Manishhbhel report3

7/28/2019 Manishhbhel report3

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BHARAT HEAVY ELECTRICAL LIMITED

HARIDWAR

TRANING REPORT IN

FABRICATION BLOCK

&

DEFENCE BLOCK

SUBMITTED BY:

MANISH PUROHITB.Tech-FINAL YEAR(2013-14)

MECHANICAL ENGINEERING

ROLL NO-10ESLME035

S.L.B.S ENGG. COLLEGE, JODHPUR

TRANING PERIOD-(1st June - 15th July 2013)

SUBMITTED TO:Mr. P.PANDIT

SENIOR ENGG.

FABRICATION SECTION

BLOCK-2

BHARAT HEAVY ELECTRICAL LIMITED, HARIDWAR

Summer Training (July-13) Manish Purohit S.L.B.S. Engg.

College, Jodhpur


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ACKNOWLEDGEMENT

Before we get into detail of the report,I feel the heartfelt

responsibility to mention my acknowledgement to several people to whom Iowe the success of my venture of training and writing this report.

I am grateful to Mr. P.PANDIT (Sr. Engg.) who allowed me to

undergo vocational summer training and guided me during training period at

BHARAT HEAVY ELECTRICAL LIMITED,HARIDWARwhich holds

the rank amongst the top Public Sectors in india , exhibiting excellent

performance with safest and most friendly enviornment, fulfilling all kinds

of standards respective to its name,reputation and fame.

I would like to give special thank to all the staff of BHELFABRICATION SECTION for their great and remarkable contribution,

support and guidance during training period.Their constant effort made this

training really a learning experience. The well planned schedule and

structure helped me in understanding the systems and equipments easily and

effectively.Manish Purohit

15th JUL 2013


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boilers to both thermal and combined cycle power plants.

The company manufactures 235 MW nuclear turbine generator sets

and has commenced production of 500 MW nuclear turbine generator sets

Typical diagram of a coal fired thermal power station

1. Cooling tower

2. Cooling water pump

3. Three-phase transmission line

4. Step up transformer

5. Electrical Generator6. Low pressure steam turbine

7. Boiler feed water pump

8. Surface condenser

9. Intermediate pressure steam turbine

10. Steam control valve


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11. High pressure steam turbine

12. Deaerator Feed water heater

13. Coal conveyor

14. Belt

15. Coal hopper

16. Coal pulverizer

17. Boiler steam drum

18. Bottom ash hoper

19. Super heater

20. Forced draught fan

21. Reheater

22. Combustion air intake

23. Economizer

24. Air preheater

25. Precipitator26. Induced draught(draft) fan

27. Fuel gas stack


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2.HEEP: AN OVERVIEWOver the years, Bharat Heavy Electricals Limited has emerged as

world class Engineering and Industrial giant, the best of its kind in entire

South East Asia. Its business profile cuts across various sectors of

Engineering/Power utilities and Industry. The Company today enjoys

national and international presence featuring in the "Fortune International-

500" and is ranked among the top 12 companies in the world, manufacturing

power generation equipment. BHEL has now 14 Manufacturing Divisions, 8

Service Centres and 4 Power Sectors Regional Centres besides a large

number of project sites spread over India and abroad.

HEEP: FACILITIES AND INFRASTRUCTURE

Modernization and regular up gradation / up gradation of facilities and

other infrastructure is a continuous endeavor at HEEP, BHEL. After initial

setting up of the plant during the year 1964-72, in collaboration with the

Soviet Union, the plant facilities and infrastructures have since been

continuously upgraded under various investment projects viz, Stamping Unit

Project, LSTG Project, Motor Project, Governing Components Project, TG

Facilities Modernization, TG Facilities Augmentation, Quality Facilities

Augmentation, EDP projects, Gas Turbine Project, Facilities have also been

added and establishments have been created for new projects in Defense and

Aviation Project. Additionally, R &D facilities have also been created underGenerators Research Institute, Pollution Control Research Institute, HTL

modernization and other such scheme

Today the Plant has unique manufacturing and testing facilities,

computerized numerically controlled machine-tools, Blade shop, heavy duty

lathes, milling machines, boring machines, machining centers and many

more. The Over Speed Vacuum Balancing Tunnel created for rotors up to

1300 MW (32T, 6.9 M dia bladed rotor, 6 rpm up to 4500 rpm) is one of

the 8 of its kind in the entire world.

