INPLATTRAININGREPORT INPRODUCTIONDEPARTMENT ATHERP,VARANASI

SUMITTEDBY SumitKumarSrivastava NITDurgapur WestBengal GUIDE SunilKumarTiwary(Sr.engg,Production)

& CKPrajapati(engineer,PDEC)

Checkby:

Acknowledgement

On successful training of my in plant training in shop of HERP I am pleasedtopresentyouthisindustrialreport.

OuttheveryoutsetIwouldliketoexpressmygratitudetoshreeAfaque Mahmud(Sr.training&placementofficer),IntegralUniversity,Lucknow.

IwouldalsoliketoexpressmyheartfelttoallstaffsofHERPfortheir guidance.

Iamthankfultoshopmanagersfortheirhelp&guidance.

Place:

Date:

A BRIEF ABOUT HERP, VARANASI In line with BHEL's objective of providing consistent service at doorstep, HERP was established in the vicinity of power stations at Varanasi. The foundation stone of HERP sprawling in 29.8 acres area at Varanasi was laid on 26th September 1984. Within a short span of 21 months, production activities were started in the plant from 1st April'1986. Having achieved break-even point in the second year of its existence itself, HERP progressed by leaps & bounds. Starting as a manufacturer of O&M spares for boiler auxiliaries, repair activities took off on firm footing in 1990 when rebabbitting of TG set bearings was taken up. Since then, rebabbiting of different ratings of TG-bearings have been carried out to entire satisfaction of the customers. HERP Varanasi has taken up various critical jobs from nearby power plants viz: NTPC Tanda, Unchahar, UPRVUNL Obra, Anpara, and Parichha and helped them to achieve maximum availability of their units. Now apart from conventional spares of Bowl Mills & boiler auxiliaries, HERP is manufacturing and supplying turbine fasteners for different

power plants, turbine tools and tackles (required for erection and commissioning/ major overhaul of turbines) for various power projects. During financial year (2008-09) we have achieved the turnover of Rs 200.00 crores and the budgeted turnover for this year (2009-10) is 240.00 crores.

HISTORICAL BACKGROUND Foundation Day : 26.09.1984

ProductionCommencement

:01.04.1986

Area

:29.80Acres

BreakEvenYear

:198788

Manpower

:Executives45 : Others 108

InitialInvestment Expansion:

:Rs497.00Lacs

ExpansionYear Investment

:199192 : Rs 725.51 Lacs

AccreditionTo ISOCertification OHSAS18001

:ISO90012000During ISO140012003

RANGE OF PRODUCTS/SERVICES

S. PRODUCTS/SERVICES NO . 01 Bowl Mill spares for XRP/XRS 623, 703HP, 783, 803, 803HP, 883, 1003 Mills. 02 Turbine fasteners & Spares. 03 Rebabbitting of TG bearings. 04 Rotor Repair. 05 Spares for Boiler Auxiliaries like Coal Burners, Fuel Piping, ESP, Air Preheater & R.C. Feeder spares etc. 06 Hydro Turbine component machining like Guide Vanes, Guide Bearings etc. 07 Tools & Tackles of Steam Turbines. 08 Limiter Assembly, Oil Filter Assembly & Speed Changer Assembly of Governing System. 09 Single & Twin rollers for transformers. 10 Turbine Steam Strainer Assly, CLH, VLH & Planetary Gear Boxes (To Be Undertaken)

Basicofmachinetools

Machinetoolisapowerdrivenmachine,sodesignedthatitiscapableof holding&supportingthejob&atthesametimedirect&drivethecutting toolorjoborbothtoperformadefinitemetalremovingoperationinorder tohavethedesiredsizeofthejobsurface. Othermetalworkingmachinesuchasforgingmachine,hammer,power pressfolding&bendingmachineetc.stilldoesnotfallinthecategoryof machinetool.Machinetoolsaregeneratingmachines&itisreckoned thatthesemachineswhentakenasagrouparecapableofreproducing themselveswhichothermachinecantdo.

Machinetooldrive

Theworddriveisusedforentiretransmissionsystemusedinmachine tool for transmitting power & motion for driving & operating different mechanism. Forperformingthemachiningoperationitisrequiredto 1) Totransmitmotion&powerfrominputshafttooutputspindleram ortable

2) Toconvertrotarymotiontotranslatorymotionorviceversa Driveareobtainedbyfollowingways 1) Mechanicaldrive:driveisobtainedbymeansofbelt,gearchains etc.

