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A Training report On HEAVY FABRICATION At

BHEL HARIDWAR
Submitted in partial fulfillment of requirements for the degree of

Bachelor of Technology In Mechanical Engineering

Submitted By: UDIT SONI B.Tech. (Final Year)

Submitted To: MOHD.YUNUS SHEIKH Sr. Lecturer

Department of Mechanical Engineering GOVT. ENGINEERING COLLEGE, BIKANER RAJASTHAN TECHNICAL UNIVERSITY, KOTA 2012-13

ACKNOWLEDGEMENT

Inspiration and motivation have always played a key role in the success of any venture. Success in such comprehensive report cant be achieved single handed. It is the team effort that sail the ship to the coast. So I would like to express my sincere thanks to my mentor MR. PARMANAND PANDIT Sir. I am also grateful to the management of Bharat Heavy Electrical limited (BHEL), Haridwar for permitting me to have training during June 2th to July 2th, 2012. It gives me in immense pleasure to express my gratitude to the department of Mechanical Engineering for their prudent response in course of completing my training report. I am highly indebted to, MR. MOHD. YOUNIS SHEIKH, their guidance and whole hearted inspiration; it has been of greatest help in bringing out the work in the present shape. The direction, advice, discussion and constant encouragement given by them has been so help full in completing the work successfully

[i]

INDEX
S.R. NO. INTRODUCTION TOPIC PAGE NO. 1

1.

BHEL 1.1.OVERVIEW 1.2.WORKING AREAS 1.2.1 POWER GENERATION 1.2.2 POWER TRANSMISSION &DISTRIBUTION 1.2.3 INDUSTRIES 1.2.4 TRANSPORTATION 1.2.5 TELECOMMUNICATION 1.2.6 RENEWABLE ENERGY 1.2.7 INTERNATIONAL OPERATIONS 1.3 TECHNOLOGY UP GRADATION AND RESEARCH AND DEVELOPMENT 1.3.1HUMAN RESOURCE DEVELOPMENT INSTITUTE 1.4 HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT 1.4.1 ENVIRONMENTAL POLICY 1.4.2 OCCUPATIONAL HEALTH AND SAFETY POLICY 1.4.3 PRINCIPLES OF THE "GLOBAL COMPACT" 1.5 BHEL UNITS 1.6 BHEL HARIDWAR 1.6.1LOCATION 1.6.2ADDRESS 1.6.3 AREA 1.6.4 UNITS

2 17 2 3 3 3 4 5 5 5 6 7 7

8 8 8 9 11 13 13 13 13 14

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1.6.5 HEEP PRODUCT PROFILE

16

2.

HEAVY FABRICATION 2.1 DEFINATION 2.2 PROCESSES 2.3 APPLICATIONS 2.4 RAW MATERIAL

18 19 18 18 18 18

3.

METAL CUTTING 3.1SHEARING MACHINE 3.2 PLASMA CUTTING 3.3 OXY-FUEL CUTTING

20 22 20 21 22

4.

BENDING 4.1 HYDRAULIC PRESS 4.2 ROLLING MACHINE

23 25 23 24

5.

WELDING 5.1 TIG WELDING 5.2 MIG WELDING 5.2.1. CARBON DIOXIDE WELDING 5.3 GOUGING

26 29 26 27 28 28

6.

INSPECTION 6.1 VISUAL INSPECTION 6.2 RADIOGRAPHY 6.3 PENETRATE TEST 6.4 ULTRASONIC FAULT DETECTOR

30 31 30 30 30 30 32 37 32 33 34

7.

MACHINING 7.1 VERTICAL BORING MACHINE 7.2 PLANER MACHINE 7.3 MANIPULATOR MACHINE
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7.3.1PURPOSE 7.3.2 SPECIFICATIONS 7.4 COPY MILLING MACHINE 7.5 CENTRAL LATHE WITH THREE & FOUR JAWS

34 34 35 36

8.

SHOT BLASTING 8.1 PURPOSE 8.2 SCOPE 8.3 SHOT DIRECTION 8.4 SETTING PARAMETER

38 39 38 38 38 38

9.

BLOCK DESCRIPTION 9.1 PREPARATION, BAY-1 9.2 ASSEMBLY & WELDING SECTION,BAY-2 9.3 BAY -3 9.4 BAY- 4

40 42 41 41 41 41

10.

MANUFACTURING PROCESSES

43 45

11.

CONCLUSION

46

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FIGURE INDEX

S.R.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

FIGURE PROCESSES PERFORMED IN HEAVY FABRICATION CNC SHEARING MACHINE CNC PLASMA CUTTING MACHINE CNC BACK PRESS MACHINE THREE ROLL BENDING MACHINE TIG WELDING MIG WELDING CO2 WELDING MACHINE GOUGING CARBON ELECTRODE DEFECT DETECTED BY ULTRA SONIC FAULT DETECTOR VERTICAL BORING MACHINE PLANNER MACHINE MANIPULATOR HOLDING GBC (GUIDE BLADE CARRIER) COPY MILLING MACHINE LATHE MACHINE SHOT BLASTING MACHINE

PAGE NO. 19 20 22 24 25 27 27 28 29 31 32 34 35 36 37 39

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TABLE INDEX

S.NO. 1. 2. 3. 4. 5. BHEL UNITS HEEP BLOCKS CFFP SECTIONS

TABLE

PAGE NO. 12 14 15 25 40

SPECIFICATION OF THREE ROLL BENDING MACHINE BLOCK 2 LAYOUT

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INTRODUCTION
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 when its first plant was setup in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India a dream which has been more than realized with a well recognized track record of performance it has been earning profits continuously since 1971-72. 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 14001 certification for environment management. The companys inherent potential coupled with its strong performance make this one of the NAVRATNAS, which is supported by the government in their endeavor to become future global players.

