Internship Report 1

See discussions, stats, and author profiles for this publication at: https://www.researchgate.
net/publication/329248129
Internship Report at Nepal Hydro and Electric Limited.
Technical Report · January 2018

DOI: 10.13140/RG.2.2.36617.90725
CITATIONS READS
0 406
1 author:
Aashish Bhandari
K L University
2 PUBLICATIONS 0 CITATIONS
SEE PROFILE
Some of the authors of this publication are also working on these related projects:
Design and Development of Agriculture Harvesting Robot . View project
All content following this page was uploaded by Aashish Bhandari on 28 November 2018.
The user has requested enhancement of the downloaded file.

Internship Report at Nepal Hydro and Electric Limited
ELABORATES THE PRACTICAL APPROACH TO HYDRO MECHANICAL WORK

THAT ARE PERFORMED INSIDE THE NHE.
Submitted in the partial fulfilment of the requirements for
the award of the degree of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
by
Aashish Bhandari
(150070449)
Under the esteemed guidance of
Mr. Er.Sagar Basnet & Er. Sanjit Sah

Engineers
Mechanical Division
DEPARTMENT OF MECHANICAL ENGINEERING
K L UNIVERSITY
Green Fields, Vaddeswaram, Tadepalli,

Guntur - 522502, Andhra Pradesh.
2018-2019
i
NEPAL HYDRO AND ELECTRIC LIMITED

Butwal, Rupandehi Nepal
Bonafide Certificate
Company Logo
This is to certify that this Internship report entitled “Elaborates the practical
approach to hydro mechanical work that are performed inside the NHE.” submitted to
Department of Mechanical Engineering, KL Deemed to be University, Guntur, in
connection with the University internship program is a bonafide record of work done by
“Aashish Bhandari” under my supervision at the “Nepal Hydro and Electric Limited”.
Ram Prasad Banjade Er. Sanjit Sah

Mechanical Division Manager Engineer
ii
K L Deemed to be UNIVERSITY
DEPARTMENT OF MECHANICAL ENGINEERING
Certificate
This is Certified that the project entitled “Elaborates the practical approach to hydro
mechanical work that are performed inside the NHE.” which is an experimental &
theoretical work carried out by Aashish Bhandari (150070449), in partial fulfilment for the
award of the degree of Bachelor of Technology in Department of Mechanical Engineering,
during the year 2018-2019. The project has been approved as it satisfies the academic
requirements.
Department Coordinator Head of the Department
University Guide External
iii
ACKNOWLEDGEMENT
It is indeed a great pleasure and privilege to present this report on training at NEPAL HYDRO
POWER AND ELECTRIC LIMITED.
I am extremely grateful to my Head of the Department and training, Practise School officer for
issuing a training letter, which made my training possible at Nepal Hydro and Electric Limited.
First, I thank the HR Head, MR. Deepak Sharma for considering my potential in doing this
training and providing this wonderful opportunity.
I would like to express my gratitude to MR. Sagar Basnet and MR. Sanjit Sah
for his invaluable suggestion, motivation, guidance and support throughout the training. His
methodology to start from simple and then deepen through made me to bring out this project
report without anxiety.
Thanks to all the NHE officials, operators and all other member of NHE, yet uncounted for
their help in completing the project and see the light of success. I am very thankful to friends,
colleague and all other persons who rendered their assistance directly or indirectly to complete
this project successfully.
Dated: - November Aashish Bhandari

150070449
iv
ABSTRACT
This report contains brief description of the 4 months Internship program inside Nepal Hydro
and Electric Limited. This report especially elaborates the practical approach to hydro
mechanical work that are performed inside the NHE. It includes all the theoretical knowledge
and practical approach that I have learned during my internship period. This report mainly
focuses on the project that are currently being handled by NHE besides highlighting some of
the projects that have been successfully completed. It also gives an insight into organization
structure along with its brief introduction. Every effort has been made to include the
manufacturing and repair and maintenance jobs that are in general the major tasks performed.
All the activities performed at NHE have been documented under different departments for
clear understanding. In short, this report has been perfectly orchestrated to give the header a
brief understanding of the organization along with its field experience.
A workshop was held to identify the welding and joining needs of the Hydro power-related
industries, and to discuss the opportunities afforded these industries to solve the needs by
applying new methodology and knowledge available from the research establishment. Specific
opportunities were matched to specific needs to suggest project areas where research and
development would make contributions providing major technological impact Among the
emerging new welding technologies, stick arc welding is used frequently for welding of high
strength Iron alloys such as Cast Iron, Stainless Steel and Mild steel etc which are very
difficult to weld by conventional fusion welding techniques. The project aims to weld the two
different thickness metal and check the maximum possible thickness of the welding.
v
OBJECTIVES
The main objectives of the Internship are: -
• To become acquainted with the future field of the mechanical engineering
student.
• To apply the acquired knowledge and skills in a practical situation.
• To become acquainted with real life problem solving.
• To work independently.
• To know about role of quality management system and its important in hydro
power sector.
• To learn how to plan things out carefully.
• To develop social and communicative skills.
• To carry out a project which is useful for the employer.
METHODOLOGY
➢ Visual Method
Different departments were and visual observation of different process of fabrication,
repair, maintenance, and machining were made. Different type of equipment machines
along with their working was visually observed.
➢ Conversation with Employees

Details of the process and machines were obtained from the conversation made with
the employees of the department. An oral interview was taken with the supervisor and
department managers.
➢ Secondary Sources
NHE brochures, website, project, and report were used to obtain the details and
information.
vi
Table of Contents
CHAPTER 1 INTRODUCTION .................................................................................................................... 1
1.1 Background Of NHE....................................................................................................................... 1
1.2 Company Objectives ..................................................................................................................... 2
1.2 Capabilities Of NHE ....................................................................................................................... 2
1.3 Mission and Vision ........................................................................................................................ 3
1.4 Initiation of projects ...................................................................................................................... 3
1.5 Past Project Of NHE....................................................................................................................... 3
1.6 Current Major Jobs at NHE ........................................................................................................... 5
1.7 NHE – AN OVERVIEW .................................................................................................................... 7
CHAPTER 2 SERVICE DIVISION ................................................................................................................ 8
2.1 Turbine Section ............................................................................................................................. 8
Tubrine Repair Procedure ................................................................................................................. 9
Repair Methods................................................................................................................................ 12
2.2 Service and Maintenance............................................................................................................ 15
CHAPTER 3 QUALITY ............................................................................................................................. 17
3.1 Quality Plan ................................................................................................................................. 17
3.2 Quality Assurance ....................................................................................................................... 17
3.3 Quality Testing ............................................................................................................................ 18
CHAPTER 4 MECHANICAL DIVISION ..................................................................................................... 23
4.1 Heavy Mechanical Workshop ..................................................................................................... 23
4.2 Mechanical Workshop (MNW) ................................................................................................... 28
CHAPTER 5 ELECTRICAL DIVISION ........................................................................................................ 30
5.1 Failure of a transformer .............................................................................................................. 30
5.2 Transformer Oil Purification ....................................................................................................... 32
CHAPTER 6 HUMAN RESOURCE AND PROJECT MANAGEMENT .......................................................... 33
6.1 Manpower................................................................................................................................... 33
6.2 Project Management .................................................................................................................. 34
6.3 Stages of Project ......................................................................................................................... 35
CHAPTER 7 MECHANICAL DESIGN....................................................................................................... 37
7.1 Design Process ............................................................................................................................ 37
PROJECT TITLE: - ............................................................................................................................... 41
CHAPTER 1 INTRODUCTION ................................................................................................................ 42
Introduction to Welding.................................................................................................................... 42
General Consideration ...................................................................................................................... 42
Welding positions ............................................................................................................................. 43
vii
Welding Terminology ........................................................................................................................ 44

Types of Welding............................................................................................................................... 44
CHAPTER 2 WELDNG USED BY NHE ...................................................................................................... 45
CHAPTER 3 THEORITICAL REQUREMENT OF ELECTRODES ................................................................... 52
3.1 Electrode ..................................................................................................................................... 52
3.2 Selection Of welding Electrode ................................................................................................... 52
3.3 The Numbers and Letters mean on Welding Rods ..................................................................... 52
3.4 Consumption of Electrode During Welding ................................................................................ 53
3.5 Theoretical Calculation ............................................................................................................... 53
CHAPTER 4 CONSUMPTION IN ACTUAL PRACTICE .............................................................................. 56
4.1 Practical calculation .................................................................................................................... 56
4.3 Actual consumption in Nepal Hydro and Electric Limited .......................................................... 57
4.3 Calculation Error ......................................................................................................................... 58
4.4 How to reduce costs?.................................................................................................................. 59
CHAPTER 5 DEVIATION ANALYSIS ......................................................................................................... 60
5.1 Stick Metal Arc Welding Consumption of Electrode ................................................................... 60
5.2 Submerged Arc Welding Consumption of Electrode .................................................................. 61
CHAPTER 5 REASON FOR DEVIATION ................................................................................................... 62
CHAPTER 5 WAYS OF MITIGATION ...................................................................................................... 63
CHAPTER 6 CONCLUSION ..................................................................................................................... 64
CHAPTER 7 REFERENCES ...................................................................................................................... 65
viii
LIST OF ABBREVIATIONS AND ACRONYMS

