KAPLAN TURBINE

ME3302-Automation in Manufacturing

Team no-24

Aswin Beckham -ME20B040

Abishek T A -ME20B010
Abdullah K - ME20B003
 INDEX

1. Introduction

2. Components

3. Components Cad model

4. Components manufacturing process

5. Plant Layout

6. Contribution
 Introduction to Kaplan Turbine

● The Kaplan turbine is used to convert the kinetic energy of flowing water into
mechanical energy that can be used to generate electricity.
● It is known to operate at low heads and high flows. It is commonly used in
hydroelectric power plants to generate electricity from water flowing through a
dam or other hydraulic structures.
● It consists of three major components which are of complex shape.
 Components of Kaplan Turbine

1. Rotor-It is the rotating portion of the turbine

2. Guide Vanes-They are stationary parts that guide the flow so that attack angle of the
incoming water stream is optimum
3. Scroll casing-As the water enters the turbine there are frictional losses , thus by
reducing area of flow passage the losses(increasing velocity) are compensated.
4. Base-Supports the turbines weight
5. Draft tube-The outlet of turbine it acts as diffuser , by changing kinetic energy to
pressure energy they ensure that back flow from atmosphere does not take
place.Allowing more efficient operation.
Kaplan Turbine Assembly
Rotor
 Components of Rotor

Rotor is an assembly of the following components:

● Blades
● Hub
● Bearings
Hub
Hub - Line and 3D diagram
 Hub Manufacturing

1.CAD/CAM Design: The design is created using

computer-aided design (CAD) software. Then simulation
optimizations are performed and CAM is generated for
milling process.

2.Material: Carbon steel

The materials used in making Kaplan turbine rotors

should have high strength, good corrosion resistance,
and good fatigue resistance.Usually materials such as
stainless steel, carbon steel,Nickel based alloys are used.
3.Casting: The Hub is cast using a foundry process, which involves melting the chosen material and
pouring it into a mold. The mold is designed to the exact shape and size of the rotor.

4.Machining: Once the basic shape of the Hub has been created, it undergoes a process of machining
to refine the shape and ensure that it meets the required specifications. This includes processes such
as drilling and milling.
5.Heat Treatment: Heat treatment is used to improve the strength, hardness, ductility, toughness,
and other properties of Carbon steel.

6.Surface finish: The surface finish of the Hub is important for reducing friction and increasing the
efficiency of the turbine. Grinding and polishing are used for this purpose.
 Hub - Time and Cost Analysis
Process Name Time Taken Cost
(Hrs) (Rs)
Raw Material 5000

Melting and Pouring 3.5 6000

Cooling and Shake out 24 2500

Machining 7 7500

Heat Treatment 10 2000

Surface Machining 2.5 2500

Total 47 25,500
Rotor Blades
Rotor Blade - Line and 3D diagram
 Blade Manufacturing

1.CAD/CAM and Simulation: The design is created using

computer-aided design (CAD) software and is based on the
requirements such as flow rate, head, blade specific speed
and stress analysis. Then simulation optimizations are
performed and CAM is generated for milling process.
2.Material selection: High Quality Toroidal Steel
The materials used in making Kaplan turbine rotors should
have high strength, good corrosion resistance, and good
fatigue resistance.
3.Pattern Making: Once the design is finalized, a pattern of
the blade is made using wood, plastic, or other materials. The
pattern is used to create the mold for the blade casting.The
pattern is created by uploading the 3D CAD model to a CNC
machine, which does the machining.

4.Casting: The blade is typically made from a high-strength

alloy, such as stainless steel or nickel-based alloys. The mold
is filled with molten metal, which is allowed to cool and
solidify. Once the metal has solidified, the mold is removed,
and the blade is removed from the casting.
5.Machining/Fabrication of Blades: Once the basic shape
of the blades has been created, it undergoes a process of
machining to refine the shape and ensure that it meets the
required specifications. This includes processes such as
drilling, turning, and milling.