1. BHEL
1.1. OVERVIEW Bharat Heavy Electricals Limited (B.H.E.L.) is the largest engineering and manufacturing enterprise in India. BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense and many more. Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the area of Scientific, Technical and Industrial Cooperation. BHEL has its setup spread all over India namely New Delhi, Gurgaon, Haridwar, Rudrapur, Jhansi, Bhopal, Hyderabad, Jagdishpur, Tiruchirapalli, Bangalore and many more. Over 65% of power generated in India comes from BHEL-supplied equipment. Overall it has installed power equipment for over 90,000 MW. BHEL's Investment in R&D is amongst the largest in the corporate sector in India. Net Profit of the company in the year 2011-2012 was recorded as 6868 crore having a high of 21.2% in comparison to last year. BHEL has already attained ISO 9000 certification for quality management, and ISO 14001 certification for environment management. It is one of India's nine largest Public Sector Undertakings or PSUs, known as the NAVRATNAS or 'the nine jewels' . The power plant equipment manufactured by BHEL is based on contemporary technology comparable to the best in the world The wide network of BHEL's 14 manufacturing divisions, four Power Sector regional centre, over 100 project sites, eight service centre and 18 regional offices, enables the Company to promptly serve its customers and provide them with suitable products, systems and services efficiently

1.2. WORKING AREAS 1.2.1. POWER GENERATION Power generation sector comprises thermal, gas, hydro and nuclear power plant business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the total installed capacity of 99,146 MW in the country, as against nil till 1969-70. BHEL has proven turnkey capabilities for executing power projects from concept to commissioning, it possesses the technology and 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. 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, Pelton and Kaplan types for different head discharge combination are also engineering 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. The power plant equipment manufactured by BHEL is based on contemporary technology comparable to the best in the world and is also internationally competitive. The Company has proven expertise in Plant Performance Improvement through renovation modernization and upgrading of a variety of power plant equipment besides specialized know how of residual life assessment, health diagnostics and life extension of plants. 1.2.2. 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
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transformers, series and stunt reactor, capacitor tanks, vacuum and SF circuit breakers gas insulated switch gears and insulators. A strong engineering base enables the Company to undertake turnkey delivery of electric substances up to 400 kV level series compensation systems (for increasing power transfer capacity of transmission lines and improving system stability and voltage regulation), shunt compensation systems (for power factor and voltage improvement) and HVDC systems (for economic transfer of bulk power). BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV Facts (Flexible AC Transmission System) project under execution. 1.2.3. INDUSTRIES BHEL is a major contributor of equipment and systems to industries. Cement, sugar, fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and other process industries lines and improving system stability and voltage regulation, shunt compensation systems (for power factor and voltage improvement) and HVDC systems (for economic transfer of bulk power) BHEL has indigenously developed the state-of-theart controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV FACTS (Flexible AC Transmission System) projects is under execution. The range of system & equipment supplied includes: captive power plants, cogeneration plants DG power plants, industrial steam turbines, industrial boilers and auxiliaries. Water heat recovery boilers, gas turbines, heat exchangers and pressure vessels, centrifugal compressors, electrical machines, pumps, valves, seamless steel tubes, electrostatic precipitators, fabric filters, reactors, fluidized bed combustion boilers, chemical recovery boilers and process controls. The Company is a major producer of large-size thruster devices. It also supplies digital distributed control systems for process industries, and control & instrumentation systems for power plant and industrial applications. BHEL is the only company in India with the capability to make simulators for power plants, defense and other applications.

The Company has commenced manufacture of large desalination plants to help augment the supply of drinking water to people. 1.2.4. TRANSPORTATION BHEL is involved in the development design, engineering, marketing, production, installation, maintenance and after-sales service of Rolling Stock and traction propulsion systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting duly applications. BHEL is also producing rolling stock for special applications viz., overhead equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use, BHEL manufactures traction propulsion systems for other rolling stock producers of electric locomotives, diesel-electric locomotives, electrical multiple units and metro cars. The electric and diesel traction equipment on India Railways are largely powered by electrical propulsion systems produced by BHEL. The company also undertakes retooling and overhauling of rolling stock in the area of urban transportation systems. BHEL is geared up to turnkey execution of electric trolley bus systems, light rail systems etc. BHEL is also diversifying in the area of port handing equipment and pipelines transportation system. 1.2.5. TELECOMMUNICATION BHEL also caters to Telecommunication sector by way of small, medium and large switching systems. 1.2.6. RENEWABLE ENERGY Technologies that can be offered by BHEL for exploiting non-conventional and renewable sources of energy include: wind electric generators, solar photovoltaic systems, solar lanterns and battery-powered road vehicles. The Company has taken up R&D efforts for development of multi-junction amorphous silicon solar cells and fuel based systems.

