INTERNSHIP REPORT on

STUDY OF WORKING PRINCIPLES AND MECHANISM OF BOILER

AUXILIARIES

Submitted to

KSR INSTITUTE FOR ENGINEERING AND

TECHNOLOGY

Submitted by
JAYAMURUGAN K.S
III Year,
Mechanical Engineering

ANNA UNIVERSITY: Chennai 600 025

JUNE 2019
CONTENTS
 Introduction
 History
 Boiler Auxiliaries Plant
 Energy Source of BAP Heavy Electricals
 Sewage Treatment Plants
 Reverse Osmosis Demineralization
 Some Major Energy Sources in India
 Coal Energy
 Uranium Energy
 Natural Gas
 Wind Energy
 Hydro Energy
 Steam or Thermal Power Plant
 Working Cycle for Steam or Thermal Power Plant
 Working Principle of Steam Power Plant
 BAP products for Thermal Power Plant
 FANS
 Functions of Fans
 Types of Fans
 Draft Fans
o Forced Draft Fans
o Induced Draft Fans

 Other Types of Fans

o Primary Air Fans
o Flue Gas Recirculation Fans

 Types of fans According to the Direction of Flow of Air

o Axial Fans
o Radial Fans
o Balancing for Radial Shaft Assembly

 Types of Fan parts

o Impeller Plate
o Cover Plate

 Operations In fabrication of Impeller

 Types of Balancing
o Static Balancing
o Dynamic Balancing

 Balancing of Impeller
 Bearing Housing Assembly
  Servo Motor Assembly
 Fan Static Parts
 Materials Used for Fans In BAP
 AIR PREHEATER
 Types of Air preheater
 Purpose of Air Preheater
 Construction of APH
 Working of Air preheater
 Regenerative Preheater
 Materials used for APH at BAP
 ELECTRO STATIC PRECIPITATORS
 Essential components in ESP
 Working Principle of ESP
o Corona Discharge
o Particle charging
o Ionization Gas Molecules
o Particle charging mechanism
o Particle collection
o Particle removal
 DAMPERS
 Types of Dampers
 Some Essential Parts of Dampers
 FGD – Flue Gas Desalinator
 Materials used for Damper at BAP
 BUNKER AND HOPPER ASSEMBLY
 GRAVIMETRIC FEEDER
 MATERIALS PREPARATION SHOP
 MACHINE SHOP
 Critical specialties at BAP
 ISRO FUEL TANK
 Parts of fuel tank
 TESTING PROCESSES FOR BAP COMPONENTS
 Welded Components testing
o Destructive test
o Non-Destructive test

 Fan Testing
 Damper and Gate Testing
 ACKNOWLEDGEMENT

I Would like to thank Mr.N.BALAMURUGAN Senior Engineer/WTC&Intm stores

And services for guiding and supporting me throughout this internship and also we like to
thank Mr.M.KANAGARAJ Deputy Engineer, HRDC for permitted me to attend the
Internship.

I would also like to thank all other Engineers and supervisors for helping me in
teaching technical concepts without which it would be impossible to complete this
internship.

I would extend my heartfelt thanks to the employees who supported my

internship by sharing their valuable knowledge.

Finally, yet importantly, I would like to express my heartfelt thanks to my

beloved parents for their blessings and wishes for the successful completion of this
project.
 Bharat Heavy Electricals Limited (BHEL) owned and founded by the government
of India, is an engineering and manufacturing company based in New Delhi, India.
Established in 1964, BHEL is India's largest power generation equipment manufacturer
and they have a technology to made larger devices which are used in various types of
power plants such as Gas and Steam Turbines, Boilers, Electric Motors, Generators, Heat
Exchangers, Pumps, Switchgears, Sensors, Automation and control Systems, Power
Electronics, Transmission Systems, Boiler Auxiliaries etc.
BHEL is an integrated power plant equipment manufacturer and one of the largest
engineering and manufacturing companies of its kind in India engaged in the design,
engineering, manufacture, construction, testing, commissioning and servicing of a wide
range of products and services for core sectors of the economy, viz. Power, Transmission,
Industry, Transportation (Railways), Renewable Energy, Oil & Gas, Water and Defense
with over 180 products offerings to meet the needs of these sectors. BHEL has been the
bedrock of India's Heavy Electrical Equipment industry since its incorporation in 1964.
BHEL's growth has been synchronous with achieving self-sufficiency in the
indigenous manufacturing of heavy electrical equipment. Out of the available 35,000
MW per annum capacity for power plant equipment manufacturing in the country, BHEL
alone constitutes a mammoth 20,000 MW per annum capacity. A widespread network of
17 Manufacturing Divisions, 2 Repair Units, 4 Regional Offices, 8 Service Centers, 4
Overseas Offices, 6 Joint Ventures, 15 Regional Marketing Centers and current project
execution at more than 150 project sites across India and abroad corroborates the
humungous scale and size of its operations.

BHEL has retained its market leadership position during 2015-16 with 74% market
share in the Power Sector. An improved focus on project execution enabled BHEL record
its highest ever commissioning/synchronization of 15059 MW of power plants in
domestic and international markets in 2015-16, marking a 59% increase over 2014-15.
With the all-time high commissioning of 15000 MW in a single year FY2015-16, BHEL
has exceeded 170 GW installed base of power generating equipment.

In FY 2016-17, the company commissioned/synchronized 8,539 MW of power

generating equipment. With this, the company’s global installed power generating
capacity has gone up to 178 GW. Notably, enhanced focus on project execution has
resulted in BHEL achieving a capacity addition of 45,274 MW during the 12th Five Year
Plan period (2012-17), surpassing the target of 41,661 MW set by the government for
BHEL, by 9%. With this, BHEL continues to remain the single largest contributor to the
country’s power generation capacity addition.

During the year, BHEL-built thermal power generating sets generated an all-time
high 549 Billion Units of electricity which was 58.2% of the total thermal power
generated in the country.

BHEL also has a widespread overseas footprint in 82 countries across all the six
continents with cumulative overseas installed capacity of BHEL manufactured power
plants nearing 10,000 MW including Belarus, Bhutan, Egypt, Indonesia, Iraq,
Kazakhstan, Malaysia, New Zealand, Oman, Rwanda, Sudan, Tajikistan and UAE. A
major highlight of the year was the largest ever export order, valued at US$1.5 billion
(Rs. 10,000 Crore), for setting up 1,320 MW (2x660 MW) Maitree Super Thermal Power
Project in Bangladesh. Significantly, won against stiff international competitive bidding,
this is BHEL’s largest power project order in the international market.

Leveraging its experience of over three decades in Solar PV (SPV), the company is
capitalizing on emerging opportunities in the segment. During the year, BHEL set a new
record in its Solar PV business, by supplying 176 MW of SPV modules in a single year,
marking a significant contribution to the nation’s green initiatives.

The high level of quality & reliability of BHEL products is due to adherence to
international standards by acquiring and adapting some of the best technologies from
leading companies in the world, together with technologies developed in its own R&D
centres. BHEL divisions like Manufacturing units, Engineering centres and Business
Sectors like Power Sector, Industry sector, International Operations are accredited to
Quality Management Systems (ISO 9001). Major Manufacturing units and Power Sector
Regions are also accredited to Environmental Management Systems (ISO 14001) and
Occupational Health & Safety Management Systems (OHSAS 18001).