NHE = Nepal Hydro and Electric Limited
QA = Quality Assurance
QC = Quality Certificate
DPT = Dye Penetration Testing
MPT= Magnetic Particle Testing
UT = Ultrasonic Testing
NDT = Non-Destructive Testing
AC = Alternating Current
HMW = Heavy Mechanical Workshop
MW = Mechanical Workshop
MVA = Mega Volt Ampere
KVA = Kilo Volt Ampere
HRM = Human Resource Management
MIG = Metal Inert gas
GMAW = Gas Metal Arc Welding
SMAW = Sub- Merged Arc Welding
TIG= Tungsten Inert Gas Welding
GTAW= Gas Tungsten Arc Welding
FCAW = Flux- Cored Arc Welding
SMAW = Shield Metal Arc Welding
PSI = Pound to square Inch
LPG= Liquid Petroleum Gas
AWS = American Welding Society
DC= Direct Current
DCEP = Direct Current Electrode Positive
DCEN = Direct Current Electrode Negative
HAZ = Heat Affected Zone
ix
LIST OF THE FIGURES
Figure 1: Cavitation on Francis Runner
Figure 2: Pitting on Francis Runner
Figure 3: Reclamation of wicket gates
Figure 4: Undergoing DPT Testing Francis Runner
Figure 5: Magnetic Particle Testing
Figure 6: Dye Penetration Testing
Figure 7: Flow Detector
Figure 8: UT Testing on Penstock
Figure 9: Heavy Mechanical Workshop
Figure 10: Rolling of Mild Steel Plate
Figure 11: Substation
Figure 12: 6*50m Rapti Bridge, Axial View
Figure 13: Electrical Division Equipment
Figure 14: Project Management
Figure 15: Edge Preparation of Butt Joint
Figure 16: Welding Terminology
Figure 17: Arc Stick Welding
Figure 18: Nozzles
Figure 19: Oxy- Acetylene Gas Welding
Figure 20: Gas Cylinders
Figure 21: Sub-Merged Arc Welding
Figure 22: Deviation Charts
Figure 23: Angle Position
x
CHAPTER 1
INTRODUCTION
1.1 Background Of NHE
NHE is a public limited company, which was established in BS 2042 (AD 1985). It is a
subsidiary of Butwal Power Company Limited in partnership with IKN Industrial AS Norway,
Butwal Technical Institute and Himal Hydro and General Construction Limited. The company
has been implementing well- structured Quality Management system since 2002 AD. It is an
ISO 9001:2008 certified company. NHE’s area of expertise includes design, manufacture and
installation of equipment of electricity generation (from Hydro Power), transmission and
distribution.
Nepal Hydro & Electric Limited (NHE) is a leading Company in Hydro-mechanical and
Electro-mechanical equipment including HV substations, manufacturing and installation &
repair for hydro & electric power sector, where 250+ employees are working together as a
team.
Its main market is equipment for electricity generation (from hydropower), transmission and
distribution. In addition, the company has significant involvement in manufacture of heavy
steel structures and many other areas. Numerous combinations of design, manufacture and
installation can be carried out including project management to customer requirements.
NHE rightly takes pride in the quality of work performed. Its quality department is considered
by most of the clients as the best one in the country. Within the team of highly talented
engineers and highly skilled technicians, NHE is capable of executing challenging projects
which has helped the organization grow into one of the leading public company in Nepal.
As an ISO certified everything is done within a system. To perform each task systematically
and scientifically, different division and made assigning task to each division which has made
the work easy to accomplish.
The Different sections of NHE are divided into the following divisions:
1. Human Resource Division
2. Service Division
• Turbine Section
• Repair and Maintenance
3. Quality Division
4. Finance Division
• Store Section
• Costing Section
5. Mechanical Division
• Heavy Machinery Workshop (HMW)
• Mechanical Workshop (MNW)
• Mechanical Design
6. Electrical Division
1
1.2 Company Objectives
Growth: - To ensure a steady growth by enhancing the competitive edge of NHE in existing
business, news area and International Operation So as to fulfil the national exceptions from
NHE.
Profitability: -
To provide a reasonable and adequate return on capital employed, primarily, through
improvement in operational efficiency, capacity utilization and productivity, and generate
internal resources to finance the company’s growth.
Customer Focus: -
To build a high degree of customer confidence by increasing value for his money through
international standard of product quality, performances and superior services.
People - Orientation: -
To enable each employee to achieve his potential, improve his capabilities, perceive his role
and responsibilities participate and contributed positively to the growth and success of the
company. To invest in Human resources continuously and be alive to their needs.
1.2 Capabilities Of NHE
1. Hydro-mechanical equipment
• Steel Liners, Penstock Pipes and Manifold (max. 8m Dia.),

Bifurcation/Trifurcation
• Hydraulic Gates (Radial, Roller, Slide & Flap) max. 24 m x 22 m
• Stoplogs and Trash racks
2. Electro-mechanical equipment
• Manufacturing of Francis Turbine Stay Ring, Spiral Casing and Draft Tube
• Manufacturing of Pelton Turbine Housing and components
• Installation and testing of complete Electro-mechanical Equipment
3. High Voltage Substation construction (Turn Key Project)

4. Manufacturing/Repairing of high Voltage Generator/Motor Coil for up to 50 MW
unit Generator and Motor Coil Workshop
5. Reclamation of Turbine Runner up to 4.5m Dia.
6. Repairing of Power Transformer and Distribution Transformer. Detail of
Transformer Plant
7. Design, Manufacturing and Installation of heavy steel structures (motorable bridges,
transmission towers etc.)
2
1.3 Mission and Vision
To satisfy customer needs in the manufacture, erection, testing, commissioning and through
life support of equipment in the hydroelectric power generation, transmission and distribution
industry, by building up our own capabilities and by maximizing the use of local resources.
Our vision is to be Nepal’s leading manufacturer and refurbisher of hydro and electric power
equipment. We will be competent in all areas of this work and apply our competence to other
markets whenever possible. We will maintain a high standard in our services and provide
high quality products, manufactured locally whenever practicable.
1.4 Initiation of projects
The project is handling by NHE may be major or minor. For major projects, first of all tender
is invited by other organization. If NHE is interested, technical group of NHE is send for the
site visit. Then quotation is applied with all the details including costs, quality, and other terms
and conditions. If it satisfies, contracts are signed by two groups and finally the project is
granted to the NHE.
In a project there are different jobs. Job number is assigned to each job and incharge is
appointed. Job incharge identifies task to be done and divides them for different divisions. the
manager division plan their respective tasks and initiates it.
1.5 Past Project Of NHE
Approx.
S.N. Clients Project Scope of Works Value, US Period
$
Supply,
Construction and
Sept
Chapali 132kV Installation of
Nepal Electricity 2014-
1 Substation 132/66kV Chapali 8,100,000
Authority January
Expansion Substation and
2017
associated works,
ADB funded
Repairing of Aug
Nepal Electricity DCS, Butwal
2 Distribution 60,000 2015-Jul
Authority Regional Office
Transformers 2016
Mnaufacturing,
Repairing and
Installation of
Synergy Power 9.6MW Siprin Jun-Aug
3 Hydro -mechanical 200,000
Development Ltd. Khola Power Plant 2015
components
damaged by recent
Quake
3
Manufacturing and Nov

Marusin Sitaka Rani Jamara
4 Installation of 1,200,000 2012-
Corporation Kuleria
Stoplogs Apr 2015
Supply and
installation of 16 Apr 2014
Nepal Electricity Grid Operation
5 MVA Transformer 270,000 - Mar
Authority Department
Bay at Chanauta 2015
Substation
Supply and
installation of 33 kV
Butwal Power Company Rangkhola Jul 2014-
6 Rangkhola 155,000
Ltd. Substation Feb 2015
Interconnection
Switching Station
Design, supply,
9.4 MW Andhi manufacturing and Jan 2011
Butwal Power Company
7 Khola Project installation of 1,160,000 – Jan
Ltd.
(Upgrading) Penstock pipes and 2015
HM Works
Design, Supply,
Construction,
Jan 2011
Nepal Electricity Butwal – Kohalpur Installation and
8 6,200,000 – Dec
Authority 132 kV Corridor commissioning of
2014
132 kV Substations,
funded by ADB
Supply,
Construction of
132/11 kV, 30MVA May
Nepal Electricity Grid Operation at Pokhara and 2013-
9 730,000
Authority Department 33/11kV, 16.6 April
MVA Transformers 2014
Bay at Damauli
Substations.
Supply,
Construction of May
Nepal Electricity Grid Operation 33/11kV, 16.6 2013-
10 270,000
Authority Department MVA Transformers April
Bay at Dhalkebar 2014
Substation.
Extension of 30
Chandranigahpur Dec 2012
Nepal Electricity MVA, 132/33 kV
11 Substation, Grid 500,000 - Feb
Authority Chandranigahpur
Operation 2014
Substation
4
32 MW Kulekhani Supply of 37.8

Nepal Electricity Apr -
12 2 Hydropower MVA, 6.6/132 kV 370,000
Authority Dec 2013
Plant Transformer
Fabrication and Aug

Shani–Bheri
DoLIDAR, Govt. of Erection of Shani – 2009 -
13 Motorable Steel 230,000
Nepal Bheri Motorable Mar
Truss Bridge
Steel Truss Bridge 2013
Jun 2009
Synergy Power Deve. 10 MW Siprin Hydro-mechanical
14 420,000 – Nov
Pvt. Ltd. Khola Equipment works
2012
Jun 2009
Hydro-mechanical
15 Nyadi Group Pvt. Ltd. 5 MW Siuri Khola 600,000 – Sept
Equipment works
2012
Supply and
Installation of 30
Nepal Electricity Jan - Oct
16 Lamahi Substation MVA, 132/33 400,000
Authority 2012
KV Power
Transformer Bay
1.6 Current Major Jobs at NHE
Approx. Value
S. N. Clients Project: Scope of Works Period
(US$)
Rasuwagadi Manufacture, Delivery, Installation 12 December-

NRs. 7,650,000
1 Hydropower and Erection of Draft Tube September
+ VAT
Company Limited Transmission Pieces 2018
USD
PC - ICB - 2074/75 - 01 Design, 1,196,353.40;
Nepal Electricity Supply, Installation, Testing and INR
2 17 May, 2018
Authority Commissioning of 132 kV Purbi- 61,221,475.38
Chitwan Substation and NRs.
296,131,913.49
PTSD/SS/2074/075 - 03 Design,
Supply, Delivery,
Installation/Erection, Testing and
Nepal Electricity Commissioning of 20/24 MVA NRs. 18, February
3
Authority Power Transformers, shifting of 150,871,436 2018
(Old) 6/8, 6/7.5 or 5 MVA Power
Transformers to specified
substations, Protection & Control
5
Switchgears and Civil Construction

works as specified in BOQ for
Rehabilitation of existing 33/11 kV
Substation Works
PTSD/SS/2074/075 - 04Design,
Supply, Delivery,
Commissioning of 20/24 MVA
Power Transformers, shifting of
Nepal Electricity (Old) 6/8, 6/7.5 or 5 MVA Power NRs. 18, February
4
Authority Transformers to specified 162,828,258 2018
Substation Works
PTSD/SS/2074/075 - 01 Design,
Supply, Delivery,
Commissioning of 20/24 MVA
Power Transformers, shifting of
Nepal Electricity (Old) 6/8, 6/7.5 or 5 MVA Power NRs. 18, February
5
Authority Transformers to specified 138,456,575 2018
Substation Works
GOD-2073/074 - 16 Supply,
Nepal Electricity Delivery, Installation, Testing and 18, October
Authority, Grid Commissioning of 1 no. of 132/33 NRs. 2017- 15,
6
Operation kV, 63 MVA Power Transformer at 89,817,748 November
Department Duhabi Substation; 1 no. of 132/11 2018
kV, 30 MVA Power Transformer at
GOD-2073/074 - 15, Supply,

Delivery, Installation, Testing and
Commissioning of 1 no. of 132/33
Nepal Electricity 18 October
Authority, Grid NRs. 2017-15
7 Butwal Substation; 1 no. of 132/11
Operation 99,152,024 November
Department 2018
Pokhara Substation; and 1 no. of
33/11 kV, 16.6 MVA Power
Transformer at Butwal Substation
6
Current project
• Current Reference List of Projects