6.Surface finish: The surface finish of the Blades is

important for reducing friction and increasing the
efficiency of the turbine. Grinding and polishing are used
for this purpose
 Blade - Time and Cost Analysis

Process Name Time Taken Cost

(Hrs) (Rs)
Raw Material 18000

Melting and Pouring 3.5 900*5

Cooling and Shake out 16 400*5

Heat Treatment 10 2000

Surface Machining 2*5 1500*5

Total 39.5 34,500

 Assembly of Blades and the Hub

1.Blade Attachment: The blades are attached to the hub using a variety of methods such as welding,
bolts, or a combination of both. The method used depends on requirements of the turbine.

2.Blade Positioning: The blades are positioned at a specific angle to the hub, based on the design
specifications and operating conditions of the turbine. The positioning is critical for achieving optimal
efficiency and performance.
Guide Vane
Guide Vane - Line and 3D diagram
Manufacturing of Guide-Vanes

1.CAD Design: The design process takes into account the

operating conditions, flow rates, and efficiency requirements
of the turbine.

2.Material selection: Stainless steel is the material of choice

for guide vanes as it provides good resistance to corrosion
and also has good strength.

3.Cutting: The selected material is cut to the required size

and shape using a CNC machine, laser cutting, or water jet
cutting. The guide vanes are then deburred to remove any
sharp edges and to smooth the surface.
4.Bending: Bending is a sheet metal forming process in which a force is applied to a sheet metal
workpiece, causing it to deform and bend into a desired shape or angle. The force is typically applied
by a punch or die.

5.Machining: The guide vanes are machined to the required dimensions and surface finish using CNC
machines or manual machining tools.

6.Surface finish: The surface finish of the vanes is important for reducing friction and increasing the
efficiency of the turbine. Grinding and polishing are used for this purpose

7.Assembly: The guide vanes are then assembled onto the turbine casing, which directs the flow of
water towards the rotor. The guide vanes are positioned to provide the desired angle of attack.
Guide-vanes - Time and Cost Analysis

Process Name Time Taken Cost

(Hrs) (Rs)
Raw Material(steel sheet) 6,000

Bending 0.5 500

Heat Treatment 10 3000

Surface Machining 2.5 2500

Total 13 12,000
Scroll Casing
Scroll Casing - Line and 3D diagram
 Manufacturing of Scroll casing

1.CAD Design: The design is created using computer-aided

design (CAD) software and is based on the requirements such
as fluid dynamics, and structural requirements of the
turbine.

2.Material selection: Stainless steel which is is used as it is

economic, has good strength, and has good corrosion
resistance.
3.Casting: The scroll casing is typically produced using a
casting process, which involves pouring molten metal into
a mold and allowing it to cool and solidify.

4.Machining: Once the casing is cast, it is machined to

achieve the final shape and dimensions. This is done by
the CNC machine.

5.Surface finish: The inner surface of the casing is hard

to reach.Surface finishing is done by Shot Blasting.
Scroll Casing - Time and Cost Analysis

Process Name Time Taken Cost

(Hrs) (Rs)
Raw Material 4000

Melting and Pouring 3.5 4000

Cooling and Shake out 16 1500

Heat Treatment 10 2000

Surface Finishing 3 5000

Total 32.5 16,500

Draft Tube
Draft Tube - Line and 3D diagram
 Manufacturing of Draft tube

1. Cutting: The initial sheet metal is cut into the required size and
shape using cutting tools such as shears, laser, or plasma
cutters.
2. Rolling: The cut sheet metal is then rolled into the required
shape using rolling machines. The draft tube usually has a
conical shape, so the sheet metal will be rolled accordingly.
3. Welding: The rolled sheet metal is welded together to form the
draft tube. Welding can be done using various methods such as
TIG, MIG, or stick welding.

