MANUFACTURING OF VALVE SPINDLE

PREFACE

This report documents the work done during the Summer Internship
at XYZ Machine Tools Pvt. Ltd. under the supervision of Mr.
Sharma. The report provides an overview of the tasks completed
during the period of internship with technical details. Process steps
for Manufacturing of the job are also discussed.
I have tried my best to keep report simple & professional yet technically
correct. I hope I succeed in my attempt.
 ACKNOWLEDGEMENT

I wish to express my profound gratitude to Mr. Sharma for his support

and providing all the facilities, due to which I have been able to
complete my internship and this report. The cooperation he gave is
greatly appreciated. Not just him I want to thank the whole staff of
Precision Machine Tools for their cooperation and effort in assisting us
at each step. I am grateful for their pool of knowledge derived from
various sources which helped us clear our doubts and questions.
 ABSTRACT

The project aims at observing the steps carried out during

manufacturing of valve spindle or spool which is an essential and a
critical component of Servo Valve used in Governing of Steam Turbine
in Power Plants. To understand the working of Servo Valve Mechanism
and how it changes the flow pattern. Apart from this most important is
to learn the work culture of an industry and acquire knowledge from
experts. Get to know the role of staff and comprehend each individual’s
responsibility in the process cycle. Get aware of the various methods
and techniques an ind
 INTRODUCTION

The world’s energy need is an everlasting hunger. Most of it is

quenched by Power Stations who produce energy either by fossil fuels
or other renewable sources of energy. Whether it be fossil fuels, solar
power, wind energy, hydropower or any other source we humans have
become capable to utilize this sources and produce energy at their
expense.
But the underlying principle behind producing energy remains the same
which is to impart motion to turbine resulting in rotation of the armature
which cuts the magnetic flux of two permanent magnets thus producing
electricity. Our only aim is to get that shaft of turbine moving.
Which brings us to the subject of Turbines. Many types of Turbines are
now found in Power Stations. A Turbine is a rotary mechanical device
that extracts energy from a fluid flow and converts it into useful work.
A turbine is a turbo machine with at least one moving part called a rotor
assembly, which is a shaft or drum with blades attached. Moving fluid
acts on the blades so that they move and impart rotational energy to the
rotor.
Two types of Turbine are mainly used in industry i.e. Impulse Type and
Reaction Type in which the latter has replaced many of the systems in
present Power Stations. In this section we will only discuss about
Thermal Power Stations using Reaction type turbines. In thermal power
stations, mechanical power is produced by a heat engine that
transforms thermal energy, often from combustion of a fuel, into
rotational energy. Most thermal power stations produce steam, so they
are sometimes called steam power stations. This mechanical energy is
further converted to electrical energy using generators. In reality there’s
much more to it than that. Various systems are in place to ensure
continuous production. Many parameters have to in certain limit to
guarantee optimum performance. But we are not going to into much
details about them. What we are really concerned with is the Governing
system of Steam Turbines which is related to our Internship Project of
Manufacturing of Valve Spindle. Valve Spindle or Pilot Valve. Which
brings us to description of our Internship.

DESCRIPTION

Before proceeding with the description we should first get an idea about
Governing of Steam Turbines. Steam turbine governing is the
procedure of controlling the flow rate of steam to a steam turbine so as
to maintain its speed of rotation as constant. The variation in load
during the operation of a steam turbine can have a significant impact
on its performance. In a practical situation the load frequently varies
from the designed or economic load and thus there always exists a
considerable deviation from the desired performance of the
turbine. The primary objective in the steam turbine operation is to
maintain a constant speed of rotation irrespective of the varying load.
This can be achieved by means of governing in a steam turbine. Many
types of Governing methods are available such as throttle governing,
nozzle governing, by pass governing and combination governing. The
main focus of this report is on throttle governing. But first let us explain
the function of Actuators as it will plays a vital role in governing of
steam turbines. What is an actuator? An actuator is a piece of
equipment that produces movement when given a signal. They are used
in computer control of an environment, industrial automation and in
robotics. These devices control the mechanical action of a machine
indirectly rather than directly or by hand. The control system can be
simple (a fixed mechanical or electronic system), software-based (e.g.
a printer driver, robot control system), a human, or any other input.
Actuator can be of 3 types:

 Electrical Actuators
 Hydraulic Actuators (work by liquid pressure)
 Pneumatic Actuators (work by air pressure)
 Thermal or Magnetic (Shape Memory Alloys)
 Mechanical Actuators

 In our work we are concerned with Hydraulic Actuators which

are operated by liquid (oil) pressure. It consists of cylinder or
fluid motor that uses hydraulic power to facilitate mechanical
operation. The mechanical motion gives an output in terms of
linear, rotary or oscillatory motion. Because liquids are nearly
impossible to compress, a hydraulic actuator can exert a large
force. The drawback of this approach is its limited acceleration.
The hydraulic cylinder consists of a hollow cylindrical tube along
which a piston can slide. The term single acting is used when the
fluid pressure is applied to just one side of the piston. The piston
can move in only one direction, a spring being frequently used to
give the piston a return stroke. The term double acting is used
when pressure is applied on each side of the piston; any difference
in pressure between the two sides of the piston moves the piston
to one side or the other. Hydraulic Actuators are of two types

