stations, petrochemical complexes,
chemical plants, integrated steel plants, non-ferrous metal units, etc.
 HISTORY: -
BHEL was established in 1964. Heavy Electrical (India) Ltd was merged with
BHEL in 1974. In 1982, it entered into power equipment, to reduce its dependence
on the power sector. It developed the capability to produce a variety of electrical,
electronic and mechanical equipment for all sectors, including transmission,
transportation, oil and gas and other allied industries. In 1991, it was converted into
a public limited company. By the end of 1996, the company had handed over 100
Electric Locomotives to Indian Railway and installed 250 Hydro-sets across India.
OPERATIONS: -

It is engaged in the design, engineering, manufacture, construction, testing,

commissioning and servicing of a wide range of products, systems and services for the
core sectors of the economy, viz. Power, Transmission, Industry, Transportation,
Renewable Energy, Oil & Gas and Defence.

With a widespread network of 17 manufacturing units, two repair units, four

regional offices, eight service centres, eight overseas offices, 15 regional centres,
seven joint ventures, and infrastructure to execute more than 150 project sites across
India and abroad, BHEL provides products, systems and services to customers
efficiently and at competitive prices. The company has established capability to
deliver 20,000 MW p.a. of power equipment to address the growing demand for power
generation equipment.

BHEL has retained its market leadership position during 2013-14 with 72%
market share in the Power Sector, even while operating in a difficult business
environment. Improved focus on project execution enabled BHEL record highest ever
commissioning/synchronization of 13,452 MW of power plants in domestic and
international markets in 2013-14, marking a 30% increase over 2012-13. The company
has added more than 1, 24,000 MW to the country's installed power generating
capacity so far.
 It also has been exporting its power and industry segment products and services
for over 40 years. BHEL's global references are spread across over 76 countries across
all the six continents of the world. The cumulative overseas installed capacity of
BHEL manufactured power plants exceeds 9,000 MW across 21 countries including
Malaysia, Oman, Iraq, the UAE, Bhutan, Egypt and New Zealand. Our physical
exports range from turnkey projects to after sales services.

Manufacturing Unit: -

 Heavy Electrical Plant (HEP), Bhopal

 Transformer Plant, Jhansi

 Industrial Systems Group (ISG), Bangalore
 Electronics Division (EDN), Bangalore
 Electro-Porcelains Division (EPD), Bangalore
 Industrial Valves Plant (IVP), Goindwal
 Heavy Electrical Equipment Plant(HEEP), Haridwar
 Central Foundry Forge Plant (CFFP), Haridwar
 Heavy Power Equipment Plant, Hyderabad
 Insulator Plant (IP), Jagdishpur
 Centralized Stamping Unit & Fabrication Plant (CSU & FP), Jagdishpur
 Boiler Auxiliaries Plant (BAP), Ranipet
 Component Fabrication Plant (CFP), Rudrapur
 High Pressure Boiler Plant (HPBP), Tiruchirapalli
 Seamless Steel Tube Plant (SSTP), Tiruchirapalli
 Power Plant Piping Unit, Thirumayam
 Heavy Plates & Vessels Plant (HPVP), Visakhapatnam
The company is also setting up a new Greenfield Power Equipment Fabrication Plant
at Bhandara, Maharashtra, the foundation stone for which was laid on 14 May 2013.
Further, BHEL is planning to enter solar manufacturing in a big scale, as it has
announced its plans for a 600 MW Solar Module Factory.

Achievements and Recognitions:

 It is the 7th largest power equipment manufacturer in the world.
 BHEL received the National Intellectual Property Award 2014 and WIPO
Award for Innovative Enterprises 2014
 In 2013, BHEL won ICAI National Award for Excellence in Cost
Management for the eighth consecutive year.
 BHEL received two awards in CII-ITC Sustainability Awards 2012 from
the President of India.
 In the year 2011, it was ranked ninth most innovative company in the
world by US business magazine Forbes.
 The Company won the prestigious ‘Golden Peacock Award for
Occupational Health & Safety 2011’ for significant achievements in the
field of Occupational Health & Safety.