• Rasuwagadi Hydroelectric
• Dordi-Corridor 132kV Transmission Line
• Butwal and Pokhara Substation
• Anarmani and Matatirtha Substations
• 33/11 kV Substation Rehabilitation Project
• Purbi-Chitwan 132 kV Substation Project
• Mistri Khola HEP, 42 MW
• Yadukwa, 33 kV Substation
• Butwal, 33 kV Substation
• Patan, 66 kV Substation
• Dhalkebar, 132kV Substation
• Sanjen and Sanjen Upper Hydropower
• Rasuwagadhi Steel Bridge
• KM - 02, 132 kV Substation
• GSRP-01, 132 kV Substation
• Lamahi-Ghorahi, 132 kV Substation
• Chameliya Hydropower
• Kali Gandaki 'A'
1.7 NHE – AN OVERVIEW
7
CHAPTER 2
SERVICE DIVISION
2.1 Turbine Section
Turbine section mainly deals with the repair, maintenances, testing, and commissioning of
turbine runners, guide vane, shaft, and hydraulic pump.
Turbine: - Turbine is a rotary mechanical device that extracts energy from a fluid flow and
converts into useful work. The work produce by turbine can be used for generating electrical
power when combined with a generator.
Runner: - In hydraulic turbines, the blades are also called as runners which rotates when the
fluid flows in the casing and comes in contact with it. While shaft is connecting medium
between the blades and the generator which rotates when the blade is in motion thus in turn
producing electricity.
Guide Vane: - The guide vanes consist of number of blades that can be adjusted in order to
increase or reduce the flow rate through the turbine. The vanes are arranged between two
parallel covers normal to the turbine shaft.
Hydraulic Pump: - The mechanical device that is used to convert mechanical power into
hydraulic energy is known as a hydraulic pump. The load that is responsible for the pressure is
overcome with this device by creating sufficient power and generating a flow.
The hydraulic pump has two functions to perform during operation, allowing atmospheric
pressure to push liquid into the inlet line from the reservoir to the pump by the mechanical
action created vacuum at the pump. The other function it performs is that the pumps mechanical
action supplies the liquid to the pump outlet and then forced into the hydraulic system.
List of Machines in Turbine Section: -
S.N. Machine Name Quantity
1 Lathe Machine tool 2
2 Horizontal Boring 1
3 Vertical Lathe Machine 1
4 Radial drill Machine 1
5 Pressure Drill Machine 1
6 Toss Universal Milling 1
7 Overhead Crane 1
8 Shaping Machine 1
9 Tool Grinding Machine 1
8
Hydro Mechanical Structures that can be repaired at NHE are Listed below:
Pelton Turbine: -
• Pelton bucket
• Turbine shaft
• Nozzle
Francis Turbine
• Francis runner blade
• Guide Vane
• Head Cover
• Bottom Ring
• Side cover
Hydraulic Pump
Following process are Under taken for repairing
1. First of all, part to be repaired is brought to the service section then, job no. is assigned
to it and the time of completion is evaluated and repairing works starts.
2. The repairing process include
• Pre-heating and Welding
• Machining profile grinding
• Heat treatment and balancing (static)
3. Different testing
• DPT (Dye Penetration test)
• MPT (Magnetic Particle testing)
• X- ray & Ultrasound test
4. Testing and commissioning
TURBINE REPAIR PROCEDURE
CAVITATION
Examination of the runner of a hydraulic turbine or the impeller of a pump often discloses
pitted areas in various stages of development. Pitted areas may also be found on turbine or
pump water passage surfaces where water velocities are high. This damage is generally termed
cavitation erosion or impingement erosion. Because of various physical conditions present in
the waterflow system, a cycle of cavitation is induced as follows:
a. Extreme low-pressure areas are produced by flow irregularities.
b. Pockets or "cavities" of vapor form.
c. Pressure and flow conditions change abruptly.
d. The pockets or "cavities" collapse causing high shock pressures.
Where the collapse occurs adjacent to a metal surface, the resultant impact tears out bits of
the metal.
9
The cycle occurs at a very high frequency. As the metal surface deteriorates, the damage rate
accelerates rapidly. Without timely repair, the cavitation process can result in the total
destruction of the surface under attack.
Figure: - Cavitation on Francis Runner

APPROACH
The repair of cavitation pitting damage on turbines is an essential part of a hydro plant
maintenance program. If left unrepaired, or if improperly repaired, the extent of damage will
increase, usually at an accelerating rate, eventually leading to an extended and costly outage of
the unit. An effective repair program can minimize the adverse problems associated with
cavitation pitting. The main objectives of such a program are:
• Restoration of runner and other components within the turbine water passages to "as new"
condition;
• Correction of any profile errors or irregularities which are responsible for the pitting; and
• Avoidance of blade shape distortion and its affect (sic) on further damage.
As with any equipment, excessive repairs to a turbine can lead to reduction in its performance
and useful operating life. Extensive weld repairs can result in runner Blade distortion,
acceleration of further cavitation damage, and possible reduction of turbine efficiency. Also,
extensive repair can cause residual stressing in the runner resulting in structural cracking at
areas of high stress. "To maximize equipment life and to maintain high availability and good
operating efficiency, cavitation pitting repairs should be done in a logical and methodical
manner. The basic steps of such a repair program are as follows:
• Inspection
• Identify cause of pitting
• Plan best approach to repairs
• Perform repairs
CAVITATION DAMAGE REPAIR
"Cavitation damage inspection should be made from both the draft tube area below the runner
and from the stay ring/wicket gate area in the spiral (or semi spiral) case. "Inspection from the
10
draft tube area should normally be done from a temporary maintenance platform installed
below the runner. On units greater than about 12-foot (3.7 m) diameter when no repairs are
planned, draft tube inspection. may be made from a portable boat floating in the draft tube
while water level is maintained below the bottom of the draft tube access door. Most areas of
the runner which are susceptible to cavitation damage can be seen from the draft tube side. The
leading edge of the blades, however, can best be inspected from the wicket gate area. On small
units where access to the runner from the wicket gate area is poor, a polished metal mirror can
be used for observing the leading-edge area from the draft tube side.
CAUSE OF PITTING
"An important step in any effort to minimize cavitation damage is to identify the cause of the
pitting. This requires careful examination of the extent and location of the pitting as well as a
review of the operating history of the unit including operating heads and loading of the
machine. Francis turbines, and pump-turbines, respectively, and identify possible causes of the
damage. "In analysing cavitation damage, first check for local discontinuities in blade shape or
profile in the area immediately upstream of the damaged surface. Also check whether or not
the cavitation patterns are the same on each of the blades. If damage varies from blade to blade
and there are no apparent discontinuities upstream, the problem may be on the overall blade
profile or blade location. In this case, a template should be made of a cavitation-free blade or
the one with the least pitting, and this template used to check the overall profile of the other
blades for possible modifications. If the pattern of damage is very similar from blade to blade,
and local profile discontinuities are not evident, the problem becomes more difficult and other
factors such as method of operation, operating heads, etc., must be considered. "The possibility
that damage is not the result of cavitation should be investigated: Damage may be from
corrosion, particularly if water has high oxygen content or high dissolved solids. On carbon
steel runners with stainless steel overlay, damage at the interface of carbon steel and stainless
steel is likely to be partially due to galvanic action. Large voids beneath overlay are caused by
galvanic corrosion which will occur when there is a small hole in the overlay. The hole may be
a defect in the weld overlay or from cavitation pitting which has penetrated the overlay. If water
contains large amounts of entrained solids, the damage may be caused by physical erosion
rather than cavitation pitting. "Input from the turbine manufacturer's hydraulic engineer in
assessing the cause of pitting is always valuable. This is one reason for inspection at an early
stage of operation. Even if damage is far less than the guaranteed amount, the manufacturer
should be asked to report on the cause of the damage.
Figure: - Pitting on Francis Runner
11
DECISION ON BEST APPROACH TO REPAIR

After inspecting and assessing the cause of damage, a plan on the best approach for cavitation
repairs must be developed. "The first decision which must be made is whether to complete
repairs during the current outage or to delay repairs for a future inspection period. This will
depend on the plant owner's normal frequency of inspection and repair, and the actual extent
of damage which is experienced. Repairs should not be delayed if:
Further delay will result in added repair costs because of the accelerating rate of cavitation
pitting.
Damage is approaching 20 percent of blade thickness or 1/2 inch in depth, whichever is less.
Welders must be mobilized for other work on the runner such as crack repair.
Often, the outage time needed to complete the repairs will influence the decision on whether
or not to make repairs. The demand to return the unit to service in as short a time as possible
may make it possible to repair only areas of severe damage, leaving areas of frosting and
minimal damage for the next inspection outage. Temporary repairs may also be made using
non-fused materials.
When the decision is reached to proceed with cavitation pitting repairs, it is necessary to
determine the method to be used for repairs and whether or not blade profile corrections should
be made. The various methods for undertaking repairs include:
Fill damaged area with weld material
Fill damaged area with non-fused materials
Weld plates over the damaged area
Remove damaged section and replace with new forced plates welded in place
REPAIR METHODS
“Weld Repair
"General. Welding is the most common and, to date, the most successful method of repairing
cavitation damage on hydraulic turbines. The various steps for repair by welding are as follows:
Initial dimensional checks
Application of braces of strong backs Surface preparation
Preheat
Weld application
Grinding to contour
Weld inspection
Removal of braces and strong backs Final dimensional checks
"In addition, prior to the start of weld repairs, the following must be established:
Composition of base material
Weld material Weld process Repair procedure
12
"Safety Considerations. As with other types of maintenance work, safety considerations must
not be overlooked. The maintenance platform under the runner must be adequately designed
for the equipment and personnel Loads to be handled during the repair program. Ventilation
during welding is important. Wicket gates and spiral/semi-spiral case man doors should be
open and exhaust fans should be available for removal of smoke and fumes. Proper and
adequate 13 lighting of high intensity should be provided. If weld procedure incorporates high
pre- or post-heat, insulated blankets are necessary to protect the personnel.
"Composition of Base Material. When planning cavitation repairs, it is important to know the
chemistry of the base material. For newer units, the ASTM specification is usually known. The
exact composition may also be available from foundry/mill tests records. If the composition of
the material is not known, a chemical analysis should be made from a small sample of the
runner or component being repaired.
"Weld Materials. The recommendations for weld materials for cavitation pitting are as
follows: Turbine Components with Carbon Steel Base Material: Areas where the depth of weld
after surface preparation is greater than 3/8-inch (10 mm) should be built up to 3/8-inch (10
mm) depth with E7018 mild steel weld material (low moisture type). The remainder of the area,
including other areas with depth of 3/8 inch (10 mm) or less, should be filled with 300 series
austenitic stainless-steel material. The first pass of material over the carbon steel should be 309
stainless, the remainder 308 stainless.
Stainless steel material should not be used in areas of deep cavitation because of the increased
possibility of blade distortion resulting from the difference in coefficient of thermal expansion
between the stainless and carbon steel.
The increase ferrite level in 309 stainless reduces the possibility of hot short cracking (micro
fissuring), and for this reason 309 is used as a first pass over the carbon steel. For minor repairs
where the plant owner does not wish to use two types of weld material, only 309 may be used.
"Weld Process. Two processes are used for cavitation repair welds:
Gas metal arc welding (GMAW) or MIG welding Shielded metal arc welding (SMAW) or stick
electrode "The GMAW process has the following advantages:
More rapid application of weld metal. Lower heat input; therefore, the increased rate of weld
material application should not increase the possibility of blade distortion. If applied correctly,
weld quality should be better, with no slag inclusion and reduced excess weld.
Repair Procedure The procedures developed for cavitation repairs are site specific because of
the many factors involved. It is recommended that procedures be established for each repair
program to maintain a consistent approach, to monitor the results and to avoid excessive costs
in any one area of the program.
These procedures should be modified to incorporate any changes which could benefit
subsequent repairs. The items discussed below illustrate some of the important points which
should be covered by the procedures.
Initial Dimensional Checks. Prior to the start of cavitation repairs to a turbine runner,
dimensional checks should be made. These will serve as a basis for determining whether or not
weld distortion has occurred and also to establish whether or not any measures are necessary
to correct distortion which may have occurred during a previous repair or during initial runner
manufacture.
13
Francis Runners. From the vent measurements, the average opening between each pair of
blades, the overall average opening, and a variance from average of each opening can be
calculated. Corrective action should be taken if there is large variation in vent openings,
particularly if oversize vent openings are grouped together on one side.
Preheating. Preheating is recommended under certain circumstances as part of good welding
practice. The purpose of preheating is to prevent hydrogen induced cracking; this type of
cracking occurs after the weld has cooled and usually runs from the toe of the weld or from
weld defects. Such a crack is difficult to detect and can be detrimental to the service life of the
turbine, particularly if welds are located in highly stressed areas of the runner. The increased
temperature from preheating increases the diffusion coefficient of hydrogen and bakes the
hydrogen out of the weld. Preheating also allows a slower cooling rate of the weld preventing
excessive loss of ductility in the weld and the heat-affected zone of the base metal.
The amount of preheat depends on the chemical content of the base material, the thickness of
the base material, the restraint and rigidity of the area being repaired, the actual heat input
during the welding process, and the type of weld material. Preheat requirements are highly
dependent on the extent of carbon in the base metal. Generally, the higher the carbon content,
the lower the critical cooling rate and the greater the necessity for preheating.
Final Dimensional Checks. Final dimensional checks should include a repeat of those
dimensions measured prior to the start of repairs. If templates are available or have been made,
the template checks should also be made.
If the power developed by the turbine is not to be decreased, then the vent opening after the
repair should be equal to or greater than that measured prior to the repair. A tolerance of -0 to
+ 3 percent of total vent is recommended.
On propeller and Kaplan runners, the blade angle should also be unchanged. A tolerance of -
0 to + 1/2 degree is recommended.
Figure: - Reclamation of Wicket gates
14
Undergoing DPT (Dye penetration Testing) after final reclamation.

