LAKSHMI NARAIN COLLEGE OF TECHNOLOGY,

BHOPAL

VOCATIONAL TRAINING REPORT

ON
"HYDRO TURBINE"
TRAINING PERIOD 23/05/19 To 05/06/19

SUBMITTED BY
UNDER THE SUPERVISION OF
PRAKHAR UPADHYAY
MR. VIKRANT MINJ MECHANICAL ENGINEERING
DY MANAGER ENROLL-0103ME191096
S.W.M (PRODUCTION) Token No.
 BHARAT HEAVY ELECTRICALS LIMITED
BHOPAL

CERTIFICATE
This is to certify that the work in the project report entitled "HYDRO
TURBINE" by PRAKHAR UPADHYAY has been carried out under my
supervision in partial fulfillment of the requirement for the degree of Bachelor of
engineering in “MECHANICAL ENGINEERING” during session 2016 in the
Department of “MECHANICAL ENGINEERING”, LNCT, BHOPAL And this
work has not been submitted elsewhere for a degree.

Date:

MR. VIKRANT MINJ

(PROJECT GUIDE)
 ACKNOWLEDGEMENT

I am highly thankful to B.H.E.L engineers and technical staff specially

MR. VIKRANT MINJ, for providing me vital and valuable
information about the different facets of an industrial system. I
express my gratitude to HUMAN RESOURCE AND
DEVLOPMENT CENTRE department for giving me a chance to
feel industrial environment and its working in B.H.E.L and I am
thankful to all engineers and staff members for giving their
precious time and help me in understanding various theoretical
and practical aspects of my project under whose supervision I
accomplish my project.

PRAKHAR UPADHYAY
 PREFACE

In this growing age of technology, the extent of correctness is a major point. This
correctness and pin pointed guess is achieved only through hard work, experience
and well guided practice. As a new comer to this field we required to have
professional knowledge that will help in improving our skills and efficiency.
Having a training work on the same topic increased our interest and made the work
simpler.

The most vital part is the presence of a guide whose knowledge and practical
experience built our self-confidence and helping hand by which we finished this
project successfully. So we all are indebted MR. VIKRANT MINJ acted as
burning candle and enlighten us about this training.
BHARAT HEAVY ELECTRICALS LIMITED : A MAHARATNA
In the post independence era when India was moving towards industrialization, the thrust by
the government was in the core sector.
BHEL was setup in Bhopal in August 1956, with a view to reach self sufficiency in industrial
products and power equipments. This plan was setup under collaboration of M/s. AEJ, U.K.

Now more plants were setup at Touchy, Hyderabad and Hardwar with Czechoslovakian and
Soviet Union assistance in May 1956, Dec.1965, and Jan. 1967 respectively. Today B.H.E.L. has
become the largest engineering plant employing approximately 72000employees. Its
headquarters are located at Delhi.

B.H.E.L. is the largest engineering and manufacturing enterprise in India in the

energy/infrastructure sector, today. B.H.E.L. was established more than forty years ago
ushering in the indigenous heavy electrical equipments industry in India a dream that has
been more than realized with a well-recognized track record of performance. It has been
earning profits since 1971-72 and paying dividends since 1976-77.

B.H.E.L. manufactures over 180 products under thirty major product groups and caters to core
sectors of the Indian Economy viz., Power Generation and Transmission, Industry,
Transportation, Telecommunication, Renewable Energy, etc. The wide network of B.H.E.L.’s
fourteen manufacturing divisions, four power sector
regional centers, over hundred project sites, eight service center sand eighteen regional offices,
enables the company to promptly serve its customers and provide them with suitable products
efficiently and at competitive prices.

The quality and reliability of its products is due to the emphasis on design, engineering and
manufacturing to international standards by acquiring and adapting some of the best
technologies from leading companies in the world, together with technologies developed in its
own R&D centers.
B.H.E.L. has acquired certifications to Quality Management Systems- ISO 9001, Environmental
Management Systems-ISO 14001and Occupational Health and Safety Management Systems-
OHSAS18001 and has also adopted the concepts of Total Quality Management.

