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I, …………….., B Tech (3rd year) of ……….. college here by declare that the
training Report entitled “Heavy Fabrication Block”, is an original work and the
same has not been submitted to any other Institute.
(Faculty)
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ACKNOWLEDGEMENT
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ABC
COMPANY PROFILE
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BHARAT HEAVY ELECTRICALS LIMITED
BHEL – AN OVERVIEW
BHEL caters to core sectors of the Indian Economy viz., Power Generation's &
Transmission, Industry, Transportation, Telecommunication, Renewable Energy,
Defense, etc. The wide network of BHEL's 14 manufacturing division, four power
Sector regional centers, over 150 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.
BHEL has already attained ISO 9000 certification for quality management, and ISO
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capability to produce thermal sets with super critical parameters up to 1000 MW
unit rating and gas turbine generator sets of up to 240 MW unit rating. Co-
generation and combined-cycle plants have been introduced to achieve higher
plant efficiencies to make efficient use of the high-ash-content coal available in
India, BHEL supplies circulating fluidized bed combustion boilers to both
thermal and combined cycle power plants.
In all, orders for more than 700 utility sets of thermal, hydro, gas and
nuclear have been placed on the Company as on date. The power plant
equipment manufactured by BHEL is based on contemporary technology
comparable to the best in the world and is also internationally competitive.
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POWER TRANSMISSION & DISTRIBUTION (T & D)
BHEL offer wide ranging products and systems for T & D applications.
Products manufactured include power transformers, instrument transformers,
dry type transformers, series – and stunt reactor, capacitor tanks, vacuum – and
SF circuit breakers gas insulated switch gears and insulators.
INDUSTRIES
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electrostatic precipitators, fabric filters, reactors, fluidized bed combustion
boilers, chemical recovery boilers and process controls.
TRANSPORTATION
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equipment and pipelines transportation system.
TELECOMMUNICATION
RENEWABLE ENERGY
INTERNATIONAL OPERATIONS
The most prized asset of BHEL is its employees. The Human Resource
Development Institute and other HRD centers of the Company help in not only
keeping their skills updated and finely honed but also in adding new skills,
whenever required. Continuous training and retraining, positive, a positive work
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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.
For fulfilling these obligations, Corporate Policies have been formulated as:
ENVIRONMENTAL POLICY
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suppliers.
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The Company is embarking upon an ambitions growth path through clear
vision, mission and committed values to sustain and augment its image as a
world class enterprise.
VISION
MISSION
VALUES
• Team playing.
• Zeal to excel.
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At Hardwar, against the picturesque background of Shivalik Hills, 2
important manufacturing units of BHEL are located viz. Heavy Electrical
Equipment Plant (HEEP) & Central Foundry Forge Plant (CFFP). The hum of
the construction machinery woke up Shivalik Hills during early 60s and sowed
the seeds of one of the greatest symbol of Indo Soviet Collaboration – Heavy
Electrical Equipment Plant of BHEL. Following is the brief profile of Heavy
Electrical Equipment Plant:-
* Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the
area of Scientific, Technical and Industrial Cooperation.
* Annual Manufacturing capacity for Thermal sets was expanded from 1500 MW
to 3500 MW under LSTG. Project during 1979-85 (Sets upto 500 MW,
extensible to 1000/1300 MW unit sizes with marginal addition in facilities with
the collaboration of M/s KWU-Siemens, Germany.
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* Motor manufacturing technology updated with Siemens collaboration during
1984-87.
2. INVESTMENTS:
* Gross Block as on 31.3.95 is Rs. 355.63 Crores (Plant and Machinery – Rs.
285.32 Crores).
* Net Block as on 31.3.95 is Rs. 113.81 Crores (Plant & Machinery – Rs. 76.21
Crores).
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* Situated within 60 to 100 KMs of Foot-hills of the Central Himalayan Ranges;
Ganges flows down within 7 KMs from the Factory area.
* Direct Board gauge train lines to Calcutta (Howrah), Delhi, Bombay, Lucknow,
Dehradun and other major cities; Railway Siding for goods traffic connected to
Hardwar Railway Station.
- 26 deep submersible Tube Wells with O.H. Tanks for water supply.
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6. FIRE PROTECTION:
- Managed by CISF with around 40 personnel and a host of latest fire fighting
equipment and fire tenders.