The total spectrum of sophisticated, unique and other facilities at HEEP,

Hardwar are the state-of-the-art in manufacturing processes and can be

utilized for a variety of products' manufacture.


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BHEL UNITS


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1. Bhopal Established 1956

Production

started1960

Heavy Electrical Plant

2. Haridwar

HEEP

CFFP

Established 1963

Production

started1967

Established 1974

Production

started1976

Heavy Electrical

Equipment Plant,

Central Foundry Forge

Plant

3.Hyderabad

HPEP

Established 1963

Productionstarted1965

Heavy Power

Equipment Plant

4.Tiruchi

HPBP

SSTP

Established 1963

Production

started1965

Production

started1979

High Pressure Boiling

Plant

5.Jhansi

TP

Production

started1976

Transformer Plant

6.Banglore

EDN

EPD

ISG

Established 1963

Established 1972

Established 1977

Control equipment

division

Electro Porcelain

division

7.Ranipet

BAP

Established 1976

8.Goindwal Established 1983

9.JagdishpurIP Productionstarted1984 High tension ceramicInsulation Plates

10.Rudrapur Production

started1984

11.Gurgoan Solar Photovoltaic Cells


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THERE ARE 8 BLOCKS IN HEEP

BLOCKS PRODUCTS

I. Electrical Machine Turbo generator, generator exciter , motor (ac,dc)

II. Fabrication Large size fabricated assemblies/components

III. Turbine &

Auxiliary

Steam ,hydro ,gas turbines, turbine blade , special to

IV. Feeder Winding of Turbo ,hydro gen. ,insulation for a

motors

V. Fabrication Fabricated parts of steam turbine , water boxes

tank ,hydro turbine parts.

VI. Fabrication

Stamping

and die

manufacturing

Fabricated oil tanks, hollow guide blades, rings

frames, and rotor spindle.

All dies. Stamping for gen. and motors

VII. Wood working Wooden packing, spacers

VIII. Heaters &

coolers

LP heaters, ejectors, glands, steam and oil coolers, o

bearing covers.


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TRAINING DEPARTMENT

Manufacturing Facilities-

Preparation ,Bay -1

It has the following sections

a) Marking cutting and straightening section.

b) Gas cutting section including CNC flame cutting section &

CNC Plasma cutting section.

c) Press section (400T and 800T, Brake press).

d) Shearing M/c section.

Assembly and Welding Section .Bay -2

a) Assembly and welding section for large size units up to 75

tons.

b) Heat treatment section.

c) Shot blasting and cleaning section.

Sections in Bay -3

a) Assembly and welding sections of small size units unto 10

tons.

b) Pipe sections.

Sections in Bay -4

a) Machine section : It is designed for machining parts and units

during fabrication stage. This section supplies small parts and

units of Steam turbine, generators, hydro-turbine etc.

The unique machines viz. CNC multi spindle drilling

machines and Horizontal ram borer are installed to help in


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machining of various components like drilling of tube plates

of different types apart from machining of big assemblies

such as front wall, casing, water boxes etc..

b) Diaphragm section : Welded diaphragms of steam turbines are

assembled, welded and stress relieved in this section.

Coolers section: In this section tubes of coolers are cut to the

required size, then turned and thereafter winding and soldering of

spirals on tubes is carried

c) out by automatic machines. These are then assembled to form

coolers which are then assembled and hydraulically tested.

Manufacturing processes-

Manufacturing starts withPreparation of individual parts before

assembly, in Bay -1.

a) The metal is first marked and cut by the following machines:-

- Gullotine Shearing machine for cutting and trimming steel

sheets and plates up to 25mm thick with straight contours.

- Stationary and portable Oxy-acetylene cutting machines forcutting machines for cutting parts out of steel plates.

- An unique Flame cutting machine is used for cutting steel

plates by CNC programming.

- CNC Plasma cutting M/c for cutting S.S & higher alloys.

- Combination punch, shear and bar cutters, circular saws

and bar shears are used for cutting angles, shapes,

flats and rods.

b) Straightening Rollers are used for straightening plates and

large sized blanks and a 160 ton friction press for

straightening small sized blanks. A roll bending machine is

used for straightening and bending rolled beams and

angles.


