DATE: 24/11/2010 and 25/11/2010.

PRESS SHOP Operations performed:

1. Tees. 2. Elbows. 3. Drums (half part).

Material specification:
1. 2. 3. 4. SA106 grade C SA335 P12. SA335 P22. SA299 (for plates).

Machines available: 1. Furnace. 2. Hydraulic press machines (8000 tons, 2000 tons, etc.)

DETAILS
All machines use hydraulic systems. Pressing of dishes, elbows, tees are done in this pressing shop. Before pressing the blank plate is heated to 900-1000C. While pressing plates the temperature should be always 620C. Tees-10-12 stages are required for this. Upper and lower dies are used and billet is pressed between them. Elbows- 2stages are required.(ex: R457, R406, D558R558, D508R508, R457R457) DishesProcess:

1.Dish

2. Bullet.

3.

4.

Pressure is applied over the hot blank and the blank plate takes the shape of the bullet.

DRUM SHOP
500 MW DRUM 226T. 600 MW DRUM 249T. 250 MW DRUM 189-133T.

Material used: SA299 is used.

Hoop stress is a factor. The two halves of the drum used are of different thickness. It saves material and also weight reduces. Drums are used to store and distribute water in boiler system. It separates water from steam.

EDGE PREPARATION

 FCAW (Flux coated arc welding) is used for welding the inside edge of the drum. SAW (Submerged arc welding) is used to weld the outside edges of the drum. Double column planning machine is used for edge preparation. Plano miller is also used.

TESTING
Two types of testing are done for the welded part. NDT (Non-Destructive Testing) and Destructive Testing. NDT Radiography, X-ray, Ultrasonic testing, etc. Ultrasonic Testing is preferably used as it gives the exact position of the flaw. Radiography can only show d flaws but it cant give the exact position.

Destructive Testing

A test plate is attached to the drum. The same welding operations as that of the drum are carried over the test plate. Then the test plate is tested in universal testing machine for tensile and compressive tests and other destructive tests are also carried over it. If the test plate passes all the tests then only the drum is accepted, otherwise the drum will be rejected too. Hydro test of the drums All the outlets are closed and drum is filled with water. 1.5 times pressure is applied.

HEADER SHOP
It is used as a junction. It distributes steam, water, fuel etc. It is of five types, named after the places where they are fixed in the boiler system. Water wall header. Super heater header. Re-heater header. Economizer header. Drain header.

Marking process of header: First using a split level the top point of the header is marked. The split level is kept over the header, when the bubble is exactly at the centre; the position is at the top. Then it is marked. After marking the top point the header is divided into four parts. After this points are marked at equal distance for drilling holes and putting stubs.

Edge preparation Edge preparation is done for easy welding. It is done using the SAFOP machine. P-style or B-style edge is used according to the need. P and B styles are standard edges.

DATE: 26/11/2010, 27/11/2010 and 28/11/2010. 1. Vertical boring machine Operations carried out: Header drilling. 52mm diameter and 90mm diameter. 2. CNC header pipe drilling machine: CNC system: FANUC 320i Total connecting load - 150KVa. Machine weight- 60 tons. Component machined- Header pipe. Height from floor to component centre- 1000mm. Spindle type-BT50. Machine floor area- 30,000 x 6000 (mm2)(w x d) Used for mass production. Once programmed 10m pipe can be worked upon.

3. CNC gas cutting LPG/O2 is used. 100mm plate was being cut. Feed rate at the time of cutting 100mm plate- 150mm/min.

4. Header pipe and fittings butt welding station Technical specification Capacity: 30 tons. Diameter range: 200-750mm Weld speed range- 200-1000mm/min. Centre height from floor- 1500mm. Welding Powersave Welding process: SAW. Power source(thyristor based)- Lincons LT-7. 1000Amps, 100% duty cycle.

 Weld current range- 150A 1300A. Volt range 15 45V. Wire feed speed 1m/min 7.5m/min.

5. Preheating: Coal gas is used Preheating is used for welding. So that cracks and other flaw may not occur during welding.

6. Double column vertical boring machine Operation done Edge preparation- For dish cover dished end. Drilling, milling, boring etc. can be done by this machine except thread cutting. 7. ATP(Advanced Technology Products) CNC drilling, boring machine Threaded holes, counter sunk, counter bore, drilling, milling can be done. Bellow cover for protection of machine body. Universal moving tool post. 8. Fit-up(nipple fitting) in header Fillet welding is done. Type of welding Arc welding. Electrode 70-18.

VALVE SHOP
A valve is a device that enables an aperture to be opened or closed for the purpose of contolling the fluid flow. Valves from BHEL Trichy are made in CS, AS and stainless steel of sizes ranging from 3mm to 600mm, capable of handling pressure from 10 to 400 times the atmospheric pressure. TYPES OF VALVES PRODUCED IN BUILDING 5. I. II. III. IV. V. Safety or safety relief valves. Quick closing and non-relief valves. HP and LP Bypass valves. Soot blower. Oil field Equipments.