1.2.7. INTERNATIONAL OPERATIONS BHEL has, over the years, established its references in around 60 countries of the world, ranging for the United States in the west to New Zealand in the far east. these references encompass almost the entire product range of BHEL, covering turnkey power projects of thermal, hydro and gas-based types, substation projects, rehabilitation

projects, besides a wide variety of products, like transformers, insulators, switchgears, heat exchangers, castings and forgings, valves, well-head equipment, centrifugal compressors, photo-voltaic equipment etc. apart from over 1110mw of boiler capacity contributed in Malaysia, and execution of four prestigious power projects in Oman, some of the other major successes achieved by the company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan, Sri Lanka, Iraq etc. The company has been successful in meeting demanding customer's requirements in terms of complexity of the works as well as technological, quality and other requirements viz. extended warrantees, associated O&M, financing packages etc. BHEL has proved its capability to undertake projects on fast-track basis. The company has been successful in meeting varying needs of the industry, be it captive power plants, utility power generation or for the oil sector requirements. Executing of overseas projects has also provided BHEL the experience of working with world renowned consulting organizations and inspection agencies. In addition to demonstrated capability to undertake turnkey projects on its own, BHEL possesses the requisite flexibility to interface and complement with international companies for large projects by supplying complementary equipment and meeting their production needs for intermediate as well as finished products. The success in the area of rehabilitation and life extension of power projects has established BHEL as a comparable alternative to the original equipment manufacturers (OEMS) for such plants.

1.3. TECHNOLOGY UPGRADATION AND RESEARCH & DEVELOPMENT To remain competitive and meet customers' expectations, BHEL lays great emphasis on the continuous up gradation of products and related technologies, and development of new products. The Company has upgraded its products to contemporary levels through continuous in house efforts as well as through acquisition of new technologies from leading engineering organizations of the world. The Corporate R&D Division at Hyderabad, spread over a 140 acre complex, leads BHEL's research efforts in a number of areas of importance to BHEL's product range. Research and product development centers at each of the manufacturing divisions play a complementary role. BHEL's Investment in R&D is amongst the largest in the corporate sector in India. Products developed in-house during the last five years contributed about 8.6% to the revenues in 2000-2001. BHEL has introduced, in the recent past, several state-of-the-art products developed in-house: low-NOx oil / gas burners, circulating fluidized bed combustion boilers, high-efficiency Pelton hydro turbines, petroleum depot automation systems, 36 kV gas-insulated sub-stations, etc. The Company has also transferred a few technologies developed in-house to other Indian companies for commercialization. Some of the on-going development & demonstration projects include: Smart wall blowing system for cleaning boiler soot deposits, and micro-controller based governor for diesel-electric locomotives. The company is also engaged in research in futuristic areas, such as application of super conducting materials in power generations and industry, and fuel cells for distributed, environment-friendly power generation. 1.3.1 HUMAN RESOURCE DEVELOPMENT INSTITUTE 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 culture and participative
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style of management, have engendered development of a committed and motivated work force leading to enhanced productivity and higher levels of quality. 1.4. HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT BHEL, as an integral part of business performance and in its endeavor of becoming a world-class organization and sharing the growing global concern on issues related to Environment. Occupational Health and Safety, is committed to protecting Environment in and around its own establishment, and to providing safe and healthy working environment to all its employees. For fulfilling these obligations, Corporate Policies have been formulated as: 1.4.1. ENVIRONMENTAL POLICY Compliance with applicable Environmental Legislation/Regulation; Continual Improvement in Environment Management Systems to protect our natural environment and Control Pollution; Promotion of activities for conservation of resources by Environmental Management; Enhancement of Environmental awareness amongst employees, customers and suppliers. BHEL will also assist and co-operate with the concerned Government Agencies and Regulatory Bodies engaged in environmental activities, offering the Company's capabilities is this field. 1.4.2. OCCUPATIONAL HEALTH AND SAFETY POLICY Compliance with applicable Legislation and Regulations; Setting objectives and targets to eliminate/control/minimize risks due to Occupational and Safety Hazards; Appropriate structured training of employees on Occupational Health and Safety (OH&S) aspects;

Formulation and maintenance of OH&S Management programmes for continual improvement; Periodic review of OH&S Management System to ensure its continuing suitability, adequacy and effectiveness; Communication of OH&S Policy to all employees and interested parties. The major units of BHEL have already acquired ISO 14001 Environmental Management System Certification, and other units are in advanced stages of acquiring the same. Action plan has been prepared to acquire OHSAS 18001 Occupational Health and Safety Management System certification for all BHEL units. In pursuit of these Policy requirements, BHEL will continuously strive to improve work particles in the light of advances made in technology and new understandings in Occupational Health, Safety and Environmental Science. Participation in the "Global Compact" of the United Nations. The "Global Compact" is a partnership between the United Nations, the business community, international labor and NGOs. It provides a forum for them to work together and improve corporate practices through co-operation rather than confrontation. BHEL has joined the "Global Compact" of United Nations and has committed to support it and the set of core values enshrined in its nine principles: 1.4.3. PRINCIPLES OF THE "GLOBAL COMPACT" HUMAN RIGHTS 1. Business should support and respect the protection of internationally proclaimed human rights; and 2. Make sure they are not complicit in human rights abuses.

LABOUR STANDARDS 3. Business should uphold the freedom of association and the effective recognition of the right to collective bargaining; 4. The elimination of all form of forces and compulsory labor. 5. The effective abolition of child labor, and 6. Eliminate discrimination. ENVIRONMENT 7. Businesses should support a precautionary approach to environmental challenges; 8. Undertake initiatives to promote greater environmental responsibility and 9. Encourage the development technologies. By joining the "Global Compact", BHEL would get a unique opportunity of networking with corporate and sharing experience relating to social responsibility on global basis. and diffusion of environmentally friendly

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1.5. BHEL UNITS

UNIT 1. Bhopal

TYPE Heavy Electrical Plant

PRODUCT Steam turbines , Turbo generators , Hydro sets , Switch gear controllers

2. Haridwar HEEP CFFP Heavy Electrical Equipment Plant Central Foundry Forge Plant 3.Hyderabad HPEP Heavy Power Equipment Plant Industrial turbo sets, Compressors Pumps and heaters, Bow mills, Heat exchangers oil rings, Gas turbines , Switch gears, Power generating set 4.Tiruchi HPBP SSTP High Pressure Boiling Plant Steam less steel tubes, Spiral fin welded tubes. Hydro turbines , Steam turbines, Gas turbine, Turbo generators, Heavy castings and forging. Control panels, Light aircrafts, Electrical machines

5.Jhansi TP Transformer Plant Transformers, Diesel shunt less AC locos and AC EMU

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6.Banglore EDN EPD Control Equipment Division Electro Porcelain Division

Energy meters, Water meters, Control equipment, Capacitors, Photovoltaic panels, Simulator, Telecommunication system, Other advanced micro processor based control system. Insulator and bushing, Ceramic liners.