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c) A 800 ton hydraulic bending and 400 ton press and a 250 ton

friction press are used for cold and hot bending from rolled

sheets and shapes. Parts to bend are pre heated in a 700

KW electric furnace, when ever needed.

d) Finished parts are inspected at the working place.

After Preparation is complete the next step is Assembly and

Weldingin Bay -2 and 3 is as follows:

a) Components of units are assembled and tack welded for

subsequent welding as per drawing and instructions onprocess cards.

b) Manual arc welding arc welding is employed in restricted

and inaccessible places or where semi-automatic or

automatic welding is not possible or has not been established.

c) Semi-Automatic submerged arc welding, GTAW and Argon

Carbon-di-Oxide shielded arc welding are also used forincreased productivity and better quality.

All assembly work is carried out on bed plates. Small size

structures are welded with the help of manipulators.

Welding of high pressure cylinders of steam turbines is

carried out after preliminary heating up to 250 C.

Heat treatment is carried out in electric furnaces of bogie

hearth, bell and pit types after welding is completed.

In multi layer welding, the roots of seams are gouged and thencleaned by mechanical means.

All assembly and welding sections have connections for

compressed air, oxygen & acetylene as well Argon carbon-di-

oxide mixture and water for semi automatic welding.


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Weld quality inspection is adopted in accordance with the

relevant specifications.

Inspection of weld quality and flaw detection is carried out

by means of X-ray machines, gammagraphy machines of cobalt

and iridium isotopes and ultrasonic flaw detectors.Pressure vessels that is boilers, heaters, condensers and

coolers undergo hydraulic tests on special test beds meant for

hydraulic testing. Kerosine leakage test is also done in case of thin

walled vessels.

Process being followed inpipe section is mentioned below:

a) Pipes with diameter of 10-60 mm and 38-108 mm are cut

on pipe cutting machines and oxy-aceytlene cutters.b) Cold bending of pipes is carried out on a pipe bending

machine. Bending of carbon and alloy steel pipes of 114

mm dia and above is performed by heating them in electric

furnaces and then by hot bending.

c) Facing of pipes and beveling for welding is carried out on

a horizontal boring machine with portable type pipe

chamfering machine.

d) For assembly and welding of pipes bed plates andmanipulators are used.

e) Heat treatment of pipes is done in electric furnace

mentioned earlier.

f) Surface cleaning is done manually or by shot blasting.

Pipe assemblies are dimensionally checked and quality of

welds is tested by X-ray and Gammagraphy.

Process being followed in machining section is as follows:

a) Casting, forging, rolled section and welded structures aredelivered to sections where assembly and welding are

done in accordance with specifications set forth in

drawings.

Pre weld machining for large sized parts for steam turbines and


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hydro turbines are carried out in block-3.

b) Provision is made for the application of highly productive

cemented carbide tiped cutting tools, high speed cutting

with maximum utilization with machine tool capacity andrapid section locating and clamping fixture.

Process being followed inpainting section is as follows:

a) Painting materials used and painting processes adopted,

conform to the standards for tropical climates.

b) Owing to different operating conditions and decoration

requirements of units and parts of turbines and electrical

machines, different processes for painting are adopted.c) Some components and units undergo only prime coating in

the steel structure section, with subsequent painting in the

painting section of the machine and assembly section.


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WORK UNDERGONE & EXPERIENCE

During my training period at the block-2 I came to know about the

main processes which went through the block.Most of the

manufacturing process have been told about earlier. Some more

machineries and processes are given here.Some of them were like

plasma cutting, NDT testing, Hydraulic presses,turning, gas cutting

etc.

The various processes and machinery are as follows:

A)Hydraulic Press:A hydraulic press is a hydraulic mechanism

for applying a large lifting or compressive force. It is the hydraulic

equivalent of a mechanical lever, and is also known as a Bramah

press after the inventor, Joseph Bramah. Hydraulic presses are the

most commonly-used and efficient form of modern press.