Figure: - Francis Runner
2.2 Service and Maintenance
This document is intended to establish recommended practice as well as to give general advice
and guidance in the maintenance of mechanical equipment owned and operated by Nepal
Hydro and Electric Limited.
Maintenance recommendations are based on industry standards and experience in Reclamation
facilities. However, equipment and situations vary greatly, and sound engineering and
management judgment must be exercised when applying these recommendations. Other
sources of information must be consulted (e.g., manufacturer’s recommendations, unusual
operating conditions, personal experience with the equipment, etc.) in conjunction with these
maintenance recommendations.
2.2.1 Preventive Maintenance
Preventive maintenance (PM) is the practice of maintaining equipment on a regular schedule
based on elapsed time or meter readings. The intent of PM is to “prevent” maintenance
problems or failures before they take place by following routine and comprehensive
maintenance procedures. The goal is to achieve fewer, shorter, and more predictable outages.
15
Some advantages of PM are:

• It is predictable, making budgeting, planning, and resource levelling possible.
• When properly practiced, it generally prevents most major problems, thus reducing forced
outages, “reactive maintenance,” and maintenance costs in general.
• It assures managers that equipment is being maintained.
• It is easily understood and justified.
PM does have some drawbacks:
• It is time consuming and resource intensive.
• It does not consider actual equipment condition when scheduling or performing the
maintenance.
Despite these drawbacks, PM has proven generally reliable in the past and is still the core of
most maintenance programs.
2.2.2 Reliability – cantered maintenance
RCM programs are gaining in popularity and have been piloted in a few Reclamation power
facilities with good results. The goal of these programs is to provide the appropriate amount of
maintenance at the right time to prevent forced outages while at the same time eliminating
unnecessary maintenance.
Implemented properly, RCM can eliminate some of the drawbacks of PM and may result in a
more streamlined, efficient maintenance program. RCM seems very attractive in times of
diminishing funding, scarcity of skilled maintenance staff, and the pressure to “stay online”
due to electric utility industry deregulation.
Maintenance and Test procedure
Maintenance activities fall into two general categories:
• Routine Maintenance - Activities that are conducted while equipment and systems are in
service. These activities are predictable and can be scheduled and budgeted. Generally, these
are the activities scheduled on a time-based or meter-based schedule derived from preventive
or predictive maintenance strategies. Some examples are visual inspections, cleaning,
functional tests, measurement of operating quantities, lubrication, oil tests, and compressor
maintenance.
• Maintenance Testing - Activities that involve using test equipment to assess condition in an
offline state. These activities are predictable and can be scheduled and budgeted. They may be
scheduled on a time or meter basis but may be planned to coincide with scheduled equipment
outages. Since these activities are predictable, some offices consider them “routine
maintenance” or “preventive maintenance.” Some examples are
.
16
CHAPTER 3
QUALITY
Quality Assurance and Quality Control is applicable in construction, production and servicing
industries. Mechanical, Civil, Electrical, Electronics, Instrumentation, production, automobile
and even other engineering branches also has QA/QC programs according to their requirement.
Usually qualified and well experienced persons are working in quality control department of
engineering companies. There for quality check comes to be the most important activity after
the manufacturing or after the companies of repair and maintenance.
The quality department of NHE deals with setting standards and having an effective
mechanism for checking whether the standards are met and also having a corrective system if
necessary. The tasks carried by this section indispensable given that it is one which make goods
or services provided dependable and reliable.
Mainly tasks can be divided in three categories.
1. Developing quality plan
2. Maintaining Quality in every aspect
3. Preparing Quality Assurance report
3.1 Quality Plan

Quality plan is a document prepared by the quality Department which depicts the job to be
performed as per the customer’s requirement. It includes the information like necessary
works to be performed before start of repair of manufacture, the material to be used,
welding electrode to be used, temperatures to be maintained, the tests to be carried out, the
extent of tests required machining processes to be employed, type of packaging to be used,
and requirement of Assurance reports. So, in short quality plan is a document containing a set
of guidelines required for the respective job. It makes the job to be performed systematic and
of higher quality as the supervisor can easily direct and follow up the works carried out by
the workers as per the plan.
3.2 Quality Assurance
All aspects required by ISO 9001 standard are controlled by the quality system, which includes
the organizational structure, procedures, processes and resources for implementing quality
management. The main idea of setting up ISO 9001 quality system is to prevent occurrence of
any non-conformance through various of preventive measures. Despite of different kinds of
such systematic measures, the main QA measures for controlling site NDT activities are:
controlling NDT inspector qualifications, valid ness of test equipment and test material,
effectiveness of test procedures, impact of environmental conditions to test results, and
monitoring actual NDT performance by quality surveillance inspectors.
At NHE, the quality report is prepared and provided to the customer and donor or investigating
agency if any. For examples, the quality Assurance Report of repair and maintenance of 4
runners and 60 Guide vanes of Trisuli is scheduled to be provided to the World bank.
Personal Qualification
Inspector qualification is essential to a reliable inspection, and it is also mandatory required by
regulatory bodies. NHE has such an NDT personnel qualification system that each industrial
sector has its specific requirements in addition to the basic NDT society requirements.
17
Therefore, in order to fulfil different requirements for different industrial application, NHE
NDT personnel hold different qualification certificate, including foreign certificate, to satisfy
different customers for different requirements. Although much expenses are spent for the
training and qualification, NHE NDT personnel are well qualified in such a way.
Test Equipment and Procedure
Test equipment and material are very important for NDT inspections. As an inspection service
organization, we developed and purchased all necessary equipment and materials for our
services, including ultrasonic testing, radiographic testing, eddy current testing, magnetic
particle testing, liquid penetrate testing, and visual testing as well as acoustic emission testing.
These equipment and materials are mainly used in power generating industry and chemical
industry for pressure vessel and related component inspections.
Monitoring of NDT processes

As an important quality assurance measure, quality surveillance inspectors are assigned to
verify the effectiveness of actual performance of NDT activities. The surveillance inspectors
have very good background knowledge of NDT, they check the prerequisite of testing for a
specific task, including NDT examiner's personnel qualification, status of test equipment and
materials to be used, test procedures adapted, and the environmental conditions presented.
They make sample checks to major test performance to verify if the test procedures are
followed by the NDT examiners. They check also the test results to verify if the results are
correct and the regulatory requirements are met. Of course, the responsibility of testing is still
on NDT examiner shoulders; the quality surveillance inspector is responsible for the
verifications. Such verifications are normally carried out by means of implementation of
witness and hold points inspections of quality plans for NDT testing.
Test Procedure
Test Procedures define the responsibilities, techniques, operational steps and control means
for specific method of testing and the objects. NHE establishes a series of test procedures for
different tasks, which we consider is necessary for carrying out quality services of testing.
Environmental Conditions
Environmental conditions affect the test results seriously on some occasions. Attention should
be taken for temperature, humidity, radioactive, and /or surrounding materials to the test
objects. For examples, the ultrasonic transmission sped in the steel changes about 8 m/s when
the temperature varies 1o; radioactive background of test objects affects the radiographic testing
results.
3.3 Quality Testing
The quality inspection is mainly performed by several of Non-Destructive Test (NDT). Under
NDT following process are followed in NHE: -
1. Radiography (X-Ray)
2. Magnetic particle testing (MPT)
3. Dye Penetration Test (DPT)
4. Ultra-Sonic Testing (UT)
18
3.3.1 Radiography Test (X- Ray)

Radiography is the most commonly known non- destructive test method. Radiography can be
used to obtain permeant image of surface and sub- surface (embedded) discontinuities. The
same discontinuities can be radiographed again after a period of service life and the
radiographic can be compared to measure the change in the size and shape of the discontinuity.
There are numerous applications of radiography in engineering applications. Radiography test
is carried out for the thickness less than 12 mm.
Procedure
• Test the X-ray generator machine before use. Fix the Voltage and current
according to the thickness of the object.
• Use lead screen of 0.2mm at the back of object where the X-ray is projected.
• Use lead letter film for identification.
• Overlap the film not less than 1 “
• Expose the film to dark room in developer upto 7 min.
• Keep the film in stop bath for 1 min and fixer for 7-15 mins.
• See the dry film into light intensity to view the defect and evaluation.
Advantages and Disadvantages
The Primary advantages and disadvantages as compared to other NDT methods are: -
Advantages
• Both surface and internal discontinuities can be detected.
• Significance variance in composition can be detected.
• It has very few material limitations.
• Can be used for inspecting hidden areas. (direct access to surface is not required)
• Very minimal or no part preparation is required.
• Permanent test record is obtained.
Limitations
• Hazardous to operator and other nearby personnel.
• High degree of skill and experience is required for exposure and interpretation.
• The equipment is relatively expensive. (especially X-Ray source)
• Highly directional (sensitive to flaw orientation)
• Depth of discontinuities is not indicated.
3.1.2 Magnetic Particle Testing (MPT)

This method is used for the detection of surface and near-surface flaws in ferromagnetic
materials and is primarily used for crack detection. The specimen is magnetised either locally
or overall, and if the material is sound the magnetic flux is predominantly inside the material.
If, however, there is a surface-breaking flaw, the magnetic field is distorted, causing local
magnetic flux leakage around the flaw. This leakage flux is displayed by covering the surface
with very fine iron particles applied either dry or suspended in a liquid. The particles
accumulate at the regions of flux leakage, producing a build-up which can be seen visually
even when the crack opening is very narrow. Thus, a crack is indicated as a line of iron powder
particles on the surface.
19
Procedure
• Clean all the surfaces that is to be MPT Tested.
• Their surface should be white panted coat of thickness 40 microns usually by white
contrast cement.
• Black ferrous Liquid material is sprayed over the surface along with magnetic field with
the help of Magnetic AC yoke.
• If any hair lining sketch is seen then that defines discontinuity or defects.
Figure: - Magnetic particle Testing
3.1.3 Dye (Liquid) Penetration test DPT: -

