A Tra T rain inin ing g rep report On “HEAVY FABRI FABRI CATIO CATI ON” At
BHEL HARI DWAR Submitted in par parti tial al ful f ulffillment of re requirem quirements for the degree gree of
Bache achellor of Te T echnol chnology ogy In M echani chanica call E Eng ngiineering
Submitted By: UDI T SONI B.Tech. (Final Y ear)
Submitted T o: M OH D.Y UNUS SHE I K H Sr. L ecturer
Depar Departm tme ent of M echanica chanicall E ngi nginee neering GOVT. GOVT. ENGI ENGIN NEERING EERI NG COL COL L EGE, BIK ANER RAJ AS ASTHAN THAN TECHNICAL TECHNICAL UNI VERSIT VERSIT Y , K OTA 2012-13
ACK NOWLEDGEM OWLEDGEM ENT
“I nspirati nspiration on and motiv otivation have alw always played played a key role rol e in the succes success of any venture.” Success in in su such ch comprehe comprehensive nsive repor reportt can’t can’t be achieve chieved d si single ngle handed. It It is is the the tea team eff effort ort that sail the the ship to the coast. st. So I would would like to expre xpress ss my my sincere thanks to my mentor M R. PARMANAND PANDIT PANDIT Sir. I am also grateful to the management ent of Bharat harat Heavy Heavy El Electri ectrical cal limited (BHE (BHEL L ), Haridwar for for perm permiitting me to have training duri during ng Jun June e 2th to J uly 2th, 2012. It gives gives me in in im immense plea pleasure to express express my gratitude atitude to the depart partm ment of of Mechanical chanical Engineering ri ng for their prudent response in course of comple pleting ting my training traini ng report. I am highly ghly iinde ndebted to, to,
MR . MOHD. Y OUN OUNII S SHEI K H ,
their
guidance and whole whole hearted arted ins inspirati piration; on; it i t has been of greatest help help in i n bringing bringing out the work work in in the prese present nt shape. The T he directi direction, on, advice, advice, discuss discussiion and constant encoura ouragement given iven by them has been so help full full in completin leting g the work work successfully
[i]
INDEX S.R . NO.
T OPI C I NT R ODUC T I ON
1.
P AGE NO. 1
BHE L
2 – 17
1.1.OVERVI EW
2
1.2.WORKI NG AREAS
3
1.2.1 POWER GENERATI ON
3
1.2.2 POWER TRANSMISSI ON &DI STRI BUTI ON
3
1.2.3 I NDUSTRIES
4
1.2.4 TRANSPORTATI ON
5
1.2.5 TELECOMMUNI CATI ON
5
1.2.6 RENEWABLE ENERGY
5
1.2.7 I NTERNATI ONAL OPERATI ONS
6
1.3 TECHNOLOGY UP GRADATION AND RESEARCH RESEARCH AND DEVEL DEVELOPMENT OPMENT 1.3.1HUMAN RESOURCE DEVELOPMENT
7 7
INSTITUTE 1.4 HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT 1.4.1 ENVIRONMENTAL POLI CY
8
1.4.2 OCCUPA UPATION IONAL HE HEA ALTH LTH AND SAFET FETY POLIC POLICY Y
8
1.4.3 PRI NCI PLES OF THE "GLOBAL COMPACT"
9
1.5 BHEL UNI TS
11
1.6 BHEL HARI DWAR
13
1.6.1LOCATI ON
13
1.6.2ADDRESS
13
1.6.3 AREA
13
1.6.4 UNI TS
14
[ii]
8
1.6.5 HEEP PRODUCT PROFI LE
2.
3.
4.
5.
6.
7.
HEA V Y FA BR I C AT I ON
16
18 – 19
2.1 DEFI NATI ON
18
2.2 PROCESSES
18
2.3 APPLI CATI ONS
18
2.4 RAW MATERIAL
18
M E T A L C UT T I NG
20 – 22
3.1SHEARI NG MACHI NE
20
3.2 PLASMA CUTTI NG
21
3.3 OXY-F UEL CUTTI NG
22
BENDI NG
23 – 25
4.1 HYDRAULI C PRESS
23
4.2 ROLLING MACHINE
24
W E L DI NG
26 – 29
5.1 TI G WELDI NG
26
5.2 MIG WELDING
27
5.2.1. CARBON DIOXIDE WELDI NG
28
5.3 GOUGI NG
28
I NSPE C T I ON
30 – 31
6.1 VISUAL INSPECTI ON
30
6.2 RADIOGRAPHY
30
6.3 PENETRATE TEST
30
6.4 ULTRASONIC F AULT DETECTOR
30
M A C HI NI NG
32 – 37
7.1 VERTI CAL BORI NG MACHI NE
32
7.2 PLANER MACHI NE
33
7.3 MANIPULATOR MACHINE
34
[iii]
8.
9.
7.3.1PURPOSE
34
7.3.2 SPECI FI CATI ONS
34
7.4 COPY MI LLI NG MACHINE
35
7.5 CENTRAL LA LATHE WITH ITH THREE & FOU FOUR JAW JAWS
36
SH OT BL AST I NG
38 – 39
8.1 PURPOSE
38
8.2 SCOPE
38
8.3 SHOT DI RECTI ON
38
8.4 SETTI NG PARAMETER
38
BL OC K DE SC RI PT I ON
40 – 42
9.1 PREPARATI ON, BAY-1
41
9.2 ASSEMBLY & WELDI NG SECTION,BAY-2
41
9.3 BAY -3
41
9.4 BAY- 4
41
10.
M A NUF A C T UR I NG PROC E SSE S
11.
CONC L USI ON
43 – 45
46
[iv]
FI GURE INDEX INDEX
S.R .NO.
F I GUR E
PA GE NO.
1
PROCESSES PERFORMED I N HEAVY FABRI CATI ON
19
2
CNC SHEARI NG MACHI NE
20
3
CNC PLASMA CUTTING MACHI NE
22
4
CNC BACK PRESS MACHINE
24
5
THREE ROLL BENDI NG MACHI NE
25
6
TI G WELDI NG
27
7
MI G WELDI NG
27
8
CO2 WELDING MACHINE
28
9
GOUGI NG CARBON ELECTRODE
29
10
31
11
DEFEC EFECT T DET DETEC ECT TED BY ULT ULTR RA SONIC FAUL FAULT T DETECTOR VERTI CAL BORI NG MACHI NE
32
12
PLANNER MACHINE
34
13
35
14
MAN MANIPULA IPULATOR HOLD HOLDIN ING G GBC (G (GUIDE UIDE BLAD LADE CARRIER) COPY MILLI NG MACHI NE
15
LATHE MACHI NE
37
16
SHOT BLASTI NG MACHINE
39
[v]
36
TABL T ABL E INDEX
S.NO.
T A BL E
PA GE NO.
1.
BH BHEL UNI TS
12
2.
HEEP BLOCKS
14
3.
CFFP SECTIONS
15
4.
SPECI F I CATI ON OF THREE ROLL BENDING MACHI NE
25
5.
BLOCK 2 LAYOUT
40
[vi]
INTRODUCTION BHEL is the largest engine gineering ring and and manuf anufactu acturi ring ng enterprise in in India India in in the the energy relate related d infr infrastruct astructure ure sector today today. BH B HEL was establ stablished more ore than 40 years ago when its its fi first plan plant was se setup in Bhop Bhopal al usheri ushering ng in the indige indigenou nous s Heavy Heavy El E lectrical ctrical Equipment Indu I ndustry stry in i n Indi India a a dream dream which which has has bee been more than than real realized with with a well recognized track record of perform performan ance ce it has be been earning earning profit profits s continuous continuouslly si since nce 1971-72. BHEL cate caters rs to core sectors of the Indian Indian Economy viz., viz., Power Gene Generation's & Tra Transmiss ission ion, Ind Industry, Tra Transportation ion, Tele Telecommunica ication ion, Renewable Ene Energy, Defense Defense, etc. The T he wide ne network of BHEL 's 14 manufacturing divi division, sion, ffour our power Sector Sector regional centers, over 150 150 proje project sites sites,, eight eight service rvi ce cente centers rs and and 18 regional off offices, ces, enables ables the Company to promptl promptly y serve its its customers and and provi provide them them with with suitabl suitable e products, system systems and servi rvices ces – eff efficien ciently tly and and at competi petiti tive ve prices prices. BH BHEL has al already attained ISO ISO 9000 certifi certification cation for qualit quality y manage anagement, and ISO 14001 14001 certif rtification cation for envir environm onment management. The company’ pany’s s inh inhe erent potential potential couple coupled with with its its strong perf perform orman ance ce make this one of the “NA “NA V RA TNAS”, which is is supporte supported by by the government in in the their ende endeav avor or to become future future globa globall playe players.
1
1. BHEL 1.1. OVERVIEW
Bharat harat Heavy Heavy Ele El ectrica ctricalls L imited ted (B.H (B.H.E .E.L .L .) is is the largest engi ngineering ring and manufact ufactu uring enterprise rprise in I ndia. dia. BH BHEL EL caters to core sectors ctors of the the I ndian dian Economy viz., viz., Powe Powerr Ge Generation's & Transmission, I ndustry, ndustry, Tran Transp sportation, ortation, Tele Telecommunica ication ion, Renewable Ene Energy, Defense and many more.
Establ stablished in in 19 1960s 60s under der the the Indo-S Indo-Sovi ovie et A Agree greements of 1959 and and 1960 1960 in in the area of Scientif Scientifiic, Te T echni chnical and and In Industri dustrial al Coope Cooperation. ration.