The hydraulic press depends on Pascal's principle: the pressure

throughout closed system is constant. At one end of the system is a

piston with a small cross-sectional area driven by a lever toincrease the force. Small-diameter tubing leads to the other end of

the system. A fluid, such as oil, is displaced when either piston is

pushed inward. The small piston, for a given distance of

movement, displaces a smaller amount of volume than the large

piston, which is proportional to the ratio of areas of the heads of

the pistons. Therefore, the small piston must be moved a large

distance to get the large piston to move significantly. The distance

the large piston will move is the distance that the small piston ismoved divided by the ratio of the areas of the heads of the pistons.

B)Oxy-Fuel Welding And Cutting: Oxy-fuel welding

(commonly called oxyacetylene welding oroxy welding or in the


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U.S. gas welding) and Oxy-fuel cuttingare processes that use fuel

gases and oxygen to either weld or cut metals.

There are a few differences between the two. In Oxy-fuel welding,

a welding torch is used to weld metals. In Oxy-fuel cutting, acutting torch is used to heat up ferrous metal to kindling

temperature (about 980C). A stream of pure oxygen is trained on

the hot metal which chemically combines with the iron which then

flows out of the cut, or kerf, as an iron-oxide slag

Torches that do not mix pure oxygen with the fuel inside the torch,

but burn it with atmospheric air, are not oxy-fuel torches and can

be identified by their single tank. (Oxy-fuel welding/cutting needs

two tanks, fuel and oxygen.) Most metals cannot be melted with

such single-tank torches, so they can only be used for soldering

and brazing, not welding.

Apparatus used in Oxy-Fuel welding and cutting:

The apparatus used in gas welding consists basically of an oxygen

source and a fuel gas source (usually cylinders), two pressure

regulators and two flexible hoses (one of each for each cylinder),and a torch. This sort of torch can also be used for soldering and

brazing. The cylinders are often carried in a special wheeled

trolley.

There have been examples of oxyhydrogen cutting sets with small

(scuba-sized) gas cylinders worn on the user's back in a backpack

harness, for rescue work and similar.

There are also examples of pressurized liquid fuel cutting torches,usually using gasoline. These are used for their increased

portability.

C)Planers: Aplaneris a type of metalworking machine tool that is

analogous to a shaper, but larger, and with the entire workpiece


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moving beneath the cutter, instead of the cutter moving above a

stationary workpiece. The work table is moved back and forth on

the bed beneath the cutting head either by mechanical means, such

as a rack and pinion gear, or by a hydraulic cylinder.

Planers and shapers were used generally for two types of work:

generating accurate flat surfaces and cutting slots (such as

keyways). Planers and shapers are now obsolescent, because

milling machines have eclipsed them as the machine tools of

choice for doing such work.

D)Plasma Cutting:Plasma cuttingis a process that is used to cut

steel and other metals (or sometimes other materials) using a

plasma torch. In this process, an inert gas (in some units,

compressed air) is blown at high speed out of a nozzle; at the same

time an electrical arc is formed through that gas from the nozzle to

the surface being cut, turning some of that gas to plasma. The

plasma is sufficiently hot to melt the metal being cut and moves

sufficiently fast to blow molten metal away from the cut.

Cutting Methods: Plasma cutters have also been used in CNC

machinery. Manufacturers build CNC cutting tables, some with thecutter built in to the table. The idea behind CNC tables is to allow

a computer to control the torch head making clean sharp cuts.

Modern CNC plasma equipment is capable of multi-axis cutting of

thick material, allowing opportunities for complex welding seams

on CNC welding equipment that is not possible otherwise.

E)Three roll bending machine: Roll benders use three rolls

(typically) to bend solids, extrusions and tube and pipe to various

diameters by adjusting one or two rolls. The pyramid style rollbenders have one moving roll, usually the top roll. Double pinch

type roll benders have two adjustable rolls, usually the bottom

rolls, and a fixed top roll. Large arcs, circles and spirals are typical

applications for roll benders.


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The roll bending machine in BHEL has following specifications:

Maximum working length:8000 mm.

Minimum diameter of forming:1300 mm.

Plate thickness:32 mm,

Upper rolled dia.:7550 mm.

Lower roll dia.:680 mm.

Speed of forming :5 m per minute.

Speed of lowering upper roll :60 mm per minute.

Speed of raising upper roll :120 mm per minute

F) Boot Press Furnace: This press was having following furnace :

Power:750KW.

Furnace size : length-4000 mm

Width :2400 mm.

Height :1600 mm.