B.H.E.L. has installed equipment for over 90,000 MW of power generation- for Utilities, Captive,
and Industrial users. It supplied over 2,25,000 MVA transformer capacity and sustained
equipment operating in transmission and distribution network up to 400 KV- AC& DC.
It supplied over 25,000 motors with Drive Control System to power projects, petrochemicals,
refineries, steel, aluminum, fertilizer, cement plants, etc. It also supplied traction electrics and
AC/DC locos to power over 12,000 Km railway network. Supplied over one million valves to
power plants and other industries.

B.H.E.L.’s operations are organized around three business sectors, namely Power Industry
including Transmission, Transportation, Telecommunication and Renewable Energy and
Overseas Business. This enables B.H.E.L. to have a strong customer orientation, to be sensitive
to his needs and respond quickly to the changes in the market.

B.H.E.L.’s vision is to become a world class engineering enterprise, committed to

enhance stakeholder value. The company is striving to give shape to its
aspirations and fulfill the expectations as a MAHARATNA Company.

The greatest strength of B.H.E.L. is its highly skilled and committed 44,905
employees. Every employee is given an equal opportunity to develop himself and
improve his position. Continuous training and retaining, career planning, a
positive work culture and participative style of management have engendered
development of a committed and motivated work force leading to enhanced
productivity and higher levels of quality.
BHEL is the largest engineering and manufacturing enterprise in India in the
energy related/infrastructure sector, today. BHEL was established more than 40
years ago, Ushering in the indigenous Heavy Electrical Equipment industry in India
- a dream that has been more than realized with a well-recognized track record of
performance.

BHEL manufactures over 180 products under 30 major product groups and caters
to core sectors of the Indian Economy viz., Power Generation & Transmission,
Industry, Transportation, Telecommunication, Renewable Energy, etc.

The wide network of BHEL's 14 manufacturing divisions, four Power Sector

regional centers, over 100 project sites, eight service centers and 18 regional
offices, enables the Company to promptly serve its customers and provide them
with suitable products, systems and services -- efficiently and at competitive
prices.
In the year 2011, It ranked ninth most innovative company in the world by US
business magazine Forbes. It is one of India's nine largest Public Sector
Undertakings or PSUs, known as the MAHARATNA.

BHEL MANUFACTURING SITES:

 BHEL Bhopal (Madhya Pradesh )

 BHEL Ranipur, Haridwar (Uttarakhand)
 BHEL Ramachandrapuram, Hyderabad (Andhra Pradesh)
 Transformer Plant, BHEL Jhansi (Uttar Pradesh)
 High Pressure Boiler Plant and Seamless Steel Tube Plant, Trichy(Tamil
Nadu)
 Boiler Auxiliaries Plant, Ranipet, vellore (Tamil Nadu)
 Electronics Division and Electro Porcelain Division, Bangalore (Karnataka)
 Jagdishpur (Uttar Pradesh)
 Rudrapur (Uttrakhand)
 Industrial Valves Plant, Goindwal (Punjab)
 Bharat Heavy Plates and Vessels Limited (Vizag)

Besides these manufacturing units there are four power sectors (PSNR-Noida,
PSWR-Nagpur , PSER-Kolkata & PSSR-Chennai )which undertake EPC contract
from various customers and are responsible for erection and commissioning of
various BHEL and bought out equipment. Power sector HQ is located in Noida.
The Research and Development arm of BHEL is situated in Hyderabad and two
repair shops are at HERP (Heavy Equipment Repair Plant), Varanasi and EMRP
(Electric machines repair plant) Mumbai.
 Bharat Heavy Electricals Limited (BHEL), Bhopal

Key people : MR. Atul sobati(CEO)

Heavy Electrical Plant, Bhopal is the mother plant of Bharat Heavy Electricals
Limited, the largest engineering and manufacturing enterprise in India in the
energy-related and infrastructure sector, today. With technical assistance from
Associated Electricals (India) Ltd., a UK based company; it came into existence on
29th of August, 1956. Pt. Jawaharlal Nehru, first Prime minister of India dedicated
this plant to the nation on 6th of November, 1960.BHEL, Bhopal certified to ISO:
9001, ISO 14001 and OHSAS 18001, is moving towards excellence by adopting
TQM as per EFQM / CII model of Business Excellence. Heat Exchanger Division is
accredited with ASME ‘U’ Stamp. BHEL Bhopal 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 laboratory of it’s in this part of the world.
BHEL Bhopal's strength is in its employees. The company continuously invests in
Human Resources and pays utmost attention to their needs.
Various Divisions at BHEL Bhopal:

• Industrial Machines
• Transportation Equipment
• Hydro Turbines and Generators
• Hydro Generators
• Heat Exchangers
• Excitation Control Equipment
• Steam Turbines
• Fabrication
• Coil & Insulation
• Casting
• Stamping
• Tool & Gauge
• Transformer
• Switchgear
• On-Load Tap Changer
• Large Current Rectifiers
• Control & Relay Panels
• Hydro Power Plant
• Thermal Power Stations
• Works Engineering & Services
HYDRO POWER PLANT
In this type of power plant energy (electricity) is produced by conversion of
potential head of water stored at some height called DAM to the mechanical
energy by running of turbine shaft which is connected to the runner blade on
which water strikes.

This turbine shaft is then coupled to the generator shaft through which electricity
is produced.

Hydro power plants can be classified on different basis like:

1. Availability of Head:
 High head : >100m
 Medium head: 30 – 100m
 Low head: <30m

2. Type of load:
 Base
 Peak

The general outline of the power plant is shown below:

The figure shows the basic parts of the hydro power plant required. The
elements of the hydroelectric power plant are – Catchment area, Reservoir,
Dam, Sluice gate, Penstock, Spillway, Surge tank, Trash rock, Fore way, Power
house, Draft tube, Switch yard for transmission lines.

Hydraulic Turbines and Their Classification:

Hydraulic turbines are the prime movers which convert the head energy of
water into shaft work.

Hydraulic turbine can be differentiated as:

Type of Turbine Maximum Head (m) Specific Speed

Pelton 300-2000 4-70
Francis 30-500 60-400
Kaplan 2-70 300-1100
1. PELTON TURBINE

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

A Pelton turbine consists of one nozzle or set of nozzles and a pelton wheel.
The runner consists of a large circular disc on the on the periphery of which a
number of two-lobe ellipsoidal buckets are evenly mounted. Each bucket has a
ridge or splitter in the middle which divides the jet into two equal stream. The
symmetry of the bucket ensures zero momentum in the axial thrust on the shaft
bearing. It works on the principle of Newton’s 2nd Law.

Main parts of the Pelton turbine are:

1. Nozzle
2. Jet
3. Runner and Bucket
4. Needle Head
5. Tail water level
6. Runner disc
7. Deflector
8. Steering wheel for needle movement
9. Turbine housing
10.Turbine shaft and Coupling
Theory of Operation:
The water leaves the penstock and strike the bucket which is connected to the
runner. 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, thus allowing
the water flow to continue uninterrupted.

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.

2. FRANCIS TURBINE
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. Medium size and larger Francis
turbines are most often arranged with a vertical shaft. Francis turbines are the
most common water turbine in use today.
Main Components:

1. Runner and runner

cone
2. Servomotor
3. Turbine shaft
4. Bearing pad and
cover
5. Turbine cover
6. Stay vane and Scroll
case
7. Guide vane
8. Link
9. Regulating ring
10. Draft tube

Design of Francis Turbine:

Francis Turbine has a circular plate fixed to the rotating shaft perpendicular to
its surface and passing through its center. This circular plate has curved
channels on it; the plate with channels is collectively called as runner. The
runner is encircled by a ring of stationary channels called as guide vanes. Guide
vanes are housed in a spiral casing called as volute. The exit of the Francis
turbine is at the center of the runner plate. There is a draft tube attached to
the central exit of the runner. The design parameters such as, radius of the
runner, curvature of channel, angle of vanes and the size of the turbine as
whole depend on the available head and type of application altogether.
Theory of operation:
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, its 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 the
conservation 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.

