BHARAT HEAVY ELECTRICALS LIMITED HUMAN RESOURCES DEVELOPMENT CENTER BHOPAL (M.P.

MAJOR TRAINING REPORT ON HEAT EXCHANGER AND CONDENSER MANUFACTURING DEPARTMENT OF MECHANICAL ENGINEERING

SESSION 2012-2013

SAMRAT ASHOK TECHNOLOGICAL INSTITUTE

Guided by:
MR. PANKAJ NIMJE DY MANAGER (HCM) BLK-1, BAY-8

Submitted by:
SHUBHAM DUBEY BE (ME-IV YEAR) 0108ME091054

ACKNOWLEDGEMENT Many lives and destinies are destroyed due to the lack of proper guidance, direction and opportunities. It is in this respect I feel that I am in much better condition today due to continuous process of motivation and focus provided by my parents and teachers in general of completion of this training was a tedious job and requires care and support at all stages. I would like to highlight the role played by individuals towards this. I am eternally grateful to HRDC staff BHEL, Bhopal for providing us the opportunity and infrastructure to complete the training as a partial fulfillment of B.E. Degree. I am very thankful to Mr. B. Khan, S.S.Madavi, Sankalp Saxena, Rajeev Shrivastav, Pankaj Nimje and other staff of HCM department for their kind support and faith on us. I would like to express my sincere thanks with deep sense of gratitude to my Training Officer, Mr. PANKAJ NIMJE , DY MANAGER of HCM Department for his keen interest to completion of this project.

CERTIFICATE
This is to certify that the project report entitled HCM which is submitted by in partial fulfillment of the department of mechanical engineering of SAMRAT ASHOK TECHNOLOGICAL, INSTITUTE VIDISHA (M.P).is record of candidates requirement degree B.E. in own work carried out by him under my supervision. The matter embodied in this is original & has been submitted for award B.E. I express our gratitude to feel the industrial environment and its working in B.H.E.L. and we are thankful to Mr. PANKAJ NIMJE , for giving their precious time and help us in understanding various theoretical and practical aspects of our project on HCM.

DY MANAGER,HCM Mr. PANKAJ NIMJE

BE(ME-IV YEAR) SHUBHAM DUBEY 0108ME091054

PREFACE
At very outset of the prologue it becomes imperative to insist that vocational training is an integral part of engineering curriculum. Training allows us to gain an insight into the practical aspects of the various topics, with which we come across while pursuing our B.E. i.e. vocational training gives us practical implementation of various topics we already have learned and will learn in near future. Vocational training always emphasizes on logic and common sense instead of theoretical aspects of subject. On my part, I pursued Three weeks training at B.H.E.L. Bhopal. The training involved a study of various departments of the organization as per the time logically scheduled and well planned given to us. The rotation in various departments was necessary in order to get an over all idea about the working of the organization.

SHUBHAM DUBEY SATI, VIDISHA

INDEX
1. INTRODUCTION TO BHEL 2. PRODUCTS MADE BY BHEL BHOPAL 3. INTRODUCTION OF HEATER 4. CONDENSERS 5. MACHINES USED IN HCM DEPARTMENT 6. BIBLIOGRAPHY