Zones: 5

G)Centre lathe with three and four jaws: A metal lathe is

generic description for a rigid machine tool designed to remove

material from a workpiece, through the action of a cutting tool.

They were originally designed to machine metals; however, withthe advent of plastics and other materials, and with their inherent

versatility, they are used in a wide range of applications, and a

broad range of materials.


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A center lathe is a dual head machine where the work remains

fixed and the heads move towards the workpiece and machine a

center drill hole into each end. The resulting workpiece may then

be used "between centers" in another operation. The usage of the

term metal lathe may also be considered somewhat outdated thesedays, plastics and other composite materials are in wide use and

with appropriate modifications, the same principles and techniques

may be applied to their machining as that used for metal.

A center lathe orengine lathe may be considered the basis for the

metal lathe and is the type most often used by the general

machinist or hobbyist.The center lathe may be considered a useful

starting point. The engine lathe is the name applied to a traditional20th century lathe. It is assumed that the 'engine' was added to the

description to separate them from the 'foot lathes' (lathes turned by

pedals) or other hand rotated pieces of machinery. Early engine

lathes were generally 'cone heads', in that the spindle usually had

attached to it a multi-step pulley designed to accept a flat belt.

Different spindle speeds could be obtained by moving the flat belt

to different steps on the cone pully. It was assumed that a cone

head lathe would be powered by a Line shaft which was the

industrial standard of the time

H)Manipulator:Parts that cannot be welded easily by ordinary

welding, specially internal curved parts are welded by

manipultaors .

I)Non Destructive Testing: Nondestructive testing (NDT) hasbeen defined as comprising those test methods used to examine an

object, material or system without impairing its future usefulness.

The term is generally applied to non medical investigations of

material integrity.

The main NDT processes at the fabrication block are as follows:


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1)Visual inspection : It is the simplest ,cheapest and most widely

used method amongst all the NDTs.A simple visual test reveal

gross surface defects easily and quickly . However for detection of

final defects, device/equipments having high degree of precision

and illumination are required.

2)Radiography: In this test the X-rays and gamma rays are used

to detect deep seated internal defects. The short wavelengths of X-

ray permitted to penetrate through the opaque material. Gamma

rays are the electro-magnetic radiations that are emitted from an

unstable nucleus.

3)Penetrant Testing- Penetrantsolution is applied to the surface

of a precleaned component. The liquid is pulled into surface-

breaking defects by capillary action. A developer is applied to pull

the trapped penetrant back to the surface where it is spread out and

forms an indication. The indication is much easier to see than the

actual defect

J) Vertical boring machine C-208: The specification of thismachine is as follows:

Chuck diameter = 4 m

Maximum chuck speed = 30 rpm

Minimum chuck speed = .2 rpm

Use to make Guide blade carrier

Feed can be given at any time .

Pendant is used for the performance on the job.


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Operations performed are turning, facing, boring, taper

machining.

K)CNC Flame Cutting

Setup in BHEL in 1982 and imported from Germany.

Maximum depth of cutting: 250mm -300mm.

Gas used oxyacetylene

Program are saved and made by the programmer.

Different nozzle are used for different jobs.

L)CNC Plasma Cutting Machine

Arc is maintained between a non consumable electrode and

work piece.

High temperature is reached upto 35000c

Cu nozzle is used through which tungsten electrode is fed.

Maximum cutting thickness is 80 mm.

Much faster.

Narrow heat affected zone.

Used for cutting non ferrous metal


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DEFENCE PROJECT

76/62 Super Rapid Gun MountingThe Otobreda 76 mm gun is a naval artillery piece built by the Italiandefence

conglomerateOtobreda. It is based on the Oto Melara76mm/L62 Allargato, which was

bigger and heavier. A vehicle-mounted version known as the Otomatic was built for theself-propelled anti-aircraft gunrole but was not put into production.

Unlike the older Allargato the Otobreda 76mm Compatto cannon system is compact

enough to be installed on relatively small warships, likecorvettes, avisos (a vesselsomewhere between a corvette and a patrol boat), orpatrol boats. The gun's high rate of

fire makes it suitable for short-range anti-missile point defence, and its calibre also allows

it to function in anti-aircraft, anti-surface, and ground support roles. Specialisedammunition is available for armour piercing, incendiary, and directed fragmentation, and

a new stealth cupola has been designed in recent years.

