1. ANALYSIS OF HEAT RECOVERY &STEAM GENERATOR MODULE WELDING V.VINOTH(80105114057) Final- Mech AVCCE Internal Guide : Mr. S.Rajkumar, M.Tech Asst.Prof /AVCCE External Guide : Mr.R.Ragupathy Deputy Manager(BPN/RM) BHEL

2. ABOUT BHEL INTRODUCTION BHEL-BHARAT HEAVY ELECTRICAL LIMITED BHEL established in 1955, BHEL( Trichi ) established in 1 st May 1965 It is largest engineering manufacturing enterprise in India. It contain 14 manufacturing units, 15 regional manufacturing division, 4 power sector, 8 service center & more than hundred ‘ service at site’.

3. It turnover of the company in 2007-2008 is Rs 21,401 corers. BHEL have Power generation & Transmission Industry Renewable energy Defense Oil & gas Transportation Technology up gradation R &D HRDC

4. CERTIFICATION ISO-9001 for quality management and all manufacturing unit/division. ISO-9001:2000 for all up grade major unit/division. ISO-14001 for environmental management system. OHSAS-18001 for occupational health & safety management system

5. dfdfdfddHEAD HEADER STRUB SPIRAL FINED TUBE WELDED AREA HEADER AND SFT ASSEMBLY

6. STATEMENT ABOUT PROBLEM If the module placed horizontally welding operation done means penetration of weld is less between Header & SFT. If pressure exceeds above the normal working condition the leakage or breakage may occur in the welded zone. Weld quality-Porosity occurring at one layer can not be repaired in subsequent passes.

7. Reason for choosing More skilled labor. More time to take welding operation. More amount of filler rod to be used. Welder have more fatigue. Penetration of weld is less. Decrease productivity.

8. Scope & Objective Increase the penetration of weld. Less skilled labor is sufficient. Pressure withstand capacity is also increased. Filler material is reduced.

9. METHODLOGY Change the position of the module in welding period - horizontal to vertical position with the help of crane. Fabrication of crane and pallet for suitable dimension. welding involved in the module assembly. Shielded Metal Arc Welding(SMAW) Gas Tungsten Arc Welding(GTAW) Flux Cored Arc Welding(FCAW) Resistance welding Used for proper welding procedure like given below,

10. 1 2 4 3 12 3 6 9 GTAW 12 3 6 9 2 1 FCAW clock

11. SUITABILITY OF WELDING FCAW :- Flux is not used, Slag inclusion are eliminated Excellent production for the weld H2 is achieved, Therefore no possibility for cracking in the weld. Welding with CO2 shielding in low cost. Weld defects arises mostly due to faulty welding procedure.

12. SMAW:- All position capability. Higher deposition rates. Less operator skilled. FCAW:- All position capability. Good quality weld metal deposit. Metallurgical benefits that can be gained from flux. Less operator skilled. RESISTANCE WELDING:- High speed. Easily automated. Suitable for high rate of production. Economical.

13. QUALITY CHECKS USED… NDT Dry magnetic particle inspection Wet magnetic particle inspection (This test will do for both before & after stress release condition). Hydro pressure test