INRODUCTION TO BHEL

BHEL, Bharat heavy electrical limited is indias largest engineering and manufacturing enterprise in the energy related sector today. It has completed its 50 years and has moved strength to strength establishing 14 manufacturing divisions , 4 power sectors and over 100 project sites all over the country . Its first plant was set up in Bhopal ushering in indigenous heavy , electrical equipment n India . The compony has been earning profits continuously since 1971-72 and paying since 1976-77. BHEL caters to core of Indian economy viz. power generation & transmission industry , transportation , telecom , renewable energy defense etc.giving a turn-over of around Rs 5500 crores . The groth of the compony depends on GDP growth of the country. It is acclaimed a Navratna compony. The wide network of BHEL has attained ISO 9000 certification for quality management , environment management systems (ISO 14001) and occupational Health & safety management systems (OHSAS 18001) and is also well on its journey towards Total Quality Management. VISION : BHELs vision is to become a world class engineering enterprise , committed to enhancing stakeholder value . The company is striving to give shape its aspirations and fulfill the expectations of the country to become a global player. Heavy Electrical Plant , Bhopal is the mother plant of Bharat Heavy Electricals Limited, the largest engineering and manufacturing enterprise in India in the energy-related and infrastructure sector, today. It is located at about 7 kms. from Bhopal Railway station, about 5 kms. from Habibganj Railway station and about 18 kms. From Raja Bhoj Airport. With technical assistance from Associated Electricals (India) Ltd., a UK based company, it

came into existence on 29th of August, 1956. Pt. Jawaharlal Nehru, first Prime minister of India dedicated this plant to the nation on 6th of November, 1960. BHEL, Bhopal with state-of-the-art facilities, manufactures wide range of electrical equipments. Its product range includes Hydro, Steam, Marine & Nuclear Turbines, Heat Exchangers, Hydro & Turbo Generators, Transformers, Switchgears, Control gears, Transportation Equipment, Capacitors, Bushings, Electrical Motors, Rectifiers, Oil Drilling Rig Equipments and Diesel Generating sets. BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving towards excellence by adopting TQM as per EFQM / CII model of Business Excellence. Heat Exchanger Division is accredited with ASME U Stamp. With the slogan of Kadam kadam milana hai, grahak safal banana hai, it is committed to the customers. BHEL Bhopal has its own Laboratories for material testing and instrument calibration which are accredited with ISO 17025 by NABL. The Hydro Laboratory, Ultra High Voltage laboratory and Centre for Electric Transportation are the only laboratories of its in this part of the world. BHEL Bhopal's strength is it's employees. The company continuously invests in Human Resources and pays utmost attention to their needs. The plant's Township, well known for its greenery is spread over an area of around 20 sq kms. and provides all facilities to the residents like, parks, community halls, library, shopping centers, banks, post offices etc. Besides, free health services is extended to all the employees through 350 bedded (inclusive of 50 floating beds) Kasturba Hospital and chain of dispensaries.

PRODUCTS MADE BY BHEL BHOPAL

Power Utilisation

AC Motors & Alternators

Transportation

Transportation Equipment

Power Generation

HydroTurbines Hydro Generators Heat Exchangers Excitation Control Equipment Steam Turbines Miscellaneous

Oil Rigs Fabrication

Power Transmission

Transformer Switchgear On-Load Tap Changer Large Current Rectifiers Control & Relay Panels Renovation & Maintenance

Thermal Power Stations

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HIGH PRESSURE HEATERS INTRODUCTION TO HIGH PRESSURE HEATER:

A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another. The media may be separated by a solid wall, so that they never mix, or they may be in direct contact.[1] They are widely used in space heating, refrigeration, air conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment. The classic example of a heat exchanger is found in an internal combustion engine in which a circulating fluid known as engine coolant flows through radiator coils andair flows past the coils, which cools the coolant and heats the incoming air. There are two primary classifications of heat exchangers according to their flow arrangement. In parallel-flow heat exchangers, the two fluids enter the exchanger at the same end, and travel in parallel to one another to the other side. In counter-flow heat exchangers the fluids enter the exchanger from opposite ends. The counter current design is most efficient, in that it can transfer the most heat from the heat (transfer) medium. Seecountercurrent exchange. In a cross-flow heat exchanger, the fluids travel roughly perpendicular to one another through the exchanger. For efficiency, heat exchangers are designed to maximize the surface area of the wall between the two fluids, while minimizing resistance to fluid flow through the exchanger. The exchanger's performance can also be affected by the addition of fins or corrugations in one or both directions, which increase surface area and may channel fluid flow or induce turbulence. The driving temperature across the heat transfer surface varies with position, but an appropriate mean temperature can be defined. In most simple systems this is the "log mean temperature difference" (LMTD). Sometimes direct knowledge of the LMTD is not available and the NTU method is used