The Otobreda 76mm Super Rapidas mounted in akora class corvette

Type Naval gun

Place of origin Italy

Service history


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In service 1964 - present

Production history

Designer Oto Melara

Designed Compact: 1963

Super Rapid: 1985

Manufacturer Oto Melara (19632001)

OtoBreda (2001 onwards)

Produced Super Rapid: 1988

Specifications

Weight Empty: 7.5 tonnes (17,000lb)

Barrel length 62 caliber: 4,724.4 mm (186.00 in)

Crew remote controlled

Shell 76900mmR (complete round)

12.34 kilograms (27.2 lb)

Caliber 76.2 mm (3.00 in)

Elevation 5/+75


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speed:35/s (acceleration: 72/s)

Traverse 360

speed: 60/s (acceleration: 72/s)

Rate of fire Super Rapid: 120 rounds/min

Muzzle velocity 925 m/s (3,030 ft/s)

Maximum range HE round fired at 45:

Super Rapid: 30,000 m (33,000 yd)

Feed system Magazine capacity:85 ready rounds on Super Rapidgun mount

Super Rapid

Also called the "Super Rapido" this weapon, developed in early '80s, is the most up to

date development of the Italian 76mm naval cannons, with an increased rate of fire of 120

rounds per minute. To achieve the higher rate of fire the Super Rapido requires aspecially developed round that can be raised, loaded and chambered at higher speeds.

While the older 76mm Allargato and 76mm Compacto can fire the new special round, it

does not increase their rate of fire. Only the Super Rapido can fire at 120 rounds per

minute. That rate is only done in short bursts, despite the water cooling of the barrel. TheSuper Rapido also improved on serious vibration problems the older Oto Melara and

Otobreda 76mm mounts experienced, resulting in poor accuracy against smaller high

speed air targets, for example anti-shipping missiles and guided bombs.

Main component of SRGMIt works on hydraulic system.

Hydrolic oil :- SRGM works on hydraulic system. The oil which is used in this systemare MIL5600 and MIL H6083

Accumulator :- It is called the heart of this system. This is like a cylinder. The pressure

of accumulator is 80 bar. Two racks are placed in the accumulator, which arecontinuously move up and down.

Rocker Arms :- Two Rocker arms are connected to the two racks of accumulator. The

work of rocker arms are to set up the bullet in the gun.

N2-O2 Cylinder :- This is used to maintain 80 bar pressure in the accumulator.


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Barrel

Users

India

Godavari class frigate

Brahmaputra class frigate

Shivalik class frigatekora class corvette

Kamorta class corvette

Veer class corvette

CONCLUSION

Gone through a rigorous four weeks training under the guidance of

capable engineers and workers of BHEL Haridwar in Block-2 headed

by DGM of block-2 Mr. B.K.Basu situated in Ranipur, Haridwar

Uttarakhand.

The training ,was specified under the Heavy Fabrication Department.

Working under the cam machining department the basic grinding,

scaling and machining was shown on heavy to medium duty lathes

planted in the same line where the specified work was undertaken.

The training brought to my knowledge the various machining and

fabrication processes went in not only in the manufacturing ofcams but other iron casted products. Thus the training was

successfully accomplished under very able guidance of the

engineers and sub-engineers of Bajaj Motors Ltd.


College, Jodhpur
http://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Godavari_class_frigatehttp://en.wikipedia.org/wiki/Brahmaputra_class_frigatehttp://en.wikipedia.org/wiki/Shivalik_class_frigatehttp://en.wikipedia.org/wiki/Kora_class_corvettehttp://en.wikipedia.org/wiki/Project_28_Anti-Submarine_Warfare_corvettehttp://en.wikipedia.org/wiki/Veer_class_corvettehttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Godavari_class_frigatehttp://en.wikipedia.org/wiki/Brahmaputra_class_frigatehttp://en.wikipedia.org/wiki/Shivalik_class_frigatehttp://en.wikipedia.org/wiki/Kora_class_corvettehttp://en.wikipedia.org/wiki/Project_28_Anti-Submarine_Warfare_corvettehttp://en.wikipedia.org/wiki/Veer_class_corvette


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Manishhbhel report3

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