2) 3)

Hydraulicdrive:driveisobtainedbymeansofoilpressure. Electrical drive: drive is obtained by means of a.c motor or by meansofd.cgenerator.

Machinetoolcontrols

Asoneobservesthemachinetools,hewillfindthenumberoflevers, handwheels,starwheels,startstopswitches,reversibleswitchesetc attached on it. All these are known as controls and a number of operations are performed with their help like starting & stopping of machines increasing & decreasing the depth of cut, feeding the tool, workorbothetc.

Cuttingtools: 1) Singlepointcuttingtool:thosehavingonlyonecuttingedgessuch aslathetools,shapertools,boringtoolsetc

2)

Multipointcuttingtools:thosehavemorethanonecuttingedge suchasmillingcutters.

Cuttingtoolmaterials: 1) Highcarbonsteel

2) Highspeedsteels
3)

Cementedcarbide,etc.

Lathe

Lathe is a machine tool which holds the work between two rigid supports. Mainpartsoflathe:
1) 2) 3)

Livecenters:Alsocalledchuckorfaceplate Deadcenters Carriage:itconsistsof(i)saddle:Itslidesalongthebed(ii)cross slide : Mounted on top of the saddle & moves in the direction perpendicular to the axis of the spindle.(iii) compound rest : Mountedoncrossslide&haveagraduatedcircularbasecalled swivelplate.(iv)toolpostmountedoncompoundrest(v)Apron:it ishangingpartofcarriagecontainsgeartrain.

Thejob isheld between twocentresrigidly. The cutting toolisrigidly held&supportedinatoolpostandisfedagainsttherevolvingwork.In doingsoitproducesthecylindricalsurfaceifitisfedparalleltotheaxis oritproducestaperedsurfaceifitisfedataninclination.

CNCMACHINES

CNCstandsforcomputerizednumericcontrol.SometimesForcorrect& quick operation, calculation & optimization of the feeds, speeds and othercuttingparametersacomputerisincorporatedwithNCsystem.It isuniquemachinebywhicheverykindofoperationcanbedone.Itis mostlyusedforPrecisionwork&profilework. IthasgotsixaxesnamelyX,Y,Z,Q,B,W.everyaxishaspositive& negativevaluedependinguponthemeasurementsfromtheorigin.Ithas gottwotypeofbed.Oneremainsstationarywhileothercanbemoved forward&backward.Onthemovabletableothertablecanalsobefixed.

Drillmachine: Drillingisanoperationthroughwhichholesareproducedinasolidmetal by means of revolving tools called drill. Drilling is followed by an operation called reaming where close dimension tolerances & fine surfacefinishisrequired. Itisdonebymultitooth revolvingtoolcalled reamer. Main parts of drilling machine: (i) Column (ii) motor (iii) base (iv) Auxiliarytable(v)spindle(vi)drillchuck(vii)spindlehead Mainlyplainradialdrillingmachineuniversaldrillingmachinesareused forheavytypeofwork.Forsmallworkportable&simpletypeofradial drillingmachineisused. Plainradialdrillingmachine: Therearethreetypesofmovementsarepossibleinsuchtypeofdrilling machine.

(i)Verticalmovementsofarmalongthecolumn (ii)Horizontalslidingmovementsofdrillingheadorspindlehead (iii)Radialswingingofthearminahorizontalplane.

Universaldrillingmachine: Therearefivetypesofmovementsarepossibleinsuchtypeofdrilling machine. (i)Verticalmovementsofarmalongthecolumn (ii)Horizontalslidingmovementsofdrillingheadorspindlehead (iii)Radialswingingofthearminahorizontalplane. (iv) There is provision for swinging of spindle about the axis which is normaltothearm.Thusspindleheadcanbeinclinedtoasuitableangle withitsnormalverticalpositiononeithersideenablingdrillingofholesat desiredinclinationwithisnormalverticalposition. (v)Armitselfcanberotatedthroughadesiredanglealongthehorizontal axisenablingdrillingatanydesiredlocation. Bedismadeupofcastironwhichhaspropertytoabsorbsthevibration Boringmachine: Boringisanoperationtoenlargetheexistingholeandalsoaxisofthe holeismadecorrect. Main parts of boring machine: (i) Column (ii) motor (iii) base (iv) Auxiliarytable(v)spindle(vi)spindlehead Bedismadeupofcastironwhichhaspropertytoabsorbsthevibration

Planner: Machiningisdonebymeansofmultipointcuttingtool. InthisToolis fixedadjobreciprocates. Desired machining operation is done by means of revolving milling cutter.Toolisfixedontoolorspindlehead&cuttingactiontakesplace bythemovementofthebedonwhichjobisfirmlyfixed.

