SUMMER INTERNSHIP

(VR20)

REPORT ON

( WELDING TECHNOLOGY )

By

(K V R V DURGA SRAVAN)
(Company name: BHARAT HEAVY ELECTRICALS
LIMITED)

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 INTERNSHIP REPORT
A report submitted in partial fulfillment of the requirements for the Award of Degree of

BACHELOR OF TECHNOLOGY

In

(MECHANICAL ENGINEERING)

By

(K V R V DURGA SRAVAN)
Regd. No.: 20L31A0377

Carried at
( BHARAT HEAVY ELECTRICALS LIMITED )

Under the Supervision of

(Mr. SURESH)

(Duration: MAY 16TH to JUNE 04TH )

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 DEPARTMENT OF MECHANICAL ENGINEERING

VIGNAN’S INSTITUTE OF INFORMATION TECHNOLOGY

(Autonomous) Affiliated to JNTU Kakinada & Approved by AICTE, New
Delhi
Re-Accredited by NBA & NAAC (CGPA of 3.41/ 4.00)
VISAKHAPATNAM – 530 049
(June) 2022

VIGNAN’S INSTITUTE OF INFORMATION TECHNOLOGY (A)

Department of MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the “Summer Internship report” submitted by

K V R V DURGA SRAVAN (Regd. No.: 20L31A0377) is work done by him
and submitted during 2021–2022 academic year, in partial fulfillment of the
requirements for the award of the degree of BACHELOR OF
TECHNOLOGY in (Welding Technology) at (BHARAT HEAVY
ELECTRICALS LIMITED, GAJUWAKA).

Industry Supervisor Head-Internships

Mr. Name of Industry Supervisor Dr. P. Sekhar
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 Head of the Department
Dr. Name of the HoD

Certificate of Internship

Space to paste Internship completion certificate/Certificate of

Internship from Industry with proper signature and stamp

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 ACKNOWLEDGEMENT

This is to acknowledge and thank Mr.RAMESH,GENERAL

MANAGER,BHARAT HEAVY ELECTRICALS LIMITED, GAJUWAKA).for

giving us the opportunity to do an internship within the organization.

I would like to express our gratitude to all the employees of BHARAT HEAVY
ELECTRICALS LIMITED, GAJUWAKA). who created an enjoyable working
ambience.
It gives us an immense pleasure to acknowledge the support and cooperation we
have received from the people from various disciplines while undergoing this B.
Tech. Full semester Internship Project.

We express our sincere gratitude to Mr.RAMESH, Department of HRDC &

Security for his constant support and guidance throughout the course. His
guidance has been a constant source of inspiration for us.
We also take the opportunity to acknowledge the contribution of Prof.
Mr.RAMBABU SARIMALLI, Head, Department of Mechanical Engineering,

for his full support and guidance during the development of the project.
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We extend our happiness in showing our gratitude to Prof. V. Madhusudan
Rao, Rector, Prof. B. Arundhati, Principal and the management for providing
us the all the required facilities.

We would like to take the opportunity to acknowledge the contribution of all the
faculty members of the department for their guidance and cooperation while
doing the project. Last but not the least, we acknowledge our parents and
friends for their contribution in the completion of the project

K V R V DURGA SRAVAN
(20L31A0377)

LIST OF TABLES AND ILLUSTRATIONS:

Bharat Heavy Electricals Limited Type Government of India Enterprise Traded

as:
BSE: 500103
NSE: BHEL ISIN INE257A01026

Industry Electrical equipment Founded 1956; 66 years ago Founder

Government of India Headquarters New Delhi, India Area served Worldwide
Key people Nalin Shinghal(CHAIRMAN AND MANAGING DIRECTOR).

PRODUCTS :
Gas and Steam Turbines
Boilers
Electric Motors Electric Locomotives Generators
Heat Exchangers Switchgears and Sensors Automation
and Control Systems Power electronics Transmission systems.

Revenue Decrease: ₹17,678.28 crore (US$2.3 billion) (2021)[1]

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Operating income Decrease :₹−3,238.51 crore (US$−430 million) (2021)[1]

Net income Decrease :₹−2,717.14 crore (US$−360 million) (2021)[1]

Total assets Decrease : ₹55,701.24 crore (US$7.3 billion)

Total equity Decrease : ₹26,484.05 crore (US$3.5 billion)

Owner :Government of India (63.17%)

Number of employees :32,131 (March 2021)[1]

Parent : Ministry of Heavy Industries , Government of India.

ABSTRACT
Brief Introduction :-

Bharat Heavy Electricals Limited (BHEL) is an Indian government

owned engineering and manufacturing enterprise based in New Delhi, India.
It is under the ownership of Ministry of Heavy Industries, Government of India.
Established in 1956, BHEL is India's largest power generation equipment
manufacturer.