Company Background:-
1956 - Company was set up at Bhopal in the name of M/s Heavy electrical
(India) Ltd. in collaboration with AEI, UK. Subsequently, three more plants were set
up at Hyderabad, Hardwar and Trichy. The Bhopal Unit was controlled by the
company, the other three were under the control of Bharat Heavy Electricals Ltd. - The
Company`s object is to manufacture of heavy electrical equipments. 1972 - In July the
Operations of all the four plants were integrated. 1974 - In January Heavy electrical
(India) Ltd was merged with BHEL. - For the manufacture of a wide variety of
products, the company has developed technological infrastructure, skills and quality to
meet the stringent requirements of the power plants, transportation, petro chemicals,
and oil etc. - BHEL has entered into collaboration which are technical in nature. Under
these agreements, the collaborators have transferred, furnished the information,
documentation, including know-how relating to design, engineering, manufacturing
assembly etc. 1982 - BHEL also entered into power equipments, to reduce its
dependence on the power sector.
BHEL caters to core sectors of the Indian economy viz; power generation &
transmission, industry, transportation, telecommunication, renewable energy, defence
etc. the wide network of BHEL’s 14 manufacturing divisions, four power sector
regional centres, over 100 project sites, eight service centres and 14 regional offices
enables the company to be closer to its customers and provide them with suitable
products, systems and services efficiently and at competitive prices. Having attained
ISO 9000 certification, BHEL is now well on its journey towards total quality
management (TQM). On the environmental management front, the major units of
BHEL have 4 already acquired the ISO 14001 certification,

Power Sector
Power generation sector comprises thermal, gas, hydro and nuclear power plant
business. As of 31-3-2004, BHEL supplied sets
account for nearly 71,255 MW or 64% of the
total installed capacity of 1, 11,151 MW in the
country, as against nil till 1969-70.
The company manufactures 235 MW
nuclear turbine generator sets and has
commenced production of 500 MW nuclear
turbine generator sets.
 Custom-made hydro sets of Francis, Pelt on And Kaplan types for different head
discharge combinations are also engineered and manufactured by BHEL. In all, orders
for more than 700 utility sets of thermal, hydro, gas and nuclear have been placed on
the company as on date.

Transmission:
BHEL also supplies a wide range of transmission
products and systems of up to 400KV class. These
include high voltage power & instrument
transformers, dry type transformers, shunt & series
reactors, sf switch gear, 33KV gas insulated
substation capacitors, and insulators etc. for economic transmission of bulk power over
long distances, High Voltage Direct Current (HVDC) systems are supplied. Series and
shunt compensation systems, to minimize transmission loses, have also been supplied.
Transportation:-
Mostly of the trains operated by the Indian
railways, including the metro in Calcutta, are
equipped with BHEL’s traction electrics and
traction control equipment. The company
supplies electric locomotives to Indian Railways
and diesel shunting locomotives to various
industries. 5000/4600 hp ac/dc locomotives
developed and manufactured by BHEL have been supplied to Indian railways. Battery
powered road vehicles are also manufactured by the company.
BHEL also supplies traction electrics
and traction control equipment for
electric locos, diesel electric locos, and
EMUs/ DEMUs to the railways
 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 pieceand 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. Theyensure smooth
rotation of column and avoid angular deflection of spindle axis.

Slotting machine- for perfect slotting and planning of materials.

Components machined:-

 Shaft
 Log for lever
 Sleeve
 Bush housing
 Guide bent stock
 Hexagonal screw head
 Guiding piece
 Bush housing

BAY-2

It houses the following machines:

 Vertical boring machine
 Table planing machine
 Lathe machine
 CNC end milling machine
 CNC horizontal table borer
Make-Craven
Boring spindle diameter-130mm
Maximum load capacity-12 tons
 Horizontal boring machine
Spindle diameter-88.9mm Swiveling
table size-1067*1067mmSliding table
size-1676*1067mm
Maximum facing head mill face-1219mm
 CNC lathe machine
Components machined:
Rubber seal clamping ring
Bottom cover plate
Bush
Guide vane
Extension tube
Deflector
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 machine