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Fig: HP HEATER

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TECHNICAL DATA OF HIGH PRESSURE HEATERS

1. Technical specification 1.1.1 The design, fabrication and acceptance shall follow Chinese standard Steel Pressure Vessel and American standard Surface Type Feed Water Heater Code 1.1.2 Regarding the materials which is delivered from other manufactures to the supplier(see item 3) the required test form shall sent to buyer . 1.1.3 The supplier should give the detail drawing for HP heaters to show the: a). General arrangement, overall dimension and nozzle schedule b). Section and material list c). Table showing the number and dimension of U tubes in each tube bunk heater d). General arrangement and equipment weight 1.1.4 Unit of measure should be metric system 1.1.5 Design of manhole should be the same as related drawing which be delivered by buyer before . 1.1.6 The dimension of the branched tubes, shell thickness, etc shall not be less than the previous heaters in local plant. 1.1.7 The design drawings of the baffle plates that manufacturer wants to perform on the new heaters should be attached and should guarantee that no malfunction will occur due to vibration inside heaters. 1.1.8 For the manufacturing of heaters a clean area for the fabrication in supplier site must be provided . 1.1.9 The feed water inlet and outlet pipes on the heaters should be beveled according to old drawings or ASME standard at the suppliers workshop and temporary cups should be provided for preservation. 1.1.10 The supplier should send reports for heat treatment performed during the manufacturing to the client 1.1.11 The supplier should send the required document such as hydro-test, U-tube plugging procedure when ready. 1.1.12 The outside surface of the heaters must be painted with suitable paint prior to shipment 1.1.13 Guarantee: When the heater is in service with 6 months or after its arrival at site for 18 months, no more than three U-tubes should be plugged per each heaters.

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1.2 Design data H.P Heater 1# Pressure shell side : 22 kg/cm2 Temperature shell side : 470 / 220 oC Pressure water box side : 279 kg/cm2 Temperature water box side : 220 oC Manhole bolt tightening force : 800 kgm. Hydrostatic test shell side : 27.5 kg/cm2 Hydrostatic test water box side : 350 kg/cm2 Surface : 513 m2 2. The overall dimension and dimension for major connection and support shall be as 5(five) drawing signed by both sides as attachment of this agreement. And the drawing should be sent to buyer before the beginning of manufacturing process for approval. 3. Main material: Heating tubes: SA-556GRC2, Dia.16x2.5. The tube shall be bent by material supplier (ASME) Water box head: SA516Gr70 Shell side: SA516Gr70 Tube side, feed water pipe, manhole: 20MnMo(China) Shell header : SA516Gr70 (low temperature zone) SA387Gr11CL2 (high temperature zone) All above mentioned main materials will be stated clearly in the drawing which should be sent for buyers approval before production. The supplier will provide the buyer with chemical and mechanical content for material 20MnMo 4. Agreement of HP heater: vertical head down with U-Tube structure 5. The connection between the U-tube and tube sheet shall use automatic welding and explosion expansion technology 6. Insert pipe shall be used for protection of water flushing at heating tube inlet, and the material of insert shall be stainless steel 7. Impingement plate of stainless steel shall be installed at steam inlet and condensate inlet 8. When the fabrication of HP heater is completed, a hydro-test shall be carried out at shop with the pressure indicated in item 1.2 above design pressure and nitrogen shall be filled after hydro-test is passed in shell and tube side with suitable pressure for transportation and notices for user. 9. Two pieces of gasket for manhole as spare parts shall be provided for each HP heeter.
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The Rankine cycle is sometimes referred to as a practical Carnot cycle because, when an efficient turbine is used, the TS diagram begins to resemble the Carnot cycle

The cycle at which steam power plant work RANKINE CYCLE

Real Rankine cycle (non-ideal)