BHEL has its its se setup spre sprea ad al all over over India I ndia na namely Ne New De Delhi, Gurgaon, Gurgaon, Haridwar, Haridwar, Rudrap udrapur, ur, J hansi nsi, Bhop Bhopal, al, Hyd Hyde eraba rabad, Jag J agdi dish shpur, pur, Tiruchirapa Tiruchirapallli, Bangalo galore re and and many more. more.
Over 65% 65% of power power gene generated rated iin n India India comes from from BHEL -suppl supplied equipmen quipment. Overall Overall it has has insta installled power power equipme equipment for ove overr 90,000 MW.
BHEL 's Inve Investment in in R&D R&D is am amongst the the largest in in the the corporate sector in in I ndia. ndia. Net Net Prof Profit of the company in the year 20112011-2012 2012 was recorded as 6868 6868 crore having ving a high high of 21 21.2% .2% in in compari parison son to last last ye year.
BHEL has has already ready attaine ttained ISO ISO 9000 certif certification cation for quality quality man manag agem ement, and I SO 14 1400 001 1 certif certification cation for for environm vironmen ent management.
I t is is one one of I ndia's ni nine large rgest st Public Public Sector Sector Und U nde ertakings or PSUs, PSU s, known as the the “NAVRATNAS” or 'the ni nine ne jewels' .
The The power pla plan nt eq equipm ipment manufac factured by by BHEL BHEL is based on on co contemporary technology nology com comparable parable to the best in i n the world world
The The wid wide e ne network of BH BHEL's EL's 14 14 ma manufacturin ring div divisio ision ns, fou four Power Sector regional regional centre, over over 100 100 project project sites, sites, eight service rvi ce centre and 18 regional regional off offices, ces, enables the Compan Company y to promptly ptly serve its customers and provide provide them them with suitable products, systems and services – efficiently
2
1.2. WORK I NG AREAS ARE AS 1.2.1. POWER POWE R GENER ATI AT I ON
Power generation eration sector comprise pri ses s ther thermal, al, gas, hydro and and nuclea nuclear power power plant busi business ness as of 31.03.2001, BH BHEL suppl supplied sets account account for for nearl nearly y 6473 737 7 MW MW or 65% of thetotal total install nstalle ed capa capacity city of 99 99,146 ,146 MW MW in the the country, country, as against nil til till 19 1969 69--70 70.. BHEL has p proven roven turnkey capabil capabiliitie ties for executing cuting power proj proje ects from from concept concept to comm commissioni ssioning, ng, it it possess possesses es thetechnology ology and capabi pabillity to to produce therm thermal sets with with super criti critical cal param parameters ters up to 1000 1000 MW MW unit rating rating and gas turbine turbine generator nerator sets of up to 240 MW MW unit rating. Co-ge o-generation ration and combi combine ned-cycl d-cycle e plants have been introduced to achi achieve highe higher plan plantt effi efficie ciencie ncies. to make effi efficien cient use of the high-ash high-ash--content coal availab vailablle in I ndia, ndia, BH BHEL suppli supplie es circula circulating ting fluidi uidize zed d bed combu combustion stion boi boillers to both thermal and combined cycle cycl e power plants. plants. The The co company manufac factures 235 MW nuclear turbine ine ge generator sets and has commenced enced production production of 500 MW nuclea nuclear turbi turbine ne generator sets. Custom made ade hydro hydro sets of Francis, Pelton Pelton and and Ka Kaplan plan type types s for for dif different head discha discharge combina binati tion on are also engineering ri ng and manufac ufactured tured by by BH BHEL . I n al all, orders for more than than 700 700 uti utillity sets of thermal, hydro, gas gas and and nuclea uclear have been pla placed ced on the Com Company pany as on on date. te. The power plant equipment manufactured by BHEL is base based on contem contemporary technology ology compa comparable rable to the be best in in the worl world and iis s also interna ternati tiona onallly com competiti titive ve. The The Com Company ha has proven expertise ise in Plant Pe Perfor formance I mprovement th through renovatio renovation n moderni odernizatio zation n and and upgradi upgrading ng of a variety of of power plan plantt equipment besides special cialiized know how of residual li l ife assessm ssessment, health diagn diagnostics ostics and and lif li fe extensi xtension on of plants. 1.2.2. POWER TRANS TR ANSM M I SSI ON & DISTRI BUTI ON (T & D)
BHEL off offer wide wide rangi ranging ng products products an and syste systems for T & D appl applicati cations. ons. Products manufactured anufactured include nclude power transfor transformers, instrum instrument ent transfor transformers, dry type
3
transform transformers, ers, seri series es – and stunt reactor, reactor, capa capacitor citor tanks, vacuum– and SF circui circuitt breakers gas insulate nsulated swi switch tch gears and insulators. nsulators. A strong strong engine ngineeri ering ng base base enables ables the Company ompany to undertake rtake turnkey turnkey del deliivery of electric electric substan substances ces up to 400 kV level seri serie es compensa pensation tion systems (f (for increasing power transfer capa capaci city ty of transmission ssion lliines nes and and impro improvi ving ng system system stabi stabillity and and voltag voltage e regulati regulation) on),, shunt compensation sation systems (for (for power factor factor and voltage voltage improvem provement) and HVDC HV DC system tems (for (for economic transfer sfer of bulk power). BH BHE EL has in indigen digenously develo develope ped d the state-ofof-the-art control controllled shunt reactor (f (for rea reactive ctive power management ent on long transm transmission li lines). nes). Pre Presently tly a 40 400 0 kV Facts acts (Fl (Flexible xible AC A C Tran T ransm smission System) proj project under executi execution. on. 1.2.3 .2.3.. I NDUSTRI NDUSTR I ES
BHEL is a major contributor contributor of equipm quipment ent and and system systems to ind industri ustrie es. Cem Cement, sugar, fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and other process industri industrie es li lines nes and and im improving proving system system stabili stability and voltag voltage e regulation, regulation, shunt compens pensa ation tion system systems (for (for power factor and voltag voltage e improvem provement) and HV HV DC system systems (for (for econom conomic transfer transfer of bul bulk power) BHEL has ind indiigenou genously sly deve develloped oped thestate-of te-of--theart controll control led shunt reactor (for (for rea reactive ctive power mana anagement on long long tran transm smission ssion li lines). Pre Presently a 40 400 0 kV FA FA CTS (Fl (Flexible exible A C Tran T ransmission System System) proje projects is und unde er execu executi tion. on. The T he range range of system system & equipment suppl supplied includes: includes: captive power plan plants, ts, cogene generation ration plants DG power plants, ind industri ustrial al steam turbine turbines, s, ind industri ustrial al boil boilers and and auxil auxiliaries aries.. Wate Waterr heat recovery boil boilers, gas turbine turbines, s, heat heat exchangers and pressure vessels, els, centrif centrifugal compressors, electri electrical cal machines chines,, pumps, valves valves,, seam seamless steel tubes, electrosta electrostati tic c preci precipitators, pitators, fab fabric ri c fi filte lters, rea reactors, flui fluidiz dize ed bed combusti ustion on boil boilers, chemical recovery recovery boil boi lers and pro proce cess ss controls. controls. The The Com Company is a major jor pr producer of large-siz -size e thruster de device ices. It also lso supplies digital digital distri distribu bute ted d control system systems for for process process iind ndus ustri tries es, and control control & instrum nstrumentation system systems for power plant and industrial industrial appl appliicati cations. ons. BHE BHEL L is th the e onl only y company pany in India I ndia with the capability to make simulators for power plants, defense and other applications.
4
The The Com Company has commenced manufacture of large desalina lination ion plan lants to help augm augment the the suppl supply of drinki drinking ng water to peopl people e. 1.2.4. TRANSPORTATION
BHEL is invol involve ved d in in the deve devellopment design, engineeri engineering, ng, marketing arketing,, production, production, install nstallation, ation, maintena aintenance and afterafter-sa salles service rvice of Roll olling Stock and and traction traction propulsion propulsion system systems. In I n the area of rol rollling stock, BHEL manuf anufacture actures electri ctric locom locomoti otives ves up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting dul duly app appllications. cations. BHE BHEL L is also produc produciing rolli roll ing stock stock for special appli applica cations tions viz., overhead equipm quipment cars, Speci Special al well well wagons, wagons, Rai Raill-cum-road road vehi vehicl cle e etc., Besides tracti traction on propul propulsion system systems for for in-hou in-house se use, BH BHE EL manufa ufactures tracti traction on propulsion propulsion system systems for other roll rolling stock producers producers of el electr ectriic locom locomotive otives, diesel diesel-electric electric locomoti ocomotive ves, ele electrical ctrical mul multipl tiple e units and and metro cars. The The electric ctric and die diesel traction traction equi equipm pment on India India Rail Railways ways are largely largely powered powered by by el electri ectrical cal propulsi propulsion on system systems produce produced by BHE BHEL . The company pany al also unde undertakes retool retooliing and and overhaul rhauliing of rol rollling stock in i n the area of urban urban transportation transportation systems. BH BHEL is geared up to turnkey execution xecution of electric electric troll trolley bus bus syste system ms, li light rail system systems etc. BH BHEL is al also di diversif rsifying in the area area of port port handing ding equipm quipment ent and pipel pipeliines transportatio sportation n system. 1.2.5. TELECOMMUNICATION
BHEL also caters to Te Telecomm communicatio unication n sector by way way of small, all, medi edium and large switching systems. 1.2.6. .6. RENEWA RENE WABL BL E ENERGY ENER GY
Tec Technolog logies that ca can be offe ffered by BH BHEL EL for for exploit loitin ing g non-co -convention ional an and renewable sources of energy include: wind electric generators, solar photovoltaic systems, sol solar lante lanterns and batterybattery-powered powered road vehicl hicles. es. The The Company has taken up R&D efforts efforts for for deve develo lopm pment of multi ulti-juncti unction on am amorphous orphous sil siliicon sol sola ar cells cells and and fuel fuel based system systems.