3. KAPLAN TURBINE
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.

The Kaplan turbine was an evolution of the Francis turbine. Its invention
allowed efficient power production in low-head applications that was not
possible with Francis turbines. Kaplan turbines are now widely used
throughout the world in high-flow, low-head power production.
 Main components:

The Kaplan turbines have the following main components:-

1. Scroll casing and stay ring

2. guide apparatus
3. Covers
4. Runner
5. runner blade servomotor
6. regulating mechanism of the runner blades
7. co-operation of regulating the runner blades and guide vanes
8. turbine shaft
9. turbine bearing
10. shaft sleeve and seal box
11. runner chamber
12. draft tube

Design of Kaplan Turbine:

To generate substantial amount of power from small heads of water using
Kaplan Turbine it is necessary to have large flow rates through the turbine.
Kaplan Turbine is designed to accommodate the required large flow rates.
Except the alignment of the blades the construction of the Kaplan Turbine is
very much similar to that of the Francis Turbine. The overall path of flow of
water through the Kaplan Turbine is from radial at the entrance to axial at the
exit. Similar to the Francis Turbine, Kaplan Turbine also has a ring of fixed
guide vanes at the inlet to the turbine.

Unlike the Francis Turbine which has guide vanes at the periphery of the
turbine rotor (called as runner in the case of Francis Turbine), there is a
passage between the guide vanes and the rotor of the Kaplan Turbine. The
shape of the passage is such that the flow which enters the passage in the
radial direction is forced to flow in axial direction. The rotor of the Kaplan
Turbine is similar to the propeller of a ship. The rotor blades are attached to
the central shaft of the turbine. The blades are connected to the shaft with
moveable joints such that the blades can be swiveled according to the flow
rate and water head available.

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.

Variable geometry of the wicket gate and turbine blades allow efficient
operation for a range of flow conditions. Kaplan turbine efficiencies are
typically over 90%, but may be lower in very low head applications.
 Because the propeller blades are rotated by high-pressure hydraulic oil, a
critical element of Kaplan design is to maintain a positive seal to prevent
emission of oil into the waterway. Discharge of oil into rivers is not permitted.

Various Components of Hydro Power Plant and its

manufacturing by BHEL Bhopal:-
1. DAM:
A dam is a barrier that impounds water or underground streams. Dams generally
serve the primary purpose of retaining water. Hydropower and pumped-storage
hydroelectricity are often used in conjunction with dams to generate electricity. A
dam can also be used to collect water or for storage of water which can be evenly
distributed between locations. Based on structure and material used, dams are
classified as timber dams, arch-gravity dams, embankment dams or masonry
dams, with several subtypes. It is onsite construction component of hydro plant.

2. SLUICE GATE:
A sluice is a water channel that is controlled at
its head by a gate. The terms "sluice gate",
"knife gate", and "slide gate" are used
interchangeably in the water/wastewater
control industry. The term sluice gate refers to
any gate that operates by allowing water to
flow under it. When a sluice gate is fully
lowered, water sometimes spills over the top,
in which case the gate operates as a weir. Usually, a mechanism drives the
sluice gate up or down. This may be a simple, hand-operated, worm drive or
rack-and-pinion drive, or it may be electrically or hydraulically powered.
3. PENSTOCK:
A penstock is a sluice or gate or intake
structure that controls water flow, or an
enclosed pipe that delivers water to
hydraulic turbines and sewerage systems. It
is a term that has been inherited from the
technology of wooden watermills.
Penstocks for hydroelectric installations are normally equipped with a gate
system and a surge tank.

Flow is regulated by turbine operation and is nil when turbines are not in
service.

4. MAIN INLET VALVE:

The conduits in all water power plants except large low head plants, are
ordinarily provided with shut off devices. Generally these components are
valves. They exist in different types and design depending on function and
requirements.
In any power plant valves for different purposes are usually needed. Normally
it is a shut-off valve just in front of the turbine. In this way the turbine may be
emptied without emptying the shaft or penstock. In addition the guide vane
cascade is depressurized so that leakage flow is avoided.

With a long head race tunnel and surge chamber it is normal to have a shut off
valve just downstream of the surge chamber. In this way the shaft or penstock
may be emptied without emptying the tunnel.

To prevent large damage at an eventual rupture of the penstock, a pipe break

valve is normally installed in the pipe just downstream of the shut off valve.
This valve closes automatically when the water velocity exceeds a certain set
value.