Liquid (Dye) penetrant inspection is a non-destructive test method which does not harm the
samples or parts being inspected. The test is very effective in detecting porosity, cracks,
fractures, laps, seams and other flaws that are open to the surface of the test piece and may be
caused by fatigue, impact, quenching, machining, grinding, forging, bursts, shrinkage or
overload. As a result, it is often used on lots of machined parts, as well as weldments,
manufactured products, castings, forgings and other items that will be placed into service.
Liquid penetrant inspection can be used successfully on nonporous and fairly smooth materials
such as metals, glass, plastics and fired ceramics.
20
The Process
The testing process can be broken down into the following distinct steps:
1. Pre-cleaning
2. Penetrant application
3. Penetrant dwell time
4. Penetrant removal
5. Developer application
6. Developer dwell time
7. Inspection
8. Post-cleaning
Figure: - Dye Penetration Testing
3.1.4 Ultrasonic Test (UT): -
Ultrasound is carried out for internal defects. It shows the occurrences of defect along with the
depth and distance from the probe used. The ultrasound flaw detector produces high frequency
sound wave which travel with high velocity of 5290 m/s in mild steel but cannot penetrate in
air and hence get reflected before air is encountered. The continuous reflection of wave
produces regular pattern on detector but if any discontinuity in specimen consists irregularities.
21
Procedure
• Visual Inspection
• First clean the object to test the defect.
• Use couplant (oil, glycerine, paper glue) to avoid air leak.
• Select probe (45o,60o,70o)
• Moving the probe in such a way that the single transmitted falls on the test surface.
• If any crack or porosity are scan the curve is seen as DAC (Direct Amplitude Curve)
because of echo.
Figure: - Flow Detector
Figure: - UT testing on Penstock
22
CHAPTER 4
MECHANICAL DIVISION
Heavy Mechanical Workshop
It is one of the biggest workshops of NHE where the tasks of heavy machinery such as
repairing and maintenance of the large size runners, cranes, etc. are done. It also carries out
major fabrication and repair works with well – equipped and highly sophisticated machines.
Different type of gates, penstock pipes, expansion joint, trash racks, and fabricated here.
Three overhead cranes are used for the material handling in the section.
Figure: - Heavy Mechanical Workshop
23
4.1.1 List of Machines
S. N Name of Machine Quantity

1 Radial Drilling 1
2 Magnetic Drilling 1
3 Heat treatment Plant 2
4 CNC Meatal Cutting 1
5 Sand Blasting 1
6 Over Head Crane (10 ,20,30, ton 3
respectively)
7 Rolling Machine 2
8 Air Compressor 4
9 Air less Painting Machine 1
10 Welding Generator 1
11 Welding Rectifier 2
12 Welding Machine (All including 10
Submerged)
13 Vertical Lathe Machine 1
14 Plano Milling Machine 1
15 Winch Machine 1
16 Hydraulic Press 1
17 Ultrasonic Flaw Detector 1
18 X-ray Machine 1
Major Tasks of Heavy Machinery Workshop
• Fabrication of Penstock Pipes

• Fabrication of Gates
• Heat Treatment
• Sand Blasting
• Painting
• CNC gas Cutting
24
4.1.2 Production of Penstock Pipe

The invention may be also considered as represented by metallic structures such as penstocks
or pressure vessels subject internally to high fluid pressures, and therefore of heavy wall
structure to withstand those pressures. Such structures include heavy plate sections formed to
the contour of a part of the ultimate product and then Welded together to form the ultimate
structure or a large component thereof. The latter may be a penstock structure, hundreds of feet
in length, and of such diameter and wall thickness that even a 2.5m length is of great weight.
Diameters and wall thicknesses may be of such orders that the limitations of shop procedure
and transportation practices compel the separate shop fabrication of relatively short sections,
and the subsequent welding together of the shop-fabricated sections.
In the HMW, the Penstock for Sanjen being manufactured. The manufacturing includes the
following main process.
Layout of Penstock
The layout and arrangement of the penstock depends upon the type of development, site
conditions, topography, and relative location of dam and power plant. The location and
arrangement of penstocks will be determined by the type of dam, location of intake and outlet
works, relative location of dam and powerplant, and method of river diversion used during
construction. At dams requiring tunnels for diversion of the river flow during construction, the
penstocks may be placed in the tunnels after diversion has been discontinued and the intake of
the tunnel has been plugged.
Rolling of mild steel plate (350BR)
Long mild steel sheets are rolled in a rolling machine constituting of 4 rollers: 1 upper roller
and 3 lower rollers. The lower rollers are capable of making vertical translation in addition to
rolling motion about fixed axis while the upper roller is fixed at one end, so the roller can make
limited amount of rotation about the fixed end in vertical plane.
The sheet is adjusted on the rolling machine with the aid of overhead crane which is controlled
by help of the controller. The process of rolling the mild steel sheet is a skill full task and so
requires proper concentration of operator. The process of rolling starts with bending one end
of sheet and machining the template profile and then continuing the bending from the other
end. After rolling from one is completed, it is followed by rolling in opposite direction from
the other end. This process of around 30 minutes end after the required profile of rolled steel
is generated, and it is transported to required place with the aid of overhead crane.
Figure: - Rolling of mild steel plate
25
Welding of Ends of Rolled Parts

After the rolling is completed, the component is loaded on a roller support with the help of
overhead crane. Then outer side of the pipe is gouged by the consume able carbon electrode.
A more intense cutting arc causes a groove too deep and narrow for most applications, so the
defocused arc is used for gouging. In carbon-arc gouging, an electric arc at the end of a
consumable carbon rod melts the metal, and a continuous blast of compressed air violently
blows the molten metal away. Grinding is done to create out the space required along the
groove created by joining of two ends of rolled sheet. The first stage of welding is root pass
along the weld section, after which grinding is done to remove the slag. Then, it is followed by
throat welding and finally cover welding, again with slag and dust removing process
sandwiched between the two.
For the cover welding the submerged arc welding machine is used. The main advantage of this
type of welding is its relative ease and higher speed of welding. The machine automatically
carries out welding once proper input is given, and the slag formed is removed manually after
the excess flux is sucked through a suction pipe.
With the advancement in welding technique and development of higher heads, all welded steel
penstocks are mostly used. The pipes are formed by butt welding the longitudinal and
circumferential joints. The main advantage of this type over riveted penstocks is: -
1.Lower Weight
2.Lesser hydraulic Losses and
3.Ease of fabrication and Erection
Most of the penstocks recently designed for hydroelectric project in Nepal are of welded type.
With the advancement in designs, higher and higher heads with larger capacity of power station
are developed for power development. As the head increases so also the thickness and varies
difficulties are faced in rolling and welding of thick plates. This difficulty is overcome by the
development of high tensile steels, multi-layered penstocks and banded or hopped penstock.
NDT Testing
Before the pipe is ready for sandblasting, the welded part must be free from defects like cracks,
porosities and small holes. The welds on branch outlets and wyes, or fillet welds, other NDT
methods of inspection can be used. Methods available are: magnetic particle testing (MT),
ultrasonic testing (UT), and various methods using dye penetrants (PT). Of these, MT will only
disclose defects close to or extending to the surface. The UT method requires considerable
experience on the part of the inspector but it is suitable for detecting internal defects. PT is
suitable only for locating surface discontinuities.
Sandblasting
Sandblasting is a method of using material at high pressure to clean surfaces. Common
materials used for sandblasting include walnut shells, pumice and glass beads. You can choose
more abrasive media to clean tougher jobs. Steel grit is a common option for blasting surface
in preparation for paint.
• Sandblasting is perhaps one of the most effective ways to remove rust from your
equipment. Rust oxidizes metal and causes damage to the equipment that you depend
on for your operation.
26
• If you have a painting project, sandblasting is an efficient method of smoothing the

surface so that the paint goes on without rough spots and looks good. This is particularly
useful if you're planning on painting a surface that has accumulated several coats of
paint over the years.
• Many cleaning processes involve several steps and harsh chemicals that are hazardous
to breathe and require more preparation to complete properly. Sandblasting, on the
other hand, is a power washing technique that utilizes materials that are non-toxic and
safe for your equipment and the environment.
• One of the biggest advantages of sandblasting is that it saves time so that your business
can remain productive with very little downtime. The particle material quickly blasts
away pollutants from surfaces. When completed by a professional sandblasting
operation, you'll enjoy a swift turn around. Depending on the size of the surface, a
cleaning job that would take hours to clean manually can be cleaned in a matter of
minutes through sandblasting.
PAINTING OF PENSTOCK
Good painting on the interior of a penstock will reduce the frequency of power house shut
downs and consequent loss of revenue during maintenance. It will also withstand high water
velocities, impact and shock; with a smooth glossy finish, friction loss in the penstock will be
minimized.
INTERIOR PAINTING
Irrespective of the type of penstock, painting on the inside consists of one coat of cold applied
coal tar primer followed by one coat of coal-tar enamel 3/32 inch to 1/32 inch. Alternatively,
3 coats of cold applied coal tar epoxy (British Epilux 5 paints) have been provided for some
penstock in Nepal. Painting. of the interior with hot coal-tar enamel is usually done in the
shop. Straight pipe courses can be spun and the coal-tar enamel is deposited in the
spinning pipes. This results in a smooth glossy finish. Sections of pipes which cannot be spun,
such as elbows or sections with man-holes are hand-daubed. The hand-daubed coating seems
to protect the steel as effectively as the spun lining, but it is quite rough and is avoided
wherever possible to minimise friction losses.
EXTERIOR PAINTING
Prior to the despatch of fabricated pipes from the shop to site, the outside of pipe is protected
with one coat of Red oxide or Zinc Chromate. A second coat of red oxide is also given in the
field followed by a coat of aluminium paint. The highly reflective surface of the
aluminium paint is believed necessary to keep the interior of the pipe, whenempty, below a
temperature that would damage the coal-tar enamel and also to minimise the movement of
expansion joints.
Outside surface of buried pipes are painted with coal-tar enamel and to keep this coat from
being damaged by the back-filling operation are given a thin coat of reinforced
gunite. Alternatively, a layer of fibrous glass mat wrap followed by a coat of Asbestos Felt
wrap and finally a coat of white wash is given
Portions of penstocks embedded in concrete anchors are given a coat of red-oxide or
zinc chromate. Penstocks embedded in tunnels form steel liners and are given a similar coat
and a coat of asphalt or bitumen 1/8-inch-thick immediately upstream from the power house
for a distance of about 25ft. so that the thrust on the liners, as a result of closing the power
house valves would not be transmitted to the power house wall.
27
USE OF SPIDER ARMS

The penstocks shells manufactured might not be uniform in diameter along its length. This is
because the quality of rolling done depends upon the operator handling the rolling machine.
this aspect of human judgment makes it difficult to accurately roll the sheet to required
diameter. This is why the diameter of the shell is measured at the different point of the
circumference varies. However, in order for the penstocks to be interchangeable, they must
have close tolerance. So, it is where the spider arms come into play. The spider arm is properly
fitted in the inside circumference of the shell, thus contracting the portion having excess
diameter. With these shells are transported to the site for the erection, these spider arms are
removed after welding of the Penstocks in required alignment.
Mechanical Workshop (MNW)
The mechanical workshop deals with the production of mechanical component like bridge,
Gantry components, as ordered by the client. Job like pole, substation, lattice power, cable tray,
conical pole and parts of suspended bridge are manufactured in the workshop.
The Machines in MNW are: -
• Welding Machine
• Turret Lathe
• Pillar Drill
• Bed Lathe
• Screw Cutter lathe
• Drill Machine
• Hydraulic straighter machine
• Punch Machine
• Pipe Cutter
• Clipper Machine
• Bending Brake
• Power hack – saw
Ongoing project under this department includes: -
• Yadukwa, 33 kV Substation
• Butwal, 33 kV Substation
• Patan, 66 kV Substation
• Dhalkebar, 132kV Substation
28
Substation
Figure: - Substation
Figure: - 6*50m Rapti Bridge, Axial View
1. Determine the parts necessary according to the drawing.