5
1.2.7. I NTERNATI NTER NATI ONAL OPERATI OPERA TI ONS
BHEL has, has, over the years, establi blished its its references references in around 60 countries of the worl world, ran rangi ging ng for for the United nited States in the west west to New New Zealand in in the far eas east. the these reference references s encom encompass pass alm almost the entir entire e product range range of BHEL , covering covering turnkey power power proje projects of thermal, hydro
and gasgas-ba base sed types, types, subs substatio tation n proje projects, rehabi abilitation tation
proje projects, besides besides a wide wide varie variety of products, li like transf transform ormers, insulators, insulators, switchge switchgears, heat exchangers, castings castings and forgi forgings, ngs, valves valves,, well well-head equi equipm pment, ent, centrif centrifugal compressors, pressors, photo-vol photo-voltaic taic equipment etc. apart apart from from over 1110 10m mw of boil boiler capacity city contribu contributed ted in Mal Malays aysiia, and and executi xecution on of four four presti prestigi gious ous power power proje projects in in Oman, an, some some of the other major ajor successes achieve chieved by the company have bee been iin n Austral Australiia, Saudi Saudi Arabi rabia, L ibya, Greece, ce, Cyp C yprus rus,, Malta, Egy E gypt, pt, Ba Bangl ngladesh, sh, Aze A zerba rbaiijan, Sri Sri L anka, IIraq raq etc. The The company has been successful ful in meeting ing demanding ing customer's require irements in terms of complex lexity of the works orks as well as technolog ologica ical, quality and other requirements viz. viz. extende xtended warrante warrantee es, associated O& O&M M, financing cing packages etc. etc. BHEL has has proved its its capabi capabillity to to undertake proje projects on fas f ast-track t-track basi basis. The company pany has been successful in meeting varying needs of the industry, be it captive power plants, utility power generation or for the oil sector requirem requirements. ents. Executing cuting of overse oversea as projects projects has has also provided BHE BHEL the experien rience of working worki ng with with world ren renowned consulti consulting ng organizations organizations and and insp inspe ection ction agencies ncies.. I n addit additiion to demonstrated capa capabil bility to unde undertake turnkey turnkey project projects s on its its own, BHEL possesses the the requi requisi site te flexibi xibillity to interface interface and complem plement with with international tional companies companies for for large proj projects by suppl supplyi ying ng complem plementary entary equipm equipment ent and meeting ting their production production needs for for interme rmediate diate as well as fi finishe nished products. The The success in the area of re rehabilita ilitation ion and life life extension ion of po power projects has establ stabliished BH BHEL as a comparabl parable e alternative tive to the origi original nal equipm quipment manuf anufact acturers urers (OEM’S) for such plants.
6
1.3. TECHNOLOGY UPGRADAT UPGRADAT I ON AND RESEARCH RESEARCH & DEVEL OPMENT OPME NT
To remain competitiv itive e and meet customers' expectation ions, BH BHEL EL lay lays great emphasis phasis on the continuous conti nuous up gradati gradation on of products products and and relate related d technologi ologies es,, and development of new products. products. The T he Company has upgraded its its products products to contemporary levels evels through conti continu nuous ous in in house house efforts forts as well as through through acquisiti cquisition on of new technologies from leading engineering organizations of the world. The The Co Corporate R&D R&D Divis Divisio ion n at at Hyd Hyderabad, sp spread ov over a 14 140 ac acre co complex lex, lea leads BH BHEL EL 's research efforts in a number of area reas of impo importa rtance to BH BHEL EL 's produ roduct range. Resea esearch rch and and product developm development ent centers centers at each of the manufacturi anufacturing divi divisi sions ons play play a complem plementary entary rol role e. BHEL 's Inve Investment in in R&D R&D is am amongst the the largest in in the the corporate sector in in I ndia ndia. Products Products devel veloped in-house in-house during during the the last fi five years contribu contributed ted about bout 8.6% to the revenues in in 2000-2001. 0-2001. BHEL has has iintroduce ntroduced, iin n the recent recent past, several veral state-of state-of--thethe-art products products developed in-house: low-NOx oil oil / gas gas burne burners, circulati circulating ng flui fluidi dize zed d bed combustion bustion boil boilers, high-ef high-effficien ciency cy Pelton Pelton hydro turbine turbines, petrol petroleu eum m depot depot automation ation sys system tems, 36 kV gasgas-iinsulated nsulated sub-stations, etc. The The Com Company pany has has also tran transfe sferred a few techn technologi ologies es developed in-hous in-house e to othe other Indian I ndian compani panies for for commercial rcialiization. zation. Some Some of the onon-going going devel velopment & dem demonstration onstration proje projects incl include ude: Smart wall wall blowi blowing ng s system ystemfor clea cleaning ning boi boiller soot deposits, and micro-control cro-controlller base based governor governor for for diesel-electric locomotives. The company is also engaged in research in futuristic areas, such as appl appliication cation of super super conducti conducting ng materials rials in power power genera generations tions and ind industry, ustry, and and fuel cells cells for for distribu distri bute ted, d, envi environm ronment-fr t-friiendly power gene generation. 1.3.1 HUM AN RESOURCE RESOURCE DEVEL DEVE L OPM ENT I NSTI NSTI TUTE TUT E
The The most prize ized asset of BH BHEL EL is its its employ loyees. The The Hum Human Resource Developmen velopment Institute I nstitute and other HR HRD cente centers of the Company pany hel help in in not only only keeping ping thei their skil ski lls upda updated and ffiinel nely honed honed but also in in adding dding new new skil skills, whene whenever ver required required.. Continuous training and retraining, positive, a positive work culture and participative
7
style styl e of management, have engendered developm development of a committed tted and moti otivated work work force le leadi ading to enhan nhance ced d productivity productivity and and higher le levels of qual quality. 1.4. HEAL TH, SAFET SAFET Y AND ENVIRONMENT ENVI RONMENT M ANAGEM ENT
BHEL , as an an inte integral part of busi business perform rformance ance and in its its ende endeavor of becomi coming a worldworld-cl class ass organization organization and sha shari ring ng the growing growing global concern concern on issu issues es related to Envir Environm onment. Occupati Occupational onal He Health alth and and Safety, is committed to protecting cting Environm nvironmen ent in i n and around around its its own establi blishment, ent, and to provi providing ding saf safe and healthy althy working environment to all its employees. For fulfilling these obligations, Corporate Poli ol icies cies have have been been form ormulate ulated as: 1.4.1. ENVI RONMENTA RONM ENTA L POL I CY
Compli pliance with with applicab pplicablle Environm nvironmental Le L egisl gislation/R ation/Re egulation;
Continua ontinuall I mprovem provement ent in in Enviro Envi ronm nment ent Man Management ent Systems to protect our natural environmen environment and and Control Control Poll Pol lution; ution;
Promoti Promotion on of activi ctiviti tie es for for conse conservation of resou resources rces by by E Envi nvironm ronmental Management;
Enhancem nhancement ent of Enviro nvironm nmental ental awarene awareness ss amongst employ ployee ees, custom customers and suppli supplie ers. BH BHE EL will wil l also assi ssist and co-operate rate with the the conce concerned Governm Government Agenci gencies es and and Regul Regulatory atory Bodies Bodies engage ngaged in in environm nvironmental activi activiti ties es,, offeri of fering ng the the Company's capabilities is this field.
1.4.2. OCCUPATI OCCUPATI ONAL ONAL HEAL TH AND SAFET SAFET Y POLI POL I CY
Com Compli pliance with with appli applicab cablle Le Legisl gisla ation tion and and Regulations;
Setting Setting obje objective ctives and and targets to eliminate/control nate/control//minim nimize risks ri sks due due to Occupational and and Safe Safety Haza Hazards; rds;
Appropriate ppropriate structured training training of employee ployees s on Occupati Occupational onal Hea Health and and Safety (OH&S) aspects;
8
Form ormulatio ulation n and and mainten maintenan ance ce of OH& OH&S Manag anagem ement programmes for for continual continual improvem provement;
Period riodic review iew of OH&S Man Management Sys System to ensure its its continu inuing ing suitabil suitability, adequa adequacy and ef effectiven ectiveness; ess;
Com Communicatio unication n of OH& OH&S Pol Poliicy to al all employee ployees and and intereste interested parties rties.
The The major jor units its of BHEL BHEL have alre lready acquire ired ISO 14001 Env Enviro ironmental Manag anagem ement System SystemCertif ertification, and other units are in in advan advance ced d stages of acqui acquiri ring ng the sam same. Action ction plan plan has has been prepa prepared red to acqui acquire OHSA OHSAS S 18001 18001 Occupati Occupational onal He H ealth and Safety Manage Management System Systemcertif rtificati cation on for all BHEL units. units. I n pursuit pursuit of the these Pol Policy requirements, nts, BH BHEL wil will continuousl continuously y stri strive ve to improve improve work work parti particl cles es in the light of advances advances made in technology chnology and and new understandings rstandings in in Occupational Health, Safety and Environmental Science. Participation in the "Global Compact" of the United Nations. The The "Glo Global Com Compact" is is a partnership between the Unit Unite ed Nat Nation ions, th the busine iness community, unity, iinte nternationa rnationall labor abor and NGOs. GOs. It I t provide provides s a forum for the them to work together and and improve corporate corporate practices practices through through co-operatio co-operation n rather rather than confro confronta ntati tion. on. BHEL has joine joi ned the "Glo "Globa bal Compact" pact" of of United Nations and has has committed tted to support support it it and and the set of core values enshrine nshrined in in its its nine princi principl ples es:: 1.4.3. PRINCI PL ES OF THE " GL OBAL COMPACT" COM PACT"
HUM HUM AN RIGHTS
1. Busi usiness shou shoulld supp support ort and resp respe ect the the prote protection ction of internatio rnationa nally proclaim proclaimed human rights; rights; and 2. Make sure sure they are are not not complic plicit it in human rights rights abuse buses. s.