SAFETY AND SAFETY RELIEF VALVES Safety and safety relief valves are used to reduce the excess pressure in the system. The safety Valves can be used to reduce the excess pressure in the system. The safety valves can only be used in steam medium, while safety relief valves can be used in any medium. They find their application in superheated boilers and also in refineries in distillation process. Electrometric relief valve is one of the special type of safety relief valve. QUICK CLOSING AND NON-RELIEF VALVES. Quick closing valves are closed in pipes connecting turbines. They are also called tooth closing Non-Return Valves. They are used to stop the gases from the turbine getting back to turbine when there is a power shut down. HP AND LP BYPASS VALVES They are used in pipes connecting boilers to turbines, to reduce the pressure of gas passing to turbine and to incorporate power shutdown. SOOT BLOWER Soot blowers are used in boilers to eliminate the slag depositions on the water walled panels. The fuel from boiler creates smoke and ash, which deposits on the panels and reducing boiler efficiency.

TYPES OF VALVES PRODUCED IN BUILDING 6. I. II. III. IV. V. Gate valves. Globe valves. Check valves. Flap Valves or Non-return valves. Y valves.

PRESSURE I. II. III. Low pressure valves(<800 psi) Medium pressure valves(800 to 1500 psi) High pressure valves(1500 to 3000 psi)

DIAMETER Various valves ranging from to 20 diameter are available. MATERIAL TYPE Alloy steel, Carbon steel, Stainless steel.

1. CNC plasma arc welding machine Specifications Hard facing: Stellite Gr.6. Width of deposit: 6-70mm. Width of deposit per pass: 6 - 50mm. Maximum thickness of deposit: 5mm. Maximum number of layers: 2. Welding current range: 15 350A. Welding voltage range: 10 40V. X-axis horizontal: 2000mm. Y-axis traverse axis: 500mm. Z-axis vertical axis: 1000mm. Table diameter: 1500mm. Application: Hard facing of seat ring and wedge of size 6 and above. Disc welding; stelliting. 2. Floor type horizontal boring machine (CNC). Milling, boring, threading, etc. can be done. Rack and pinion gear is used for movement. Tetra table Work piece is kept over it. Work table can rotate 360. Generally used for grooving and threading of valves in this workshop.

3. Hydro Test bench Specification Body test with water up to: 1200bar. Seat test with water up to: 1200bar. Seat test with air up to: 9bar. Max length of the test valve: 2100mm. Min. length of the test valve: 360mm. Min. bore of the valve: 42mm. Max. weight of the valve loading: 8000kg.

Application: Hydro test of valves before dispatching of valves for further operations. The valves are clamped between the centres at the edges and are tested for different pressures.

4. CNC Horizontal machining centre. Fanuc series 320i. Threading, boring, reaming etc can be done. Used for part facing too. Inserted type centres are used. 14 diameter was being drilled. 60 tool pockets are there. 40 of them are taping tools. Few tools: H3 tool offset. T3 tool no. M 29 Rigid taping. Z depth cycle. G43 Z50 H3 MO8. Used for edge preparation of valves. Material of valves: Carbon, Steel, alloy steel. 5. CNC Vertical machining centre. Used for machining yoke of valves. Specifications same as the CNC horizontal machining centre discussed above.

6. SB CNC (slant bed CNC) Valve body. Threading, milling, cutting etc. 12 tools can be fitted at a time. In this the job rotates.

Operation Boring Feed: 0.06 mm/rev. Speed: 60rpm. 7. Slotting machine Frequency: 50hz. Operating voltage: 420V. Control voltage: 220V. Connected load: 25Kw. Nominal current: 42Amps.

ACKNOWLEDGMENT

The authors gratefully acknowledge the guidance provided by the project supervisor Mr. R.Nagaraj throughout the In Plant Training. The authors also wish to thank the other BHEL Trichy officer employees for their valuable suggestions and directions.

Candidate's Declaration We hereby declare that this In Plant Training report submitted towards the completion of training in 6th semester of B.Tech in National Institute of Technology, Trichy is an authentic record of our work carried out under the guidance of Mr. R.Nagaraj, Deputy Manager, Boiler Production. Date: November, 2010 Place: BHEL, Tiruchirappalli.

Certificate
This is to declaration made certify that by Mr Soumya the above Barman and

Mr.Anshuman Shivam is true to the best of my knowledge and belief. Date:November, 2010 Place: BHEL, Tiruchirappalli. Mr. R.Nagaraj Deputy Manager, Boiler Production BHEL, Trichy-620014.