2. Manufacturing and purchasing of required parts.
3. Assembling the components to check for interchangeability.
4. Dissembling of the Gantry after the assemble is inspected and deemed.
5. Dispatching the components to the sites.
6. Assembling the components at the sites.
Note: During all the above processes there is parallel quantity inspection.
29
CHAPTER 5
ELECTRICAL DIVISION
This section deals with the repair and maintenance of motor, generator, and mainly of
transformer. The work is done in customer orientation basic.
Failure of a transformer
1. Winding failure
2. Bushing failure
3. Tap Changer Failure
4. Core Failure
5. Tank Failure
6. Protection system failure
7. Cooling system failure
List of Machines
Winding Machine 1 MVA Transformer
Drying Oven 3.2*3.5*,20kw heating
Vacuum Oil Filling Chamber 3m dia. Length 3.5m
Oil treatment plant High vacuum filter, 1000lit/hr ,18kw
Overhead crane 5 tons, 10m span
Induced potential test set 4 KVA ,100HZ
Separated source voltage withstand test 200KV lighting voltage
Impulse Test Generator set 6 tons capacity
Major Task of Electrical Department
• Tapping
• Winding
• Testing
Tapping
Tapping’s are provided on a transformer winding for selecting/cutting out a certain number of
turns on the transformer winding thus obtaining a variable turns ratio. This is done in order to
maintain the output voltage within desirable limits because the equipment’s work satisfactorily
at a somewhat fixed voltage and voltage variation is a common phenomenon in the power
system. Tapping of a transformer means the connection point along the transformer winding to
select the suitable number of terms. By Tapping, you can get different turns ratio and be able
to control output & voltage regulation. Like, from the figure 1,2,3,4 are tapping’s on primary
& A, B, C, D are tapping’s on the secondary. You can tap the transformer at the tapping points
so as to get the required turns ratio. Example, if I tap at 1,2 & D, C I would get the turns ratio
of 64:2000.
30
Figure: - Tapping in Transformer
Testing
For confirming the specifications and performances of an electrical power transformer it has to
go through numbers of testing procedures. Some tests are done at manufacturer premises before
delivering the transformer. Mainly two types of transformer testing are done at manufacturer
premises- type test of transformer and routine test of transformer. In addition to that some
transformer tests are also carried out at the consumer site before commissioning and also
periodically in regular and emergency basis throughout its service life.
• Inspect transformer and parts for shipping damage and moisture.
• Check nameplate and prints for proper voltages and external phasing connection to the
line or bus.
• All banks above 150 MVA should be vacuum dried. Do not apply test voltages to the
winding during the vacuum drying process. Make certain the terminals are shorted and
grounded during oil circulation because of the large amount of static charge that can
build up on the winding.
• After the tank has been filled with oil, confirm that an oil sample was sent to the
Chemical Lab and that its results are entered in the bank test reports. Note the oil level
and temperature at completion of filling.
Check proper phasing and voltage of the bank to the system before load is picked up. When
possible, large transformers (>1 MVA) should remain energized for eight hours before carrying
load.
Winding
Transformers have two windings, being the primary winding and the secondary winding. The
primary winding is the coil that draws power from the source. The secondary winding is the
31
coil that delivers the energy at the transformed or changed voltage to the load. Usually, these
two coils are subdivided into several coils in order to reduce the creation of flux.
TRANSFORMER OIL PURIFICATION
Transformer oil serves to insulate the energized parts and components of electric power transformers
and also acts as a heat transfer medium. Additionally, it protects the solid insulation from damaging
moisture. Besides transformers, insulting oil is used in switches, high voltage capacitors and power
cables. In switches, the oil acts as an arc extinguisher preventing fires and possible explosions.
Over the course of the transformer’s service life, that may span many years of operation, the insulting
oil will accumulate various contaminants that adversely affect the oil’s performance
characteristics. Once the insulating oil’s performance characteristics have been diminished, the
transformer’s solid insulation will be in greater risk of failure. In order to restore them, the oil must
be purified of foreign substances and contaminates (water, gases and solid particles). Today, we’d
like to look into the methods of transformer oil purification. Different methods of purification can be
used depending on the substance(s) that need to be removed from the oil.
Figure: - Electrical Division Equipment
32
CHAPTER 6
HUMAN RESOURCE AND PROJECT MANAGEMENT
HRM is concerned with the human beings in an organization. “The management of man” is a
very important and challenging job because of the dynamic nature of the people. No two people
are similar in mental abilities, tacticians, sentiments, and behaviours; they differ widely also as
a group and are subject to many varied influences. People are responsive, they feel, think and
act therefore they cannot be operated like a machine or shifted and altered like template in a
room layout. They therefore need a tactful handing by management personnel HRM is the
process of managing people of an organization with a human approach. Human resources
approach to manpower enables the manager to view the people as an important resource. It is
the approach through which organization can utilize the manpower not only for the benefits of
the organization but for the growth, development and self-satisfaction of the concerned people.
Thus, HRM is a system that focuses on human resources development on one hand and
effective management of people on the other hand so that people will enjoy human dignity in
their employment.
6.1 Manpower
Manpower No. Of Employee

Chief Executive Officer 1
Deputy General Manager 1
Division Managers 6
Engineers 12
Officers (Technical/ Administration) 11
Supervisors, Technical / Administration 22
Technicians / Overseers 45
Highly Skilled Worker 21
Skilled Worker 19
Semi-Skilled Worker 13
Unskilled Worker 3
BTI Apprentices 61
Project Contact 43
Daily Wages /part Time Consultant 8
Total 266
33
Among the various activities under the human resources, the following are quite noticeable: -
1. Maintaining Daily Record of employees
2. Calculating hours worked and over time of applicable.
3. Handling leave request of employees.
4. Preparing document foe sending employees on sites works.
5. Identifying the need of good manpower.
6. Observing and evaluating the work of every employees
PROJECT MANAGEMENT
Project management is the practice of initiating, planning, executing, controlling, and closing
the work of a team to achieve specific goals and meet specific success criteria at the specified
time. A project is temporary in that it has a defined beginning and end in time, and therefore
defined scope and resources. And a project is unique in that it is not a routine operation, but a
specific set of operations designed to accomplish a singular goal.
Project management processes fall into five groups:
1. Initiating
2. Planning
3. Executing
4. Monitoring and Controlling
5. Closing
Figure: - Project Management
34
STAGES OF PROJECT
Cost Estimation and Bidding
Typically, any project at NHE starts after the bidding has been accepted by the customer or
client. Based on the relevant information in the tender document, pre – costing, estimation is
done by the technical staff. During this part, every effort is made to make the estimated cost as
accurate as possible. The cost estimation must include all the sources of costs which include
but not limited to: -
1. Material Cost Quotation and Purchasing
2. Manpower – For design, fabrication, erection, and commissioning.
3. Machine – Used for different operation, includes energy cost and deprecation cost
4. Transportation
5. Accommodations – Manpower must be accommodated at sites
6. Client / Guest Facilities
Then the company sets required profit margin and the bidding is made.
Contract Agreement
The actual inspection of the project is contract agreement between the bidder and the client.
Both the parties negotiate and set up the terms and conditions for the project. It in general
includes the project duration, obligations, from both parties, project cost, penalty to be snapped
in case of violation of the terms by either party, criteria for project expansion, manufacturing
details like materials to used, processes to be employed, quality consideration, tests to be
performed and so on.
Manpower Requirement
Any project requires a number of unskilled m, semi-skilled, skilled, and highly skilled
manpower including engineers and technicians. So, the project manager discusses with the
Human Resource Department about the quality and quantity of manpower required. Then, the
HR department looks for manpower within the company, and if needed vacancy are announced
for hiring manpower for the project. Now the team for the project is ready. It generally includes.
a. Project Manager
b. Engineers
c. Supervisor
d. Technical Officers
e. Draft man
f. Skilled, semi-skilled, and un-skilled manpower
35
Design
The next step is the designing of the system or product to be made. The Design includes.
• All the parts, components, sub- assembly’s requirement.
• Detailed drawing of those parts or components.
• Assembly Drawing
This is very critical stage since the success of the entire project depends on the design
made by the engineers. Once the manufacturing is stated, any changes in design could
result in delaying in the project and huge losses to the company.
Procurement
Before staring the fabrication of component identifying a requirement or need of the company
through the final step of the award of the product or contract. This is made sure by the
procurement department.
Procurement Steps
1. Need Recognition 6. Delivery
2. Specific Need 7. Expediting
3. Source Options 8. Receipt and Inspection of purchase
4. Price and Terms 9. Invoice Approval and Payment
5. Purchase Order 10. Record Maintenance
Fabrication
The next step is the fabrication of product in the respective department at NHE. In general, the
fabrication is divided into several stages depending on the size of the project, and planning is
done for the project. The start and completion points are sets for each stage of fabrication
depending on the items required at certain time at the site for erection.
Transportation
Then the manufacturing components must be transported safely to site. The arrangements for
transportation are generally done by the bidding company.
Erection and Commissioning

After the components reach the site, theses component has to be assembled and installed which
is technically termed as erection. Then finally, the installed components have to be tested in
actual working condition. Again, some part of payment is made to the bidder after erection and
commissioning.
36
CHAPTER 7
MECHANICAL DESIGN
7.1 Design Process
Most engineering designs can be classified as inventions-devices or systems that are created
by human effort and did not exist before or are improvements over existing devices or systems.
Inventions, or designs, do not suddenly appear from nowhere. They are the result of bringing
together technologies to meet human needs or to solve problems. Sometimes a design is the
result of someone trying to do a task more quickly or efficiently. Design activity occurs over a
period of time and requires a step-by-step methodology.
The basic five-step process usually used in a problem-solving works for design problems as
well. Since design problems are usually defined more vaguely and have a multitude of correct
answers, the process may require backtracking and iteration. Solving a design problem is a
contingent process and the solution is subject to unforeseen complications and changes as it
develops.
The five steps used for solving design problems are:
1. Define the problem
2. Gather pertinent information
3. Generate multiple solutions
4. Analyse and select a solution
5. Test and implement the solution
1. Define the Problems

The first step in the design process is the problem definition. This definition usually contains a
listing of the product or customer requirements and specially information about product
functions and features among other things. The definition of a design problem may evolve
through a series of steps or processes as you develop a more complete understanding of the
problem.
a) Identify and Establish of the need.
b) Develop the problem statement
c) Establish Criteria for success
This list would be included in the problem definition statement.
• Design must be low cost.
• Design should be safe, and easy to install.
• Design should not be detrimental to the environment.
37
• Design should be aesthetically pleasing.
• Design should be simple to operate, with minimum human effort.
2. Gather Pertinent Information

