ANALYSIS OF HEAT RECOVERY &STEAM GENERATOR MODULE WELDING

V.VINOTH(80105114057)Final- Mech

AVCCE

Internal Guide : Mr. S.Rajkumar , M.Tech

Asst.Prof /AVCCEExternal Guide: Mr.R.Ragupathy

Deputy Manager(BPN/RM)BHEL

ABOUT BHELINTRODUCTION

BHEL-BHARAT HEAVY ELECTRICAL LIMITEDBHEL established in 1955, BHEL( Trichi )

established in 1st May 1965It 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’.

It turnover of the company in 2007-2008 is Rs 21,401 corers.

BHEL havePower generation & TransmissionIndustryRenewable energyDefenseOil & gasTransportationTechnology up gradationR &DHRDC

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

dfdfdfddHEADHEADER

STRUBSPIRAL FINEDTUBE

WELDED AREA

HEADER AND SFT ASSEMBLY

STATEMENT ABOUT PROBLEMIf 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.

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.

Scope & ObjectiveIncrease the penetration of weld.Less skilled labor is sufficient.Pressure withstand capacity is also

increased.Filler material is reduced.

METHODLOGYChange 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,

12

4312

3

6

9

GTAW

123

6

9

2

1

FCAW

clock clock

SUITABILITY OF WELDINGFCAW :-

Flux is not used, Slag inclusion are eliminatedExcellent 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.

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.

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