BHEL(bharat heavy electricals limited ) Haridwar Block 2 Heavy Fabrication
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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………!!!!!!!!!!!!!!!!!
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