7. MANPOWER:
(Kaplan, Francis, Pelton and reversible Turbines of all sizes and matching
generators and auxiliaries’ maximum runner dia – 6600 mm)
* ELECTRICAL MACHINES:
(For various industrial applications, pump drives & power station auxiliaries,
Unit capacity upto 20000 KW AC / DC)
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* CONTROL PANELS
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in the entire world.
Details of facilities:
The fabrication block in block-2 which is the domain of our study is the feeder block
for various products, steam turbine, hydro turbines, turbo generators, hydro
generators, electrical machine, apparatus and control gears, gas turbine, and navel
guns.
Block-2 consists of 4 bays, namely Bay no. I, II, III, IV of sizes 24*192, 36*192,
24*192 and 24*192 meters respectively and is provided with over head crane facility
for movement of plates, gas cut blanks and finished products. This block has facilities
for compressed air, oxygen, acetylene and carbon-di-oxide gas pipe lines.
Here, the brief description of manufacturing processes and facilities is given below:
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Manufacturing facilities:
Preparation, Bay-I
b) Gas cutting section including CNC flame cutting section and CNC Plasma section.
The various machines that are used in different section in this Bay are followed:
• Marking section:
First of all marking is done on the work piece according to the drawing given and
then it is send to next section or machine for operation.
• Press section:
In this section mainly bending operation is done. The machine used and their
introduction is given below:
Description:
This is a manual control machine. In this machine hydraulic pressure is used for
bending operation.
Description:
This is a manual control machine. In this machine hydraulic pressure is used for
bending operation.
Description:
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according to the job requirement.
• Cutting section:
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Description:
This is also a CNC cutting machine. Consumable electrode is used to produce arc
and air is used to provide pressure for cutting. In this machine consumable
electrode works as positive electrode and work piece as negative.
Description:
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Cutting speed: vary according to work piece thickness
Description:
Description:
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Cutting thickness: up to 150mm
Description:
• Other machines:
1. Straightening machine:
Description:
3. Furnace:
The jobs are heated into the furnace for easy working and to give desired shape
usually rolled section.
• Fettling section:
In this section the various operations are performed on the job. This section
includes of operations like grinding, fitting, cleaning etc.
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b) Heat treatment section.
The various machines that are used in different section in this Bay are followed:
• Rolling section:
This is a manual control machine. The machine rollers are run through a gear
mechanism powered by a heavy motor.
Description:
This is a manual control hydraulic pressure based machine. The machine rollers
are run through a gear mechanism powered by a heavy motor.
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Description:
• Welding section:
1. MIG welding:
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert
gas (MIG) welding or metal active gas (MAG) welding, is a semi-automatic or
automatic arc welding process in which a continuous and consumable wire
electrode and a shielding gas are fed through a welding gun. A constant voltage,
direct current power source is most commonly used with GMAW, but constant
current systems, as well as alternating current, can be used.
2. TIG welding:
Gas tungsten arc welding (GTAW), or tungsten inert gas (TIG) welding is a
manual welding process that uses a non-consumable tungsten electrode, an inert or
semi-inert gas mixture, and a separate filler material. Especially useful for
welding thin materials, this method is characterized by a stable arc and high
quality welds, but it requires significant operator skill and can only be
accomplished at relatively low speeds. GTAW can be used on nearly all weldable
metals, though it is most often applied to stainless steel and light metals. It is often
used when quality welds are extremely important, such as in bicycle, aircraft and
naval applications.
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3. Electric arc welding:
These processes use a welding power supply to create and maintain an electric arc
between an electrode and the base material to melt metals at the welding point.
They can use either direct (DC) or alternating (AC) current, and consumable or
non-consumable electrodes. The welding region is sometimes protected by some
type of inert or semi-inert gas, known as a shielding gas, and filler material is
sometimes used as well.
Electro slag welding (ESW) is a highly productive, single pass welding process
for thick (greater than 25mm up to about 300mm) materials in a vertical or close
to vertical position. (ESW) is similar to electro gas welding, but the main
difference is the arc starts in a different location. An electric arc is initially struck
by wire that is fed into the desired weld location and then flux is added. Additional
flux is added until the molten slag, reaching the tip of the electrode, extinguishes
the arc. The wire is then continually fed through a consumable guide tube (can
oscillate if desired) into the surfaces of the metal work pieces and the filler metal
are then melted using the electrical resistance of the molten slag to cause
coalescence. The wire and tube then move up along the work piece while a copper
retaining shoe that was put into place before starting (can be water cooled if
desired) is used to keep the weld between the plates that are being welded. Electro
slag welding is used mainly to join low carbon steel plates and/or sections that are
very thick. It can also be used on structural steel if certain precautions are
observed. This process uses a direct current (DC) voltage usually ranging from
about 600A and 40-50V; higher currents are needed for thicker materials. Because
the arc is extinguished, this is not an arc process.