4. Finishing: After the welding process, the draft tube will be

cleaned, polished, and painted to provide a smooth and
corrosion-resistant surface.
 Time and cost analysis of Draft Tube

Process Name Time Taken Estimated Cost

(Hrs) (Rs)
Raw Material 1500

Cutting 0.1 300

Rolling 0.1 300

Welding 0.3 400

Finishing 0.6 500

Total 1.1 3000

Base
 Base(outsourced)

1. Casting: The draft tube is cast as a single piece. This portion of the draft tube is typically cast
from a high-strength alloy, such as stainless steel or a nickel-based alloy.
2. Machining: The draft tube undergoes a final machining process to ensure that it is properly
shaped and dimensioned. This process involves using computer-controlled milling machines and
lathes to remove excess material and create the necessary features of the draft tube, such as the
inlet and outlet ports.
3. Finishing: Once the machining is complete, the draft tube undergoes a final finishing process,
which may include polishing, cleaning, and coating to improve its durability and resistance to
corrosion.
 Cost of Base

Base Cost -4000 Rs

Reasons for Base being outsourced:

● Unlike the other components it doesn't have specifications other that weight
carrying capacity so its readily available in the market.
● It would be cheaper to buy it rather than make it in-house.
Overall Analysis
 Overall manufacturing time and cost
Component Name Time Taken(Hrs) Cost(Rs)
1. Hub 47 25,500

2. Blades(5 Pcs) 39.5 34,500

3. Guide-Vanes 13 12,000

4.Scroll-casing 32.5 16,500

5.Draft-tube 1 3,000

6.Base - 4,000

Lead Time …………………………….. = 47 Hrs

Manufacturing cost per unit………. = 95,500 Rs
 Retail pricing of Kaplan Turbine

Overhead…………………………………..= 30%

Price with overhead included………..= ₹1,24,150

Mark up…………………………………….= 250%

Selling price……………………………….= ₹3,10,375

Profit………………………………………..= ₹1,86,225
 Bottleneck analysis - Plant Capacity

Bottleneck component : Hub

Bottleneck process: Cooling and shake out = 24 hr

Weekly work hours = 2(shifts)*8(hours per shift)*5(working days per week)

= 80 hr

Yearly work hours = 80 * 42 (working weeks)

= 3360 hr

Plant capacity = 140 pc/year

 Market Analysis
Expected yearly demand = 100 pc/year (just for indian market)

Utilisation = 71.4 %
Initial Investment - Fixed Cost
Asset Nos Cost
Solidworks Software ₹3,50,000
Hand Buffing machine 4 ₹18,000
Casting machine 4 ₹15,00,000
Sand Casting setup 4 ₹10,00,000
CNC setup 5 ₹1,00,00,000
Water jet cutting machine 1 ₹6,00,000
Metal foaming device 1 ₹5,00,000
Acetylene Gas weld 1 ₹10,00,000
Sheet Cutting Machine 1 ₹5,00,000
Metal Bending Machine 1 ₹7,00,000
Land cost (15 years) ₹10,00,00,000
Total ₹16,37,22,000
Return On Investment(ROI)

Hence, after 8.79 Years or 8y 9m 15days

we begin to get pure profits !!!
Note !
Our plant can produce kaplan turbines of varying
capacities. We have performed all analysis on a
medium capacity turbine.

So the max size of turbine is limited by our CNC

machine. And the CNC we chose can practically
handle a very high capacity turbine used in large
power plants.

CNC machine - TARUS - TBH-5 Heavy Gantry Machine

Hypothetical Plant Layout
Technomatix Plant Layout
Entire Manufacturing Layout
Hub Manufacturing Sub-Layout
Rotor Manufacturing Sub-Layout
Guide Vane Manufacturing Sub-Layout
Scroll Casing Manufacturing Sub-Layout
Draft Tube Casing Manufacturing Sub-Layout
Jack Simulation
https://drive.google.com/file/d/15c_kiKZwLTluwH9yQjWJYb4YyDiWjlqV/view?usp=share_link
 Contribution

N Aswin Beckham Aswin Beckham N - CAD modelling, line diagrams, cost analysis - 35%
initial investment, retail pricing, bottleneck analysis, market analysis,
return of investment, PPT

Abishek T A Manufacturing process analysis, CAD modelling ,process 35%

optimisation, Time analysis, Cost analysis - variable costs, team
coordinator, PPT

Abdullah K Plant Layout design, Technomatix design, Jack simulation 30%

Thanks