7.Ranipet BAP Boiler Auxiliaries Plant Electrostatic precipitator, Air pre-heater, Fans, Wind electric generators, Desalination plants. 8.Goindwal 9.Jagdishpur IP Insulator Plant. High tension ceramic, Insulation Plates and bushings 10.Rudrapur Component Fabrication Plant 11.Gurgoan Amorphous Silicon Solar Cell Plant. Solar Photovoltaic Cells, Solar lanterns chargers , Solar clocks Windmill, Solar water heating system Industrial Valves Plant Industrial valves and Fabrication

TABLE 1

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1.6. BHEL HARIDWAR 1.6.1. LOCATION It is situated in the foot hills of Shivalik range in Haridwar. The main administrative building is at a distance of about 8 km from Haridwar. 1.6.2. ADDRESS Bharat Heavy Electrical Limited (BHEL) Ranipur, Haridwar PIN:- 249403 1.6.3. AREA BHEL Haridwar consists of two manufacturing units, namely Heavy Electrical Equipment Plant (HEEP) and Central Foundry Forge Plant (CFFP), having area HEEP area:- 8.45 sq km CFFP area:- 1.0 sq km The Heavy Electricals Equipment Plant (HEEP) located in Haridwar, is one of the major manufacturing plants of BHEL. The core business of HEEP includes design and manufacture of large steam and gas turbines, turbo generators, hydro turbines and generators, large AC/DC motors and so on. Central Foundry Forge Plant (CFFP) is engaged in manufacture of Steel Castings: Up to 50 Tons per Piece Wt & Steel Forgings: Up to 55 Tons per Piece Wt. 1.6.4. UNITS There are two units in BHEL Haridwar as followed: 1) Heavy Electrical Equipment Plant (HEEP) and another 2) Central Foundry Forge Plant (CFFP).

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THERE ARE 8 BLOCKS IN HEEP

BLOCKS

WORK PERFORMED IN THE BLOCK

I. Electrical Machine

Turbo generator, generator exciter , motor (ac and dc)

II. Fabrication

Large size fabricated assemblies or components

III. Turbine & Auxiliary

Steam ,hydro ,gas turbines, turbine blade , special tooling

IV. Feeder

Winding of Turbo ,hydro generators ,insulation for ac & dc motors

V. Fabrication

Fabricated parts of steam turbine, water boxes, storage tank, hydro turbine parts

VI. Fabrication Stamping and die manufacturing

Fabricated oil tanks, hollow guide blades, Rings, stator frames and rotor spindle, all dies, stamping for generators and motors

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VII. Wood working VIII. Heaters & coolers

Wooden packing, spacers. LP heaters, ejectors, glands, steam and oil coolers, Oil tank, bearing covers

TABLE 2

THERE ARE 3 SECTIONS IN CFFP

SECTIONS

WORK PERFORMED IN THE SECTION

I.

Foundry

Casting of turbine rotor, casing and Francis runner

II.

Forging

Forging of small rotor parts

III. Machine shop

Turning, boring, parting off, drilling etc.

TABLE 3

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1.6.5. HEEP PRODUCT PROFILE

1. THERMAL SETS: Steam turbines and generators up to 500 MW capacity for utility and combined cycle applications Capability to manufacture up to 1000 MW unit cycle.

2. GAS TURBINES: Gas turbines for industry and utility application; range-3 to 200 MW (ISO). Gas turbines based co-generation and combined cycle system.

3. HYDRO SETS: Custom built conventional hydro turbine of Kaplan, Francis and Pelton with matching generators up to 250 MW unit size. Pump turbines with matching motor-generators. Mini / micro hydro sets. Spherical butterfly and rotary valves and auxiliaries for hydro station.

4. EQUIPMENT FOR NUCLEAR POWER PLANTS: Turbines and generators up to 500MW unit size. Steam generator up to 500MW unit size. Re-heaters / separators. Heat exchangers and pressure vessels.

5. ELECTRICAL MACHINES: DC general purpose and rolling mill machines from 100 to 19000KW suitable for operation on voltage up to 1200V. These are provided with STDP, totally enclosed and duct ventilated enclosures. DC auxiliary mill motors.

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6. CONTROL PANEL: Control panel for voltage up to 400KW and control desks for generating stations and EMV substations.

7. CASTING AND FORGINGS: Sophisticated heavy casting and forging of creep resistant alloy steels, stainless steel and other grades of alloy meeting stringent international specifications.