Before you can go further in the design process, you need to collect all the information available
that relates to the problem. Gathering pertinent information can reveal facts about the problem
that result in a redefinition of the problem. You may discover mistakes and false starts made
by other designers.
3. Generate Multiple solution

The next step in the design process begins with creativity in generating new ideas that may
solve the problem. Creativity is much more than just a systematic application of rules and
theory to solve a technical problem. You start with existing solutions to the problem and then
tear them apart-find out what's wrong with those solutions and focus on how to improve their
weaknesses. Consciously combine new ideas, tools, and methods to produce a totally unique
solution to the problem.
4. Analyse and Select the solution

Once you've conceived alternative solutions to your design problem, you need to analyse those
solutions and then decide which solution is best suited for implementation. Analysis is the
evaluation of the proposed designs. You apply your technical knowledge to the proposed
solutions and use the results to decide which solution to carry out. You will cover design
analysis in more depth.
At this step in the design process, you must consider the results of your design analysis. This
is a highly subjective step and should be made by a group of experienced people. This section
introduces a systematic methodology you can use to evaluate alternative designs and assist in
deciding.
Analysis of Design Solutions Before deciding which design solution to implement, you need
to analyse each alternative solution against the selection criteria defined in step. You should
perform several types of analysis on each design. Every design problem is unique and requires
different types of analysis. The following is a list of analysis that may need to be considered;
bear in mind that the importance of each varies depending on the nature of the problem and the
solution.
• Functional analysis • Industrial design/Ergonomics
• Mechanical/Strength analysis • Electrical/Electromagnetic
• Manufacturability/Testability • Product safety and liability
• Economic and market analysis • Regulatory and Compliance
38
Bill of quantities BOQ

The bill of quantities (sometimes referred to as 'BoQ' or 'BQ') is a document prepared by
the cost consultant (often a quantity surveyor) that provides project specific measured
quantities of the items of work identified by the drawings and specifications in the tender
documentation.
The quantities may be measured in number, length, area, volume, weight or time. Preparing
a bill of quantities requires that the design is complete and a specification has been prepared.
The bill of quantities is issued to tenderers for them to prepare a price for carrying out
the works. The bill of quantities assists tenderers in the calculation of construction costs for
their tender, and, as it means all tendering contractors will be pricing the same quantities
(rather than taking off quantities from the drawings and specifications themselves), it also
provides a fair and accurate system for tendering.
The contractor tenders against the bill of quantities, stating their price for each item.
This priced bill of quantities constitutes the tenderer's offer. As the offer is built up of
prescribed items, it is possible to compare both the overall price and individual items directly
with other tenderers' offers, allowing a detailed assessment of which aspects of a tender may
offer good or poor value. This information can assist with tender negotiations.
Advantages
Consistency is another advantage of using a BoQ. It saves time in terms of analysing and
comparing the bills since they will follow the standard format and measured information,
providing a consistent basis for obtaining competitive bids. This means the client can focus
more attention on the different quality considerations. For tenderers, it helps create a low-risk
and low-cost tendering environment, which encourages the submission of competitive bids
since the risk is better understood and defined.
A BoQ can provide a clear and extensive statement of the work that is to be completed, as well
as a reliable base for budget control and accurate cost reporting. It enables the preparation
of cash flow forecasts and provides a basis for the valuation of variations, the preparation
of interim payments, and the final account.
Standard of the Bill of Quantities
It is very important that bills of quantities are prepared according to a standard, widely
recognised methodology. This helps avoid any ambiguities or misunderstandings and so helps
avoid disputes arising through different interpretations of what has been priced.
39
Preparing Bills of Quantities
Bills of quantities can be prepared elementally or in works packages, by a process of 'taking

off' which involves identifying elements of construction works that can be measured and
priced. See Taking off for more information.
Bills of quantities are most useful to the contractor when they are prepared in work sections
that reflect likely sub-contract packages. This makes it easier for the contractor to obtain prices
from sub-contractors and is more likely to result in an accurate and competitive price.
The bill of quantities should identify the different kinds of work required, but should not
specify them as this can lead to confusion between information in the bill of quantities and
information in the specification itself.
Disputes can occur where there is discrepancy between the bill of quantities and the rest of
the tender documents (for example where an item is included in
the drawings and specification but not in the bill of quantities), or where there has been an
arithmetical error.
SAMPLE OF Bill of Quantity
PART NO. DESCRIPTION Unit QTY MATERIAL STANDARD SPECIFICATION REMARKS

1 1'' Pipe for Railing and Truss Metre 50 Mild Steel IS:2062 Medium
2 1.25" Pipe for Railing and Truss Metre 42 Mild Steel IS:2062 Medium
3 2" Pipe for Railing and Truss Metre 12 Mild Steel IS:2062 Medium
4 Corrugated GI Sheet Nos. 14 Mild Steel IS:2062 (6'X3') 18 gauge Blue color
5a Steel Grating Angle Nos. 4 Mild Steel IS:2062 ISA40X4 L=685
5b Steel Grating Frame Nos. 4 Mild Steel IS:2062 ISA40X4 L=1680
5c Hinge Bracket Nos. 12.00 Mild Steel IS:2062 42X30X8
5d Hinge Bush Nos. 6.00 Mild Steel IS:2062 Rod Dia. 25 L=30
5e Hinge Pin Nos. 6.00 Mild Steel IS:2062 Rod Dia. 20 L=73
5f Connecting Plate Nos. 6.00 Mild Steel IS:2062 50X30
5g Hex. Nut Nos. 6.00 Mild Steel IS:2062 M12
6 Steel Grating Flat Nos. 76 Mild Steel IS:2062 520X25X3
7 Checker plate support Angle Nos. 28 Mild Steel IS:2062 ISA 40X40X4 L=80 mm
8 Anchor Pad Type A Nos. 22 Mild Steel IS:2062 100X100X8
9 Anchor Pad Type B Nos. 8 Mild Steel IS:2062 150X150X8
10 Connecting Plate Nos. 36 Mild Steel IS:2062 100X40X6
14 Ladder Beam, meter Metre 10 Mild Steel IS:2062 ISMC 100
15 Chequered Plate Nos. 14 Mild Steel IS:2062 650X200X6
16 Bolts and Nuts Nos. 100 MS (4.6 Grade) IS:2062 M12X40
17 J Hooks Nos. 50 Mild Steel IS:2062 1"
40
PROJECT TITLE
Detail Analysis of Welding Electrodes
Requirements to perform welding on different
thickness materials.
41
CHAPTER 1
INTRODUCTION
Introduction to Welding
The interface of the two parts to be joined is brought to a temperature above the melting point
and then allowed to solidify, so that a permanent joining takes place
(or)
Metal joining process in which two or more parts are joined or coalesced at their contacting
surfaces by suitable application of heat or/and pressure.
Welding sources are chemical reaction, electric arc, electrical resistance, frictional heat, sound
and light energy. Operation may have carried out with / without application of pressure and
filler metal.
Welding process are classified into two categories: -
1. Fusion welding: In this process, base metal is melted by means of heat. Often, in fusion
welding operations, a filler metal is added to the molten pool to facilitate the process and
provide bulk and strength to the joint. Commonly used fusion welding processes are: arc
welding, resistance welding, oxyfuel welding, electron beam welding and laser beam welding.
2. Solid-state welding: In this process, joining of parts takes place by application of
pressure alone or a combination of heat and pressure. No filler metal is used. Commonly used
solid-state welding processes are: diffusion welding, friction welding, ultrasonic welding.
1.2 General Consideration
• Types of joints
• Butt- used to join two members aligned in same plane
• Lap- overlap of 2 plates, overlap is about three to 5 times the thickness of
plates
• Corner- used to join two members located at right angles to each other
• Tee- welding one element to another at an angle of 90, thin walled structures
are made
• Edge- joint is formed by joining two parallel plates, economical for plates
having thickness less than 6 mm
42
Welding positions
• Flat, Horizontal, Vertical, Overhead

Edge preparation
• V, U, J, Bevel etc.
Welding Position
Fig: - Edge preparation: Butt Joint
43
Welding Terminology
Backing: It is the material support provided at the root side of a weld to aid in the
control of penetration.
Base metal: The metal to be joined or cut is termed as the base metal.
Bead or weld bead: Bead is the metal added during a single pass of welding. The bead
appears as a separate material from the base metal.
Crater: In arc welding, a crater is the depression in the weld metal pool at the point
where the arc strikes the base metal plate.
Fillet weld: The metal fused into the corner of a joint made of two pieces placed at
approximately 90 o to each other is termed fillet weld.
Penetration: It is the depth up to which the weld metal combines with the base metal
as measured from the top surface of the joint.
Puddle: The portion of the weld joint that melted by the heat of welding is called puddle.
Tack weld: A small weld, generally used to temporarily hold the two pieces together
during actual welding, is the tack weld.
Toe of weld: It is the junction between the weld face and the base metal
Weld face: It is the exposed surface of the weld
Weld metal: The metal that is solidified in the joint is called weld metal. It may be
only base metal or a mixture of base metal and filler metal.
Weld pass: A single movement of the welding torch or electrode along the length of
the joint, which results in a bead is a weld pass.
Types of Welding
1. MIG (Metal Inert Gas) welding or GMAW (Gas metal arc welding)
2. Arc Welding or SMAW (Shielded arc metal welding)
3. TIG (Tungsten Inert gas welding) or GTAW (Gas tungsten ARC welding)
4. FCAW (Flux- cored arc welding)
5. Plasma arc welding
6. Submerged Arc welding
44
CHAPTER 2
WELDING USED BY NHE
2.1 Types of Welding Used by NHE
1. Stick or Shielded Metal arc welding

2.Oxy- Acetylene Gas Welding
3. Submerged Arc Welding
2.1.1 stick or Shielded Metal Arc Welding

Stick Welding, also known as Shielded Metal Arc Welding (SMAW) or Covered Electrode,
the most widely used of the various arc welding processes, utilizes a fixed length electrode and
an electric power source to join a variety of different metals. The core of the covered electrode
consists of a solid metal rod that is surrounded by a covering of mineral compounds and metal
powders mixed with a binding agent to help them adhere to the surface of the electrode. The
core rod conducts electric current to the arc and provides filler metal for the joint. The sizes
and types of electrodes for Stick Welding define the arc voltage requirements (within the
overall range of 16 to 40 volts) and the amperage requirements (within the overall range of 20
to 550 amp). The current may be either alternating or direct depending on the electrode used,
but the power source must be able to control the level of current within a reasonable range to
respond to the complex variables of the welding process itself.
The primary functions of the electrode covering are to provide arc stability and to shield molten
metal from the atmosphere with gases created as the coating decomposes from the heat of the
arc. This shielding controls the mechanical properties, chemical composition, and metallurgical
structure of the weld metal, as well as the arc characteristics of the electrode. The composition
of the electrode covering varies according to the type of electrode.
45
Why Use Stick Welding?

