AN INDUSTRIAL TRAINING REPORT

IN
M/S BHARAT HEAVY ELECTRICALS LIMITED

HEAVY PLATES & VESSELS PLANT

VISAKHAPATNAM-530 012

Submitted in partial fulfillment of requirements under

Engineering Trainee for the award of

METALLURGICAL ENGINEERING

Under the esteemed guidance of

______________________________________________________

Submitted By

                                       KOYYANA SAI KUMAR           PIN: 01UG18050L43

Department of METALLURGICAL AND MATERIALS ENGINEERING

OP JINDAL UNIVERSITY

M/s BHARAT HEAVY ELECRICALS LIMITED

 HEAVY PLATES & VESSELS PLANT

VISAKHAPATNAM-530 012

CERTIFICATE

This is to certify that the following bonafide students of OP   JINDAL   UNIVERSTY,

PUNJIPATRA, RAIGARH (CG).who have undergone industrial training for one month at M/s
BHARAT HEAVY ELECTRICALS LIMITED, HEAVY PLATES & VESSELS PLANT-
VISAKHAPATNAM During the period 04th July of 2019 to 03rd August of 2019.

STUDENTS NAME PIN. NO.

     KOYYANA SAI KUMAR                          01UG18050L43

During the above period her conduct and performance was found to be ________________________

Dy. Manager (QA) Dy. Manager (HRDC&TI)

ACKNOWLEDGMENT
 We acknowledge with profound gratitude, the management of M/s   Bharat   Heavy

Electricals Limited, Heavy Plates &Vessels Plant Visakhapatnam for providing us the

opportunity in getting industrial training in their esteemed organization, especially to Mr. G KURU
MURTHY, Dy. MANAGER (HRDC)..

I thankfully acknowledge with intense gratitude to our Head of Chemical Engineering

Department Sri. B.V.LAKSHMAN RAO and our beloved training incharge
___________________________, and our beloved lecturer Smt. M. VIJAYA LAKSHMI and other
faculty members of Government   Institute   of   Chemical   Engineering,   Industrial   Estate
Visakhapatnam­07 for giving this opportunity for the successful completion of Industrial Training.

We express our deep felt gratitude to Additional General Manager Sri. B. ROY (Quality),
Dy.Manger Sri. V. Sampath Kumar (QA) and all the Quality Assurance staff, for their valuable
guidance throughout the training period.

Finally I thank one and all who helped us directly or indirectly for the successful completion of our
Training Programme.
 M/s BHARAT HEAVY ELECTRICALS LIMITED

HEAVY PLATES & VESSELS PLANT

VISAKHAPATNAM­530 012
1. INTRODUCTION :-
“BHARAT HEAVY PLATE AND VESSELS LIMITED “was established
in 1966 at Visakhapatnam, Andhra Pradesh. It was undertaken by “BHARAT HEAVY
ELECTRICALS LIMITED” and is renamed as BHARAT HEAVY ELECTRICALS
LIMITED, HEAVY PLATES AND VESSELS PLANT (BHEL-HPVP). Now it
became the 17th unit of BHEL not only that it is the first coastal unit of BHEL.

BHPV`S beginnings were humble; it had a turnover of just 5 lakhs in 1971 –

1972 when commercial production first commenced.

Since then, BHPV has come a long way and exceeded a turnover of 200 cores
expanding its product line to include high technology equipment and systems like Multi-
layer Vessels, Turn Key Cryogenic Plants, Storage and Distribution Systems, Industrial
Boilers, Waste Heat Recovery Systems, Oil and Gas Processing Systems etc.

 PRODUCTION FACILITY :-
Factory Area : 197 Acres
Total Covered Area : 90,000 Sq. Meters Covered area of
Production
Production Shops : 56,000 Sq. Meters
Power Requirement : 3,000 KW from APSEB
No. of Ancillary Units : 11
 View of BHEL HPVP Shops

Lay Out Of BHEL HPVP

DEPARTMENTS: -
BHEL-HPVP has the following departments which play a crucial role to complete a job

1. Commercial Dept
2. Projects Management
3. Engineering Dept
4. Material Management Dept (M.M)
5. Planning And Technology Dept
6. Industrial Engineering Dept
7. Production Dept
8. Quality Dept
9. Welding Technology Dept
10. Electric & Instrumentation Dept
11. Works Engineering
12. Erection & commissioning
13. Research & Development Dept
14. Out sourcing Dept
15. Sub contracting machining Dept
16. Finance Dept
17. Corporate Planning Dept
18. Human Resources