BHEL's investment in R&D is amongst the largest in the corporate sector in India.

BHEL places strong emphasis on innovation and creative development. The R&D
efforts of the company are aimed not only at improving the performance and efficiency of
existing products, but also developing new products using state-of-the-art technologies
and processes, relevant to the needs of the country to remain current both in terms of
technology and features vis-à-vis global benchmarks.
With its innovation-led growth strategy, the company continues to rank among the
highest R&D spenders in the country in the engineering and manufacturing segment with
an R&D expenditure at 2.75% of its turnover. The R&D efforts of the company are
aimed at improving the existing products as well as developing the new ones, relevant to
the needs of the country both in terms of technology and features, vis-à-vis global
benchmarks. The company is also developing Advanced Ultra Super
Critical (AUSC) technology for thermal power plants in consortium with NTPC &
IGCAR. In 2016-17, BHEL filed the highest-ever 508 patents and copyrights in a year,
enhancing the company's intellectual capital to 3,915 as on 31st March 2017, which are
in productive use in the company’s business.

During the year 2012-13, the company invested about Rs. 1,252 Crore on R&D
efforts, focusing on new product and system developments and improvements in
existing products for cost competitiveness, higher reliability, efficiency, availability and
quality etc. To meet customer expectations, 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 IPR
(Intellectual Property Rights) capital of BHEL grew by 21.5% in the year, taking the total
to 2170.

The Corporate R&D division at Hyderabad leads BHEL’s research efforts in a

number of areas of importance to BHEL’s product range. Research & product
development (RPD) Groups for each product group at the manufacturing divisions play a
complementary role. BHEL has established Centers of Excellence for Simulators,
Computational Fluid Dynamics, Permanent Magnet Machines, Surface Engineering,
Machine Dynamics, Centre for Intelligent Machines and Robotics, Compressors &
Pumps, Centre for Nano Technology, Ultra High Voltage Laboratory at Corporate R&D;
Centre of Excellence for Hydro Machines at Bhopal; Power Electronics and IGBT &
Controller Technology at Electronics Division, Bengaluru, and Advanced Fabrication
Technology and Coal Research Centre at Tiruchirappalli.

BHEL has established four specialized institutes, viz., Welding Research Institute
(WRI) at Tiruchirappalli, Ceramic Technological Institute (CTI) at Bangalore, Centre for
Electric Traction (CET) at Bhopal and Pollution Control Research Institute (PCRI) at
Haridwar. Amorphous Silicon Solar Cell plant at Gurgaon pursues R&D in Photo Voltaic
applications.

Significantly, BHEL is one of the only four Indian companies and the only Indian
Public-Sector Enterprise figuring in 'The Global Innovation 1000' of Booz & Co., a list of
1,000 publicly traded companies which are the biggest spenders on R&D in the world.

Continuing its focus on globalization, BHEL has achieved consistent growth in its
exports. Recently, BHEL also secured maiden export orders from Benin, Togo, Chile and
Estonia, expanding its global footprints to 82 countries across all the six continents.
A major highlight of FY 2016-17 was the largest ever export order, valued at US$1.5
billion (Rs. 10,000 Crore), for setting up 1,320 MW (2x660 MW) Maitree Super Thermal
Power Project in Bangladesh. Significantly, won against stiff international competitive
bidding, this is BHEL’s largest order in the international market.

BHEL's greatest strength is its highly skilled and committed workforce of around
39,821 employees that have been the cornerstone of BHEL's journey ensuring success.
Excellence of the company and its people has been recognized at various national and
international platforms. ‘Top 25 Best Companies to Work for in India’, ‘Prime Minister’s
Shram Awards’, ‘Vishwakarma Rashtriya Puraskars’, ‘National Safety Award’ and,
recognition by Hon’ble Prime Minister for contribution in skill development are a few
notable ones.

Further, the concept of sustainable development is inculcated in the DNA of BHEL

which is evident from its mission statement-"providing sustainable business solutions in
the fields of energy, industry and infrastructure". As part of this, focus is on creating new
verticals within the company to capitalize on the massive infrastructure spending by the
Govt. of India, with a special focus on sustainable energy development by offering EPC
solutions in solar and environment-friendly supercritical technology in the thermal sector,
besides transportation, defense and other industrial products to drive the next wave of
growth.

Towards meeting its Quality Policy, BHEL is using the vehicle of Quality
Management Systems, which are certified to ISO 9001:2000 series of standards by
internationally acclaimed certifying agency, BVQI.
HISTORY
BHEL was established in 1964 ushering in the indigenous Heavy Electrical
Equipment industry in India. Heavy Electricals (India) Limited was merged with BHEL
in 1974. In 1991, BHEL was converted into a public limited company. Over time, it
developed the capability to produce a variety of electrical, electronic and mechanical
equipment for all sectors, including transmission, transportation, oil and gas and other
allied industries. However, the bulk of the revenue of the company is derived from sale of
equipment for power generation such as turbines, boilers, etc. As of 2017, BHEL
supplied equipment contributed to about 55% of the total installed power generation
capacity of India. The company has also supplied thousands of Electric Locomotives
to Indian Railway, as well as defense equipment such as the Super Rapid Gun Mount
(SRGM) naval guns and Defense Simulators to the Indian Armed Force.
Here is the company’s achievements and milestones in a detailed manner
1972
- In July the Operations of all the four plants were integrated.

1974
- In January Heavy electrical (India) Ltd was merged with BHEL.
- BHEL has entered into collaboration which are technical in nature. Under these
agreements, the collaborators have transferred, furnished the information, documentation,
including know-how relating to design, engineering, manufacturing assembly etc.

1991
- On 24th December converted into a public Limited company.

1992
- During the year, 10 thermal sets, 2 gas sets and 11 hydro sets were commissioned.

1994
- During the year the company established Asia's largest fuel evaluation test facility at
Trichy.

1997
- The public-sector Bharat Heavy Electricals Ltd (BHEL) has won the national best
exporter award for 1995-96, instituted by the Engineering Export Promotion Council, of
the eighth consecutive year from Madurai.
1998
- The public-sector Bharat Heavy Electricals Ltd (BHEL) has entered into an agreement
with the Indian Space Research Organization (ISRO) for manufacture and supply of solar
panels for upcoming Indian satellites.

2000
- The Company has won the top exporters award among the public and private sector
companies in India for the 11th Consecutive year.
- The electronics division of public sector Bharat Heavy Electricals Ltd. has been given
the ISO 140001 certification by the Det Norske Veritas.
- The Company has won the `Best Productivity Performance Award' in the heavy
engineering industries category for the year 1997-98.

2001
- Bharat Heavy Electricals Ltd. has bagged the prestigious Golden peacock national
quality award for the second consecutive year for achieving excellence in quality
conforming to global standards.

2002
-Awarded the top exporters’ award by Engineering Export Promotion Council for the
year 1999-2000

2003
-Awarded ISO 14001 and OHSA 18001 certifications by Det Norske Veritas,
Netherlands. The company bags the award for implementing an integrated management
system, HSE Health, Safety and Environment Management System.