In a real power plant cycle (the name 'Rankine' cycle used only for the ideal cycle), the processes are non-reversible and entropy is increased during the two processes. This somewhat increases the power required by the pump and decreases the power generated by the turbine. In particular the efficiency of the steam turbine will be limited by water droplet formation. As the water condenses, water droplets hit the turbine blades at high speed causing pitting and erosion, gradually decreasing the life of turbine blades and efficiency of the turbine. The easiest way to overcome this problem is by superheating the steam. On the Ts diagram above, state 3 is above a two phase region of steam and water so after expansion the steam will be very wet. By superheating, state 3 will move to the right of the diagram and hence produce a drier steam after expansion .

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Variations of the basic Rankine cycle to increase efficiency The overall thermodynamic efficiency (of almost any cycle) can be increased by raising the average heat input temperature of that cycle. Increasing the temperature of the steam into the superheat region is a simple way of doing this. There are also variations of the basic Rankine cycle which are designed to raise the thermal efficiency of the cycle in this way; two of these are described below. Rankine cycle with reheat In this variation, two turbines work in series. The first accepts vapor from the boiler at high pressure. After the vapor has passed through the first turbine, it reenters the boiler and is reheated before passing through a second, lower pressure turbine. Among other advantages, this prevents the vapor from condensing during its expansion which can seriously damage the turbine blades, and improves the efficiency of the cycle, as more of the heat flow into the cycle occurs at higher temperature. Regenerative Rankine cycle The regenerative Rankine cycle is so named because after emerging from the condenser (possibly as a sub cooled liquid) the working fluid is heated by steam tapped from the hot portion of the cycle. On the diagram shown, the fluid at 2 is mixed with the fluid at 4 (both at the same pressure) to end up with the saturated liquid at 7. This is called

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"direct contact heating". The Regenerative Rankine cycle (with minor variants) is commonly used in real power stations. Another variation is where bleed steam from between turbine stages is sent to feed water heaters to preheat the water on its way from the condenser to the boiler. These heaters do not mix the input steam and condensate, function as an ordinary tubular heat exchanger, and are named "closed feed water heaters". The regenerative features here effectively raise the nominal cycle heat input temperature, by reducing the addition of heat from the boiler/fuel source at the relatively low feed water temperatures that would exist without regenerative feed water heating. This improves the efficiency of the cycle, as more of the heat flow into the cycle occurs at higher temperat

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In order to increase the thermal efficiency of boilers the following heaters are used

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LP HEATER : low pressure heater 1.Low Pressure Heater: A heater located (with regard to feed water flow) between the condensate pump and either the boiler feed pump or, if present, an intermediate pressure (booster) pump. It normally extracts steam from the low pressure turbine. HP HEATER: high pressure heater .High Pressure Heater: A heater located downstream of the boiler feed pump. Typically, the tube side design pressure is at least 1500 psig, and the steam source is the high pressure turbine

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PARTS OF HEATER 1. TUBE PLATE

HP HEATER TUBE PLATE TUBE PLATE

LP HEATER

MATERIAL REQUIRD & DIMENSION

carbon steel; 0.5 molybdenum steels; 1 chromium steels; 2 chromium steels; stainless steels; And Thicknesses: up to 160 mm for plates; up to 500 mm for forged tube sheets.

WORKING OF TUBE PLATE TO PROVIDE BEETER ALINGNMENT TO U TUBE & TO DIFFRENTIATE HEATER IN DIFFERENT ZONE ACCORDING TO FEED WATER SUPPLY & HEAT TREATMENT OPERATION PERFORED ON TUBE PLATE BEFORE ASSEMBLED

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1. Cladding of Tube Plate

Process Used:

Submerged arc welding using SS strip of 25mm width and 0.8 mm thickness. Required thickness of 6 mm achieved by welding of two layers and than machining.