The most relevant types of valves which are manufactured by BHEL are:
 -- Spherical valves

-- Butterfly valves

a) SPHERICAL VALVE:

FIG a.1 and a.2

Spherical valves are applied mostly as shut off valves in front of high head
water turbines. They are however, used as pipe brake valves as well. Spherical
valves are presently covering a pressure range of 160 m to 1250 m water head.
The spherical valves consist of the valve housing with flanges, valve rotor,
bearings and seals. The valve housing has a spherical shape. It may either be
axially split permanently in two halves and bolted together with heavy flanges,
or these two halves may be welded together after the rotor has been installed.
Fig. a.1 shows a picture of a complete spherical valve in open position, and
Fig.a.2 shows a picture of a spherical valve rotor.

The opening and closing operation of the valve is carried out by one or two
servomotors.
b) BUTTERFLY VALVE:

Butterfly valves are normally applied

in front of low and medium head
water turbines, i.e. heads up to 200
m. For high head power plants the
butterfly valve is from time to time
used as a closing device in inlet
tunnels and alternatively as
emergency closure valves.

Valves consist of mainly of a ring

shaped housing, the valve disc,
operating mechanism and counter
weight.

The butterfly valve shall be able to

open and close under equalized
water pressure on the disc sides as
well as to close at full turbine discharge. In addition emergency closure valves
shall close automatically in the case of penstock rupture.

The opening is done by means of one (or two) servomotors. This may be
mounted on the side of the valve and is acting on the counterweight arm
which is bolted to the trunnion.

valve is also manufactured. Its housing on which disc (door) is housed, valve
disc, operating mechanism i.e., servomotor etc is manufactured and
assembled and tested in BHEL Bhopal.
5. SPIRAL CASING:

These are the connecting link

between penstock and stay rings.
Spiral casing are gradually
decreasing conduct around the
circumference of the wheel
(maximum at the entrance and
minimum at the tip). These carry
water from the penstock and supply
to the runner. These are made of
decreasing cross section because the
losses occur during the flow can be
avoided.

6. STAY RING:

The stay ring consists of an

upper and a lower ring to which
the stay vanes are welded. The
stay vanes are given a favorable
hydraulic shape to conduct the
water towards the guide vanes
with minimal losses. The stay
vanes also carry the axial forces
inside the scroll casing. The
vanes in the stay ring conduct
the water towards the guide
vanes. In addition the hydraulic
forces are transferred through
the stay ring and the stay vanes which are anchored to the concrete with large
pre stressed stay bolts.
7. TOP COVER AND PIVOT RING:

These are the circular ring with seat or projection provided on them to
accumulate the guide vanes. Top cover is provided on the top of the guide
vanes in which the hub of the guide vanes are connected which is connected
with the lever to the arm which is bolted on the regulating ring. As the
regulating ring rotates with the help of servomotor the arm rotates, rotating
the lever to the guide vanes and hence flow of water is regulated.

Pivot ring is provided on the base of the guide vanes which act as supporting
or pivot to the guide vanes. It is also of circular shape. For Kaplan the runner
starts from the pivot ring while in Francis it starts from the guide vanes.

7. GUIDE VANES:

The basic purpose of the guide vanes or stay

vanes is to convert a part of pressure energy
of the fluid at its entrance to the kinetic
energy and then to direct the fluid on to the
runner blades at the angle appropriate to the
design. Moreover, the guide vanes are
pivoted and can be turned by a suitable
governing mechanism to regulate the flow
while the load changes. The guide vanes are
also known as wicket gates. The guide vanes
impart a tangential velocity and hence an
angular momentum to the water before its
entry to the runner. The flow in the runner of
a Francis turbine is not purely radial but a combination of radial and tangential.
The flow is inward, i.e. from the periphery towards the centre. The height of the
runner depends upon the specific speed. The height increases with the increase in
the specific speed. The main direction of flow change as water passes through the
runner and is finally turned into the axial direction while entering the draft tube.
8. REGULATING RING:

The guide blades of a Francis turbine are pivoted and connected by levers and
links to the regulating ring. The regulating ring is attached with two regulating
rods connected to the regulating lever. Thus regulating lever in turn is connected
with regulation shift, which is operated by the piston of servomotor.