2008
- Bharat Heavy Electricals Limited (BHEL), Trichy, has secured orders worth Rs 15,000
crore, its all-time high. BHEL, said the recent MoU with the TNEB for setting up two
800 Mw thermal power stations near Chennai had resulted in the power plant major
bagging orders.
- Bharat Heavy Electricals Ltd has secured the Engineering Export Promotion Council's
top export award for the 18th successive year Conferred on BHEL in the category 'Star
Performer in 2006-07: Project Exports - Large Enterprise', the award was presented by
the Minister for External Affairs, Mr. Pranab Mukherjee. It has identified overseas
business as a major thrust area as part of its 'Strategic Plan 2012'.
2010
- BHEL employees win 8 Prime Minister's Shram Awards
- BHEL employees win 5 Vishwakarma National Awards and BHEL Units bag 3
National Safety Awards

2013
-BHEL wins ICAI National Award for Excellence in Cost Management for the eighth
consecutive year.
-BHPV Merged with BHEL; Becomes Seventeenth Unit of BHEL

2014
-BHEL bags National Intellectual Property Award 2014
-BHEL wins DSIJ Award 2013 for the Most Efficient Maharatna PSU
-BHEL bags India Today Best Maharatna PSU Awards for Global Presence & Innovation
& R&D

2017
- BHEL celebrates Utkrishthta Utsav, presents 'Excel Awards' to meritorious employees
and Units.
- Hon'ble President of India presents 'Vayoshreshtha Samman' 2017 to BHEL for
promoting well-being and welfare of senior citizen.
- BHEL wins Six National Safety Awards
- BHEL wins ICAI National Award for Excellence in Cost Management
- BHEL shines as the only PSU in the Top 25 Best Companies to Work for in India
- BHEL wins Golden Peacock HR Excellence award 2016

BOILER AUXILIARIES PLANT

Boiler Auxiliaries Plant (BAP), the 13th manufacturing unit of BHEL was set up at
Ranipet in 1980 as a part of the 4000 MW expansion of the High-Pressure Boiler Plant,
Trichy. BAP at Ranipet was set up as a spin-off plant for the manufacture of boiler
auxiliaries viz. Electrostatic Precipitators (ESP), Air Pre-Heaters (APH) and fans.
Over the years, the following products are also added to BAP's portfolio:
Steel chimneys, Gates and Dampers, RO based Desalination (for Industrial and
Potable application), Flue Gas Conditioning Systems (FGC), Flue Gas Desulphurization
Systems (FGD), Wind Electric Generators (WEG) and Missile Launchers for Defense.
The Company has been a fore runner in creating history with its State-of-the-art
Design facilities, Research and development capabilities, modernized manufacturing
facilities with sophisticated Metrology laboratory and NDT facilities to meet the growing
demand for Quality power.
The Company has an extensive outsourcing facility which makes it possible to
grow consistently over the years. The Company nourishes 400 ancillary small-scale units
by off-loading structural fabrication and machining jobs through annual rate contracts.
The Company is also an ISO 9001, ISO 14001, ISO 27001 and OHSAS 18001
company, and has the unique distinction of becoming the first unit of its whole
corporation to upgrade to ISO 9001:2015 Quality Management System.

ENERGY SOURCE OF BAP HEAVY ELECTRICALS

BHEL to use Solar Energy for Ranipet boiler plant. Boiler Auxiliaries Plant of
Bharat Heavy Electricals Limited (BHEL-BAP) in Ranipet is installing a 5 MW solar
power plant that will cover the entire energy needs of the plant.

The Photovoltaic panels of the plant are manufactured by Bangalore unit of BHEL
and the plant is expected to be commissioned by December this year. According to the
words of BHEL-BAP Executive Director T.N.Veeraraghavan, Rural Electrification
Corporation subsides the project and it's total cost comes about Rs. 42 crore for built the
plant. But if we consider the cost involved running diesel generators during the hours of
power cut we could take the cost back within two years.

Though we are going to install the panels in the open spaces, we even think of
utilizing rooftops in order to generate solar power. But that would involve modification
of roofs that was noted by Mr. Veeraraghavan.

However, the BAP will not be able to directly consume the electricity produced. It
will have to channel the power to and draw it back from the grid. BAP will be the first
unit in the BHEL to install such a solar power plant.
 Sewage Treatment Plants

BAP has entered in to a new business of setting up of Sewage Treatment

Plant(STP) with the latest membrane Bio Reactor technology. To begin with the BAP
will concentrate on setting up of STPs for the in-house requirements of its sister units

like those in Trichy, Hyderabad and Bangalore.

Two plants with a capacity of 2 MLD (million liters per day) each have been set up
for BAP Ranipet itself, one for the factory and another one for the Township which are in
the commission stage.

 Reverse Osmosis Demineralization (RO DM)

Water treatment plant for a 600 MW unit has been set up for the first time at North
Chennai Thermal Power Station by BAP. The system comprises a pressurized
Ultra Filtration System to provide make up water to the boiler.

SOME MAJOR ENERGY SOURCES IN INDIA

 COAL ENERGY: This type plant uses coal as a fuel for produce the steam with
sequence of operations. The process produces 900 TW (Terra Watt) per year to the
global. This type of energy used in Thermal plants.

 URANIUM ENERGY: This is a nuclear energy-based power plant where the source
for produce the heat energy is fission reaction of a heavy atoms such as Uranium. That
produces 90-300 TW.

 NATURAL GAS: The natural gas is the source for power production which is one of
the non-renewable energy sources.

 WIND ENERGY: It is one of the most significant renewable energy source of India,
that utilize the fast-moving air to rotate the blades of the impeller which compounded
with a generator.

 HYDRO ENERGY: The flow of hydro substances is controlled with high velocity
which is enough to rotate the turbine. That's also produce power about 3-4 TW.
STEAM OR THERMAL POWER PLANT
 WORKING CYCLE FOR STEAM (OR) THERMAL POWER PLANT:

The Thermal Power Plants are basically working under the Rankine cycle process.

The Rankine cycle closely describes the process by which steam-operated heat
engines commonly found in thermal power generation plants generate power.

 The processes involved in this cycle

Process 1–2: The working fluid is pumped from low to high pressure. As the fluid is a
liquid at this stage, the pump requires little input energy.

Process 2–3: The high-pressure liquid enters a boiler, where it is heated at constant
pressure by an external heat source to become a dry saturated vapour. The input energy
required can be easily calculated graphically, using an enthalpy–entropy chart (h–s chart,
or Mollier diagram), or numerically, using steam tables.

Process 3–4: The dry saturated vapour expands through a turbine, generating power. This
decreases the temperature and pressure of the vapour, and some condensation may occur.
The output in this process can be easily calculated using the chart or tables noted above.

Process 4–1: The wet vapour then enters a condenser, where it is condensed at a constant
pressure to become a saturated liquid.