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Submerged arc welding (SAW) is a high-productivity welding method in which
the arc is struck beneath a covering layer of flux. This increases arc quality, since
contaminants in the atmosphere are blocked by the flux. The slag that forms on
the weld generally comes off by itself, and combined with the use of a continuous
wire feed, the weld deposition rate is high. Working conditions are much
improved over other arc welding processes, since the flux hides the arc and almost
no smoke is produced. The process is commonly used in industry, especially for
large products and in the manufacture of welded pressure vessels.
6. Oxy-acetylene welding:
The most common gas welding process is oxyacetylene welding, also known as
oxy fuel welding. The equipment is relatively inexpensive and simple, generally
employing the combustion of acetylene in oxygen to produce a welding flame
temperature of about 3100 °C. The flame, since it is less concentrated than an
electric arc, causes slower weld cooling, which can lead to greater residual
stresses and weld distortion, though it eases the welding of high alloy steels.
• Other machines:
Basically this is a cleaning machine where scale formation is removed from the
work pieces through the manual shot of steel spherical ball of 1mm diameter.
These balls are pressurized by a motor blades running with 200rps; these blades
forces the shots towards the work piece.
2. 2MW Furnace:
This is an electric coil furnace with 12 zones. In this furnace the jobs are heated
up to 1200 ͦ C so that all the impurities present over the surface of the job
removed.
Description:
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Length of furnace: 10meters
Furnace zone: 12
Power: 1960KW
Sections in Bay-III
b) Pipe sections.
The various machines that are used in different section in this Bay are followed:
• Welding section:
In this section the various types of welding is done on the jobs. These welding are
same as used in Bay-II but the difference is that here it is done one the small size
jobs.
• Fettling section:
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In this section mainly fitting operation is done. Also some other types of operation
like grinding, cleaning, finishing are also done on the jobs.
In this section mainly the cleaning operation is done on the finished jobs. This
includes the operation like grinding etc. and some finishing operations. After the
cleaning the painting is done on the jobs. The painting provides resistance to
corrosion and improves visual properties.
• Other machines:
This is a manual control machine. The machine rollers are run through a gear
mechanism powered by a heavy motor. But this machine is small as used in Bay-
II.
Description:
This is a power saw which uses the mechanical power for cutting. Here, mainly
pipes are cut.
Description:
HP: 15
This is a manual control machine. This machine is used for the bending of pipes of
large radius and of large thickness.
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5. Furnace:
There are two furnaces both the furnace are electric coil furnace with maximum
temperature of 1300 ͦ C. These furnaces are used to heat the pipes which are going
to be bent.
It is a numerical control machine. This machine uses the single point tool for
operation. Both boring and counter boring operation are performed on this
machine.
Description:
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Vertical feed: 4150mm
RPM: 1 to 800
Sections in Bay-IV
a) Machine section: It is designed for machining parts and units during fabrication
stage. This section supplies small parts and units of steam turbine, generators,
hydro-turbines etc.
The unique machines viz. CNC multi spindle drilling machines and horizontal ram
border are installed to help in machining of various components like drilling of
tube plates of different types apart from machining of assemblies such as front
wall, casings, water boxes etc.
c) Coolers section: In this section tubes of coolers are cut to the required size, then
turned and thereafter winding and soldering of spirals on tubes is carried out by
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automatic machine. These are then assembled to form coolers which are then
assembled and hydraulically tested.
The various machines that are used in different section in this Bay are followed:
• Drilling section:
Here, these machines are five in numbers. All the machines differ from each other due
to their power. Mainly taping and drilling operations are performed on these
machines. These machines can do the hole from 5mm diameter to approx 150 mm
diameter holes.
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• Coiling and cooler section:
1. Tinning machine:
This machine is also called as polishing machine. Here tinning is done on the
copper pipes which are going for coiling. In this machine, firstly pipe cleaned with
Zn-acid by washing then pipe is heated and send to tinning bath where the
temperature is about 400 ͦ C, after then it is send to buffer where extra tinning is
removed, and then pipe is cooled by water.
2. Coiling machine:
This is a manual machine which performs the coiling operation. The main purpose
of coiling is that when water flow through these pipes at very high pressure and
high speed, thus this process improves the strength of pipe. Also this process
increases the surface area for cooling of gas as it is used in coolers.