PRODUCTS : Gas and Steam Turbines; Boilers; Electric Motors; Electric

Locomotives; G...
Traded as : BSE: 500103
NSE : BHEL Industry

Electrical equipment
In this company we are having following departments:-
1. Engineering
2. Material management
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3. Production
4. Quality checking
5. Erection & commission team

STORAGE TANKS
BOILERS

ORGANIZATION INFORMATION :

BHEL was established in 1956 ushering in the Heavy Electrical

Equipment industry in India. Heavy Electricals (India) Limited was
merged with BHEL in 1974.
[2] When it was set up in 1956, BHEL was envisaged as a plain
manufacturing PSU, with technological help from the Soviet Union.
[3] In 1980's it was cutting edge in thyristor technology.
[4] In 1991, BHEL was converted into a public company. Over time,
it developed the capability to produce a variety of electrical,
electronic, and mechanical equipment for various sectors, including
transmission, transportation, oil and gas, and other allied industries.
[5] However, the bulk of the company's revenue is still derived from
the sale of power generation equipment such as turbines and boilers.
As of 2017, equipment supplied by BHEL constituted around 55% of
the total installed power generation capacity in India.
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[6] The company also supplies electric locomotives to the Indian
Railways and defence equipment such as the Super Rapid Gun Mount
(SRGM) naval guns manufactured in partnership with the Ordnance
Factory Board and simulators to the Indian Armed Forces. BHEL is
engaged in the design, engineering, manufacturing, construction,
testing, commissioning and servicing of a wide range of products,
systems and services for the core sectors of the economy, viz. power,
transmission, industry, transportation, renewable energy, oil & gas,
and defence. It has a network of 16 manufacturing units, 2 repair
units, 4 regional offices, 8 service centres, 8 overseas offices, 15
regional centres, 7 joint ventures, and infrastructure allowing it to
execute more than 150 projects at sites across India and abroad. The
company has established the capability to deliver 20,000 MW p.a. of
power equipment to address the growing demand for power
generation equipment. BHEL has retained its market leadership
position during 2015–16 with 74% market share in the Power Sector.
An improved focus on project execution enabled BHEL record its
highest ever commissioning/synchronization of 15059 MW of power
plants in domestic and international markets in 2015–16, marking a
59% increase over 2014–15. With the all-time high commissioning of
15000 MW in a single year FY2015-16, BHEL has exceeded 170 GW
installed base of power generating equipments.

[7] During the year 2012–13, the company invested about ₹1,252
Crore on R&D efforts, which corresponds to nearly 2.50% of the
turnover of the company, focusing on new product and system
developments and improvements in existing products. The IPR
(Intellectual Property Rights) capital of BHEL grew by 21.5% in the
year, taking the total to 2170.

METHODOLGIES
IN WELDING TECHNOLOGY :

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Welding is a fabrication or sculptural process that joins materials, usually
metals or thermoplastics, by causing fusion, which is distinct from lower
temperature metaljoining techniques such as brazing and soldering, which do
not melt the base metal. In addition to melting the base metal, a filler material is
typically added to the joint to form a pool of molten material (the weld pool)
that cools to form a joint that, based on weld configuration (butt, full
penetration, fillet, etc.), can be stronger than the base material (parent metal).
Welding also requires a form of shield to protect the filler metals or melted
metals from being contaminated on oxidized.

ADVANTAGES OF WELDING JOINTS:

1. As no hole is required for welding, hence no reduction of area. So structural

members are more effective in taking the load.
2. In welding filler plates, gusseted plates, connecting angles etc, are not used,
which leads to reduced overall weight of the structure.
3. Welded joints are more economical as less labor and less material is required.
4. The efficiency of welded joint is more than that of the riveted joint.
5. The welded joints look better than the bulky riveted/butted joints.
6. The speed of fabrication is faster in comparison with the riveted joints. 7.
Complete rigid joints can be provided with welding process.
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8.The alternation and addition to the existing structure is easy.
9. No noise is produced during the welding process as in the case of riveting.
10. The welding process requires less work space in comparison to riveting. 11.
Any space of joint can be made with ease.