9
LABOUR STANDARDS
3. Busi usiness shou shoulld uphold uphold the fre freedom of associ ssociation ation and and the effective ctive recogniti recognition on of the righ rightt to coll collective ctive bargai rgaining ning;; 4. The elim li mination ination of all form of forces an and compulsory pulsory la labor. 5. The effe ffective aboliti olition on of chi child labor, labor, an and 6. Elim El imina inate te dis discrim crimina ination tion..
ENVIRONMENT
7. Businesse usinesses should support support a precautionary utionary approa approach ch to environm vironmental ntal challenges nges;; 8. Unde ndertake initia nitiative tives s to prom promote grea reater environm vironmental ntal resp responsibi onsibillity and and 9. Encourag ncourage e the develo velopm pment and and dif diffusion of envir environm onmental ntally fri friendly dly technologies. By joi joining ning the "Glo "Globa ball Compact", pact", BH BHEL would get a unique unique opportunity opportunity of networki networking ng with with corporate and sha shari ring ng expe experien ri ence relati relating ng to social responsibi responsibillity on gl global basi basis.
10
1.5. BHEL UNITS UNI TS
UNI 1. Bh Bho opal
TY PE Heavy Electrica ical Plan Plant
PRODUCT Steam Steamturbine turbines , Turbo urbo genera generators tors , Hydro sets , Switch gear controllers
2. Ha idwa idwa HEEP CFFP
Heavy Electrical
Hydro turbine turbines , Stea Steamturbine turbines, Ga Gas
Equipment Plant
turbine turbine, Turbo gene generators, Heavy castings castings
Central Foundry Forge Plant
and forging forging.. Control Control pane panels, Li L ight aircrafts, Electrical machines
3.Hyde 3.H yderabad HPEP
Heavy Power Equipment
I ndustri trial turbo – sets, Com Compressors pressors Pum Pumps
Plant
and hea heaters, Bow Bow mills, He Heat exchange xchangers oil oil rings, Gas turbines , Switch gears, Power generating erating set
4.Tiruchi HPBP SSTP
High Pressure Boiling
Steam Steam less steel tubes, tubes, Spir Spiral al fin welded
Plant
tubes.
5.Jha 5.J hansi TP
Tra Transform former Pla Plant
Tra Transform formers, Die Diesel shunt less AC loc locos and AC EMU
11
6.Banglor EDN EPD EP D
Control Equipment
Energy nergy meters, Wate Water meters, Control ontrol
Division
equipment, Capacitors, Photovoltaic panels,
Electro Porcelain Division
Sim Si mula ulator, tor, Telecomm communicatio unication n system system, Othe Other advanced advanced micro cro processor processor based control system system. I nsul nsulator ator and bushi bushing, ng, Ceramic liners.
7.Ranipe BAP
Electrostatic tic precipi precipita tator, tor, A ir prepre-heater, ter,
Boiler Au Aux xiliaries Plant
Fans, ans, Wind Wind electric electric ge generators, Desal Desalinati nation on plants.
8.Goin .Goind dwal
I ndustria triall Va V alves lves Plan Plant
I ndus ndustri trial al valves and Fabri Fabrica cati tion on
I nsulator Plant.
High tension sion ceramic, Insulati I nsulation on Pla Plates and
9.Ja 9.J agdishpur gdishpur IP
bushings 10.Rudrapu
Component Fabrication
Windmill, Solar water heating system
Plant 11.Gurgoan
Amorphous Silicon Solar
Solar Photovoltaic Cells, Solar lanterns
Cell Plant.
chargers , Solar clocks
TABL TA BL E 1
12
1.6. BHEL BHE L HARI HA RI DWAR 1.6.1 .6.1. L OCA TI ON
I t is situ ituated in the foo foot hills of Shiva Shivalik range in Harid Haridw war. The The main administra nistrati tive ve buil building ding is is at at a distance stance of about 8 km from romHaridwa aridwar. r. 1.6.2. ADDRESS
Bhara Bharatt He Heavy Ele Electri ctrica call L imite imited d (B (BHE HEL L) Ranipur, Haridwar PIN: PI N:-- 249403 1.6.3. AREA
BHE BH EL Haridwar Haridwar consists consists of two man manufacturi ufacturin ng units, namely Heavy Heavy Elec E lectri trica call Equipment Plant (HEEP) and Central Foundry Forge Plant (CFFP), having area HEEP area:- 8.45 sq km CFFP area:- 1.0 sq km The The Heavy Electric ricals Equ Equipm ipment Pla Plant (HEEP (HEEP)) loc located in Harid ridwar, is one of the major manufactu ufacturing ring plants of BH BHE EL . The core bus busine iness ss of HEE HE EP include includes design and and manufacture of large steam and gas turbine turbines, tturbo urbo generators, generators, hydro turbi turbine nes s and generators, large AC AC/DC /DC motors otors and and so so on. Central Foundry Forge Plant (CFFP) is engag engage ed in in manuf anufac acture ture of Steel Steel Casti asting ngs: s: Up to 50 Tons per Piece Wt & Steel Forgings: Up to 55 Tons per Piece Wt. 1.6.4 .6.4.. UNI UNI T S
The There are two units its in BHEL BHEL Har Haridw idwar as foll follo owed: 1) He Heavy El Electrica ctricall Equipm quipment Plan Plant (HE (HEEP) and anothe nother 2) Central Foundry Forge Plant (CFFP).
13
THERE TH ERE ARE AR E 8 BL OCK S I N HEEP HE EP
BL OCK S
WORK PERF ORM E D I N T HE BL OCK
I . Electrica Electrical Ma M achi chine
Turbo rbo ge generato rator, r, ge generato ratorr excite xciterr , motor otor (ac (ac and dc)
II. II . Fa Fabric rication ion
Lar Large size ize fabrica icated assemblies lies or co components
I I I. Turb Turbine ine & Auxil A uxiliary iary
Stea Steam,hydro ,hydro ,ga ,gas turbin turbine es, ttu urbi rbine blade blade , spe special tooli tooling ng
I V. Fe Feeder
Winding Winding of Turbo T urbo ,hydro generators ,ins ,insul ula ation tion for ac & dc motors
V. Fabrication
Fabricate abricated d parts of of steam turbine turbi ne, wate waterr boxes, storage storage tank, hydro turbine parts
VI. Fabrication Stamping ping and die die
Fabrica ricate ted d oil oil tanks, hollow hollow guide guide bl blades, des, Ri Rings, stator fram frames and rotor rotor spindle, spindle, all dies dies,, stam stamping ping for for gene generators and motors otors
manufacturing
14
VII. VI I. Wo Wood working ing
Wooden packin king, sp spacers.
V I I I . Heaters & coole coolers rs
L P heaters, rs, ejec ejecto tors rs,, glan glands, st ste eamand oil coole coolers rs,, Oil tank, bearing covers
TABL TA BL E 2
THERE TH ERE ARE AR E 3 SECT I ONS I N CFF P
SEC ECTIO TION NS
WORK PERF PERFO ORMED IN THE THE SEC ECTIO TION N
I.
Fou Foundry
Cas Casting ing of tu turbine ine rotor, casing ing and Fra Francis run runner
II.
Forging
Forging of sm small ro rotor parts
I I I. Mac Machine shop
Turn Turning ing, b bo oring ring, p pa artin rting g off, drill drilling ing etc. tc.
TABL TA BL E 3
15
1.6.5. HEEP HEE P PRODUCT PR ODUCT PROFI PR OFI L E
1. THERM THE RM AL SETS ET S:
Steam Steam turbine turbines and and gene generators up to 500 M MW W capacit capacity y for for util utility and combine bined cycle applications
Capab apabiility ity to manuf anufa acture up to 1000 1000 MW MW unit cycle cycle.
2. GAS TURBI TUR BINES: NES:
Gas turbines turbines for in i ndustry dustry and and utili util ity appli applica cati tion; on; range range-3 to 200 200 MW (I SO). SO).
Gas turbine turbines based co-ge co-gene nerati ration on and combine bined d cycl cycle system.
3. HY DRO SETS:
Custom ustom– bui built conventional ntional hydro hydro turbine of K apla plan, Fran Franci cis s and and Pel Pelton with matching atching generators rators up to 250 MW unit unit si size. ze.
Pump turbine turbines with with matching atching motorotor-ge genera nerator tors. s.
Mini / micro hydro hydro sets. ts.
Spherica ricall butte butterf rflly and and rotary valves a and nd auxi auxilliaries ries for hydro hydro station. tion.
4. EQUIPM ENT FOR NUCLEAR NUCL EAR POWER PL ANTS: ANTS:
Tur Turbine ines and generators up to 500MW unit size ize.
Stea Steamgenerator up to 500M 500MW W unit unit size. size.
Re-heaters e-heaters / separators. tors.
Heat exchangers and pressur pressure e vessels. vessels.
5. EL ECTRI CAL M ACHI NES: NES:
DC genera generall purpose and roll rolling mill machi achines nes from from100 to 19000 00K K W suitab suitablle for operation tion on voltage voltage up to 1200 1200V V. The These are provide provided with with STD STDP, totally totall y enclosed closed and duct ventil ntilated encl enclosures. osures.
DC auxiliary mill motors.
16
6. CONTROL PANEL:
Control pane panel for vol voltage tage up to 400K W and control control desks for for gene generating rating s stations tations and EMV sub– sub–stations tions..
7. CAS CA ST I NG AND FORGI NGS: NGS:
Sophisti Sophisticate cated heavy casti casting ng and forgi forging ng of creep creep resi resistant stant al alloy steels, stainle stainless steel steel and and other other grades of all alloy meeting ting stri string ngen ent inte international rnational specif cifications cations..