Reason for Cladding:

HP Heaters Tube Material Tube Plate Material Tube to tube Sheet joint is achieved by Seal Welding and Expansion . It is difficult to weld dissimilar materials. Water side face of the Tube Plate is subjected to more erosion because of Feed water flow.

2. DRILLING OF TUBE PLATE

DRILLING REQUIREMENT
In HP Heaters manufacturing drilling of tube holes in the Tube Plate and baffle plates is one of the major and critical operation. TUBE PLATE Number of holes : 700 to 2500 Hole Size : 16.08 16.18 Hole Finish : 3.2 micron Depth of the hole : 100 mm to 400 mm

CNC DEEP HOLE DRILLING MACHINE Working Area : 1800 MM X 2800 MM No.of Spindles : 2 Max. Thickness : 600 MM
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TESTING ON TUBE PLATE

1. DIE TESTING 2. MPI (MAGNETIC PARTICAL INSPECTION ) 3. UT ( ULTRA SONIC ) 4. HYDRO TEST (NOT APPLICABLE FOR LP HEATER) 5.AIR TEST

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2. U-TUBE

Common Types of Tubing MaterialUsed in Heat Exchangers Nonferromagnetic 300 Series Stainless Steel (304 and 316) Higher Grade of Stainless Steel (AL6XN, AL6X) Yellow Metals (Admiralty Brass, 90/10 CuNi, Aluminum Brass, Copper Prime Surface, andFinned) Titanium Ferromagnetic
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Tube to Tube plate Joint

Expansion Expansion

Expansion Seal Welded with Groove

Seal Welding &

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3.water box

Water box is fabricated from a plate 75-100 mm thick . Different operation performed are : 1. Pressing of hemi head. 2.Cutting and machining of three openings. 3.Welding of Feed Branch and Manhole facing. 4.Non-destructive Testing. 5.Stress Relieving. 6.Final machining . This Water Box is then Assembled with Tube Plate

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OPERATION PERFORMED ON WATER BOX

Welding of Water Box with T/P This operation is done on the Narrow Gap Welding Machine .The Heater is placed on two rollers and welding head of the machine is position on the groove . By continuous rotation of The heater the joint get welded. NARROW GAP SAW WELDING MACHINE FULLY AUTOMATIC, HIGH PRODUCTIVITY M/C FOR WELDING THICK SHELLS UP TO 350 MM FOR OVERLAYING / STRIP CLADDING STAINLESS STEEL ON CARBON STEEL TUBE PLATES

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4.Baffle

Baffles are used to align u tubes in a proper way Operation perform on baffle Drilling

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Single spindle drilling m\

CONDENSERS
In addition to heating up or cooling down fluids in just a single phase, heat exchangers can be used either to heat a liquid to evaporate (or boil) it or used as condensers to cool a vapor and condense it to a liquid. In chemical plants and refineries, reboilers used to heat incoming feed for distillation towers are often heat exchangers. Distillation set-ups typically use condensers to condense distillate vapors back into liquid. Power plants which have steam-driven turbines commonly use heat exchangers to boil water into steam. Heat exchangers or similar units for producing steam from water are often called boilers or steam generators.

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In the nuclear power plants called pressurized water reactors, special large heat exchangers which pass heat from the primary (reactor plant) system to the secondary (steam plant) system, producing steam from water in the process, are called steam generators. All fossil-fueled and nuclear power plants using steam-driven turbines have surface condensers to convert the exhaust steam from the turbines into condensate (water) for re-use. To conserve energy and cooling capacity in chemical and other plants, regenerative heat exchangers can be used to transfer heat from one stream that needs to be cooled to another stream that needs to be heated, such as distillate cooling and reboiler feed pre-heating.