Table diameter-6705mm Maximum
job diameter-7696mmMaximum
capacity-90 tons

 CNC vertical boring machine

 Runner blade turning machine

Maximum length of work-8000mm
Maximum diameter that can be turned-4000mm
Length of job that can be done-7200mm
 Column boring machine
Table diameter-5523mm
Maximum external diameter that can be machined-9000mmStroke
of RAM-3353mm
Maximum 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 machine
 CNC lathe machine
 Table planing machine
 End milling machine
Distance between columns-4242mm Maximum
underbridge movement-3276mm Maximum
length of machines-9144mm Maximum height
upto vertical head-3200mmMaximum capacity-
100 tons
 Horizontal boring and milling machine
Spindle diameter-203mm
Traverse X-8992mm, Y-4500mm, Z-1981mm
Minimum height of spindle center to bed-
760mm
 Break lathe machine
Sliding bed and center height-1422mm Base
plate and center height-2108mm Saddles
rotation over sliding bed-2286mmDistance
between centre-7621mm
Length of sliding bed-9905mm
Diameter of face plate-2438mm
Weight capacity-50 tons

 Vertical milling machine

Height between spindle nose and table-660mm
Spindle to face column-559mm
 Slotting machine
Maximum stroke -530mm
Minimum stroke -190mm
 Radial drilling machine
 Vertical boring machine
 CNC horizontal floor borer
Boring spindle diameter-200mm
Column guide way-1050mm Headstock
vertical movement-5000mm
Spindle / rack movement-2000/1600mm
Rotary table size-3150*3150mm

Components machined:
Trunnion
Sleeve screw
Bottom sleeve
Top cover

FABRICATION SHOP

BAY-5

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

 Electro slag welding machine

Job completed in one pass
for job of thickness 40-110mm single nose is used
for job of thickness greater than 110mm double nose is used lesser
defects as compared to manual arc welding
Oven
heating fuel-LPG
Maximum heating temperature-150 degree Celsius Maximum
size- W-5250mm
Transformer tank assembly-H-5000mm

Components fabricated:
Distributor
Pivot ring
Transformer 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 welding
Robotic arm welding

Shot blast plant-Used for treating corroded parts

Paint shop-Used to paint shot blasted
components.
Components fabricated:
Transformer tank
Spacer flange

Bay-8

It houses the heat exchanger and cooler assembly. Following machines aresituated
in this bay:
 Lahar deep gun drilling machine
 Radial drilling machine
 Arboga CNC drilling machine
 Multi-spindle drilling machine
Traverse x-7000mm y-8500mm z-350mmNo.
of spindles-8
Min. pitch-100mm
Max.pitch-200mm
per spindle drilling capacity-40mm
Spindle speed-71-1400 RPM
Spindle feed-10-1000 mm/min
 No. of drilling motors-2
 Lathe machine
Components machined:

Buffel Tube plate

Sleeve

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 water driven prime movers known as water turbines.
The water or hydraulic Turbine converts the kinetic and potential energies
possessed by water into mechanical power. The hydraulic turbine when coupled to a
generator produces electric power.

2. Advantages of hydraulic electric power:

a. Cheap and immune to inflation

b. inexhaustible
c. 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 benefits
i. No pollution to environment.

WATER TURBINE MANUFACTURING

 Turbine:
A water turbine is a rotary machine that converts kinetic energy and
potential energy of water into mechanical work.
  Types:
There are two main categories of hydro turbines: impulse and reaction.
The type of hydropower turbine selected for a project is based on the
height of standing water—referred to as "head"—and the flow, or volume
of water, at the site. The most common type of impulse turbine is Pelton
turbine.
On the other side, the most common reaction turbine is Francis turbine
but there are also Kaplan turbine, Tyson turbine, Gorlov helical turbine.