Description:
Wire diameter: 0.9mm for 33mm diameter coiling, 0.69mm for 39mm and 44 mm
diameter coiling
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• Marking section:
In this section, very accurate marking is done on the work pieces that are going to
be worked. Choke is painted on the work pieces to improve the visual condition of
work pieces. The tools used in this section are following:
1. Calipers
3. Punches
4. Dividers
5. Hammer
6. Template plate
Etc.
• Other machines:
1. Milling machines:
There are two type of milling machines are used first horizontal milling machine
and second vertical milling machine. Here mainly the surface cutting operation is
done on the small size work pieces.
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Description:
Max rpm: 518 to 635 for vertical and 1075 to 1270 for horizontal
These machines are two in numbers. Mainly boring operation is performed in this
machine. During operation the job is fixed and tool is moved in this machine. This
machine uses the single head tool.
Description:
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Table movement: horizontally, vertically and circular
Cutting speed: according to working material and machine tool, rpm, feed
These machines are three in numbers. This machine can do all the operations that
can be done on a lathe machine. In this machine tool is fixed and job is moving.
The tool is double head and the cutting can be done at any angle.
4. Planer machines:
Mainly the planning operation is done on these machine but some other operations
like taper planning or chamfering, surface finishing, taper cut, slot cut, groove cut
etc. are also done. These machines use the one direction cut with quick return
mechanism. During operation the tool is fixed and the job is move in this machine.
These machines use both the single point tool and multi point tool.
5. Lathe machines:
All the lathe machine that are used here are central axis lathes. Here these
machines use the carbide tool for cutting and other operations. These machines are
of different size, different power and also their table is different.
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Manufacturing processes:
• Guillotine shearing machine for cutting and trimming steel sheets and plates up to
25mm thick with straight contours.
• Stationary and portable oxy-acetylene cutting machines for cutting parts out of
steel plates.
• A unique flame cutting machine is used for cutting steel plates by CNC
programming.
• CNC plasma cutting M/c for cutting stainless steel & higher alloys.
• Combination punch, shear and bar cutters, circular saws and bar shears are used
for cutting angles, shapes, flats and rods.
b) Straightening rollers are used for straightening plates and large sized blanks and
a160 ton friction press for straightening small sized blanks. A roll bending
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machine is used for straightening and bending rolled beams and angles.
c) An 800 ton hydraulic bending and 400 ton press and a 250 ton friction press are
used for cold and hot bending from rolled sheets and shapes. Parts to bend are pre
heated in a 700 KW electric furnace, when ever needed.
a) Components of units are assembled and tack welded for subsequent welding as
per drawing and instructions on process cards.
All assembly work is carried put on bed plates. Small size structures are welded
with the help of manipulators.
Heat treatment is carried out in electric furnaces of bogie hearth, bell and pit types
after welding is completed.
In multi layer welding the roots of seams are gouged and then cleaned by
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mechanical means.
All assembly and welding sections have connections for compressed air, oxygen&
acetylene as well as Argon carbon-di-oxide mixture and water for semi automatic
welding.
Inspection of weld quality and flow detection is carried out by means of X-ray
machines, Gammagraphy machines of Cobalt and Iridium isotopes and ultrasonic
flaw detectors.
Pressure vessel i.e. boilers, condensers, heaters and coolers undergo hydraulic test
on special test beds meant for hydraulic testing. Kerosene leakage test is also done
in case of thin walled vessels.
a) Pipes with diameter of 10-60mm and 38-108mm are cut on pipe cutting machine
and oxy-acetylene cutters.
b) Cold bending of pipe is carried out on a pipe bending machine. Bending of carbon
and alloy steel pipes of 114mm diameter and above is performed by heating them
in electric furnaces and then by hot bending.
c) Facing of pipe and beveling for welding is carried out on a horizontal boring
machine with portable type pipe chamfering machine.
d) For assembly and welding of pipes bed plates and manipulators are used.
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Pipe assemblies are dimensionally checked and quality of welds is tested by X-ray
and Gammagraphy.
a) Casting, forging, rolled section and welded structures are delivered to sections
where assembly and welding are done in accordance with specifications set forth
in drawings.
b) Pre-weld machining for large sized parts for steam turbine and hydro turbines are
carried out in block-III.
Painting section:
a) Painting materials used and painting processes adopted, conform to the standards
for tropical climates.
BIBLIOGRAPHY
www.google.com
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BHEL Manuals(for company profile)
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