8. DEFENCE: Naval guns with collaboration of Italy.

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2. HEAVY FABRICATION
2.1. DEFINATION:Fabrication as an industrial term refers to building metal structures by cutting, bending and assembling. The cutting part of fabrication is done via sawing, shearing, or chisel machine (all with manual and powered machine variants); torching with handheld torches (such as oxy-fuel torches or plasma torches); and via CNC cutters (using a laser, torch, or water jet). The bending is done via hammering (manual or powered) or via press brake and similar tools. The assembling (joining of the pieces) is via welding and binding with adhesives, riveting, threaded fasteners, or even yet more bending in the form of a crimped seam. Structural metal and sheet metal are the usual starting materials for fabrication, along with the welding wire, flux, and fasteners that will join the cut pieces. As with other manufacturing processes, both human labor and automation are commonly used. The product resulting from (the process of) fabrication may be called a fabrication. 2.2. PROCESS:Processes involved in Fabrication are:Cutting & Burning. Forming Machining. Welding. 2.3. APPLICATIONS:Equipment for Industrial Applications. Equipment for Specialty Gases Applications. 2.4. RAW MATERIAL Standard raw materials used by metal fabricators are:Plate metal Formed and expanded metal
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Tube stock Square stock Sectional metals ( I beams, W beams, C-channel ) Welding wire Castings Fittings

FIG.1 PROCESSES PERFORMED IN HEAVY FABRICATION

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3. METAL CUTTING
3.1. SHEARING MACHINE:A shearing machine is hydraulic machine used to cut metal work-pieces with help of Shearing mechanism. In this machine the metal work-piece are passed through the machine through roller transmitters called guides which moves too-and fro and then stopped with help brake stops which works hydraulically which operates by pressing foot pedal provided at the foot of machine setup. These stops hold the work-piece tightly so that it doesnt disturb due to high impact of shearing cutters. Then valve is operated which causes the fluid to pressurize and further moving the cutter down which strikes the work-piece and causing cutting action of work-piece. Metals that can be cut are mild steel, stainless steel etc. Maximum thickness that can be cut is 10mm. Main component of Shearing machine is as follow:a) Jack:-support the plate or metal parts which are to be cut. b) Blade:-cutting the metal parts (cutter). c) Guide:-Numerical controlled length adjustment. d) Hydraulic Oil tank.

FIG.2 CNC SHEARING MACHINE

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3.2 PLASMA CUTTING:Plasma cutting is a process that is used to cut steel and other metals (or sometimes other materials) using a plasma torch. In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut. Plasma cutters have also been used in CNC machinery. Manufacturers build CNC cutting tables, some with the cutter built in to the table. The idea behind CNC tables is to allow a computer to control the torch head making clean sharp cuts. Modern CNC plasma equipment is capable of multi-axis cutting of thick material, allowing opportunities for complex welding seams on CNC welding equipment that is not possible otherwise. Welding torch used has outer torch made up of brass and inner one made of copper. Minimum gap between torch and work-piece is 5mm. This machine can be used to cut the work-piece of mild steel and stainless steel. The differences between the cutting methods for both of these metals are the use of nozzles & the pressure of gases applied to pass through nozzles so that cutting action is done easily. Work-piece of thickness 100mm to 210mm can be cut from this type machine. For e.g. For a mild steel job of thickness 100mm the cutting speed is 131.55mm/min. Gases used in this type of machine are oxygen and Bharat Metal Cutting Gas (BMCG). Oxy-acetylene is avoided due to less purity& heavier as compared to BMCG. It is less pure which causes repeated cleaning of burner. The gap between Nozzle & plate is 5mm. If gap is increased sensor adjust the pressure according to it. Large diameter Nozzle is used for thick metal sheet & higher pressure and vice versa for thin metal sheet.

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FIG.3 CNC PLASMA CUTTING MACHINE 3.3. OXY-FUEL CUTTING:Oxy-fuel cutting is the most widely applied process for cutting mild steels and low alloyed steels. The process covers the entire thickness range from 1 mm to 2500 mm (0.04-100 inches), it gives an excellent cut quality and the investment costs are low. Furthermore the process can easily be mechanized. Oxy-fuel cutting is a combustion process. An oxygen jet burns the metal in a narrow section to make a cut and removes the combustion products (slag) from the kerfs. The purity of the cutting oxygen is of great importance for the cutting speed that can be achieved. A higher purity level means a higher cutting speed. Oxy-fuel cutting are processes that use fuel gases and oxygen to either weld or cut metals. In Oxy-fuel cutting, a cutting torch is used to heat up ferrous metal to kindling temperature (about 980C). A stream of pure oxygen is trained on the hot metal which chemically combines with the iron which then flows out of the cut, or kerfs, as an ironoxide slag. There have been examples of oxy-hydrogen cutting sets with small (scuba sized) gas cylinders worn on the user's back in a backpack harness, for rescue work.
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4. BENDING
Bending is a process by which metal can be deformed by plastically deforming the material and changing its shape. The material is stressed beyond the yield strength but below the ultimate tensile strength. The surface area of the material does not change much. Bending usually refers to deformation about one axis. 4.1. HYDRAULIC PRESS:A hydraulic press is a hydraulic mechanism for applying a large lifting or compressive force. It is the hydraulic equivalent of a mechanical lever, and is also known as a Bramah press after the inventor, Joseph Bramah. Hydraulic presses are the most commonly-used and efficient form of modern press. The hydraulic press depends on Pascal's principle: the pressure throughout closed system is constant. At one end of the system is a piston with a small cross-sectional area driven by a lever to increase the force. Small-diameter tubing leads to the other end of the system. A fluid, such as oil, is displaced when either piston is pushed inward. The small piston, for a given distance of movement, displaces a smaller amount of volume than the large piston, which is proportional to the ratio of areas of the heads of the pistons. Therefore, the small piston must be moved a large distance to get the large piston to move significantly. The distance the large piston will move is the distance that the small piston is moved divided by the ratio of the areas of the heads of the pistons. There were two hydraulic presses at present which are: CNC Back Press-340 ton. Manually operated- 400 ton, 800 ton.