When load on the turbine increases, regulating ring is moved in reversed direction
to increase the passage between the guide blades thus allowing more water to
meet the increased load demand. Similar is the function and connection in case of
Kaplan turbine except that servomotors are connected to runner blade also to
give the required motion, hence this system is known as “Double Regulation” and
gives higher efficiency.

9. RUNNER:

It is basically a rotating part of the turbine on which blades are either casted or
bolted and then it is mounted on the shaft which transmits energy. Runners are
classified on the basis of type of working head.

Runner of a Pelton wheel consists of a circular disc mounted on a horizontal shaft.

On the periphery of the runner, a number of buckets are fitted uniformly. The
Pelton runners may be designed either for casting of the disc and buckets in one
piece or the disc and each of the buckets are casted in separate pieces and the
bolted together. The first method mentioned is preferred and common for the
Pelton turbines in modern power plants where the turbine units are of the high
power and bigger sizes.

Runner of the francis is a circular wheel on which a series of radial curved vanes
are fixed. The runner may be either cast or fabricated. For a large unit, cast steel
or stainless steel may be used and for small unit, cast iron. The surface of runner
is made smooth to reduce losses. The runner is so shaped that water flow through
the runner in combination of radial and tangential flow and leaves runner without
shock.
Kaplan consists of an axial flow runner usually with four to six blade of aerofoil
shape. In consist of a slot in which blades can be bolted and can be rotated with
the help for servomotors according to the load.

Runners for Pelton, Francis and Kaplan for projects like Parbati III, Srinagar,
Pulichintala, Rampur had been manufactured in BHEL Bhopal. Other than this
guide vanes are finished here, drilling of blades of Kaplan are also done here.

10. DRAFT TUBE:

 It makes possible the installation of the turbine above the tail race level
without the loss of head.
 The velocity of water at the runner outlet is very high. By employing a draft
tube of increasing cross sectional area, the discharge takes place at a much
lower velocity and thus, a part of the kinetic energy that was going as a
waste is recovered as a gain in the pressure head, and this increases the
efficiency of the turbine.
 The draft tube prevents the splashing of water coming out of the runner
and guides the water to the tail race.

Types of draft tubes are :

 Simple elbow tubes

 Conical draft tube
 Circular inlet and square outlet
 Moody’s bell- mounted tube
FOUNDRY SHOP
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them
into a liquid, pouring the metal in a mould, and removing the mould material or casting after the
metal has solidified as it cools. Most common metals processed are aluminium and cast iron.

However, other metals, such as bronze, steel, magnesium, copper, tin, and zinc, are also used to
produce castings in foundries.

Bhel Bhopal foundry shop is situated near gate no 5 it is integral part of this industry which
supply major portion of items like an electric motor , generator, alternates core auxiliary items
in various divisions.

Bhel foundry shop is mainly divided in two parts

 Ferrous material shop

 Non ferrous shop

DIVISION 1 : FERROUS MATERIAL CASTING

In metalworking, casting involves pouring liquid metal into a mould, which contains a hollow
cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also
known as a casting, which is ejected or broken out of the mould to complete the process. Casting
is most often used for making complex shapes that would be difficult or uneconomical to make
by other methods.

MELTING:
 Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and
alloying elements are used to charge the furnace.

 Virgin material refers to commercially pure forms of the primary metal used to form a
particular alloy.

 The process includes melting the charge, refining the melt, adjusting the melt chemistry and
tapping into a transport vessel.

 Certain fluxes may be used to separate the metal from slag and/or dross and degasers are
used to remove dissolved Gas frommetalsuch that readily dissolve certain gases. During
the tap, final chemistry adjustments are made.
FURNACE:
Several specialised furnaces are used to melt the metal. Furnaces are refractory lined vessels that
contain the material to be melted and provide the energy to melt it. .

For ferrous materials, EAFs, cupolas, and induction furnaces are commonly used.

I NDUCTION FURNACE
An induction furnace is an electrical furnace in which the heat is applied
by induction heating of metal.Induction furnace capacities range from less
than one kilogram to one hundred tonnes capacity and are used to
meltiron and steel, copper, aluminium and precious metals.
The advantage of the induction furnace is a clean, energy-efficient and well-

controllable melting process compared to most other means of metal melting.