 PRODUCTS MADE BY BHEL-HPVP :-

1. PRESSURE VESSELS AND COLUMNS :-
From multi-layer construction with design pressure of 280 kg/sq.cm to simple
low and medium pressure columns are manufactured. Tall and Heavy Columns with
lengths up to 90 meters and weights up to 450 tons. Pressure ranges from vacuum to 55
kg/cm2. With the backup of experienced engineers and a host of heavy capacity cranes
and other equipment, BHEL HPVP undertakes site fabrication and erection of heavy
equipment of any size and weight. Pressure vessel range includes agitator vessels,
jacketed vessels & autoclaves limpet coils.
Columns

2. TRANSPORTATION TANKS :-
Transportation tanks of stainless steel and carbon steel, rail or truck mounted including
low temperature applications are manufactured.
Transportation tanks

3. STORAGE SPHERES: -
Storage spheres of any size and thickness including low temperature service.
BHEL also undertakes erection and site stress relieving of these spheres.

Storage Tanks Storage Spheres

4. CRYOGENIC PRODUCTS :-
BHEL HPVP manufactures cryogenic products which are used to store liquids,
liquid gases at low temperature (below -150°C,-238°C or 123 K).

Cryogenic vessels

5. DEAERATORS HEATERS :-
BHEL HPVP manufactures complete feed water heater systems including
Deaerator, high-pressure heaters and low-pressure heaters.

6. AIR FIN COOLERS :-

Air fin coolers of forced draft type for refineries, petro chemicals, and fertilizers.
Complete units with fans, driving systems, structural scheme, louvers and paneling.
Boiler unit Refinery unit
7. OTHER PRODUCTS :-
Heat Exchangers Combustion System Products

2. Quality: -

 QUALITY :-

 The word “QUALITY” itself indicates fit for use or degree of excellence.
  Degree to which a set of inherent characterstics fulfills requirements. It is
about customer satisfactions.
 It actually has no meaning until we translate it in to a series of specific
terms that related to the actual needs & expectation of the targeted
customer.

QUALITY DEPARTMENTS :-

QUALITY

QUALITY QUALITY QUALITY QUALITY NDE

ASSURANCE CONTROL LABORATORY STORES

QUALITY CONTROL: -

 QUALITY CONTROL SHOP FLOOR: -

 The method of in process Inspection and testing at various stages from material
issue to final assembly of products.
 Engineer (QC) [E (QC)] shall inspect Materials / Components / Sub-Assemblies /
Main Assemblies as per Bill of Materials / Drawing / QAP / Technology / Work
instruction / Welding Procedure Specification (WPS) / activity procedure as
applicable during production process.
 E (QC) shall inspect components manufactured in bulk quantities.
 E (QC) shall clear the offered stage of inspection for each operation by signing on
the Route card/Daily inspection record, if found to comply with the requirements
as applicable and release for subsequent operation.
 E (QC) shall take all possible precautions in storing, handling and usage of
measuring instruments and gauges during inspection and testing.
 E(QC) shall check the various operations performed in shops like
 Marking & Cutting
 Pressing
 Bending
 Rolling
 Machining
 Assembling
 Welding
 Heat Treatment

 QUALITY CONTROL DOCUMENTATION :-

 The activities to be performed in Document Control by individual department

for issue and updating of various documents.
 Head of concerned issuing department is responsible for issue and control of
latest revision of documents to all users as per standard distribution lists
maintained by them.
 Documents in BHEL are broadly classified into three levels:
First level : QS Manual
Second level : Department/Activity Procedures.
Third level : Work instrumentation and other job related documents
 Master copies of procedure shall be identified and filed by concerned procedures
issuing department.
  Issue status of First level documents is broadly classified into CONTROLLED
and UNCONTROLLED. Second level documents shall be issued under
Controlled classification.
 Each page of controlled copy shall be stamped as Controlled in red color.
These are issued for regular use to comply with job requirements.
 Each copy of uncontrolled copy shall be stamped as Uncontrolled in blue color
and issued for information purpose only.
 Third level documents such as fabrication drawings, QA plan, Master
Technology, Job cards, Route cards etc. are classified documents and are issued
with due approval of concerned departments.
 Head (QA) shall issue controlled copies of QS manual and procedures to the
designated person as per the standard distribution list maintained by QA and
obtain acknowledgements. He shall also issue the subsequent revision to all
holders of controlled copies of QS manual after retrieving and destroying the
superseded revision.
 Head (QA) may also issue uncontrolled copies of QS manual on request to
outside agencies for information only. Holders of uncontrolled copies of QS
manual may not receive any subsequent revision.