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FIG.4 CNC BACK PRESS MACHINE

4.2. ROLLING MACHINE:THREE ROLL BENDING MACHINE: Roll benders use three rolls (typically) to bend solids, extrusions and tube and pipe to various diameters by adjusting one or two rolls. The pyramid style roll benders have one moving roll, usually the top roll. Double pinch type roll benders have two adjustable rolls, usually the bottom rolls, and a fixed top roll. Large arcs, circles and spirals are typical applications for roll benders. The roll bending machine in BHEL has following specifications:-

S.R.NO. 1. 2. 3. 4.

SPECIFICATIONS MAXIMUM WORKING LENGTH MINIMUM DIAMETER OF FORMING PLATE THICKNESS UPPER ROLL DIAMETER

DIMENSIONS 8000 MM 1300 MM 32 MM 7550 MM

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5. 6. 7. 8.

LOWER ROLL DIAMETER SPEED OF FORMING SPEED OF LOWERING UPPER ROLL SPEED OF RAISING UPPER ROLL

680 MM 5 M/MINUTE 60 MM/MINUTE 120 MM/MINUTE

TABLE 4- SPECIFICATION OF THREE ROLL BENDING MACHINE

FIG.5 THREE ROLL BENDING MACHINE

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5. WELDING
Welding section is the most important section of this block as all the main parts of Steam Turbine from generator to casing or from shafts to blades requires welding to join their surfaces. Mainly the welding methods used are Shielded Metal Arc Welding (MIG), Carbon Di-oxide welding (MIG welding) and TIG welding etc. Air Products' shielding gases are commonly used in several welding processes, mostly MIG and TIG welding. The selection of a suitable welding gas is essential for the welding process. The welding gas not only protects the weld metal from the surrounding air, it can also contribute to higher productivity and to better mechanical properties of the weld. Air Products offers a full range of standard shielding gas mixtures for MIG welding for all common material types. 5.1. TIG WELDING:TIG welding is a high-quality welding technique with a low fusion rate. The arc burns between a tungsten electrode and the work piece; the electrode does not melt, so it acts only as a current conductor and arc carrier. The shielding gases protect the weld area from atmospheric gases, such as oxygen, nitrogen, carbon dioxide, and water vapor. Depending on the materials being welded, these atmospheric gases can reduce the quality of the weld or make the welding process more difficult to use. In this type of welding, tungsten electrode is used which is non-consumable. Filler material used is either copper wire or wire of same material to be weld. When current through tungsten electrode is passed, than a spark is produced, which is of a very high intensity. Along with above a blow of argon gas is passed through holder to provide inert atmosphere at welding. The strength of TIG welding is more than any other type of welding. The temperature of flame is varied by adjusting voltage/ current as per requirement. This type of welding is used mainly for welding pipes. Defects occur mainly in this type of Welding is porosity caused by stopping the flow of argon gas.

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FIG.6 TIG WELDING

5.2. MIG WELDING:In MIG welding, the metal electrode is used to produce spark. The current is allowed to flow through filler metal which passes through welding holder & a blow of gases is passed through holes provided on holder which provide safeguard to welding area from atmospheric gases. Voltage can be adjusted according the speed of filler material, feeding is adjusted as per requirement.

FIG.7 MIG WELDING

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5.2.1. CARBON DIOXIDE WELDING:- In this type of welding, copper coated wire is made in contact with metal to be weld and then high current is allowed to flow through wire which causes spark of very high intensity. Then carbon dioxide & argon gas is blown to welding area which helps in maintaining the inert atmosphere nearby welding area and free from oxygen. Composition of carbon dioxide & argon gas is 80:20(%). Temperature is maintained at 3600 to 4000 C. The strength of Welding with CO2-gas welding is much better as compared to metal Arc. So for mass production and high productivity with greater quality this welding method is used. Main defect of carbon dioxide welding is porosity.

FIG.8 CO2 WELDING MACHINE 5.3. GOUGING:Thermal gouging is an essential part of welding fabrication. Used for rapid removal of unwanted metal, the material is locally heated and molten metal ejected usually by blowing it away. Normal oxygen fuel gas or arc processes can be used to produce rapid melting and metal removal.

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Manual metal arc Gouging is a process in which a process a electrical arc is generated to melt the material. Other techniques like special electrodes or a jet of compressed air are used to blow away the molten material. No specific high purity or compressed gases are needed in these processes.

FIG.9 GOUGING CARBON ELECTRODE

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6. INSPECTION
Usually in BHEL Nondestructive testing (NDT) is performed. It is defined as comprising those test methods which are used to examine an object, material or system without impairing its future usefulness. The term is generally applied to non medical investigations of material integrity. The main NDT processes at the fabrication block are as follows:6.1. VISUAL INSPECTION It is the simplest, cheapest and most widely used method amongst the entire NDTs. A simple visual test reveals gross surface defects easily and quickly. However for detection of final defects, device/equipments having high degree of precision and illumination are required. 6.2. RADIOGRAPHY In this test the X-rays and gamma rays are used to detect deep seated internal defects. The short wavelengths of X-ray permitted to penetrate through the opaque material. Gamma rays are the electro-magnetic radiations that are emitted from an unstable nucleus. 6.3. PENETRATE TESTING Penetrate solution is applied to the surface of a pre-cleaned component. The liquid is pulled into surface-breaking defects by capillary action. A developer is applied to pull the trapped penetrate back to the surface where it is spread out and forms an indication. The indication is much easier to see than the actual defect. 6.4. ULTRASONIC FAULT DETECTOR In this process job is painted with oil and then high frequency sound waves is passed through the job. Then the echo is recorded on detector. If the echo is recorded with disturbance earlier than the other end then the job is defective.