 PELTON TURBINES:
Pelton turbine or wheel is an impulsive turbine used mainly for high head
hydroelectric schemes. The Pelton wheel is among the most efficient types of
water turbines. The fluid power is converted into kinetic energy in the nozzles.
The total pressure drop occurs in the nozzle. The resulting jet of water is
directed tangentially at buckets on the wheel producing impulsive force on
them.

Pelton wheel has the following main components:

 Nozzle
 Runner and buckets
 Casing
 Breaking jet

Function
Nozzles direct forceful, high-speed streams of water against a rotary series of
spoon-shaped buckets, also known as impulse blades, which are mounted
around the circumferential rim of a drive wheel
 As the water jet
impinges upon the
contoured bucket-
blades, the direction
of water velocity is
changed to follow
the contours of the
bucket. Water
impulse energy
exerts torque on the
bucket and wheel
system, spinning the
wheel, the water stream itself does a "U-turn" and exits at the outer sides of
the bucket, decelerated to a low velocity. In the process, the water jet's
momentum is transferred to the wheel and thence to a turbine.

Thus, "impulse" energy does work on the turbine. For maximum power and
efficiency, the wheel and turbine system is designed such that the water jet
velocity is twice the velocity of the rotating buckets.

A very small percentage of the water jet's original kinetic energy will remain in
the water, which causes the bucket to be emptied at the same rate it is filled and
thereby allows the high-pressure input flow to continue uninterrupted and
without waste of energy.

Typically, two buckets are mounted side-by-side on the wheel, which permits
splitting the water jet into two equal streams. This balances the side-load forces
on the wheel and helps to ensure smooth, efficient transfer of momentum of the
fluid jet of water to the turbine wheel.

 FRANCIS TURBINES:
The Francis turbine is a reaction turbine where water changes pressure as it
moves through the turbine, transferring its energy. A watertight casement
is needed to contain the water flow.

Generally, such turbines are suitable for sites such as dams where they are
located between the high pressure water source and the low pressure water exit.
Francis turbines are the most common water turbine in use today.
They operate in a water head from 40 to 600 m (130 to 2,000 ft) and are
primarily used for electrical power production.

Francis turbine has the

following main components:

 Spiral casing.
 Stay ring and stay
vanes.
 Runner.
 Draft tube.

Function
Water flows from the
penstock into the spiral
casing. In the spiral casing
the water is distributed
around the complete periphery. The water is then guided by the stay vanes and
guide vanes in the correct angle towards the runner.

The guide vanes are adjustable and can change the angle depending on the inlet
and outlet conditions of the turbine, they are controlled by a governor servo
motor. The runner transfers the energy from the pressure and velocity in the
water to a rotational momentum. The water exits through a draft tube that
extracts the remaining energy in the water. The torque produced in the runner is
transferred to a power producing generator through a shaft.

KAPLAN TURBINES:
The Kaplan turbine has adjustable blades. The main advantage of Kaplan
turbines is its ability to work in low head sites which was not possible with
Francis turbines.
Kaplan turbines are widely used in high-flow, low-head power
production 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.

The design combines radial and axial features. 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 onto 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 that may lead to
cavitation’s due to the pressure drop.

Typically, the efficiencies achieved for Kaplan turbine are over 90%,
mainly due to the variable geometry of wicket gate and turbine blades.
This efficiency however maybe lower for very low head applications.
Since the propeller blades are rotated by high-pressure hydraulic oil, a
critical design turbine is to maintain a positive seal to prevent leakage
of oil into the waterway.
 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 shaft from wearing.
Forged shaft Fabricated shaft

Power of Water Turbine

The 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 APPLICATION
Turbine selection is based mostly on the available water head, and less soon 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 0.2 < H < 4

•Archimedes' screw turbine
1 < H < 10
•Kaplan
2 < H < 40
•Francis
10 < H < 350
•Pelton
50 < H < 1300
•Turgo
50 < H < 250

Specific speed
The 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 laws
Affinity 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 requiring similitude between 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 speed
The 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.
 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.
Asa mechanical engineering student I hope that the training I got here would help me in
coming future. I hereby thank all the authorities at BHEL for their kind cooperation and
guidance.