Presentation of Bhel and Steel making and other secondary operations.

1. Summer training presentation

2. Content:-
Introduction
Central Foundary Forge Plant(CFFP)
Steel Melting Shop
Electric Arc Furnace
Secondary Steel Making
Sample Testing
Non Destructive testing
Destructive Testing

3. 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

4. CFFP is divided into following shops:-
Central Foundary Forge Plant
CFFP
SMS
STEEL
FOUNDARY
FORGE
SHOP
MACHINE
SHOP

5. Steel Melting Shop
The 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.

6. 10 T Electric
Arc Furnace
30 T Electric
Arc Furnace
70 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

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

8. 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

9. •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

10. Preheating of ladle before pouring molten metal in ladle

11. 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.

12. Composition analysis
During 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

13. 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.

14. Forge Shop
Forging is a manufacturing process involving the
shaping of metal using localized compressive forces.
Decrease in diameter and increase in length.
Increase in thickness of a bar at the expense
of its length
It is a process of producing holes by
using a hot punch passing through
the cylindrical die.

15. Non Destructive Testing
Dye 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)

16. 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.

17. 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.

18. 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

19. Destructive Testing
Destructive
Testing
Tensile
Test
Hardness
test

20. 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(m
m2)
Yield
Load(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.

21. 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.

22. 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.

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

24. 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