NON-DESTRUCTIVE EXAMINATION :-

 NON-DESTRUCTIVE EXAMINATION :-

Non-destructive examination (NDE) or non destructive testing is defined as those

inspection methods, which allow materials to be examined without changing or
destroying their usefulness.NDE is an integral part of the quality assurance program. A
number of NDE methods are employed to ensure that the weld meets design specification
and does not contain defects.

The inspector should choose an NDE method capable of detecting the discontinuity
in the type of weld joint due to the configuration and lists the common types and location
of discontinuities and illustrates their positions within a butt weld.
The six most common testing methods used for weld examinations are:
 Visual Testing :-
Visual testing is the most basic and common inspection method. Visual
testing is a process done by naked eye to identify the surface defects. Usually after
each and every testing process, visual examination is required. Visual examination
also includes equipments like magnifying glasses, fiber scope, mirror, micro scope
and etc. Advanced robotic techniques are also being used to get observation of
hazardous and tight areas such as reactors, pipelines and etc.
 Dye Pentrant Examination :-
Dye Penetrate methods have been developed to detect Cracks, Porosity,
Blow holes and Flaw in non porous material. This will not reveal defects, which are
not open.
In this method, visible (or) fluorescent dye penetrate, which are surface
active in nature, are applied to cleaned surface of specimen by suitable means. After
allowing sufficient time (dwell time) for penetration of pentrant. On the surface is
approximately removed. Care to be taken not to disturb the penetration in the
discontinuity. The developer which is absorptive in nature is applied to the
specimen, which aids the bleeding out of pentrant to the surface after sufficient time
thereby outlining the discontinuity. The specimen is post cleaned to remove the
remaining pentrant & developer materials & coating to prevent corrosion is also
applied.
 Magnetic Particle Examination :-

This method uses electric current or a permanent magnet to create a

magnetic field in the surface to be checked which the magnetic particles indicated
where the field is broken by a discontinuity. Fluorescent magnetic particles are also
used for enhanced identification of defects. This method is used on Ferro magnetic
metals.

 Ultrasonic Test :-
 Ultrasonic tester is a portable precise direct reading and easy to operate type
of instrument, to measure the depth of cracks & internal defects etc.
In ultrasonic testing, ultrasound waves are generated by piezo electric
transducers which converts electrical energy to mechanical vibrations and vice
versa. These waves are made to fall on the material to be tested. As the wave travels
through the material, it may get reflected, refracted, scattered (or) transmitted
depending upon the structure of material. As they reach deflects they reflected
back& these waves are displayed on the monitor at verse time & inspector can
visualize a cross section specimen shaving depth of futures that are recorded.

Deflected waves in UT

QUALITY TESTING LABORATORY: -

 DESTRUCTIVE TESTING: -

Destructive testing, tests are carried out to the specimen's failure/fracture, in order
to understand a specimen's structural performance or material behavior under different
loads. These tests are generally much easier to carry out, yield more information, and are
easier to interpret than nondestructive testing
THE TYPES OF DESTRUCTIVE TESTING ARE AS FOLLOWS: -

 Tensile Testing: - It’s method of testing in which uniaxial tensile load is gradually
increased until fracture. Test measurements are recorded in PSI (Pounds per Square
 Inch). For example, tensile strength of E7018 electrode weld = 70,000 PSI Tensile.
Tensile strength, Elastic limit, Yield point, and Ductility can be measured in this
testing method.

Universal Testing Machine Tensile Test Specimens

 Bend Testing :-
The samples which are having surface flaws are unable to perform tensile test on
them. Therefore, bend test are employed on such samples. A rectangular specimen
placed with two bottom supports and load is applied from top which cause a bend.
The load is gradually increased until the specimen failure. The stress level at which
fracture occurs is known as flexural strength or transverse rupture test.
Specimen Under Bending Test
 Impact Testing :-

The main objective of impact testing is to measure the toughness of a given material.
Toughness is the property of a material to absorb some energy before it fracture. In
an Impact test, a heavy pendulum is used to apply sudden impact on the specimen
having V-notch, by which the amount of force required to fracture the sample is
measured for welds “Heat Affected Zone” (HAZ). Impact testing may be performed
using either the Izod or Charpy method. The common principle for both the testing
method is that, the specimen is supported as a simple beam with a notch in the
center. The figures below show the dimensions of the Izod and Charpy Impact Test
specimen notch, the positions of the striking edge of the pendulum and the specimen
in the anvil. The specimen is broken by the impact of a heavy pendulum hammer,
falling through a fixed distance (constant potential energy) to strike the specimen at
a fixed velocity (constant kinetic energy). Tough materials absorb a lot of energy
when fractured.
 Torsion test :-