The cycle described by the below diagram:

 WORKING PRINCIPLE OF STEAM POWER PLANT:
Working fluid cycle steam power plant is a closed cycle, which uses the same fluid
repeatedly. First, the water is filled into the boiler to fill the entire surface area of heat
transfer. In the boiler water is heated by the hot gases of combustion fuel with air so that
turned into vapor phase. Steam produced by boiler with pressure and temperature are
directed to do work on the turbine to produce mechanical power in the form of rotation.
The former steam out of the turbine, and then flowed into the condenser to be cooled
with cooling water that turned to water. Condensate water is then used again as boiler feed
water. Thus, the cycle goes on and repeats.
Rotation of turbine is used to turn a generator that is coupled directly to the turbine.
So, when the turbine rotates, the generator output terminals generate electricity. Although
working fluid cycle is a closed cycle, but the amount of water in the cycle would
decrease. The reduction is due to the leakage of water either intentional or unintentional.

Dia. for Basic construction of Thermal power plant

BAP PRODUCTS FOR THERMAL PLANTS
Boiler Auxiliaries Plant (BAP), Ranipet is currently manufacturing some integrated parts
which are essentially used in the Steam or Thermal Plants. The major components are
various types of Fans assembly, Air preheater assembly, Electrodes of Electro Static
Precipitator (ESP) and Bunker Hopper assembly.

FANS

A fan can be considered as a mechanical device that moves a volume of fluid such
as air, gas or vapour through a pressure driven flow.

Draft fans play an important role in thermal power plants because they regulate the
air pressure inside boiler system. Draft fans are broadly divided into two types – Forced
Draft (FD Fan) and Induced Draft (ID Fan). Apart from the draft fans, there are also other
basic types of process fans used in power plants. They are primary air fans and flue gas
recirculation fans.

Functions of Fans:

1. Supply air required for combustion

2. Remove the products of combustion
3. Deliver fuel to the burners
4. Circulate the gases for better heat transfer
Types of Fans:
 Forced Draft Fans
 Induced Draft Fans
 Primary Air Fans
 Flue Gas Recirculation Fans
Draft Fans
Generally, the Draft fans are the responsible for maintaining flow of gases through
the boiler. The primary difference between a forced draft and induced draft is, FD fan
forces outside air into the heating system whereas ID fan draws flue gases from the
system out into the atmosphere. Both FD fan & ID fan operate in such a way that it
balances the air system in the boiler to make the combustion process efficient.

 Forced Draft Fan

FD fan or forced draft fan, draws air from the atmosphere and forces it into the
furnace through a preheater. These fans are located at the inlet of the boiler to push high
pressure fresh air into combustion chamber, where it mixes with the fuel to produce
positive pressure. The most common centrifugal fans used as FD fans are backward
curved and airfoil centrifugal fans.
In power plants, where coal is used as fuel for combustion, FD fans are used as secondary
air fans to regulate proper combustion and maximize efficiency of the fuel.
A typical FD fan arrangement uses inlet and outlet dampers to control and maintain the
required air pressure inside the system. These fans have a wheel at the center that is hung
on the shaft along with inlet boxes, silencer, filter and rain hood.
When compared to ID fans, FD fans are easier to maintain and have cleaner operating
conditions.
 Induced Draft Fan
Induced draft fan is normally located at the outlet between dust collector and
chimney.
The fan takes hot flue gases from the boiler through dust collector and delivers it to the
chimney into the open atmosphere. ID fan creates negative pressure or suction to
discharge the gases out after combustion from the furnace.
Since ID fans can handle hot flue gases, they have more corrosion and erosion problems
even when used with Electrostatic precipitators.
The most common type of fans that can be used as ID fans are radial fans and backward
inclined blade centrifugal fans used at the expense of efficiency loss, if greater wear
resistance is necessary.

Other types of Fans

 Primary Air Fans

The main function of the Primary air fan or PA fan is to carry fuel to the furnace for
combustion. It is a high-pressure fan.
In power plants PA fans supply air for conveying of the pulverized coal from coal
mills to the furnace area. These fans produce a pressure upstream the pulverizer, to push
the coal and air mixture through pulverizer into the furnace.
The most common centrifugal fan used as PA fan is backward curved centrifugal
fan.
Cold PA fans typically airfoil centrifugal fans (or) multistage axial fans similar to FD
fans.

 Flue Gas Recirculation Fans

Flue Gas recirculation fans (FGR) are typically used in power plant boilers to reduce
the flue gas pollution content in the gases exhausted from thermal combustion processes.
They used to control steam temperature, furnace heat absorbtion and slagging of of
heating surfaces.
Flue gas re-circulation is a highly effective technique that significantly reduces the
Nitrogen oxide (NOx) emissions from burners. Controlling NOx is critical as it the
largest contributor to other types of harmful pollutants. NOx emissions are mostly
derived from the nitrogen in the combustion air (thermal NOx). These pollutants are
produced during combustion process when nitrogen and oxygen react at elevated
temperatures. NOx emission levels can be greatly reduced in industrial boilers by
recirculating the flue gases from the boiler exhaust duct into the main combustion
chamber.

TYPES OF FANS ACCORDING TO DIRECTION OF FLOW OF AIR:

The Fans commonly classified into two major types according to their direction of
flow of air as given below

 Axial Fans
 Radial Fans
Axial Fans

In this type of fan, the direction of air is parallel to the rotating axis.Some of the main
components is main shaft, blade shaft, angular contact ball bearing, cylindrical roller
bearing, flanges etc.
All the blades of the impeller is rotated simultaneously to control the flow of air
with the help of servo motor operated with piston and oil (hydraulic system) inside it on
one side and other side is connected to main shaft

Radial Fans

In this type of fan, air is flown from the fan perpendicular to the rotating
axis. This type of fans placed before the chimney at 250 W capacity plants.
The efficiency is less than axial fans and it is easy to construct.
The main components used in radial fan is Centre plate and cover plate. Initially
Centre plate is cut and welded according to the basic shape of rotating part of fan, after
which blades are welded with Centre plate to complete the rotating part. Another plate is
welded with blades as a protective layer to prevent the damage of blades from corrosion
and wear due to hot air flowing through them thus increasing the life time of fan.
Some of its advantages is less number of components is required therefore it is easy to
assemble.
It has some disadvantages too. Blades of it cannot be rotated unlike axial fan due to which
air flow cannot be controlled. Larger in size than axial fan so transportation and storage is
difficult.
Balancing for Radial shaft assembly
Dynamic balancing is being done to ISO 1940. The balancing plane and grade will
be mentioned in the drawing. normally balancing will be carried out at 450 rpm.
permissible unbalance is 1947555 gm.mm per plane (800 gms).
TYPES OF FAN PARTS

The fan parts are mainly classified into two types, there are

 Dynamic parts
Some parts are in motion relative to their functional operations such as
Impeller, Blades, Bearings Shaft etc.
 Static parts
Some parts are designed to protect the dynamic parts of the fan that they
don't have any relative motion such as Housing, Diffuser, Suction chamber, OGV etc.

IMPELLER COVER PLATE

The plates are cut in CNC flame cutting machine. Double section impeller Centre
plates are machined on both sides. Generally higher diameter impeller Centre plates are
built with saw tooth extension all-round. The soundness of the saw tooth butt joints is
checked with X-Ray.

COVER PLATE

After completion of blade fit up and cover plate fit up the impeller assembly is set
to welding, then to SR.