8. DEFENCE:
Naval val guns with coll collaborat boration ion of I taly taly.
17
2. HEAVY FABRI CATI ON 2.1. .1. DEF DEFII NATI NAT I ON:-
Fabri abricatio cation n as an an indus industri trial al term term refe refers to buil building ding metal structures structures by cutti cutting ng,, bending and and asse assembli bling. The The cutting cutting part part of fabri abrication cation is is done via via sawing, awing, shearing, ri ng, or chise chisell machi achine (all (all with with manual anual and powered powered machine varian variants); ts); torching torching with with handheld torches (such as as oxy-f oxy-fuel torches or plas plasm ma torches); and via via CNC CNC cutters cutters (using (using a laser, torch, or water water je jet). t). The bending is done via hammering ri ng (manual anual or powered) powered) or via via press press brake and similar tools. The assembling (joining of the pieces) is via welding and binding with with adhesives dhesives, ri riveting, veting, threaded threaded fastene asteners, or even yet more ore bendi bending ng in in the form orm of a cri crimped ped seam seam. Structural Structural metal and sheet metal are the usual usual starting starti ng material rials s for for fabri abricatio cation, n, al along with with the welding welding wire, wire, fl flux, and fasteners that wil will join oin the cut pi pieces. ces. A s with with other manufacturi anufacturing processes, both both human labor and automation ation are commonly onl y used. The product resulting from (the process of) fabrication may be called a fabrication. 2.2. PROCESS:-
Processe Processes invol involve ved d in in Fa Fabrica brication tion are are::
Cutting & Burning.
Forming
Machining.
Welding.
2.3. APPL I CATI CA TI ONS:ONS:
Equipm quipme ent for for Ind I ndus ustrial trial Appl pplications cations.
Equi quipment for for Spe Specialty cialty Gases Appli Applica cati tions. ons.
2.4. RAW M ATERI AT ERI AL
Stan Standard raw materi aterial als s used by metal fabri fabricators cators are:
Plate metal
Form ormed and expanded metal
18
Tub Tube stock
Square stock
Sectional Sectional metals ( I beams, W beams, CC-channel )
Weldi Welding ng wire
Castings
Fittings
FIG. FI G.1 1 PROCESS PROCESSES PERFORM PERFORM ED IN HEA VY FABRI CATI ON
19
3. M ETAL CUTTI NG 3.1. SHEA SHEA RI NG MACH M ACHII NE:-
A shearing aring machine achine is hydraul hydrauliic machi achine used to cut metal work work--pie pieces ces with with help of Shearing mechani echanism. I n this this machine achine the metal workwork-pi piece ece are passed sed through through the machi achine through through roll rol ler transm transmitters call called guide guides s which which moves too-an too-and d fro fro and then then stopped with with help help brake stops stops which works works hydraul hydrauliically call y which which operate operates s by pressi pressing ng foot peda pedall provide provi ded at at the foot of of machi achine se setup. The T hese stops hol hold d the workwork-piece tightl tightly y so that that it it doesn’ doesn’tt disturb disturb due to high im i mpact of shearing cutters. cutters. The Then valve is is operate operated d which which cause causes s the fluid uid to pressurize ressurize and further moving ovi ng the cutter down which which strikes strikes the workwork-piece and causing using cutti cutting ng action of workwork-piece. Me M etals tals that can be cut are are mild steel, stai stainl nles ess s steel steel etc. Maxim aximum thick thickne ness that that can be cut is is 10mm. Mai M ain n component of Shearing machine is as follow:a) J ack:-sup ck:-support port the the plate or metal parts parts which are to be be cut. b) Blade:-cu :-cutting tting the the metal tal parts (cutte (cutter). r). c) Guide:Guide:-N Numerica ricall control controllled le length ngth adjustment. nt. d) Hyd Hydraulic Oil tank.
FI G.2 G.2 CNC SHEARI SHEARI NG MACHI MACH I NE
20
3.2 PL ASMA CUTT I NG:-
Plasma cutting cutting is is a process that is is used to cut steel steel and and other metals (or (or sometim etimes other other mate materials) rials) using using a plasm plasma torch. I n this proce process, ss, an inert gas (in (in some unit units, s, compresse compressed air) air) is blown blown at high high sp spee eed out of a nozzl ozzle; e; at the same tim ti me an electri ctrical arc is for form med through that gas from from the nozzl ozzle e to the surface surface being cut, turning turni ng some of tha thatt gas to plasm plasma. The The plasm plasma is suff sufficientl ciently y hot to melt elt the metal being being cut and moves oves suffi suff icien ciently tly fas fast to blow blow mol molten ten metal away from from thecut. Plas Plasm ma cutters cutters have also been used in in CNC CNC machi achinery. Manuf anufactu acturers rers build buil d CNC cutting cutting tables, some with with the cutter buil built in in to the the table. The The idea behi behind nd CNC CNC tabl tables is to all allow a computer to control the torch head making aking cle clean sharp cuts. Mode M odern CN CNC plasma equipment is capa capabl ble e of multi ulti-axis cutting of thick materi terial, al, allowi allowing ng opportuniti opportunities for complex plex welding ding s se eams on CNC CNC welding welding equipmen quipment that that is is not possi possibl ble e otherwise otherwise.. Weldi elding ng torch torch used has outer outer torch torch made made up of brass and and inne innerr one one made of copper. Mi M inim nimum gap between torch torch and and workwork-piece piece is 5mm. This machine achine can be used to cut the workwork-piece of mild steel steel and stai stainle nless steel. steel. The The diff diffe erences be between th the cu cutting ing me methods for for bo both of of these metals are th the us use of of nozzles & the pressure of gases applied to pass through nozzles so that cutting action is done easil sily. Work Work--piece piece of thick thickne ness ss 1 100m 00mm to 210mm can be cut fro from m this this type machi achine. For e.g. For a mild steel steel job of thicknes thickness s 10 100m 0mm the cutting cutting spe speed iis s 131.55mm/min. Gases used in in this this type of machi achine are oxygen and and Bha Bharat Me M etal Cutting utting Gas (BMCG). Oxy-acetylene is avoided due to less purity& heavier as compared to BMCG. It is less less pure which which cause causes s repeated clea cleani ning ng of burne burner. r. The gap gap between Nozz Nozzlle & plate plate is 5mm. I f gap is increa increased sensor sensor adjust the pressure pressure according according to it. it. L arge diameter Nozz Nozzlle is is use used for for thick thick metal sheet & highe higher pressure and vice vice versa for thin thin metal sheet.
21
FI G.3 G.3 CNC PLASMA CUTTI NG MACHI NE 3.3. OXY -FUEL CUTT I NG:-
Oxy-fuel Oxy- fuel cutti cutting ng is the the most wide widelly appl appliied process for cutting cutting mild steels and and low all alloyed steels. The process process covers the entir entire e thickne thickness ss range range from from 1 mm to 25 2500 00 mm (0.04 (0.04--100 inche nches), it gives gives an exce excelllent cut qual quality and the investm nvestment costs are low. low. Furthermore rmore the process process can eas easiily be mechaniz echanize ed. OxyOxy-fuel fuel cutting cutting is is a combusti bustion on proces process. s. An oxygen jet jet burns the metal in i n a narr narrow ow section section to make a cut and removes the combustion bustion products products (sla (slag) g) from from the kerfs. The purity of the the cutti cuttin ng oxyge oxygen is of of great importan portance ce for the cutting cutting spe speed ed that can be achieve achieved. A highe higherr purity purity leve levell means a highe higher cutti cutting spee speed. OxyOxy-ffuel uel cutting cutti ng are processes that that use fuel gases and oxygen to either either weld or cut metals. etals. I n Oxy-fuel Oxy-fuel cutting cutting,, a cutting cutting torch is is use used to heat up fe ferrous rrous metal tal to kin kindling dling temperature perature (about 980°C) 980°C).. A stream of pure oxygen is tr trai aine ned on the hot metal which which chemicall cally combi combine nes with with the the iron which which then then flows out of the cut, or kerfs, as an ironoxide oxide sl slag. ag. There have been examples ples of oxy-hydroge oxy-hydrogen n cutting cutting sets with with small all (scuba scuba sized) sized) gas cyli cylinders worn worn on the the user's back in a backpack ackpack harness, for for rescue rescue work.
22
4. BENDI NG Bending Bending is a process by which metal tal can can be deformed by pla plastical stically deform forming the materi aterial al and changi changing ng its its shape shape. The T he material is stressed stressed beyond beyond the yield yield strength but bel below the the ulti ultim mate tensi tensille strength. The T he surface surface area area of the the materi aterial al does does not change change much. Ben B ending ding usuall usually y refers refers to def deformation ormation about about one axis. xis. 4.1. .1. HY DRAUL I C PRESS PR ESS::-
A hydrauli hydraulic c press press is a hydra hydraul uliic mechani anism for applyi applying ng a large lift liftiing or compressi pressive ve force force.. It I t is is the hydraul hydrauliic equiv equivalent alent of a mechani chanical cal leve l ever, and is also also known as a Bramah press after the inven inventor, tor, J oseph Bramah. Hydraul Hydrauliic presses are are the most commonlyonly-use used d and and effi eff icie cient form form of modern odern press. press. The The hydraulic press depends on Pascal's l's princ inciple iple: the pressure throughout clos losed system systemis constant. At one one end of the syste system is a piston wit with h a small cross-sectiona ctionall area drive dri ven n by a le lever to incre i ncrease ase the the force force.. Smal Smalll-diam diameter tubing le leads ads to the othe other end of the system system. A fluid, uid, such such as as oil, oil, is displace displaced when ei either ther piston is pushed inwa inward. The small all piston, piston, for for a given given distan distance ce of movement, displ displace aces a small aller am amount of volum volume than than the large piston piston,, which which is is proportion proportional to the rati ratio o of areas of the heads of the pistons. pistons. Therefore, the small piston piston must ust be moved oved a la large dista distance to get get the la large piston piston to move si signif gnificantl cantly. y. The T he dista distance nce the large piston piston wil will move is is the the dista distance that that the the small piston is is moved divide divided by the ratio ratio of the the areas of the the heads of the the piston pistons. The There were two hydraulic presses at present which ich are:
CNC Back Press-340 ton.