 Open-Close Type (On-Off Type)

 Controlling Type

Hydraulic Actuators require accessories such as:

 Oil
 Oil Tank
 Pump
 Motor
 Actuator
 Positioner (Servo-Unit for controlling type)
 Solenoid for On-Off Actuator
 CONTROL VALVES

Control valves are valves used to control conditions such

as flow, pressure, temperature, and liquid level by fully or partially
opening or closing in response to signals received from controllers
that compare a "set point" to a "process variable" whose value is
provided by sensors that monitor changes in such conditions. Control
Valve is also termed as the Final Control Element. The opening or
closing of control valves is usually done automatically
by electrical, hydraulic or pneumatic actuators. Positioners are used to
control the opening or closing of the actuator based on electric, or
pneumatic signals.
A control valve consists of three main parts in which each part exist in
several types and designs:

 Valve's actuator
 Valve's positioner
 Valve's body
BASIC HYDRAULIC SYSTEM OPERATION
Here we will discuss how the feedback is taken and a
manipulation signal is sent to the servo actuator. From Program
input a signal is received this signal is calculated for error based
upon the feedback received by the mechanical actuation which
took place in the actuator.
This feedback is fed to a transducer via a conditioner and a
feedback selector. Based upon the values of input and feedback
an error is calculated. This error is used by the controller to
provide the manipulation signal for the actuator.
The actuator has the hydraulic power supply which has to be
controlled to provide the valve control action. Based upon the
manipulation signal received by the actuator the throttling of the
servo valve takes place between 0-100 % of the valve open and
close conditions.
The difference in the feedback and the signal received from the
program input is the main cause of actuation which takes place in
the servo valve mechanism.

SERVOVALVE MECHANISM
First developed in the 1940s Servo valves operate with very high
accuracy, high repeatability and high frequency response. They are
highly responsive and capable of handling miniscule flow changes both
rapidly and accurately over a broad range of flow rates but at an extra
cost. Servo Systems have a method of feedback that assures the actuator
is doing what the controller is telling it to do. Most industrial
applications use electronic, linear, rotary or forced transducers. A
transducer is a device that produces an electrical signal in direct relation
to a position, force or speed. These devices feed a precise position or
speed indication back to an electronic controller via the feedback wire
which adjusts the valve.

Servo Valve Components:

 Filter
 Spool or Valve Spindle
 Feedback Wire
 Flapper
 Armature
 Electrical Input

Fluid from pump inlet is tapped off through filter elements and passes
through orifices, both ends of spool goes onto nozzle and out to the
return line. A feedback wire attached to the flapper terminates in a ball
end that sits in a much closed spit slot in the spool. When the coils of
the valve receive an input signal the armature rotates clockwise or
anticlockwise and pushes the flapper closer to one nozzle and farther
away from the opposite nozzle. This allows pressure to increase at one
end of the spool ad decrease at the other. The spool then starts to move
away from the higher pressure. If the armature turns clockwise high
pressure builds on the left end of the spool and it moves to the right.
With these very accurate feedback devices a fast response servo valve
an actuator’s position, speed or force can be repeatedly established
within an extremely closed range.
Electronics provide the accuracy while hydraulics provide the force
via a super responsive servo valve.
 VALVE SPINDLE OR SPOOL

The above diagram is a schematic representation of Valve Spindle or

Spool which advances inside a Servo Valve which is one of the
components used in Governing System of Steam Turbine. The shown
spool contains sleeve at only one end.

Manufacturing Steps:
I. Material Number is HW10683
II. Grade of Material Used is EN10269 (density 7.7 gm./cm2 alloy
special martensitic creep-resisting steel)
III. Blank Size (45x230) mm
IV. Hold the blank in Lathe with the help of self-centering 3-jaw
chuck from one end.
 V. Apply facing operation, turn to diameter 30.5±0.1mm over length
210mm.
VI. Apply Grooving operation 15mm from starting point for length
51mm and turn to diameter 11.8±0.2mm. (A)
VII. Advance the tool by 5mm from A and apply the second grooving
operation for length 18mm and turn to diameter 19.8±0.2mm.(B)
VIII. Advance the tool by 12.5mm from B and apply the third grooving
operation over a length of 108.5mm and turn to diameter 12mm.
IX. Make center drill of diameter 1.6mm.
X. Prepare the setup for threading operation.
XI. Ensure O.D. (Outer Diameter) is 12mm for cutting M12 thread of
pitch 1.75mm (coarse).
XII. Reduce the spindle speed to one-fourth of the speed required for
turning.
XIII. Engage the half-nut and start the threading operation.
XIV. Employ several cuts to ensure full depth of 1.0745mm is reached.
XV. Stop the machine and hold the job from other side with soft jaws.
XVI. Apply the fourth grooving operation from end over a length of
3mm and turn to diameter 25mm.

Precautions:

 Correct dress is important, remove rings and watches, and roll

sleeves above elbows.
 Always stop the lathe before making adjustments.
 Do not change spindle speeds until the lathe comes to a
complete halt.
 Handle sharp cutters, centers, and drills with care.
 Remove chuck keys and wrenches before operating.
 Be aware of the emergency stop before operating the lathe.
 Use pliers or a brush to remove chips, never use hands.
 Never lean on the lathe.