OPERATIONS IN FABRICATION OF IMPELLER:

 Rolling
 Welding
 Marking
 Machining
 Assembly
 Balancing
 Initially, two or more rectangular plate is rolled and welded together to form the
circular frames of impeller. Then it is marked before machining to bore holes to mount
blade shafts and other parts. Then other crucial parts are assembled and after which
balancing is carried out to check the equality of distribution of masses equally in all
directions.
The balancing of rotating bodies is important to avoid vibration. In heavy industrial
machines, vibration can cause catastrophic failure, as well as noise and discomfort .
Types of balancing:
 Static balancing
 Dynamic balancing
Static balancing:
It is based on the fact that a body free to rotate will seek a position where its center
of gravity is lowest. Thus, the heavier side of the rotor will seek the lowest position,
automatically indicating the angular position of the unbalance weight. The magnitude of
unbalance is determined experimentally by adding weight in the form of wax or putty to
the light side of the disc until it is in balance, or when the disc no longer rotates. The
roller stand, pendulum and horizontal ways can be used to determine static unbalance via
gravity.
Dynamic balancing:
The dynamic balancing is a checking process of rotating elements while they are
in motion. It is a very accruable mass balancing process of rotating elements.
Types of dynamic balancing
 Soft bearing balancing
 Hard bearing balancing
The soft bearing balancing is based on the fact that a body free to rotate will seek a
position where its center of gravity is lowest. Thus, the heavier side of the the rotor will
seek the lowest position, automatically indicating the angular position of the unbalance
weight. The magnitude of unbalance is determined experimentally by adding weight in
the form of wax or putty to the light side of the disc until it is in balance, or when the disc
no longer rotates.
 The roller stand, pendulum and horizontal ways can be used to determine static
unbalance via gravity.
Hard-bearing balancing machines have stiff work supports and rely on sophisticated
electronics to interpret the vibrations. This requires a massive, stiff foundation where they
must be permanently set and calibrated in place by the manufacturer. The theory behind
this balancing system is that the rotor is fully constrained and the forces that the rotor
puts on the supports are measured. Background vibration from adjacent machines or
activity on the work floor can affect balancing results. Commonly, hard-bearing
machines are used in manufacturing production operations where a fast cycle time is
required.
In BAP, hard bearing balancing is carried out for more accuracy.
PA fans sometimes have double impeller it should provide more pressurized air to
carry the pulverized coal powder to the furnace.

BALANCING AND MACHINING OF IMPELLER

After welding and NDT, reference machining is done on one side. Cover plates are
corrected to ensure the width at the tip of the impeller. Finish machining is carried out on
the rings, cover plates, Centre plates.

Wear plates are assembled before balancing. Balancing mass is being welded or
riveted depending upon the material.

POINTS TAKE CARE DURING BALANCING:

Calibration status of balancing mandrels and coupling. Then the balancing machine
calibration is also a significant factor where the machine is calibrated using a master rotor
with known unbalance at known planes and angles is balanced on the machine for
accuracy and repeatability of some values.

Hub and support body are assembled and line bored. Co axiality of line bearing
checked with co axial receiver gauges.
 Blade bearing assembly is done after rough balancing. Servo motor assembly and
blade movement is checked after final balancing.

BEARING HOUSING ASSEMBLY

The critical operations carried out during bearing housing assembly,

 Soundness of the casting is checked by NDT
 Bearing seating diameter (30 microns)
 Distance between bearing seating flanges concentrically of bearing diameters (20
microns).

SERVO MOTOR ASSEMBLY

The critical components of the servo motor are Piston and Cylinder.

Piston after machining is hard chrome plated on the sliding surface to reduce the
wear and improve life of the component. Nitriding of cylinders done to enhance the
corrosion resistance and life.

Functional hydro test done to ensure leak proof. movement of piston in the cylinder
is checked for smooth operations.

FAN STATIC PARTS:

Important parts of fan static:
 Diffuser
 Suction chamber
 Outlet Guided Valve (OGV)
 Fan housing
Fan housing is of two types:
 Core type
 Bullet type
Bullet type holds single impeller fans and the other side of it is extended with OGV
which will direct the air flow coming from impeller in one direction.
The axial flow of air from the fan is in multiple direction, so the OGV is used to
direct the air flow in uniform direction.
MATERIALS USED FOR FANS IN BAP:

1. ASTM A106 2. ASTM A216 3. ASTM A240

4. DIN 1629 5. EN 10083 6. FORGINGS
7. NAXTRA 8.SA 517 GRF 9. XAR 400
 AIR PREHEATER
INTRODUCTION
Air preheaters are used in thermal power plants. Many types of air preheaters are
available but in Ranipet BHEL the regenerative APH are used. Auxiliaries play vital role
both in thermal power plants and process industries. APH, a boiler auxiliaries is used to
recover economically the million o0f costly calories normally lost up the stack to put them
back to work in the boiler are process equipment there by increasing the overall plant
efficiently. BHEL is manufacturing regenerative type Air pre-heater (RAPH). For the past
30 years, BHEL with its vast experience made many improvements in (RAPH) to suit high
ash Indian coal.

More than 500 air pre-heater by BHEL is in service performing this vital role of energy
conservation in India, Malaysia, Libya and Egypt. BHEL carries out stringent quality control
and inspection from raw material to the final assembly in line with international standard and
practice. BHEL built APH final many applications in power and unity boilers. BHEL has
also designed special purpose APH application for ammonia plants and cements plants.

The Air Pre Heater is defined as a heat exchanger used to transfer heat directly
from hit flue gases to combustion air without the use of an intermediate heat transfer
fluid . Air Pre Heaters are important auxiliary equipment in the modern industrial and
power boilers.

DEFINITION

APH is auxiliary equipment in foe oiler streams. It is a heat exchanger that absorbs
waste heat from exit in boiler and transfer to a cold air. In utility and process boiler it is used
to heat air required for process and to dry and transport coal.
 An essential element of fuel fired steam power plants. This is a device which
increases the temperature of air before it supplies to the furnace using heat from the flue
gases passing through chimney. The Air Preheater Has Hot and Cold ends. The hot end is
placed at the top of the APH and the cold end is placed at the bottom.
TYPES OF APH
 Recuperative type
 Tubular heater
 Plant type heater
 Stream coil heater
 Regenerative type
 Rothemuhle heater
 Lyungstrom heater

RECUPERATIVE TYPE
Tubular type:
Air passes through the tubes and gas passes around the tubes or vice-versa
Plant type:
Alternative passage for hot medium (flue gas) and coal medium (air) are provided
by parallel plates instead of tubes.
REGENARATIVE APH
Rothemuhle type:
The APH is a rotary generative type, operative in counter flow. The heating elements
are containing in sector the air hoods and blow sector rotates synchronously on the common
shaft and is driven from air driving unit by a gear on the lower (cold) air hood. The cold is
process through the inlet air hood to heating the element where it takes up the heat previously
given in the heating surface by the flue gas. The heating air passes through the outlet hood
to the boiler.
Lyungstrom type:
This design is being produced and used in our country in most of the boiler. In the
following pages design regenerative APH absorbs the heat from flue gas and transfer this
heat to incoming cold air by means of continuously relative heat transfer elements of
specially formed metal plates.
MAJOR PARTS
The air pre heater has three major parts.
1. Hot end
2. Rotary part
3. Cold end