It’s a testing technique in which modules of rigidity and ultimate shear strength are
measured in universal test machine. A specimen of circular cross-section is placed in
a testing machine having two heads, one for twisting and applying torque and
another head is the weighing head to measure torque.
 Hardness Testing :-

Hardness may be defined as the resistance to permanent indentation. Three common

hardness measuring tests are.

 Rockwell test :-

The Rockwell testing machine operates like a press, using an indenter to

penetrate the surface of the test sample. The depth of the indentation determines
the materials hardness on a scale of 0-100. Different hardness scales are used for
different materials. The different scales used are A scale, B scale, C scale, D scale
and so on. The depth of the indentation is measured depending on the scale as
HRA, HRB, HRC and HRD and so on.
 Vickers test :-

The Vickers hardness test method consists of indenting the test material with a
diamond indenter having a square base and an angle of 136° between opposite
faces subjected to a test force of between 1gf and 100kgf. The full load is
normally applied for given period of time. The two diagonals of the indentation
are measured using a microscope and their average is calculated. The area of the
sloping surfaces of the indentation is calculated. The Vickers hardness is the
obtained by dividing the kgf load by the square mm area of indentation.
 Brinell Test :-

The Brinell hardness test uses a ball indenter of diameter, D, which is pressed
into the surface of the test piece using a prescribed force, F. The time for the
initial application of the force, is 2 s to 8 s, and the test force is maintained for
10 s to 15 s. The diameter of the indentation, d, is measured after the force has
been removed. The Brinell hardness number, HB, is given by:

HB = Constant × F / Surface area of indentation

 The designation "HBW" specifies the use of a tungsten carbide ball indenter.
The designation "HBS" specifies the use of a hardened steel ball indenter but is
now deleted from standards. It should be noted that measurements of HBW and
HBS on the same sample may differ in value due to differences in the tri-
biological characteristics of the indenter-specimen interface.

3. WELDING TECHNOLOGY: -
AS B.H.E.L. HPVP is a fabrication plant and is mainly based on
“Welding” for its manufacturing techniques, welding technology department
has a vital role in BHEL HPVP.

 WELDING :- Welding is a process of making a permanent joint by

establishing inter atomic bond between two or more pieces of metal by
using heat or heat &pressure metals
 ELECTRODE :-Electrode is a conductor from which current is applied during
welding. The electrode is made in a circular section from approximately the same
material as the base material.
 FUNCTIONS :-

1. To convey welding current to work piece.

2. To act as filler material.

 TYPES OF ELECTRODE: -

1. Consumable Electrode
 Bare Electrode
 Coated Electrode
2. Non- Consumable Electrode

 TYPE OF ELECTRODE USED DEPENDS UPON:-

1. The type of metal to be welded

2. The position in which the weld is to be done
3. The power source
4. Polarity in case of D.C
5. Thickness of base metal
6. Expected properties of welded joint

Bare electrodes are used for welding low-carbon steel or wrought iron. They are
mostly used in submerged arc welding.Coated electrode is employed for welding high
carbon steel, alloy steel& non ferrous metals& their alloys.

TYPES OF WELDING :-
 ARC WELDING

 SHIELD METAL ARC WELDING(SMAW)

 SUBMERGED ARC WELDING(SAW)

 GAS WELDING
 GAS TUNGSTEN ARC WELDING (GTAW)
 GAS METAL ARC WELDING(GMAW)

 ARC WELDING :-
The source of heat in this process is an electric arc. The temperature of arc is about
3600°c. which can melt &fuse the metal very quickly to produce joint.

 SHIELD METAL ARC WELDING (SMAW) :-

The Shielded Metal Arc Welding (SMAW) process is commonly known as “stick”
welding. An electric arc is produced between the tip of the electrode and the base metal.
The molten weld pool/completed weld is a mixture of base metal and electrode materials.