Most modern foundries use this type of furnace, and now also more iron foundries
are replacing cupolas with induction furnaces to melt cast iron, as the former emit lots
of dust and other pollutants.

Since no arc or combustion is used, the temperature of the material is no higher

than required to melt it; this can prevent loss of valuable alloying elements.[5] The
one major drawback to induction furnace usage in a foundry is the lack of refining
capacity; charge materials must be clean of oxidation products and of a known
composition and some alloying elements may be lost due to oxidation (and must be
re-added to the melt).
FEATURES OF INDUCTION FURNACE

An electric induction furnace requires an electric coil to produce the charge. This
heating coil is eventually replaced. The crucible in which the metal is placed is
made of stronger materials that can resist the required heat, and the electric coil
itself cooled by a water system so that it does not overheat or melt. The induction
furnace can range in size, from a small furnace used for very precise alloys only
about a kilogram in weight to a much larger furnaces made to mass produce clean
metal for many different applications. The advantage of the induction furnace is a
clean, energy-efficient and wellcontrollable melting process compared to most
other means of metal melting. foundries use this type of furnace and now also
more iron foundries are replacing cupolas with induction furnaces to melt cast
iron, as the former emit lots of dust and other pollutants. Induction furnace
capacities range from less than one kilogram to one hundred tonnes capacity, and
are used to melt iron and steel, copper, aluminium, and precious metals. major
drawback to induction furnace usage in a foundry is the lack of refining capacity;
charge materials must be clean of oxidation products and of a known composition,
and some alloying elements may be lost due to oxidation (and must be re-added to
the melt).

CONSTRUCTION OF INDUCTION FURNACE There are many different

designs for the electric induction furnace, but they all center around a basic idea.
The electrical coil is placed around or inside of the crucible, which holds the metal
to be melted. Often this crucible is divided into two different parts. The lower
section holds the melt in its purest form, the metal as the manufacturers desire it,
while the higher section is used to remove the slag, or the contaminants that rise to
the surface of the melt. Crucibles may also be equipped with strong lids to lessen
how much air has access to the melting metal until it is poured out, making a
purer melt. TYPES OF INDUCTION FURNACE There are two main types of
induction furnace: coreless and channel. Coreless induction furnaces The heart of
the coreless induction furnace is the coil, which consists of a hollow section of
heavy duty, high conductivity copper tubing which is wound into a helical coil.
Coil shape is contained within a steel shell. To protect it from overheating, the
coil is water-cooled, the water being recirculated and cooled in a cooling tower.
The crucible is formed by ramming a granular refractory between the coil and a
hollow internal. The coreless induction furnace is commonly used to melt all
grades of steels and irons as well as many non-ferrous alloys. The furnace is ideal
for remelting and alloying because of the high degree of control over temperature
and chemistry while the induction current provides good circulation of the melt.

ADVANTAGES OF INDUCTION FURNACE: Induction furnaces offer certain

advantages over other furnace systems. They include: Higher Yield. The absence
of combustion sources reduces oxidation losses that can be significant in
production economics. Faster Startup. Full power from the power supply is
available, instantaneously, thus reducing the time to reach working temperature.
Cold charge-to-tap times of one to two hours are common. Flexibility. No molten
metal is necessary to start medium frequency coreless induction melting
equipment. This facilitates repeated cold starting and frequent alloy changes.
Natural Stirring. Medium frequency units can give a strong stirring action resulting
in a homogeneous melt. Cleaner Melting. No by-products of combustion means a
cleaner melting environment and no associated products of combustion pollution
control systems. Compact Installation. High melting rates can be obtained from
small furnaces. Reduced Refractory. The compact size in relation to melting rate
means induction furnaces require much less refractory than fuel-fired units Better
Working Environment. Induction furnaces are much quieter than gas furnaces, arc
furnaces, or cupolas. No combustion gas is present and waste heat is minimized.
Energy Conservation. Overall energy efficiency in induction melting ranges from
55 to 75 percent, and is significantly better than combustion processes.
DISADVANTAGES OF INDUCTION FURNACE 1. Refining in Induction
Furnace is not as intensive or effective as in Electric Arc Furnace (EAF). 2. Life of
Refractory lining is low as compared to EAF. 3. Removal of S & P is limited, so
selection of charges with less impurity is required.