Types of Condensers
A surface condenser is an example of such a heat-exchange system. It is a shell and tube heat exchanger installed at the outlet of every steam turbine in thermal power stations. Commonly, the cooling water flows through the tube side and the steam enters the shell side where the condensation occurs on the outside of the heat transfer tubes. The condensate drips down and collects at the bottom, often in a built-in pan called a hotwell. The shell side often operates at a vacuum or partial vacuum, often produced by attached air ejectors. In chemistry, a condenser is the apparatus which cools hot vapors, causing them to condense into a liquid. See "Condenser (laboratory)" for laboratoryscale condensers, as opposed to industrial-scale condensers. Examples include the Liebig condenser, Graham condenser, and Allihn condenser. This is not to be confused with a condensation reaction which links two fragments into a single molecule by an addition reaction and an elimination reaction. A condenser unit used in central air conditioning systems typically has a heat exchanger section to cool down and condense incoming refrigerant vapor into liquid, a compressor to raise the pressure of the refrigerant and move it along, and a fan for blowing outside air through the heat exchanger section to cool the refrigerant inside. A typical configuration of such a condenser unit is as follows: The heat exchanger section wraps around the sides of the unit with the compressor inside. In this heat exchanger section, the refrigerant goes through multiple tube passes, which are surrounded by
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heat transfer fins through which cooling air can move from outside to inside the unit. There is a motorized fan inside the condenser unit near the top, which is covered by some grating to keep any objects from accidentally falling inside on the fan. The fan is used to blow the outside cooling air in through the heat exchange section at the sides and out the top through the grating.

Direct contact condenser

In this type of condenser, vapors are poured into the liquid directly. The vapors lose their latent heat of vaporization; hence, vapors transfer their heat into liquid and the liquid becomes hot. In this type of condensation, the vapor and liquid are of same type of substance.

MACHINES USED IN HCM DEPARTMENT

1. MULTISPINDLE CNC DRILLING MACHINE:Model Bridge travel x-axis Head staff travel y-axis Spindle stroke z-axis No. of spindles Min spindle pitch Max spindle pitch Range min spindle pitch Range max spindle pitch Per spindle drilling max capacity Spindle speed Spindle feed no. of drilling motors KOLB MPN G 8.40 7000 mm 5500 mm 350 mm 8 100 mm 200 mm 7000*6200 mm 7000*6900 mm 40 mm 71 to 1400 rpm 10 to 1000 mm/min 2
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motor capacity

50 H.P.(11.5 KW)

MULTI SPINDLE DRILLING MACHINE

2.VERTICLE BORING MACHINE:Table working diameter Max working diameter Tool holder to below height Speed of table/chuck Cross slide to under height

4570 mm 4950 mm 2744 mm 0.48 to13 rpm 3500 mm

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3. CENTRE LATHE MACHINE:Table length Height up to center Length between centers Max swing on saddles Max swing on table

10363 mm 692 mm 6700 mm 1118 mm 1372 mm

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CAPSTAN AND TURRET LATHE 4.RADIAL ARM DRILLING MACHINE:Spindle diameter Spindle feed travel Spindle speed Spindle feed Size of base plate 5. GRINDERGrinder is a machine tool used to give surface finish to the job . It is the process of removing the metal , but comparitively is small volume. In grinding the material is removed by means of a rotating abrasive wheel. This process results in a geometric accuracy of a component and improvement of surface finish the Universal grinder is used here. 57 mm 381 mm 0.775 rpm 0.050/1.016 mm 4204*1562 mm

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6. RADIAL DRILLING MACHINEIt is a drilling machine that drills upto the required depth without actually changing the position of the job . once the job has been mounted on the table the tool post is moved upto the specified position for the next drill. This machine can move vertically upwards backward and is vertical plane and perpendicular to the horizontal.

7. MILLING MACHINEThe milling machine is a machine tool that is used to remove the undesired metal from the job. The vertical milling machine has the tool post mounted in vertical direction. The table on which the job is mounted can be swivelled and it can be moved to and fro in horizontal plane.

Vertical milling machine

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8. GUN DRILLING MACHINE:-

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BIBLIOGRAPHY

WWW.BHEL.COM WWW.GOOGLE.COM WW.SCRIBD.COM

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