Manua anuallly operated operated-- 400ton, 800ton.
23
FI G.4 G.4 CNC BACK PRESS PRESS M ACHI NE
4.2. ROLL ING M ACHI NE: THREE TH REE ROL R OL L BENDING MA CHI NE: Roll benders use three rolls (typically) to bend
solids, extrusions and tube and pipe to various diameters by adjusting one or two rolls. The The pyramid style roll be benders have one moving ing roll, ll, us usually the top roll. Dou Double pinc inch type roll benders have two adjustable rolls, usually the bottom rolls, and a fixed top roll. L argearcs, circl circle es and and spir spirals als are typical appli plications for roll roll bende nders. The The roll bending ing machine ine in BH BHEL EL ha has foll follo owing ing specifica ification ions:-
S.R.NO.
SPE CI F I CA T I ONS
DI M ENSI ONS
1.
MA X I MUM WORK I NG L ENGTH
8000 MM
2.
MI NI MUM DI A METER OF FORMI NG
1300 MM
3.
PL ATE THI CK NESS
4.
UPPER ROL L DI AMETER
32 MM 7550 MM
24
5.
L OWER ROL L DI AMETER
680 MM
6.
SPEED OF FORMI NG
7.
SPEED OF L OWERI NG UPPER ROL L
60 MM /MI NUTE
8.
SPEED OF RAI SI NG UPPER ROL L
120 MM /MI NUTE
5 M /M I NUTE
TABL TA BL E 44- SPECI FI CATI CA TI ON OF THREE THR EE ROL L BEND BE NDII NG M ACHI ACH I NE
FI G.5 G.5 THREE ROL L BEND BENDI NG MACHI NE
25
5. WEL DI DING NG Weldi Welding ng section ction is is the most im important section ction of this this block block as al all the main parts of SteamTurbine urbine from gene generator to casing or ffrom rom shafts to blad blades es requires wel welding ding to joi join their surfaces. Mainl M ainly y the wel welding ding methods thods use used are are Shi Shielded elded Me Metal Arc A rc Welding Welding (MI (MI G), G), Carbon Carbon Di-oxi i-oxide de wel welding (MI (MI G welding) and and TI G weldi welding ng etc. Air Products' Products' shieldi shielding ng gase gases are commonly only used used iin n several veral welding welding processe processes, mostly ostly MI MI G and and TI TI G welding welding.. The T he selection lection of a suitable welding welding gas is esse essential for the the welding welding process. process. The T he wel welding ding gas gas not only only protects protects the weld me metal from rom the surrounding surrounding air, air, it can also contri contribute bute to higher productiv productiviity and to bet better ter mechani chanical prope propertie rties of the wel weld. Ai Air Produc Products ts offers offers a full ful l ran range of standa ndard shi shielding elding gas gas mixtures xtures for for MI MI G welding welding for all all common materi teria al types. types. 5.1. TI G WEL DING:DING: -
TIG we weldin lding g is a high igh-qu -quality lity weldin lding g techniqu ique with ith a low low fus fusion ion rate. The The arc burns betwee between a tun tungste gsten ele electrode ctrode and the work pie piece; the the electrode ctrode does does not melt, melt, so it acts only only as a curren current conductor and arc carrier. carrier. The shield shieldiing gases gases prot protec ectt the weld area area from from atmospheric ospheric gases, such as oxygen, nitr nitrogen ogen,, carbon diox dioxiide, de, and water vapor. por. Dep Depen ending ding on the material rials s being welde welded, d, tthe hese atmospheric ospheric gases can reduce reduce the qual quality of of the weld or make the welding weldi ng process more dif difficult cult to use. I n this type of we welding ding,, tungs tungste ten n el electrode is use used which is nonnon-consumabl able. Fi Filler materi terial al use used is either coppe copper wire or wire of same material terial to be weld. When When curre curren nt through tungste tungsten el electrode ctrode is passe passed, tha than a spark spark is produced, produced, which which iis s of a very very high high intensity. ntensity. A long with with above a blow of argon gas gas is passe passed through holde holderr to provide provide inert nert atmosphere at weldi welding. The stre trength of TI G weldin lding g is more ore than any oth other typ type of welding lding. The temperature of flame is is varie varied by adjusting adjusting voltag voltage e/ current as per per re requirement. ent. This type type of welding is used mainly for welding pipes. Defects occur mainly in this type of Weldi Welding ng is porosity porosity cause caused d by stopping stopping the flow of argon argon gas.
26
FI G.6 G.6 TI G WELDING WEL DING
5.2. MI G WEL WE L DI NG:-
I n MI MI G weldi welding, ng, the metal ele electrode ctrode is used to produce produce spark. rk. The T he current current is is allowe allowed d to flow through filler metal which passes through through wel welding ding holder holder & a blow of gases is passed through holes provided on holder which provide safeguard to welding area from rom atmospheric ri c gases. Vol V oltage tage can be adjusted adjusted according according the speed of filler material, feeding ding is is adj adjusted usted as per requirem requirement. ent.
FI G.7 G.7 M IG WEL DI NG
27
5.2.1 .2.1. CARBON CAR BON DIOXI DIOX I DE WEL WE L DING :- I n thi this type type of wel welding, copper copper coate coated d wire is is
made ade in in contact contact with with metal to be weld and then then high high current is allowed allowed to fl flow through through wire wire which cause causes spark spark of very high high intensi intensity. Then hen carbon dioxi dioxide de & argon gas gas is is blown blown to welding weldi ng area area which hel helps in in maintaini aintaining ng the inert atmosphere nearby wel welding ding area and free from from oxygen. Com Compositi position on of carbon dioxi dioxide & argon gas gas is 80 80:20(%) :20(%).. Tem Temperature is maint intaine ined at 3600 to 4000 ºC. The The strength of Weldin lding g wit with h CO CO2-gas wel welding ding iis s much better as compared pared to metal Arc. So for mass ass productio production n and and hi high productivit ctivity y with with grea greater ter qual quality ity this this wel welding ding method is used. Main defect of carbon dioxide welding is porosity.
FI G.8 CO 2 WELDING MACHI NE 5.3. .3. GOUGI GOU GI NG:NG: -
The Thermal gouging ing is an an essential ial part of weldin lding g fabric rication ion. Use Used for for rapid removal of unwanted metal, the material rial is loc local allly heated ated and molten olten metal ejecte ejected usually by blowi blowing ng it away. Norm Normal al oxygen oxygen fuel fuel gas gas or arc processe processes can be used to produce produce rapid rapid melt meltiing and and metal rem removal. oval.
28
Manua anuall metal arc Gougi Gouging ng is a process process in in whi which a process process a electrical ctrical arc is gene generated to melt the the material. Othe Other technique techniques li like special cial electrodes electrodes or a jet of compresse pressed air are used to blow blow away the molten olten material. rial. No specifi specific high high purity purity or com compressed pressed gases are needed in in these proc processes. esses.
FI G.9 G.9 GOUGING CARBON EL ECTROD ECT RODE E
29
6. I NSPEC NSPECT T I ON Usua sually in in BHE BHEL Nonde Nondestructive structive testing (NDT (NDT) is perform rformed. It I t is is defined as as compri comprisi sing ng those test methods which which are used to examine an object, object, mate material or system without impairing its future usefulness. The term is generally applied to non medical investiga nvestigati tions ons of materi terial al integrity. grity. The main ND NDT processe sses at at the fabri fabrica cati tion on block are as follows:6.1. VISU VI SUAL AL I NSPEC NSPECTI TI ON
I t is the the simple simples st, che cheapest and most ost widely use used method thod amongs ongstt the the entire NDT’ DT ’s. A simpl simple e visual visual test test reve reveals als gross surface surface defects ea easil sily and and quickly. quickl y. However for detection of final defects, device/equipments having high degree of preci precisio sion n and il illumination tion are required. quired. 6.2. .2. RADI RA DIOGR OGRAP APHY HY
I n this this test the X -rays and gamma rays are used to detect deep seated internal def defects. The short wavelengths of X -ray permitted to pene penetrate through the opaque material. Gamma rays are the electro-m ectro- magneti agnetic c radi radiatio ations ns that are em emitted from roman unstable unstable nucleu nucleus. s. 6.3. PENETRA TE TES TE ST I NG
Penetrate soluti olution on is is appli plied to the the surface urface of a pre-clea cleaned component. The T he liquid quid is pul pulled into into surface surface--brea breaking king de defects by capil pillary action. A deve develloper is is appli applie ed to pull pull the trapped pene penetrate trate back back to the surface surface where it is spread spread out and form forms an indication. indication. The indication ndication is is much easi asier to to see see than the actual actual defect. 6.4. UL TRASO TR ASONI NIC C FAUL T DETECT DETE CT OR
I n this process job is is painted with with oil oil and and then high high frequency sound sound waves is passed throu throug gh the the job. job. Then the the echo is reco record rde ed on detector. tor. I f the the echo is recorde recorded d with with disturbance disturbance earlier than the other end then the job is is def defective. ective.