Applications :-
1. Today, almost all the commonly employed metals and their alloys can be welded by
this process.
2. Shielded metal arc welding is used both as a fabrication process and for maintenance
and repair jobs.
 SUBMERGED ARC WELDING (SAW): -
It’s a fully automatic process consisting of electrode wire and fusible flux. In this
process, electrode wire and flux are continuously fed. The molten weld and the arc zone
are protected from atmospheric contamination by being “submerged” by the granular
fusible flux consisting of lime, silica, manganese oxide, calcium fluoride, and other
compounds. When electrode melts, the flux provides a current path between the electrode
and the work piece. This thick layer of flux completely covers the molten metal thus
preventing spatter and sparks as well as suppressing the intense ultraviolet radiation and
fumes that are a part of the SMAM process.
Applications :-

1. Fabrication of pipes, penstocks, pressure vessels, boilers, structural shapes, rotary

kilns, rail road, and earth moving equipment, cranes, bridge girders and under
structure of railway coaches and locomotives.
2. Automotive, Aviation, ship building and nuclear power industry.
3. Rebuilding of worn out parts and depositing wear resisting alloys.
For welding metals like mild steel, medium and high tensile low alloy steels.
 GAS WELDING: -
 GAS TUNGSTEN ARC WELDING (GTAW) :-

Gas Tungsten Arc Welding (GTAW), Also Known As Tungsten Inert Gas (TIG)
welding is an arc welding process that uses a non-consumable tungsten electrode to
produce the weld. The weld area is protected from atmospheric contamination by a
shielding gas (usually an inert gas such as argon), and a filler metal is normally used,
though some welds, known as autogenously welds, do not require it. A constant-current
welding power supply produces energy which is conducted across the arc through a
column of highly ionized gas and metal vapors known as plasma. GTAW is most
commonly used to weld thin sections of stainless steel and non-ferrous metals such as

aluminum, magnesium, and copper alloys.

Applications: -
1. Welding aluminum, magnesium, copper, nickel and their alloys, carbon, alloy or
stainless steels, inconel, high temperature and hard surfacing alloys like zirconium,
titanium etc.
2. Welding sheet metal and thinner sections.
3. Welding of expansion bellows, transistor cases, instrument diaphragms, and can
sealing joints

 GAS METAL ARC WELDING (GMAW) :-

Gas metal arc welding (GMAW) is also known as metal inert gas welding (MIG). It
is a process where a continuously fed metal electrode wire contacts the base metal and
produces heat. The arc is shielded by an inert gas. Gas metal arc welding is generally
used due to the high efficiency of filler metal that can be deposited per hour. The wire
feed rate or speed is set using the dial on the wire controller. This setting increases or
decreases current or “Heat” . This setting is measured in AMPS or IPM (inches per
minute). Air in the welding zone is displaced by inert gas to “Shield” the molten weld
pool and prevent it from contamination from Oxygen, Nitrogen and Water present in the
atmosphere.

Applications:-
1. The process can be used for the welding of carbon, silicon and low alloy steels,
stainless steels, aluminum, magnesium, copper, nickel, titanium, etc.
2. For welding tool steels and dies.
3. For the manufacture of refrigerator parts.
4. MIG welding has been used successfully in industries like aircraft, automobile,
pressure vessel, and ship building.
 5. WELD JOINTS:-

Welding joints are formed by welding two or more work pieces according
to a particular geometry.
THE FIVE BASIC TYPES OF WELD JOINTS ARE:-

 BUTT JOINT:- It’s a most common joint in welding process as in this process the
edges of two base metals are joined together which lies in the same plane.

 CORNER JOINT:- In this process, edges of the two perpendicular plates are joined
together.

 TEE JOINT:- In this type of joint, two plates lie in the perpendicular plane and the
edge of the one plate is joined to the surface of the other.

 LAP JOINT:- In lap joints, the two plates lie in parallel planes but not in the same
plane. (One plate on another).

 EDGE JOINT:- It’s a joint between the edges of two or more parallel or nearly
parallel plates
 SAFETY PRECAUTIONS:-

1. Always wear safety glass with side shields in any work area, even if
welding helmets, face shields and goggles are also required.
2. Use a face shield fitted with the correct fitter and cover plates to protect eyes, neck,
face and ears from sparks and rays of the ark when operating or observing
operations.
3. Wear flame proof gloves, heavy long sleeve shirt, high – topped shoes and a
welding helmet or cap for hair protection, to protect against arc rays and hot spark
or hot metal.
4. A flame proof apron may also be desirable as protection against radiated heat and
sparks.
5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs or pockets.
6. Protect other personnel from arc rays and hot sparks with a suitable non flammable
partition or curtains.
7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may
be hot and can fly far. Bystanders should also wear goggles over safety glasses.