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FIG.10 DEFECT DETECTED BY ULTRA SONIC FAULT DETECTOR

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7. MACHINING
Machining can be defined as the process of removing material from a work piece in the form of chips .The term metal cutting is used when the material is metallic. Most machining has very low set-up cost compared to forming, molding, and casting processes. However, machining is much more expensive for high volumes. Machining is necessary where tight tolerances on dimensions and finishes are required. 7.1. VERTICAL BORING MACHINE In this machine there is one Ram Head On Cross Rail, Jaw Chucks, and Automatic Lifting & Lowering of Cross Rail. There is Lubrication System on all Sliding Ways to avoid frictional losses. A Centralized Control Station with Interlocked Electrical Control Pane is provided. A Set of Service tools is also provided. Some Special Accessories are also provided with this machine like as follows:a) Additional Ram Head On Cross Rail. b) Turret Head On Cross Rail. c) Threading Head On Cross Rail. d) Side Ram Head. e) Slotting Attachment On Cross Rail

FIG.11 VERTICAL BORING MACHINE


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7.2. PLANNER MACHINE A planner is a type of metal working machine tool that is analogous to a shaper, but larger, and with the entire work piece moving beneath the cutter, instead of the cutter moving above a stationary work piece. The work table is moved back and forth on the bed beneath the cutting head either by mechanical means, such as a rack and pinion gear, or by a hydraulic cylinder. The carriage is heavy duty and long to gives balanced bearing to the bed even at the end of the stroke. The bed is of heavy duty box type construction. It is ribbed throughout the length and breadth giving vibration free movement under the heaviest cut. Table is heavily ribbed and proportionally dimensioned heavy duty close grained cast iron box type construction. It has 'v' slides matching the 'v' grooves on the bed and is hand scrapped to give oil film lubrication. Cross slide has a box type construction carrying the tool slide which can be operated by hand as well as by automatic feed. Gearbox consists of Machine Cut gears running in anti friction bearings with oil immersed. Tool post is a cast-iron close grained construction. Tool holders machined out of steed blocks. Uprights are Heavy duty cast iron construction bolted to the sides of the bed .ribbed inside to avoid vibration. Operations that can be performed by it:a) Vertical planning. b) Horizontal planning. c) Angular Planning. d) Slot Cutting.

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FIG.12 PLANNER MACHINE 7.3. MANIPULATOR MACHINE Parts that cannot be welded easily by ordinary welding, especially internal curved parts are welded using manipulators. In manipulator machine parts to be welded is fixed with the help of fixture attached to the table of the manipulator machine. Table can be rotate through 0-360 and tilting of table is 0-135 7.3.1 PURPOSE:- Metal parts which are heavier in weight and difficult to change their position can be weld by the use of manipulator machine which can change the position of parts according to our requirement. Guide blade carriage blade is weld by the use of manipulator machine. Carriage or ring is mounted on the table with the help of fixture and then guide blade carrier blade is weld to the inner ring to both side of curved surface by tilting the table 7.3.2 MACHINE SPECIFICATION a) Gross weight = 7600 kg. b) Size =393*383*180 cm3.

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c) Table diameter = 3500mm (without extension), 4500mm (with extension). d) Rotation of table = 00 to 3600 (clockwise or anti clock) e) Tilting of table = 00 to 1350. f) Table rotation speed = 0.012-0.5 rpm.

FIG.13 MANIPULATOR HOLDING GBC (GUIDE BLADE CARRIER) 7.4. COPY MILLING MACHINE This machine is designed for milling profiles or relief contours (three-dimensional milling) on articles made of various materials by means of a cutting tool (milling cutter), which reproduces on the article the surface or contour of a master devicefor example, a master cam in the shape of a flat template, a three-dimensional model, or a contour drawing. The master device is mechanically, pneumatically, or hydraulically connected to a servomechanism, which directs the cutting tool.

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The servomechanism acts on an amplifying device on the one hand and, on the other hand, on an actuating device. Hydraulic, electromagnetic, or electro-optical relays are used in the amplifying devices of such machines. The actuating member may be a screw, a slide valve, an electromagnetic coupling, a solenoid, a differential, or some other device, and it may be driven by an electric motor or a hydraulic power cylinder.

FIG.14 COPY MILLING MACHINE 7.5 CENTRE LATHE WITH THREE AND FOUR JAWS: A metal lathe is generic description for a rigid machine tool designed to remove material from a work piece, through the action of a cutting tool. They were originally designed to machine metals; however, with the advent of plastics and other materials, and with their inherent versatility, they are used in a wide range of applications, and a broad range of materials. A center lathe is a dual head machine where the work remains fixed and the heads move towards the work piece and machine a center drill hole into each end. The resulting
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work piece may then be used "between centers" in another operation. The usage of the term metal lathe may also be considered somewhat outdated these days, plastics and other composite materials are in wide use and with appropriate modifications, the same principles and techniques may be applied to their machining as that used for metal. A center lathe or engine lathe may be considered the basis for the metal lathe and is the type most often used by the general machinist or hobbyist. The center lathe may be considered a useful starting point. The engine lathe is the name applied to a traditional 20th century lathe. It is assumed that the 'engine' was added to the description to separate them from the 'foot lathes' (lathes turned by pedals) or other hand rotated pieces of machinery. Early engine lathes were generally 'cone heads', in that the spindle usually had attached to it a multi-step pulley designed to accept a flat belt.

