bhel cffp training

PRESENTED BY:-VIPUL NIGAM

CSJMA13001390332

Summer training presentation

Content:-

Introduction

Central Foundary Forge Plant(CFFP)

Steel Melting Shop

Electric Arc Furnace

Secondary Steel Making

Sample Testing

Non Destructive testing

Destructive Testing

Introduction• BHEL or Bharat Heavy Electricals Limited is one of

the engineering and manufacturing organizations in the Country.

• BHEL,Haridwar is broadly divided into two parts-

BHEL

CFFP HEEP

CFFP is divided into following shops:-

Central Foundary Forge Plant

CFFP

SMS STEEL FOUNDARY

FORGE SHOP

MACHINE SHOP

Steel Melting ShopThe main purpose of Steel making is to supply Liquid metal /Liquid steel to Foundary to form ingots ,Castings and forging of ingots.

Steel Melting Shop has :-

•Electric Arc Furnace of 10 ton,30ton and 70 ton.•For Secondary steel making One VOD and Two VAD.•Ingot mould of various sizes.•Ladle of various sizes.

10 T Electric Arc Furnace



Scrap VAD Ladle

VAD-1

VOD

VAD-2

Pouring of metal for casting and ingot

Flow chart of process in SMS

Electric Arc Furnace•Heats the Charged materials by electric arc•Three phase AC Electric Arc Furnace•Heat upto 1800°C

EAF Operation:-

•Furnace charging :- According to desired chemistry,the scrap and other metals(ex-Nickel,chromium,etc.)are charged into the furnace from the roof of furnace.

•Melting:- In melting,Scrap melts by electric arc.Oxygen is blown into the scrap to combusting or cutting the scrap. At the start of melting the arc is unstable. As the atmosphere of furnace is heated up the arc stabilizes and once the molten pool is formed, the arc become stable and the average power input increases

•Tapping:- When desired steel composition and temperature is achieved,the tap-hole is opened and furnace tilted and pours into the preheated ladle for transfer to the secondary refining process ( VAD & VOD).

EAF tilted at 45° during tapping

Preheating of ladle before pouring molten metal in ladle

Secondary Steel Making

During secondary steel making,some elements are added and some have to be removed to meet the desired specification.Secondary refining is done through :- •Vaccum Arc Degasser (VAD):- Used to remove oxygen,Nitrogen & Hydrogen gases under Vaccum.

•Vaccum Oxygen Decarburiser (VOD):- Used to reduce carbon content of Steel.

Composition analysisDuring the Primary steel process ,a sample is taken to measure elemental composition.This is done by Glow Discharge Spectrometer (Leco GDS 500A). Glow Discharge Spectroscopy (GDS) provides rapid, direct bulk analysis and depth profiling analysis of solids.

(On Testing , Sample showing the removed surface material)

Elem

ent

Fe P Cu C S Al Mn Cr Co Si V

% 99.62

0

0.00

8

0.027

5

0.022

8

0.005

3

0.056

2

0.192

8

0.020

9

0.007

5

0.011

7

0.001

8

Composition of Measured Low carbon steel

Carbon steel: C (0.18% - 0.50%), Mn (0.5% - 1.5%)

Stainless steel: C (0.040%), Cr (13.5%), Ni (4.5%) Supercritical steel: HW19683, HW19688 & HW19689→ C (0.080% – 0.120%), W (0.110% - 0.140%), Mo (0.110% - 0.120%), Cr (8% - 9.5%), Ni (0.050%)

Alloy steel: low and medium alloy steel.

GRADES OF STEEL PRODUCED IN BHEL BY SMS:

Forge Shop

Forging is a manufacturing process involving the shaping of metal using localized compressive forces.

Blooming:- Decrease in diameter and increase in length.

Upsetting:- Increase in thickness of a bar at the expense of its length

Piercing & Punching:- It is a process of producing holes by using a hot punch passing through the cylindrical die.

Non Destructive TestingDye Penetration test:- used to locate surface-breaking defects.

1.)Section of material with a surface-breaking crack that is not visible to the naked eye.2.)Penetrant is applied to the surface.3.)Excess penetrant is removed.4.)Developer is applied, rendering the crack visible.

(Explanation of Dye Penetration Test)

Radiography Testing:- Radiography Testing is method for inspecting flaws by using the ability of short wavelength (High Photons Energy) electromagnetic radiation to penetrate various materials. The intensity of the radiation that penetrates and passes through the material is either captured by a radiation sensitive film or by planer array of radiation sensitive Sensors.

Ultrasonic Testing:- • Use ultrasonic sound waves to detect cracks and flaws in

almost material that can conduct sound.• Sound waves that vibrate with frequency greater than

20,000 Hz are inaudible and are called ultrasonic.• Waves are produced by Piezoelectric transducer.• transducer must be joined to the piece being tested by a

liquid coupling such as a paste of starch,glycerin or oil.• High frequency waves are transmitted through the

material.• Flaws reflect the sound waves and detected on

osscillscope.

The probe is scanned over the piece being tested. In this case, an indication (peak) through the red line indicates a good piece (crack free); an indication to the left of that range indicates a crack.

Ultrasonic testing

Destructive Testing

Destructive Testing

Tensile Test

Hardness test

Tensile Test :-

Tensile test determines the strength of the material subjected to a simple stretching operation. Typically, standard dimension test samples are pulled slowly (static loading) and at uniform rate in a testing machine.

Engineering Strain = (change in length)/(original length) Engineering Stress =(applied force)/(original area)

Initial Length(mm)

Final Length(mm)

Area(mm2)

YieldLoad(KN)

Ultimate Load(KN)

%E Y.S.(KN/mm2)

UTS(KN/mm2)

50 60 78.5 60 80 20 764 1019

Example:- Sample which have 10 mm diameter.

Hardness test :-

Hardness is the measure of resistance to indentation or scratch on the surface. Hardness is measured on three scale i.e. BHN, Vicker, Rockwell according to the material.

Brinell Hardness test: Hardness is measured in BHN. Indenter: Steel balls of diameter 2.5 mm, 5 mm & 10 mm. Load range: 250-3000 kg . It is used for medium hard material like Al, Cu etc.

Vickers Hardness test:

Hardness is measured in HV. Load range: 5-120 kg.Load is not fixed.It is used for more hard material basically for surface hardened job.

Example-440Hv30/20;where 440 is the hardness number,30 indicates the load used in Kgf and 20 indicates the time in second.

I did my summer training from Bharat Heavy Electricals Limited ,Haridwar . During which I observe these processes taking place in manufacturing.

Conslusion

References :-

• www.bhelhwr.co.in

• B. R. Nijhawan, Proc. Emerging Technologies for New Mat. and the Steel Industry (Cincinnati: October 1991), 215

• Verlag Stahleisen GmbH, D-Düsseldorf, MPT International“ Volume 30 (2007), issue No. 6, page 38-42

• Panametrics-NDT ultrasonic transducer (www.envirocoustics.gr

Thank You