Slotter: Itisjustlikeverticalshaper. Mainpartsofboringmachine:(i)Column(ii)motor(iii)base(iv)ram. Rammovesverticallyup&down.Cuttingisdoneduringthedownward strokesoitiscalledcuttingstroke&upwardstrokeiscalledidlestroke. Slotsaremadeinthejob.Mainlyusedforkeywaycuttinginthejob. Thejob isheld between twocentresrigidly. The cutting toolisrigidly held&supportedinatoolpostandisfedagainsttherevolvingwork.In doingsoitproducesthecylindricalsurfaceifitisfedparalleltotheaxis oritproducestaperedsurfaceifitisfedataninclination. HERPShophasgottwoshops. (1)Machineshop (2)Heavymachineshop:

Therearetwobaysinmachineshop&onebayinheavymachinesshop

TheseBayscontainfollowingmachine

CENTRIFUGAL BABBITTING MACHINE SLOT BLASTING CHAMBER TINNING BATH BABBIT MELT.FURNACE STRESS RELIEVING FURNACE
EQUIPMENT

1 No. 1 No. 1 No. 1 No. 1 No.

Dia.800mm, upto 1 Ton 2.5Mx0.3Mx2.5M 1M Dia., 800kgs. Cap, 600C 200 kgs., 800C 2.5Mx2Mx1.5M Chamber Size, 750C

QTY. BRIEF DESCRIPTION

1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 2 Nos. 1 No. 1 No. 1 No. 1 No. 1 No. 2 Nos. 1 No. 1 No. 1 No. 1 No. 1 No.

HOR.BORING MACHINE HOR.BORING MACHINE VERT.BORING MACHINE VERT.BORING MACHINE VERT.BORING MACHINE CENTER LATHE CENTER LATHE FACING LATHE CENTER LATHE CENTER LATHE CENTER LATHE CENTER LATHE CNC LATHE MILLING MACHINE MILLING MACHINE RADIAL DRILLING PORTABLE DRILLING M/C SLOTTING MACHINE CYLINDRICAL GRINDING M/C VER.SURFACE GRINDER PLANO-MILL

Sp.dia.100mm,Table Sp.dia.160mm,Table Table dia.1.2M - VTL Table dia.2.3M Table dia.2.5M Swing 900mm, Length 5M Swing 1.6M, Length 10M Swing 2M, Length 2M Swing 550mm, Length 3M Swing 550mm, Length 1M Swing 250mm, Length 1M Swing 550mm, Len.1.5M Swing 760mm, Length 3M Table 1600x300 Universal Table 1200x200 Universal Drill Cap.in Steel - Dia.50 Drill Cap.in Steel - Dia.50 Stroke 500mm Dia.200mmx2.2M Table 1500x200 Table 1Mx2.5M

SHEARING MACHINE

1 No.

16mm MS, 10mmSS X2.5M

1 No. 150 Tons 3M W idth BRAKE PRESS 1 No. CO2 W ELDING SET 1 No. TIG W ELDING SET W ELDING RECTIFIERS 5 Nos. 1 W ELDING TRANFORMER No. 300 Amp.x2 1 No. Cap.12mm X 3 M 4-ROLL BENDING MACHINE

POWER SAW PUG CUTTING SET PLASMA CUTTING M/C

1 No. 1 No. 1 No.

DIA.200mm Circle 75 - 1140 Air Plasm a

D.G.SET D.G.SET AIR COMPRESSOR EOT CRANE EOT CRANE EOT CRANE EOT CRANE EOT CRANE FORK LIFT TRUCK HYDRA

1 No. 1 No. 2 Nos. 1 No. 1 No. 1 No. 1 No. 1 No.

160 kva 250 kva 6 kg/sq.cm. 20/4 Tons (Remote 10/2 Tons (Remote Optd.) 5 Tons (Pendent Optd.) 2 Tons (Pendent Optd.) 75/10 Tons(RemoteOptd.) 2.5 Tons 5 Tons

1 No. 1 No.

Stud

Heavydutylathe

CBH100&VBMACHINES

DRILLOPERATIONINMAINVERTICALSHAFT

V.B.SKODA