FIG.15 LATHE MACHINE

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8. SHOT BLASTING
8.1. PURPOSE Used for hardening the root of the low pressure rotor turbine blade in fatigue load. Shot blasting is carried out to introduce compressive stress to depth of blade. In blades, fatigue strength and improvement in resistance to stress omission is checked along with corrosion removal. Blasting process consists of bombarding exposed surface of fir tree root with steam of hardened spherical metallic dots from robotics controlled nozzle by applied air pressure. 8.2. SCOPE Shot blasting of steam turbine blade roots with cast steel shots type S280 to S390 in blasting intensity of range 0.3 to 0.35. 8.3. SHOT DIRECTION Notch radii should be blasted in average normal direction. This blasts that steel shots have to hit the radius in perpendicular direction since blasting is most effective under this condition. Nozzle has to be point to centre of root curve. 8.4. SETTING PARAMETER: The setting parameters for machine are:a) Air pressure b) Shot size c) Nozzle diameter d) Shot flow e) Distance between blasted surface and nozzle. f) Blasting time g) Reservoir pressure

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FIG.16 SHOT BLASTING MACHINE

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9. BLOCK DESCRIPTION

TABLE 5- BLOCK 2 LAYOUT

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9.1 PREPARATION, BAY -1 It has the following sections: a) Marking cutting and straightening section. b) Gas cutting section including CNC flame cutting section & CNC Plasma cutting section. c) Press section (400T and 800T, Brake press). d) Shearing M/c section. 9.2 ASSEMBLY AND WELDING SECTION, BAY -2 It has the following sections: a) Assembly and welding section for large size units up to 75 tons. b) Heat treatment section. c) Shot blasting and cleaning section. 9.3 BAY -3 It has the following sections: a) Assembly and welding sections of small size units unto 10 tons b) Pipe sections. 9.4 BAY -4 It has the following sections: 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-turbine etc. The unique machines viz. CNC multi spindle drilling machines and Horizontal ram borer are installed to help in machining of various components like drilling of tube plates of different types apart from machining of big assemblies such as front wall, casing, water boxes etc. b) DIAPHRAGM SECTION: Welded diaphragms of steam turbines are assembled, welded and stress relieved in this section.

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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 automatic machines. These are then assembled to form coolers which are then assembled and hydraulically tested.

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10. MANUFACTURING PROCESSES


Manufacturing starts with Preparation of individual parts before assembly, in Bay -1. a) The metal is first marked and cut by the following machines:- 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 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 S.S & 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 a 160 ton friction press for straightening small sized blanks. A roll bending machine is used for straightening and bending rolled beams and angles.

c) Hydraulic bending press of 800 ton and 400 ton 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. d) Finished parts are inspected at the working place.

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After Preparation is complete the next step is Assembly and Welding in Bay -2 and 3 is as follows: a) Components of units are assembled and tack welded for subsequent welding as per drawing and instructions on process cards. b) Manual arc welding is employed in restricted and inaccessible places or where semi-automatic or automatic welding is not possible or has not been established. c) Semi-Automatic submerged arc welding, GTAW and Argon Carbon-dioxide Shielded arc welding are also used for increased productivity and better quality. All assembly work is carried out on bed plates. Small size structures are welded with the help of manipulators. Welding of high pressure cylinders of steam turbines is carried out after preliminary heating up to 250 C. 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 mechanical means. All assembly and welding sections have connections for compressed air, oxygen & acetylene as well Argon carbon-dioxide mixture and water for semi automatic welding. Weld quality inspection is adopted in accordance with the relevant specifications. Inspection of weld quality and flaw detection is carried out by means of X-ray machines, gamma-grapy machines of cobalt and iridium isotopes and ultrasonic flaw detectors. Pressure vessels that are boilers, heaters, condensers and coolers undergo hydraulic tests on special test beds meant for hydraulic testing. Kerosene leakage test is also done in case of thin walled vessels. Process being followed in pipe section is mentioned below: a) Pipes with diameter of 10-60 mm and 38-108 mm are cut on pipe cutting machines and oxy-acetylene cutters. b) Cold bending of pipes is carried out on a pipe bending machine. Bending of carbon and alloy steel pipes of 114 mm dia. and above is performed by heating them in electric furnaces and then by hot bending.

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c) Facing of pipes 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. e) Heat treatment of pipes is done in electric furnace mentioned earlier. f) Surface cleaning is done manually or by shot blasting. Pipe assemblies are dimensionally checked and quality of welds is tested by Xray and Gamma grapy. Process being followed in machining section is as follows: 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 turbines and hydro turbines are carried out in block-3. c) Provision is made for the application of highly productive cemented carbide tipped cutting tools, high speed cutting with maximum utilization with machine tool capacity and rapid section locating and clamping fixture. Process being followed in painting section is as follows: a) Painting materials used and painting processes adopted, conform to the standards for tropical climates. b) Owing to different operating conditions and decoration requirements of units and parts of turbines and electrical machines, different processes for painting are adopted. c) Some components and units undergo only prime coating in the steel structure section, with subsequent painting in the painting section of the machine and assembly section.

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11. CONCLUSION
Gone through rigorous one month training under the guidance of capable engineers and workers of BHEL Haridwar in Block-2 HEAVY FABRICATION headed by Senior Engineer of department MR. PARMANAND PANDIT situated in Ranipur, Haridwar, Uttarakhand. The training was specified under the Heavy Fabrication Department. I came to know about the basic grinding, scaling and machining processes which were shown on heavy to medium machines. Duty lathes were planted in the same line where the specified work was undertaken. The training brought to my knowledge the various machining and fabrication processes done not only in the manufacturing of cams but also in other iron casted products.

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