HOT END
It is placed at the top of the air pre heater. Initially the hot air from boiler enters here.
It is also known as hot end.
ROTARY PART
It is a rotary part. It exchanges the heat from hot air to cold air and from cold air to hot
air. It has fan and module. It is also known as Rotor.
BOTTOM END
It is placed at the bottom of air pre heater. It supplies the atmospheric air to the boiler.
It is also known as Cold end.
The Cold end consists of
 Top plate
 Side walls
 Bottom plate

While assembling the side wall of center section plate in cold end may face problems
likeMetal tear and Sagging of plate. To overcome these problems we decided to design and
fabricate “SIDE WALL LIFTING FIXTURE”
By the use of this side wall lifting fixture we can eliminate the problems of metal tear
and sagging of plate.
PURPOSE OF AIR PREHEATER

The purpose of Air Preheater (APH) is to recover the heat from the boiler flue gas.
As a consequence, the flue gases are also conveyed to the flue gas stack (Chimney) at a
lower temperature allowing simplified design of the conveyance system and flue gas
chimney. It also allows control over the temperature of the gases leaving the stack.

CONSTRUCTION OF APH

The Air Preheater consist of following parts

 Duct assembly
 Modular assembly
 Centre section
 Housing
 Rotor post
 PCS
 Pinion and Pin Rack
In Air Preheater, Duct assembly, Housing, Centre section and PCS are Considered
as a static part. Then the Dynamic parts are Module, Heating elements, Pinion and Pin
Rack and Rotor post respectively.

The duct assembly, Centre section are placed both Hot and Cold end of the APH.
The height of the cold end duct is higher than the hot end. Then the APH separated
sectionally as Air side and Gas side.

The gas side provided for flow of exhaust gas to heat the heating elements. The
atmospheric air is allowed at the air side. When the rotor is rotated, the heated elements
travels to the air side where the primary and secondary air get heated.

The APH consist of large number of tubes which arranged in the path flue gases
shell. Inlet air is provided at lower end. Baffles are provided inside air preheater. The
hopper is provided at the bottom.
Types of baskets inside module:
 Hot end basket
 Cold end basket
Modules are welded to rotor post which is driven by motor. Heating element possess
modularity because it must be changed at regular intervals frequently and not all heating
element is replaced at the same time so it is easy to replace if it is small and more in number.
Typically, the number of baskets can be put is 8 and baskets are produced in such a way
that it matches with the shape of modules. The material of heating element is same as
material of collecting electrode and i.e. IS 513 DD. The distance between two heating
elements is 11.6 mm (3.3 + 8.3 mm) and one heating element consists of uneven crests and
troughs while another heating element is flat. The uneven and flat heating elements are
arranged alternatively and tied up closely and inserted in basket frames.

WORKING OF AIR PREHEATER:

After combustion process, flue gas flow through hot end section of the air preheater
from top to bottom heating the elements inside it. Whereas, in the other side i.e. cold end
section is separated by primary Centre section, air flows from bottom to top and air is
transferred from heating element to air and this air is used to burn the fuel. While, air
preheater is continuously rotated at the rate of 5-6 rpm to transfer the heat from hot end
section to cold end section.
 Another important component is sector plate which blocks air going from one
section to another heater which motion is free from the Centre section and it is operated
by an actuator provided at the top of the Centre section.

Regenerative Preheaters
It rotates with low speed. Rotor is divided into 12 or 24 sections and 12 or 24
radial divisions. Each sector is divided into several trapezoidal sections with transverse
division plates. Heat storage plates are placed in these sections.
Weight of APH is nearly 500 Tons.
MATERIALS USED FOR APH AT BAP
1. ASTM A217 GR WC 6 2. ASTM A424 Type 2 3. ASTM A588
4. Corrosion resistance 5. CARTON A/B 4. ERW Tubes
7. Pins for Pin rack - AISI 1053.

Use of Air Preheater in a Boiler:

 Fuel saving and ability to burn low grades of fuel more efficiently are
the two principal advantages of using an Air Preheater in a steam
generator .
 Improved combustion leaves very less carbon deposit that normally fouls
a furnace and limits the boiler output . For every 20’C drop in flue gas
temperature (by heat recovery) the boiler efficiency will increase by
1%.
 The use of an Air Preheater allows a smaller boiler to produce the
same amount of steam , as that of a larger boiler not equipped with
an Air Preheater . For coal fired furnace , an Air Preheater system
provides hot air for fuel drying.
Advantages:
 Stability of combination is improved by use of hot air.
 Intensified and improved by use of hot air.
 Permitted to burn poor quality coal.
 High heat transfer rate in the furnace and hence lesser heat transfer area
requirement.
 Less unburned fuel particle in flue gas thus combustion and boiler
efficiency is improved.
 Intensified combustion permits faster load vibration and fluctuation.
In the case of pulverized coal combustion, hot air can be used for drying the
coal as well as for transporting the pulverized coal to burners.
Disadvantages:
 Air heaters are non pressure part which will not allow shutdown of units
due to corrosion of heat transfer surfaces.
 ELECTRO STATIC PRECIPITATORS
An electrostatic precipitator (ESP) is a filtration device that removes fine
particles, like dust and smoke, from a flowing gas using the force of an
induced electrostatic charge minimally impeding the flow of gases through the unit.
U.S. Environmental Protection Agency (EPA) has regulates particulate
emissions and why industry has responded with various control devices.

ESSENTIAL COMPONENTS IN ESP

 Discharge electrodes
 collection electrodes
 High voltage electrical systems
 Rappers
 Hoppers
 Shell
WORKING PRINCIPLE OF ESP
Electrostatic Precipitators (ESPs) work under the principle electrstatic attraction.
CORONA DISCHARGE:

The first use of corona discharge to remove particles from an aerosol was by Hohlfeld
in 1824. However, it was not commercialized until almost a century later.
The small area around the discharge electrode, the applied voltage is increased until
it produces a corona discharge which can be see luminous blue glow around the discharge
electrode.
This process also found as free electron generation. The free electron created by the
corona are rapidly fleeing the negative electric field.
By this way gas molecules are positively ionized, it all happens very close to the
discharge electrode. This process results more and more free electrons and positive ions.
The free electrons are multiplying itself more and more, this type electron generation
is called Avalanche multiplication.
PARTICLE CHARGING:

The thin wires called discharge electrodes which evenly spaced between large
plates called collection electrodes which are grounded and they must transmit electricity.
A negative, high voltage, pulsating, direct current is applied to the discharge
electrode creating a negative electric field.
We can divide this field into 3 regions, which are
 Strong region
 Inter electrode region
 Weak region
The strong region is right next to the discharge. The region around the discharge
electrodes is known as strong region. Weaker in areas between the discharge and collection
electrodes the inter electrode region. This region weak near the collection electrode.
The region around discharge electrode where the charging process begins.
IONIZATION OF GAS MOLECULES:

After Corona discharge or Free electron generation, the free electrons tries to fleeing
out of the strong region. The fast-moving electrons from the strong region gets slow down
away from there. They are now at inter electrode region.
In this region the electrons are violently collide with gas molecules. So, imparts
negative charge to the gas molecules which creating the negative gas ions.
PARTICLE CHARGING MECHANISM:
Particles are charged by negative gas ions. In field, the particles capture the negatively
charged gas ions as the ions move towards the grounded collection plate.
PARTICLE COLLECTION:
 When charged particle reaches the grounded collection electrode, the charge on the
particle is partially discharged. The gas molecules release the electrons to the collection
plate escape from them.
The dust layer is allowed to build up on the plate to a desired thickness.
PARTICLE REMOVAL:

When the dust layer reaches the required thickness, then the electrode is removed by
the one of two processes depending upon the type of collection electrode (Plates or Tubes).
The plates and tubes are usually cleaned by water sprays that the process is called
rapping. The rapping process is done by mechanical impulses or vibrations while
maintaining continuous flue gas process.
Dust layer relative thickness is 0.08 to 1.27 cm or 0.03 to 0.5 inch. The dust flow from
the top of the hopper and flow inside the hopper. They are approximately 50° to 70° angled.
Then it is transported to conveyer.
Advantages of ESP
 This is more effective to remove very small particles like smoke, mist and fly ash.
Its range of dust removal is sufficiently large (0.01 micron to 1.00 micron). The
small dust particles below 10 microns cannot be removed with the help of
mechanical separators and wet scrubbers cannot be used if sufficient water is now
available. Under these circumstances, this type is very effective.
 This is also most effective for high dust loaded gas (as high as 100 grams per cu.
meter)

 The draught loss of this system is the least of all forms (1 cm of water)

 It provides ease of operation.

 The dust is collected in dry form and can be removed either dry or wet

Disadvantages of ESP
 The direct current is not available with the modern plants, therefore considerable
electrical equipment is necessary to convert low voltage (400 V) A.C to high voltage
(60000 V) D.C. This increases the capital cost of the equipment as high as 40 to 60
cents per 1000 kg of rated installed steam generating capacity.
 The running charges are also considerably high as the amount of power required for
charging is considerably large.

 The space required is larger than the wet system.

 The efficiency of the collector is not maintained if the gas velocity exceeds that for
which the plant is designed. The dust carried with the gases increases with an
increase of gas velocity.

 Because of closeness of the charged plates and high potential used, it is necessary to
protect the entire collector from sparking by providing a fine mesh before the
ionizing chamber. This is necessary because even a smallest piece of paper might
cause sparking when it would be carried across adjacent plates or wires.

However, in spite of costs it is frequently used with pulverized coal-fired

stations for its effectiveness on fine ash particles with other type of collectors.
COLLECTING ELECTRODES
BHEL BAP contributes to electrostatic precipitators in power plants by manufacturing
collecting electrodes. Typically, the collecting electrode is 15 m length and a thin sheet of
material named IS 513 DD.
Generally, these sheets are bundled together and hanged from top. The flue gas is
passed through them to filter the dust particles. The dust particles settled on the electrode
are rammed at regular intervals mechanically. The G-shaped bend is made to avoid slack
of sheets. The sheets are bent at different stages to get the preferred shape. The emitting
electrode comes in-between them to carry out ionization process.

MATERIALS USED FOR ESP IN BAP

1. ASTM A500 GR B 2. GARBA 904L 3. IS 1239 4. IS 1570
5. IS 1978 6. IS 4923 7. IS 513 8. IS 737
9. JIS G 3101 10. JIS G 3131 11. JIS G 3445
DAMPERS
A damper is a valve or plate that stops or regulates the flow of air inside a duct,
chimney, VAV box, air handler, or another air-handling equipment. A damper may be
used to cut off central air conditioning (heating or cooling) to an unused room, or to
regulate it for room-by-room temperature and climate control. Its operation can be
manual or automatic. Manual dampers are turned by a handle on the outside of a duct.
Automatic dampers are used to regulate airflow constantly and are operated by electric or
pneumatic motors, in turn controlled by a thermostat or building automation system.
Automatic or motorized dampers may also be controlled by a solenoid, and the degree of
air-flow calibrated, perhaps according to signals from the thermostat going to the actuator
of the damper in order to modulate the flow of air.

Dampers are structures which regulate amount of flue gases that must be flown.
Types of Dampers
 Biplane Damper
 Louver Damper
 control Damper
Biplane damper produces efficiency of 99.75% whereas louver damper can give 95%
efficiency.
Some essential components of Damper
Blades: The Blades or Flaps are used regulate the air flow through the dampers. Where
we are required to adjust or arrest the flow of fluid such as air, the damper blades do that
work. The Blades or made up of MS Steel plates
Frame: This is the outer casing of a damper, that made up of Carton material. All the
assemblies are mounted on the frame construction.
Seals: It is a elaborated protection part of the damper. The seals restrict even very fine
amount of leakage and it also a essential factor for high efficiency. That made up of hast
alloy steels with 0.1 mm thick.
Jamb: The blade material will be elongated during higher temperature. So, it is controlled
by the Jamb. That is made up number of sheets with 0.8 mm tolerance.
Thrust plate: it is used to separate and hold the two plates of the blade.
Actuator: It is a device which is used to actuate blade operations such as open or close
and also regulates the flow. That is a motorized device which drives the shaft that
helically grooved as a worm gear which drives the drive shaft. We can use pneumatic
actuators for high efficiency.
Lever shaft: It is a connecting device which connects the actuator and drive shaft.
FGD - Flue Gas Desalinator damper
Now a day, pollution control board required this type damper for use in power plants.
This one of the Biplane type damper but the construction usually differs from Biplane
damper.
Pneumatic piston cylinder is used as a actuator, then the FGD more accurately
operates the damper functions very efficiently.
MATERIALS:
 Frame - SS steel
 Blade - Carton
 Shell plates - SS steel
Operating temperature around 600° C.
MATERIALS USED FOR DAMPER AT BAP
1. IS 2062 2. CARTON 3. A588 GR A
4. SA105 5. SS 304 6. SS 450

BUNKER AND HOPPER ASSEMBLY

Hopper is a huge conical structure which helps in storage of coal. As the hopper is very
huge, the manufacturing is carried out in stages. Typically, hopper produced in BAP
consists of 9 tiers each of varying diameters. The hopper is split into 9 fulcrums to be
produced and welded together to form hopper. The thickness of a hopper used for 800MW
power plant is 12mm and stainless-steel liner is provided inside the hopper for smooth flow
of coal and to prevent damage and corrosion due to large pieces of coal.
The hopper is assembled with bunker where the coal is imparted and stored. The outer
diameter of the hopper is 6.8 m and inner diameter of the hopper is 5.7 m.
 GRAVIMETRIC FEEDER
Gravimetric feeder is a device which transports required amount of coal from hopper
to combustion at a specific time. It is automatic and amount can be measured and varied
with the help of sensors present inside it. It is air tight and it is tested for the same before
transporting it to the site. It should be air tight because the varying temperature between
inside and outside gravimetric feeder can ignite the coal.
It automatically sense the amount coal to be inputed to the feeder and transmit it to
the furnace and it maintains the required rate coal input.