DISADVANTAGES OF WELDING JOINTS :

1. Welded joints are more brittle and therefore their fatigue strength is less than
the members joined.
2. Due to uneven heating & cooling of the members during the welding, the
members may distort resulting in additional stresses.
3. Skilled labor and electricity are required for welding.
4. No provision for expansion and contraction is kept in welded connection &
therefore, there is possibility of racks.
5. The inspection of welding work is more difficult and costlier than the riveting
work.
6. Defects like internal air pocket, slag inclusion and incomplete penetration are
difficult to detect
.
CHARACTERISTICS OF BASE METAL (NON – FERROUS
METALS):

PHYSICAL PROPERTIES:
1. Ultimate Tensile Strength
2. Yield Point
3. Elongation

CHEMICAL PROPERTIES:
1. Addition of main alloys like Chromium, Nickel, Copper, Zinc etc .,
2. Addition of micro alloys like Vanadium, Tantalum etc.,
3. Base Metals Easily Hardfaced. -
4. Low & medium carbon steels

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ELECTRODE:
An electrode is an electrical conductor used to make contact with a nonmetallic
part of a circuit (e.g. a semiconductor, an electrolyte, a vacuum or air). In arc
welding, an electrode is used to conduct current through a workpiece to fuse
two pieces together. Depending upon the process, the electrode is either
consumable, in the case of gas metal arc welding or shielded metal arc welding,
or non-consumable, such as in gas tungsten arc welding. For a direct current
system, the weld rod or stick may be a cathode for a filling type weld or an
anode for other welding processes. For an alternating current arc welder, the
welding electrode would not be considered an anode or cathode.
FUNCTIONS:
1. To convey welding current to workpiece
2. To act as a filler material.

TYPES OF ELECTRODE:
1. Consumable Electrode
Bare Electrode
I. Coated Electrode
2. Non – Consumable Electrode.

An AC or DC power source, fitted with whatever controls may be needed, is

connected by a work cable to the workpiece and by a "hot" cable to an electrode
holder of some type, which makes an electrical contact with the welding
electrode. An arc is created across the gap when the energized circuit and the
electrode tip touches the workpiece and is withdrawn, yet still with in close
contact.
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DIFFERENT TYPES OF WELDING :

• Oxy-fuel welding – also known as oxyacetylene welding or oxy welding, uses

fuel gases and oxygen to weld and cut metals.
• Shielded metal arc welding (SMAW) – also known as "stick welding" or
"electric welding", uses an electrode that is coated in flux to protect the weld
puddle. The electrode holder holds the electrode as it slowly melts away. Slag
protects the weld puddle from atmospheric contamination.
• Gas tungsten arc welding (GTAW) – also known as TIG (tungsten, inert
gas), uses a non-consumable tungsten electrode to produce the weld. The weld
area is protected from atmospheric contamination by an inert shielding gas such
as argon or helium.
• Gas metal arc welding (GMAW) – commonly termed MIG (metal, inert
gas), uses a wire feeding gun that feeds wire at an adjustable speed and flows an
argon-based shielding gas or a mix of argon and carbon dioxide (CO2) over the
weld puddle to protect it from atmospheric contamination.
• Flux-cored arc welding (FCAW) – almost identical to MIG welding except it
uses a special tubular wire filled with flux; it can be used with or without
shielding gas, depending on the filler.
• Submerged arc welding (SAW) – uses an automatically fed consumable
electrode and a blanket of granular fusible flux. The molten weld and the arc
zone are protected from atmospheric contamination by being "submerged"
under the flux blanket.
• Electroslag welding (ESW) – a highly productive, single pass welding
process for thicker materials between 1 inch (25 mm) and 12 inches (300 mm)
in a vertical or close to vertical position.

• Electric resistance welding (ERW) – a welding process that produces

coalescence of laying surfaces where heat to form the weld is generated by the
electrical resistance of the material. In general, an efficient method, but limited
to relatively thin material. Many different energy sources can be used for
welding, including a gas flame, an electric arc, a laser, an electron beam,
friction, and ultrasound. While often an industrial process, welding may be
performed in many different environments, including in open air, under water,
and in outer space. Welding is a hazardous undertaking and precautions are
required to avoid burns, electric shock, vision damage, inhalation of poisonous
gases and fumes, and exposure to intense ultraviolet radiation.

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14
SHIELDED METAL ARC WELDING :

It uses a Metallic Consumable Electrode of a proper composition for generating

Arc between itself and the parent work piece. The molten electrode metal fills
the weld gap and joins the work pieces.
This is the most popular welding process capable to produce a great variety of
welds. These electrodes are coated with a shielding flux of a suitable
composition.
The flux melts together with the electrode metallic core, forming a gas and a
slag, shielding the arc and the weld pool.

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The flux cleans the metal surface, supplies some alloying elements to the weld,
protected the molten metal from oxidation and stabilizes the arc. The slag is
removed after Solidification.

Advantages of Shielded Metal Arc Welding (SMAW):

1. Simple, portable and inexpensive equipment;
2. Wide variety of metals, welding positions and electrodes are applicable;
3. Suitable for outdoor applications.