30
FI G.1 G.10 DEFECT DETECTE DETE CTED D BY BY UL ULTRA TRA SONI SONI C FAUL T DETECT OR
31
7. M ACHI NING NI NG Machi achining ning can be defined ned as the the process process of removing oving mate aterial rial from rom a work pie piece in the form form of chips chips .The .The term metal cutting cutti ng is used when the material is metall tallic. Most M ost machi achining ning has very low low setset-up up cost compared pared to forming, forming, moldi olding, ng, and casting sting processes. However, machining is much more expensive for high volumes. Machining is necessary where tight tight tolera tolerance nces s on dim dimensions ensions and and fi finishe nishes s are are required. required. 7.1. VERT I CAL BORI BORI NG MACHI MA CHI NE
I n this mach machiine there is one RamHead On Cross Cross Rail, Rail, J aw Chu Chucks, cks, and and Automatic tic L Liiftin fti ng & Lowe L owering ring of Cross Cross Rail. Rail. There is L ubri ubrica cation tion Syste System mon all Sli Sliding Ways to avoid avoid fri frictional losse losses. A Cen Centralize tralized d Control Control Station with with I nterlocked rlocked Electrical lectrical Control Pan Pane is provi provide ded. A Set of Se Service rvice tools is is also provi provide ded. Some Speci Special al Accessories are also provided with this machine like as follows:a) Additi ddition ona al Ra RamHead On Cross Rail. Rail. b) Turre urret Hea Head On Cross Cross Rail Rail.. c) Thre hreading Hea Head On Cross Cross Rail. d) Side Ram RamHead. e) Slotting Attach ttachm ment On Cross Cross Rail Rail
FI G.1 G.11 VERTI CAL BORI BORI NG MACHI NE
32
7.2. PLANNER PL ANNER M ACHI ACH I NE
A plann planner is is a type of metal worki working machi achine tool tool that that is is analogous to a sha shaper, but large larger, r, and with with the entire ntire work piece piece moving ovi ng beneath neath the cutter, instea i nstead of the cutter moving ovi ng above above a stati stationa onary ry work work pie piece. ce. The work table is is moved back and forth forth on the bed beneath the cutting cutting head eithe either by mechanical chanical means, such as a rack and pini pinion on gear, or by a hydraul hydrauliic cyli cylinder. The carriage carriage is heavy duty and and long long to gives gives bal balance anced d bearing aring to the bed even at the end of the strok stroke e. The bed is is of heavy duty box type constructi construction. on. I t is ribbe ribbed throughout the length ength and breadth givi giving ng vibrati vibration on free free movem ovement ent under the heavie aviest cut. Tab Table le is is heavil avily ribbe ribbed and and propor proportio tiona nallly dim dimensio ensione ned heavy duty duty close close graine grained cast iron iron box type construction. truction. It I t has has 'v' sli slides des matching the 'v' 'v' groove grooves s on the bed and and is hand scrapped to give oil oil film lubricatio ubrication. n. Cross Cross sli slide has has a box type construction construction carr carryi ying ng the the tool sli slide which which can can be ope operated rated by hand as wel well as by autom automatic fe feed. ed. Ge Gearbox consi consists sts of Mach M achiine Cut gears running in in anti fri fricti ction on be bearings arings 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 side sides s of the bed .ri .ribbed inside inside to avoid avoid vibration. vibration. Operati Operations ons that that can beperforme rformed by it:a) V ertica rtical plan planning. ing. b) Horizon Horizontal tal plan planning. ing. c) A ngular ular Plann Planning. ing. d) Slot Cut Cutting ting.
33
FI G.1 G.12 PL ANNER M ACHI NE 7.3. MANI PUL PUL ATOR M ACHI NE
Parts that that cannot be welded easily asil y by ordina ordinary weldi welding, ng, espe especial ciallly inte internal curved curved parts parts are wel welded using using manipulators. anipulators. I n mani anipulator pulator machine parts to be welded welded is is fi fixed with the help of fixture attached to the table of the manipulator machine. Table can be rota rotate through through 0º-360º and tilting of table is 0º-135º 7.3.1 PURPOSE:- Metal etal parts which which are he heavier in in weight and dif difficult cult to change change thei their
positi position can be weld by the use of manipulator anipulator machi achine which which can can change the the posi positi tion on of parts accor accordi ding ng to our requirem requirement. Gui Guide de blade blade carriage carriage blade blade is weld by the use of mani anipulator pulator machi achine. ne. Carriag arriage e or ring ring is is mounted ounted on the the table table with with the help of fixture and then then guide bla blade carrie rri er blad blade e is wel weld to the inner inner ri ring to both si side of curve curved surface surface by tilting the table 7.3.2 M ACHI ACH I NE SPECI SPECI FI CATI CA TI ON
a) Gross weigh weightt =7600 =7600 kg. kg. b) Size =393*383*180 cm3.
34
c) Table di diameter ter = 3500 3500m mm (withou (withoutt exte exten nsion), 4500m 4500mm (with (with extension). d) Rota Rotation tion of table =00 to 3600 (clockwise or anti clock) e) Tilting Tilting of table =00 to 1350. f) Table rota rotation spe speed =0.012-0.5 =0.012-0.5 rpm.
FIG. FI G.1 13 M ANIPULA TOR HOLDING H OLDING GBC (GUIDE (GUIDE BLA DE CARRI CA RRIER) ER) 7.4. COPY M I L L I NG MACHI NE
This This machine ine is design igned for for milling illing profiles or relief lief contours (three-dim -dimension ional milling) on articles made of various materials by means of a cutting tool (milling cutter), which which reproduces reproduces on the the articl rticle e the the surface rface or contour of a master aster devi device— ce—fo forr example, ple, a master cam in the shape shape of a flat flat template plate, a three-dim three-di mensional ensional model model, or or a contour drawing. The master device is mechanically, pneumatically, or hydraulically connected to a servomechanism, which directs the cutting tool.
35
The The servomechanism ism acts on an amplifyin lifying g device ice on the one hand and, on on the other hand, on an actuating device. Hydraulic, electromagnetic, or electro-optical relays are used in in the ampli plifying yi ng devices vices of such machi machines. nes. The The actuati actuating ng member may be a screw, a slide valve, an electromagnetic coupling, a solenoid, a differential, or some other devi device ce,, and it may be be driven driven by an an electric ectric motor or a hydraul hydrauliic power cyli cylinder.
FIG.1 FIG.14 COPY COPY MI L L ING MA CHINE 7.5 CENTRE L ATHE WIT H THRE E AND FOUR J AWS:
A metal lathe athe is gen generi eric c descri descripti ption on for for a rigi rigid d machi achine tool desi designe gned to remove mater terial from from a work pie piece, ce, throug through h the the action of a cutti cuttin ng tool. They were were origi origina nally designe designed d to machine achine metals; however, wi with the advent of plas plastics tics and other materi terials, als, and with with their inh i nheren erent versatil ti lity, ity, they are used used in a wide wide range of appli pplicati cations, ons, and and a broad range range of material rials. s. A center lathe lathe is a dual head head machine achine where the work work rem remains ains fi fixed and the hea heads move towards the work piece and machi achine a center dril dri ll hole hole into into each end end.. The result resultiing
36
work work piece piece may then be used "be "between tween centers" in anothe other operation. operation. The usage usage of the term metal lathe may also also be consi considered dered somewhat outdated these days, pl plastics astics and othe other composite posite materials rials are in wi wide use use and and with with appro appropri pria ate modif odifications cations,, the sam same princi pri ncipl ples es and techniques may be be appli pplied to their machini achining ng as as that that used used for for metal. A center lathe or engine engine lathe may be conside considered red the basis for the metal lathe lathe and is the type most often often use used d by the gen general eral machini achinist st or hobbyist. hobbyi st. The T he center lathe lathe may be conside considered a useful starting starting poi point. nt. The T he engine lath lathe e is is the nam name appl appliied to a tradi traditional tional 20th century century lathe lathe. I t is is assum assumed that the 'engi 'engine' ne' was added to the descripti scription on to separa separate them from rom the 'foot 'foot lathe lathes' (l (lathes turned by peda pedalls) or or other hand rotate rotated pieces of machine achinerry. Earl Early y engine ngine lathes were generall erally 'cone heads', heads', in in that the spi spindl ndle e usuall usually had had attache attached to it it a multi ulti--step step pull pulley designe signed to accept accept a fl flat belt.