Essential parts in the Gravimetric Feeder are conveyer belt, clean out driver and some
sensors used to efficient working of gravimetric feeder.
 MATERIALS PREPARATION SHOP
Two main processes are carried out in MP shop.
 Shearing
 Cutting
Material thickness with less than 25 mm are sheared with the help of two shearing
machine. The shearing machine uses hydraulic systems to achieve the greater amount of
force required to shear the plate.
Types of cutting:
 Gas cutting
 Plasma cutting
Gas cutting are processes that use fuel gases and oxygen to weld and cut metals,
respectively. French engineers Edmond Fouché and Charles Picard became the first to
develop oxygen-acetylene welding in 1903. Pure oxygen, instead of air, is used to increase
the flame temperature to allow localized melting of the work piece material (e.g. steel) in
a room environment.
Plasma cutting is a process that cuts through electrically conductive materials by
means of an accelerated jet of hot plasma. Typical materials cut with a plasma torch
include steel, Stainless steel, aluminium, brass and copper, although other conductive
metals may be cut as well.
The basic plasma cutting process involves creating an electrical channel of
superheated, electrically ionized gas i.e. plasma from the plasma cutter itself, through the
work piece to be cut, thus forming a completed electric circuit back to the plasma cutter
via a grounding clamp. This is accomplished by a compressed gas (oxygen, air, inert and
others depending on material being cut) which is blown through a focused nozzle at high
speed toward the work piece. An electrical arc is then formed within the gas, between an
electrode near or integrated into the gas nozzle and the work piece itself. The electrical arc
ionizes some of the gas, thereby creating an electrically conductive channel of plasma. As
electricity from the cutter torch travels down this plasma it delivers sufficient heat to melt
through the work piece.
 At the same time, much of the high velocity plasma and compressed gas blow the
hot molten metal away, thereby separating i.e. cutting through the work piece.
Water bed is used to absorb dust which is harmful if it mixes with atmospheric air.

MACHINE SHOP
Machine shop consists of lathe, drilling and boring machines mostly.
Lathe:
The lathe is a machine tool used principally for shaping pieces of metal
(and sometimes wood or other materials) by causing the workpiece to be held and
rotated by the lathe while a tool bit is advanced into the work causing the cutting
action.
The main operations carried out in lathe here is turning, facing, threading.
Some of the components machined in lathe is trunion, drive shaft, fan shaft
etc.
 Variety of lathes present here form traditional manual lathe to modern CNC
lathe.
Boring is the process of enlarging a hole that has already been drilled (or cast) by
means of a single point cutting tool (or of a boring head containing several such tools).
Boring is used to achieve greater accuracy of the diameter of a hole, and can be used to cut
a tapered hole. Boring can be viewed as the internal-diameter counterpart to turning, which
cuts external diameters.
With the help of extensions, other process such as milling can also be carried out in
boring machine.

Critical Specialties at BAP

The following machineries are used for production of larger devices that are
mentioned above,
 CNC Flame cutting Machines
 Section Rolling Machines

 Three Roller Bending Machines

 Press Breaks

 Heat treatment furnaces

 CNC Lathes

 CNC Vertical Turret Lathes

 CNC Horizontal Boring Machines

 Balancing Machines

 Flanging Machines
 Sectional Rolling
That is used roll the component respected to its thickness such as flanges.

 Heat treatment furnaces

 Balancing Machines

ISRO FUEL TANK

Interestingly, BAP contributes to satellites for Indian Space Research Organization
(ISRO) by manufacturing fuel tank for satellites which can compressed air. This fuel tank
helps to control the direction of satellite by ejecting the compressed air in a very small
amount in the direction opposite to the desired direction of destination. So, the compressed
air thrusts the satellite forward and change the direction of satellite if needed.
Parts of fuel tank
 Upper hemisphere
 Lower hemisphere
 Suspension Ring
 Central Ring
 Retainer Ring
 Intermediate 'Y' Ring
 Intermediate 'U' Ring
 The suspension ring provided for holding the satellite because there is no possible to
produce holes for holding the fuel tank. So the suspension ring are used. The V plates
don't be closely contact with the surface of the fuel tank otherwise it maintains some
distance.

Plasma Arc Welding is used to weld the machined fuel tank assembly. The filler
considered as same metal.
 The material used is titanium alloy. The thickness of fuel tank ranges from 0.55 mm to
1 mm, volume ranges from 260 liters to 1212 liters respectively and it is not dealt with
regular jaw chuck while turning. And the fixer is used to hold the work piece. The
workpiece is held by vacuum.
ISRO funded for CNC Lathe machines present in BAP plant in 2000.Further it
funded two precision lathes in 2011.
2017 orders received for PSLV fuel tank. BHEL made tanks for Chandrayan 1&2.
86 tanks supplied till 2017-18.

TESTING PROCESS FOR BAP PRODUCTS

WELDED COMPONENTS TESTING
The weld test processes carried out for find the defects in welded area like cracks,
cavity formation, lack of fusion and pore. The weld test process is mainly held in two
ways these are
 Destructive test
 Non - Destructive test
Destructive test:
In this process, the welding quality is checked by break the welded area and find
strength of the weld. Mostly this type of test is carried out in a sample piece.
Non - Destructive test:
In this process, welding defects are found by without break the welded job with
several techniques.
Liquid Penetration Test: In this type of testing process, the surface crakes which are
present in the welded area are clearly identified. First the surface is thoroughly cleaned
before testing.

Magnetic Test: Two poles of the magnet is settled to the welded area and the magnetic
powder (some attraction powder) spreaded on the welded surface. If there is any crack is
present in the inside area where the magnetic field is created and the magnetic powder
particles are concentrated at defected area. This is efficient to find cracks up to 6 mm
depth.
Ultrasonic Test: Ultrasonic waves are high frequency waves and non-audible. This passed
through the welded area, if any defect is available where the frequency waves are quickly
reflecting than the other areas. which resulted on the display as a method of graphical
analysis.
Radiography Test: This process is done by the radioactive rays such as X-Ray. This is
hazardous than other tests. But it gives more accuracy. This is taken only at protected
areas.

FAN TESTING
This is done every fan with particular testing track which has various dimensions for
each other. The end portion of the testing track has the throttling part for pressure
analyzing. The fans are tested for below factors,
 Pressure developed by the fan (Static and Dynamic)
 Power consumption
 Volume of Fluid flow
 Temperature of flow
DAMPERS AND GATES TESTING
Testing process for Dampers and Gates are Leak Tightness Test, which is conducted
for analyzing the leakages restriction efficiency.
 The expected efficiency of Damper is 99.5%
 The expected efficiency of Gate is 99.95%
 The internship of four weeks provided a very good insight on the current trends and
the happenings around the world of boilers and auxiliaries. I earn a large knowledge about
a overall view Thermal Power Plants.
Learned a lot about power plant engineering, concepts of thermodynamics applied
in thermal power plants, structure and working as an organization and in-depth technical
details about fans, air preheaters, dampers, electrostatic precipitators and mechanisms,
working, design and manufacturing technicalities and difficulties and problems faced in
each stage. Also learned about continuous application of innovative technologies to make
a product which were not even present in the curriculum (these technologies are just found
and immediately applied). Learned a lot about CNC machines, vertical boring machine and
their multipurpose usage, locomotive techniques etc.
The staff and coordinators were very genuine and helpful. This experience was a
memorable one and was an experience of a lifetime.