A PRESENTATION ON VOCATIONAL TRAINING AT

Bharat Heavy Electricals Limited Ranipur, Haridwar

HEAVY FABRICATION

Submitted by:-Udit SoniEngineering College Bikaner

INTRODUCTION

BHEL OVERVIEW Established in the year 1964. Amongst the Navratana’s of India. Accredited to ISO 9001:2008, ISO 14001:2008,

OHSAS 18001:2007. It is the 12th largest power equipment

manufacturer in the world. 9th most innovative company according to Forbes. BHEL is contributing nearly 69 per cent to the

total power generated from utility sets in India. It has 15 manufacturing divisions, 2 repair units,

4 regional offices, 8 service centres, 8 overseas offices and 15 regional centres and currently operates at more than 150 project sites across India and abroad.

BHEL BUSINESS SECTOR

Power GenerationIndustryTransportationTransmissionDefenceInternational projects

BHEL HARIDWAR:

BHEL

HEEP

8.45 km²

CFFP

1 km²

HEAVY FABRICATION

WHAT IS FABRICATION ?

Fabrication as an industrial term refers to building metal structures by cutting, bending and assembling. For this purpose various methods and machines are used such as plasma cutters, hydraulic press, lathe, welding machines etc.

PROCESSES IN FABRICATIONCutting & BurningBending Welding/assemblingMachining

CUTTING & BURNING

1. Shearing Machine2. Plasma Cutting Machine3. Oxy-fuel Cutting Machine

SHEARING MACHINE Cut’s metal work-pieces with help of Shearing

mechanism. Metals that can be cut are mild steel, stainless

steel etc. Maximum thickness that can be cut is 10mm.

PLASMA CUTTING MACHINE In this process, an inert gas/compressed air is blown at

high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut.

Work-piece of thickness 100mm to 210mm can be cut.

OXY-FUEL CUTTING MACHINE

Oxy-fuel cutting is a combustion process. a cutting torch is used to heat up ferrous metal to kindling temperature (about 980°C). A stream of pure oxygen is trained on the hot metal which chemically combines with the iron which then flows out of the cut, or kerfs, as an iron-oxide slag . Oxy-fuel cutting are processes that use fuel gases and oxygen to either weld or cut metals.

The process covers the entire thickness range from 1 mm to 2500 mm(0.04-100 inches)

BENDING1. Hydraulic press2. Three roll bending machine3. Four roll bending machine

HYDRAULIC PRESS A hydraulic mechanism for applying a large

lifting or compressive force. The hydraulic press depends on Pascal's

principle.

THREE ROLL BENDING MACHINE Roll benders use three rolls (typically) to bend solids,

extrusions, tube and pipe to various diameters by adjusting one or two rolls. The pyramid style roll benders have one moving roll, usually the top roll.

Double pinch type roll benders have two adjustable rolls, usually the bottom rolls, and a fixed top roll. There is clearance provided along the feeding edges.

FOUR ROLL BENDING MACHINE Here instead of three, four rolls are used

which removes the need of clearance at the edges. The two side rollers are the moving rollers.

WELDING1. TIG-welding

2. MIG-welding

TIG-WELDING MACHINE TIG welding is a high-quality welding technique with a

low fusion rate. The arc burns between a tungsten electrode and the work piece; the electrode does not melt, so it acts only as a current conductor and arc carrier.

In this type of welding, tungsten electrode is used which is non-consumable. Filler material used is either copper wire or wire of same material to be weld.

MIG-WELDING MACHINE In MIG welding, the metal electrode is used to produce

spark. The current is allowed to flow through filler metal which passes through welding holder & a blow of gases is passed through holes provided on holder which provide safeguard to welding area from atmospheric gases.

Voltage can be adjusted according the speed of filler material, feeding is adjusted as per requirement.

MACHINING 1. Vertical boring machine

2. Planner machine

3. Manipulator

4. Lathe

5. Shot blasting

VERTICAL BORING MACHINE

PLANNER MACHINE A planner is a type of metal working machine tool that is

analogous to a shaper, but larger, and with the entire work piece moving beneath the cutter, instead of the cutter moving above a stationary work piece. The work table is moved back and forth on the bed beneath the cutting head either by mechanical means, such as a rack and pinion gear, or by a hydraulic cylinder.

MANIPULATOR MACHINE Parts that cannot be welded easily by ordinary welding,

especially internal curved parts are welded using manipulators. In manipulator machine parts to be welded is fixed with the help of fixture attached to the table of the manipulator machine. Table can be rotate through 0º-360º and tilting of table is 0º-135º.

LATHE

SHOT BLASTING This process consists of bombarding exposed surface

of object with stream of hardened spherical metallic dots from robotics controlled nozzle by applied air pressure.

Used for hardening the root of the low pressure rotor turbine blade in fatigue load. It is also carried out to introduce compressive stress to depth of blade.

ANY QUARRIES ….?

Thanks for listening………!!!!!!!!!!!!!!!!!