FI G.1 G.15 L ATHE ATH E M ACHI NE
37
8. SHOT SHOT BL ASTI NG 8.1. .1. PURP PU RPOSE OSE
Used for hardening the root of the low pressure rotor turbine blade in fatigue load. Shot blas blasti ting ng is is carr carriied out to introduce introduce compressi pressive ve stress stress to depth of bla blade. I n bla blades, fatigue atigue stren strength and im improvem provement ent in in resi resistance stance to stress omission ssion is is checked cked along along with with corrosion removal. Blasting process consists of bombarding exposed surface of fir tree root with steam steam of hardene rdened spherical ri cal metall tallic dots from from robotics robotics controll controlled nozzle nozzle by by appl appliied air pressure. 8.2. SCOPE
Shot blasting blasting of steam turbine turbine blade blade roots with with cast steel shots type S280 to S390 in blasting blasting intensit intensity y of ran range 0.3 to 0.35. 8.3. SHOT SHOT DIRECT DIR ECT I ON
Notch radii should be bl blasted iin n ave average rage normal directi direction. on. This T his blasts blasts that that steel steel shots shots have have to hit the the radius in in perpen perpendi dicul cular ar direct directiion since blasting blasting is most ef effective ctive under this condition. Nozzle has to be point to centre of root curve. 8.4. SETTI ET TI NG PARAM ETER: ET ER: The The setting ing parameters for for machine ine are:-
a) A ir pre pressure b) Shot size ize c) Nozzle diameter d) Shot flow flow e) Distance istance be betwee tween blasted surf surface aceand nozzle nozzle. f) Blas Blasting ting time g) Rese Reservoir pressure sure
38
FI G.1 G.16 SHOT BL ASTI ASTI NG MA CHI NE
39
9. BLOCK BL OCK DESCRI DESCRI PTI ON
TABL TA BL E 55- BL OCK 2 L AY OUT
40
9.1 PREPARAT PREPA RAT I ON, BAY -1
It has the following sections: a) Markin rking cutting cutting and straigh straighte tening ning se section. b) Gas cutting cutting se section includ includiing CNC CN C flame cutting cutting se section & CNC CN C Plasm Plasma cutting cutting section. c) Press Press section (400T (400T and 800T, Brake rake pre press ss). ). d) She Shearing M/c section ction.. 9.2 ASSEM ASSEM BL Y AND WEL DING SECT SECT I ON, BAY -2
It has the following sections: a) A sse ssembly bly and and wel welding ding s se ection ction for la l arge size size units up to 75tons. tons. b) Heat Heat trea treatment section. c) Shot blasting blasting and clea cleaning se section. 9.3 BAY BA Y -3
It has the following sections: a) A sse ssembly bly and and wel welding ding sections ctions of sma small size size unit units s unto unto 10 tons b) Pipe section ctions s. 9.4 BAY BA Y -4
I t has the the fol followi lowing sections ctions:: a) MACHINE SECTION: It is is designe signed for for machini machining ng parts parts and units during during fabri abricatio cation n stage. This T his section supplies suppli es small part parts s and and units of of S Stea team turbine 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 vari various ous componen ponents lliike dril drilling of tube plates of dif different types apa apart from from machining of big assemblies such as front wall, casing, water boxes etc. b) DI APHRAGM SECTION: Welded Welded diaphrag diaphragm ms of steam steamturbine turbi nes are asse assem mbled, bled, welded welded and stress stress rel relieved in in this section. section.
41
c) COOLERS SECTION: I n this this section tube tubes of coole coolers rs are cut to the the require required d size, then turned and thereafter winding and soldering of spirals on tubes is carri carried out by autom automatic atic machi machine nes. s. The T hese are then assem assembled bled to for form m coolers coolers which which are then assem assembled bled and hydrauli hydraulicall cally tested. tested.
42
10. MANUFA M ANUFACT CTURI URI NG PROCES PROCE SSES Manufacturi nufacturing ng sta starts rts with with Preparation of individua ndividual parts parts befor before e assem ssembly, bly, in Bay -1. -1. a) The The metal is firs first marked and cut by the foll follo owing ing machine ines:-
- Guillotine Shearing machine for cutting and trimming steel sheets and plates up to 25mmthick thick wi with straight contours. contours. - Stationa Stationary and and portable Oxy-ace Oxy-acetylen tylene cutti cutting ng machi achines nes for for cutting mach machiines for for cutting cutting parts out of steel steel plate plates. - A unique Flame cutting cutting machi achine is used for for cutting cutting steel steel plate plates by CNC CNC programming. - CNC Plasma cutting M/c for cutting S.S & higher alloys. - Com Combinati bination on punch, shear and bar cutters, cutters, ci circular rcul ar saws and bar shears are used used for for cutting cutting angles, gles, shape shapes, flats and rods. b) Straighte Straighteni ning ng Rol Rollers are use used for for straighte straightening ning plates plates and and large sized sized bl blanks anks and a
160 16 0 ton fricti friction on press for straighte straightening ning small size sized d blanks. A roll roll bendi nding machi achine ne is used for for straighteni straightening ng and bendi bending ng roll rolled beam beams and angles. ngles. ydrauli c bendi bending ng press of 80 800 0 ton and and 400 400 ton and a 250 ton fri fricti ction on press press are c) Hydraulic used used for for col cold and hot bending ding fro from mrol rolled sheets sheets and shape shapes. Parts Parts to bend bend are pre heated in in a 700 KW KW electri electric c furnace furnace,, when ever needed. ded. d) Finished parts are inspected at the working working place.
43
A fter Prep Prepa aration is is comple plete the next step is is Ass Assem embly and Welding Welding in Bay -2 and 3 is as follows: a) Components ponents of units units are assembled bled and tack welded welded for subsequent weldi welding ng as
per drawing and instructio instructions ns on process cards. b) Manua anuall arc wel welding ding is is em employe ployed d iin n restri restricted cted and and iina naccessi ccessibl ble e place places or where
semi-automatic atic or automatic atic weldi welding ng is not possibl possible e or has not been establi stablished. c) Semi-A i- A utomatic tic submerged rged arc arc welding, welding, GTA GT AW and Argon Argon Carbon-di Carbon-dioxi oxide de
Shie Shielded arc arc weldi welding ng are also used used for for incre i ncreased productivi productivity ty and be better quality. A ll assem assembly bly work is carr carriied out on bed plates. plates. Smal Smalll size size structures structures are welded welded with with the help of manipulators. Welding of high pressure cylinders of steam turbines is carried out out after fter pre prelim li minary inary heating ting up to 250° C. Hea Heat treatment is carried rried out out in elect lectric ric furnace urnaces s of bogie hearth, bel bell and pit types types af after welding ding is is comple pleted. ted. In I n multi ulti layer weldi welding, ng, the roots roots of seams are gouged and tthe hen clea cleaned ned by mechanical nical means. A ll asse assem mbly and weldi welding ng sections have ave conn connections for compresse ssed air, ir, oxyge oxygen & acetylen tylene e as wel well Argon carbon-dioxi carbon-dioxide de mixture and and water ter for for semi autom automatic welding. welding. Weld Weld qual qualiity inspe inspection ction is is adopte adopted in accordance accordance with with the relevant relevant spe specif cificati cations. ons. I nspe nspecti ction on of weld weld quali quality ty and and fl flaw det dete ection ction is is carrie rried out by by means of XX -ray machines, gamma-grapy machines of cobalt and iri iridi dium um isotopes isotopes and ultrasoni ultrasonic c fl flaw detectors. tectors. Pressure vessels that are boil boilers, heaters, conde condensers and cool coolers unde undergo rgo hydraul hydrauliic tests on special cial tes testt beds meant for for hydrauli hydraulic testing. ting. Kerosen K erosene leakage leakage test is al also done in case of thin thin walled vesse vessells. Process rocess b being eing fol folllowed in pipe pipe secti section on is men mentione tioned d below: below: a) Pipes with with diam diameter of of 10-60 mm mm and 3838-108 108 mm are cut on pipe pipe cutting cutting
machine achines s and and oxyoxy-ace acetylen tyl ene e cutters. b) Cold old bending of pipe pipes s iis s carri rried out on a pipe pipe bending nding machi achine. Be Bending nding of
carbon and and all alloy steel pi pipes of 114 mm dia. dia. and above is is perfor rform med by by heating ting themin electric ectric furnace furnaces s and then by hot bending. ding.
44
c) Facing cing of pipe pipes s an and beve bevelling for weldi welding ng is carried rried out out on a horizonta orizontall boring boring
machine achine with with portable portable type pipe pipe chamfering ering machine. achine. d) For assembly bly and welding ding of pipe pipes s bed plate plates and manipul anipulators ators are used. e) Heat treatm treatment of pipe pipes s is is done in electric electric furna furnace ce mentione tioned d earli rl ier. f) Surface Surface clea cleaning ning is done manuall anually y or by shot bl blasti asting. ng.
Pipe assembli blies are dim dimensio ensiona nally checked checked and quality uality of welds is is teste tested d by XXray and Gam Gamma grapy. Process being followed in machining section is as follows: a) Casting, ting, forgi forging, ng, roll rolled secti section on and and welded structures structures are are delivered to
sections sections where assembly bly and weldi welding ng are are done in accordan accordance ce with with spe specif cificati cations ons se set forth forth in in drawing wings. s. b) Pre Pre wel weld machi achining ning for for large sized sized parts for for steam turbine turbines s and hydro
turbine turbines s are carri rried out in blockblock-3. 3. c)
Provision is made for the application of highly productive cemented
carbide tipped cutting tools, high speed cutting with maximum utilization with machi achine tool capacity capacity and rapi rapid d section ction locati locating ng and clam clamping ping fi fixture. Proce Process ss being follo followe wed d in in painti painting ng sectio section n is as as fol follows: lows: a) Painti ainting materi aterial als s used and painti painting processes processes adopted, confor conform m to the
standa standards for for tropical tropical cli climates. b) Owi Owing to to dif different operating ting conditi conditions and and decoration coration requi requirem rements of units units
and parts parts of turbine turbines s and electrical electrical machines, achines, dif different processe processes for for painti painting ng are adopted adopted. c) Som Some components and uni units ts undergo only only pri prime coating coating in in the steel structure structure
secti section, on, with with subse subsequent painting painting in in the painti painting ng secti section on of the machi achine and and assembly section.
45
11. CONCL CONC L USION USI ON Gone through rigor rigorous ous one month traini training ng under the guidan guidance ce of capable engi ngineers and workers workers of BHE BHEL L Haridwar Haridwar in Block-2 Block-2 “HEAVY FABRICATION” headed by Senior Senior Engine ngineer er of department ent MR. PARMANAND PANDIT situated in Ranipur, Haridwar, Uttarakhand. The The trainin ining g wa was sp specified un under th the Heavy Fabric rication ion Department. I came to know about the basic grinding, scaling and machining processes which were shown on heavy to to medium edium machines. achines. Duty Duty lathe lathes were planted in in the same line line where the specified work was undertaken. The The tr trainin ining g br brought to to my my kno knowledge th the va variou ious machinin ining g an and fab fabric rication ion proc proce esses done one not only only in the the manufact ufactu uring of cam cams but also in other iron casted products.
46