Disadvantages of Shielded Metal Arc Welding (SMAW):

1. The process is discontinuous due to limited length of the electrodes;
2. Weld may contain slag inclusions 3. Fumes make difficult the process
control.

Tungsten Inert Gas Arc Welding (Gas Tungsten Arc Welding):

This is a welding process, in which heat is generated by an electric arc struck

between a tungsten non-consumable electrode and the work piece. The weld
pool is shielded by an inert gas (Argon, helium, Nitrogen) protecting the molten
metal from atmospheric contamination.The heat produced by the arc melts the
work pieces edges and joins them. Filler rod, may be used, if required.Tungsten
Inert Gas Arc Welding produces a high quality weld of most of metals. Flux is
not usedin the process.

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 Advantages of Tungsten Inert Gas Arc Welding (TIG, GTAW):
1. Weld composition is close to that of the parent metal;
2. High quality weld structure
3. Slag removal is not required (no slag);
4. Thermal distortions of work pieces are minimal due to concentration of heat
in small zone.

Disadvantages of Tungsten Inert Gas Arc Welding (TIG, GTAW):

1. Low welding rate;
2. Relatively expensive
3. Requres high level of operators skilL.

Metal Inert Gas Welding (Gas Metal Arc Welding):

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This is a arc welding process, in which the weld is shielded by an external gas
(Argon, helium, CO2, argon + Oxygen or other gas mixtures).Consumable
electrode wire, having chemical composition similar to that of the parent
material, is continuously fed from a spool to the arc zone. The arc heats and
melts both the work pieces edges and the electrode wire. The fused electrode
material is supplied to the surfaces of the work pieces, fills the weld pool and
forms joint.
Due to automatic feeding of the filling wire (electrode) the process is referred
to as a semiautomatic. The operator controls only the torch positioning and
speed.

Advantages of Metal Inert Gas Welding (MIG, GMAW):

1. Continuous weld may be produced (no interruptions)
2. High level of operators skill is not required
3. Slag removal is not required (no slag)

Disadvantages of Metal Inert Gas Welding (MIG, GMAW):

1. Expensive and non-portable equipment is required
2. Outdoor application are limited because of effect of wind, dispersing
theshielding gas.

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Submerged Arc Welding:

This is a welding process, which utilizes a bare consumable metallic electrode

producing an arc between itself and the work piece within a granular shielding
flux applied around the weld. The arc heats and melts both the work pieces
edges and the electrode wire. The molten electrode material is supplied to the
surfaces of the welded pieces, fills the weld pool and joins the work pieces.
Since the electrode is submerged into the flux, the arc is invisible. The flux is
partially melts and forms a slag protecting the weld pool from oxidation and
other atmospheric contaminations.

Advantages of Submerged Arc Welding (SAW):

1. Very high welding rate;
2. The process is suitable for automation;
3. High quality weld structure.

Disadvantages of Submerged Arc Welding (SAW):

1. Weld may contain slag inclusions
2. 2. Limited applications of the process - mostly for welding horizontally
located plates.

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Oxy-fuel welding :

(commonly called oxyacetylene welding, oxy welding, or gas welding in the

U.S.)

Oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut
metals, respectively. Oxy-fuel is one of the oldest welding processes, besides
forge welding. In recent decades it has been obsolesced in almost all industrial
uses due to various arc welding methods offering more consistent mechanical
weld properties and faster application. Gas welding is still used for metal-based
artwork and in smaller home based shops, as well as situations where accessing
electricity (e.g., via an extension cord or portable generator) would present
difficulties.

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 TYPES OF WELD JOINTS :
THERE ARE MAINLY FIVE DIFFERENT TYPES OF
WELDED JOINTS FOR JOINING.THEY ARE:

1. BUTT JOINT
2. CORNER JOINT
3. LAP JOINT
4.TEE JOINT
5. EDGE JOINT

BUTT JOINT :
THE PARTS LIE IN THE SAME PLANE AND ARE JOINED AT THEIR
EDGES.

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LAP JOINT :
IT CONSISTS OF OVERLAPPING PARTS.

TEE JOINT :
ONE JOINT IS AT THE RIGHT ANGLE TO THE OTHER JOINT TO
APPROXIMATE THE SHAPE OF A LETTER “T”.

CORNER JOINT :
PARTS IN A CORNER JOINT FORM A RIGHT ANGLE AND ARE JOINED
AT THE CENTER OF THE ANGLE.

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EDGE JOINT :

PARTS IN AEDGE JOINT ARE PARALLEL WITH AT LEAST ONE OF

THEIR EDGES IN COMMON AND THE JOINT IS MADE AT THE
COMMON EDGE.

INDUSTRIAL EQUIPMENT AT BHEL :

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