▪ Stick Welding is an extremely versatile process with respect to location and environment of
the operation. Welding can be done inside, outside, on a production line, a ship, a bridge, an
oil refinery, a cross country pipeline, or similar types of locations. Gas and water hoses are
not needed, and welding cables extend significantly beyond the power source. In remote
areas, gasoline or diesel-powered units can be used
▪ Equipment is relatively simple, inexpensive and portable
▪ Auxiliary gas shielding or granular flux are not required
▪ The process is less sensitive to wind and draft than gas-shielded arc welding processes
▪ It can be used in areas where access is limited
▪ The process is suitable for most of the commonly used metals and alloys
Limitations
▪ Operator duty cycles are low compared with semi-automatic and automatic processes; this
makes the cost per pound of deposited weld metal high with Stick Welding
▪ Deposition rates are generally lower than for other welding processes
▪ The process is considered to be manual as it is not easily mechanized
▪ Stick Welding is not suitable for reactive metals such as titanium, zirconium, tantalum, and
columbium because the shielding does not prevent oxygen contamination of the weld.
2.1.2 Oxy-Acetylene Arc Welding

Oxyacetylene gas welding is commonly used to permanently join mild steel. A mixture of
oxygen and acetylene, burns as an intense / focussed flame, at approximately 3,500 degrees
centigrade. When the flame comes in contact with steel, it melts the surface forming a molten
pool, allowing welding to take place. Oxyacetylene can also be used for brazing, bronze
welding, forging / shaping metal and cutting. This type of welding is suitable for the
prefabrication of steel sheets, tubes and plates.
Preparation the Cylinders For welding
Slowly open the main valve of the acetylene tank and adjust the acetylene pressure regulator
to 5 PSI (pounds to square inch). Open the needle valve on the torch and adjust the pressure
on the acetylene regulators to show 5PSI. Close the needle valve.
Go through the same procedure for the oxygen cylinder
46
IGNITING THE ACETYLENE / OXYGEN MIXTURE
TURNING ON:
Acetylene slowly turned on (quarter/half turn of the needle valve) and ignited, producing a
small flame. At this stage, a small amount of soot/smoke is given off the end of the flame
Acetylene increased and oxygen turned on slowly.
Acetylene increased slowly and oxygen more rapidly, to produce an intense, localised flame,
capable of precise welding.
TURNING OFF:
Turn off the oxygen first, followed by the acetylene
47
2.1.3 NHE used Propane (LPG) instead of Acetylene
Facts
• The flame temperature when burning Propane in Oxygen is 2800oC

• The flame temperature when burning Acetylene in Oxygen is 3100oC
Welding
Firstly: Propane cannot be used for Gas Welding. When acetylene burns in oxygen, it creates
a reducing zone that cleans the steel surface. Propane do not have a reducing zone like
acetylene and can hence not be used for Gas Welding.
Propane can like acetylene be used for cutting. If you cut with acetylene, you normally put
the tip of the inner flame cone on the metal (1mm from the plate surface). If you do the same
with propane, you will be waiting for a long time. If you raise the torch so that the outer
flame cone is used the preheat process is started faster. Propane releases only a small
proportion of heat in the inner flame cone (less than 10%), so most of the heat in the flame is
located in the outer cone. Acetylene releases almost 40% of its heat in the inner flame cone.
Therefore, acetylene is better for cutting than propane. While temperature wise acetylene is
hotter than propane the fact is that people are using propane for cutting incorrectly. The
mistake they make is that they are cutting with propane as they would cut with acetylene.
Where the heat is in the propane preheat flame is not where it is with acetylene. In short, it
takes a different technique to use propane for cutting and in general, acetylene preheats faster.
The Ship breaking/ ship demolition yards and scrapyards are often using propane for cutting
because cutting quality is of no concern.
48
Equipment
Cutting require different cutting attachments and cutting nozzles.
Economy
Propane has greater stoichiometric oxygen requirements than acetylene. For the maximum
flame temperature in oxygen, the ratio of the volume of oxygen to fuel gas are 1,2 to 1 for
acetylene and 4.3 to 1 for propane. So, there is far more oxygen being consumed when using
Propane. Despite Propane being less expensive than acetylene, this is counteracted by the
higher oxygen consumption.
Safety
The most important drawback using propane on-board are never the less the safety aspect.
Acetylene’s specific gravity is 0,9 so it is lighter than air (1). If gas leaks out it will raise. The
Specific Gravity of Propane is 1,6 and heavier than air (the same for other hydrocarbon gases
like butane and MAPP* (modified propane gas)). Any propane leak in an enclosed area will
sink and become concentrated at the deck level, accumulate and sometime avoid detection. For
propane to burn effectively, the oxygen-to-gas mixture must be within a certain range. For
49
ideal conditions, there should be four parts propane to 96 parts oxygen. When the gas burns
outside of these parameters, the result is incomplete combustion; this produces excessive
carbon monoxide. This can be very dangerous if the space does not have proper ventilation.
Onboard a ship one sometime work in enclosed areas like ballast tanks and double bottoms.
Carbon monoxide poisoning can result in death, as the toxic gas replaces the oxygen in the
bloodstream.
2.1.4 SUBMERGED ARC WELDING
Principle
Submerged arc welding is commonly used in industries where thick steel sheets are involved
on where long weld are required. The process consists in creating a welded joint between
steel components using an electric arc submerged beneath a layer of powdered flux.
Principle of the Process
Submerged-arc welding (SAW) involves the formation of an arc between a continuously fed
wire and the workpiece. A blanket of powdered flux creates a protective gas shield and a slag
for the weld zone. A shielding gas is not required. The arc is submerged beneath the flux
blanket and is not normally visible during welding. The
main feature of this welding is that – The weld and the arc area is protected from environmental
contamination by the application of a granular flux which is fusible. The weld pool is protected
by a blanket of flux. So that area is actually submerged under that flux. When temperature rises
and molten the flux becomes conductive. And thus, this creates a path for electron flow
between electrode and workpiece. SAW or Submerged Arc welding can be done
by manual procedure or automatic process. But it can be done by semi-automatic process where
welding gun is hold by hand. Here pressurized gravity flux feed is given. Both DC and AC
can be used as power supply. In multiple electrode system DC – AC combination is very
common. Constant voltage power supply machines are used very frequently.
Figure: Submerged Arc Welding
50
Advantages
• This welding process has high deposit rate. Almost 45kg/h can be
deposited.
• In mechanized applications.
• Very little welding fume is seen.
• No edge preparation is needed.
• This process is applicable indoor as well as outdoor.
• No chance of weld spatter as it is submerged in flux blanket.
Limitation
• Operation is limited to some specific metals.
• The application is limited to straight seams and pipes and vessels.
• The flux handling can be tough.
• Health issue can be caused because of the flux.
• Slag removal is needed after welding.
Application
• Joining of pressure vessels such as boilers.
• Many structural shapes, earth moving equipment, pipes.
• Railroad construction, locomotives and ship building.
• Repairing machine parts.
51
CHAPTER 3
THEORITICAL REQUREMENT OF ELECTRODES
3.1 Electrode
An electrode is a coated metal wire. It is made of materials similar to the metal being welded.
For starters, there are consumable and non-consumable electrodes. In shield metal arc welding
(SMAW) also known as stick, electrodes are consumable, which means that the electrode is
consumed during its use and melts with the weld. In Tungsten Inert Gas welding (TIG)
electrodes are non-consumable, so they don’t melt and become part of the weld. With Gas
Metal Arc Welding (GMAW) or MIG welding, electrodes are continuously fed wire. Flux-
cored arc welding requires a continuously fed consumable tubular electrode containing a flux.
3.2 Selection Of welding Electrode
Choosing an electrode is determined by the requirements of the welding job. These include:
• Tensile strength
• Ductility
• Corrosion resistance
• Base metal
• Weld position
• Polarity
• Current
There are light and heavy coated electrodes. Light coated electrodes have a light coating that
is applied through brushing, spraying, dipping, washing, wiping, or tumbling. Heavy coated
electrodes are coated by extrusion or dripping. There are three main kinds of heavy coatings:
mineral, cellulose, or a combination of the two. Heavy coatings are used for welding cast iron,
steels, and hard surfaces.
3.3 The Numbers and Letters mean on Welding Rods
The American Welding Society (AWS) has a numbering system that offers information about
a specific electrode, such as what application it is best used for and how it should be operated
for maximum efficacy. (See table)
52
Digit Type of Coating Welding Current

0 High cellulose sodium DC+
1 High cellulose potassium AC, DC+ or DC-
2 High Titania sodium AC, DC-
3 High Titania potassium AC, DC+
4 Iron powder, Titania AC, DC+ or DC-
5 Low hydrogen sodium DC+
6 Low hydrogen potassium AC, DC+
7 High iron oxide, potassium powder AC, DC+ or DC-
8 Low hydrogen potassium, iron powder AC, DC+ or DC-
The “E” indicates an arc welding electrode. The first two digits of a 4-digit number and the
first three digits of a 5-digit number stand for tensile strength. For example, E6010 means
60,000 pounds per square inch (PSI) tensile strength and E10018 means 100,000 psi tensile
strength. The next to last digit indicates position. So, “1” stands for an all position electrode,
“2” for a flat and horizontal electrode, and “4” for a flat, horizontal, vertical down and overhead
electrode. The last two digits specify the type of coating and the welding current.
E 60 1 10
Electrode Tensile Strength Position Type of Coating & Current
We must know the different types of electrodes and their applications in order to perform the
welding job correctly. Considerations include welding method, welded materials,
indoor/outdoor conditions, and welding positions. Practicing with various welding guns and
electrodes can help you determine which electrode to use for what welding project.
3.4 Consumption of Electrode During Welding
Has a direct impact on the performance and duration of the workflow. The used welding
consumable must be replaced with a new one. If the welder does not have the right electrodes
at hand, this will affect the timing of the welding upward. Adding filler material is not the main
problem. Everything is complicated by the fact that it requires pre-training. Electrodes must be
calcined and dried. It takes from one and a half to two hours.
When the electrodes are needed for surfacing a few kilograms of metal, the situation is not so
critical, unlike the welding of overall metal structures. Any simple is fraught with both time
and financial costs. That the process of work did not brake anything, it is extremely important
to perform the correct calculation of how many electrodes are required per one ton of metal
structures.
3.5 Theoretical Calculation
The theory of the process of calculating the consumption of electrodes consists in calculating
the rate of flow per one meter of the seam and dividing this value by the weight of one electrode.
As a result, we get the consumption rate not in kilograms of surfacing, but in the number of
53
electrodes per unit number. After that, the piece rate is multiplied by the yardage, and the result
is rounded to the whole value (in the larger side).
The consumption rate in kilograms is determined by the mass of the weld metal: the volume of
the section is one meter long and is multiplied by the density of the metal. And to simplify the
calculation, the volume of the partition can be calculated as the volume of a cylinder with a
diameter equal to the larger (external) side of the joint.
The obtained value is increased by 1.4-1.8 times (correction for cinder from electrodes). Each
of the six groups of electrodes has its own value of the coefficient mentioned. Therefore, it is
worth looking for specific figures in the directory.
The formula for calculating the flow rate is as follows:
H = Mk,
Where H - this is the normalized flow rate per meter weld seam, M Is the mass of welded metal
in the seam, k is the correction factor for cinder.
3.6 NHE Data
Length of the section =2500mm
Width of the section = 20mm
Thickness of the section = 28mm
Volume of the section = 2500 *20*28 = 1.4*106 mm3
Density of the electrode = 7.86 gm/ cm3 = 7.86*10-3gm/mm3
Mass of the electrode required = volume * density
=1.4*106mm3 * 7.86*10-3 gm/mm3
=11004 gm = 11.004 kg ~ 11 kg
Correction factor(K) = 1.8
Normalize flow rate per meter weld stream (H) = Mk
= 11*1.8 = 20 kg
54
3.7 The flow rate depends on the input parameters:
• deposition mass;
• length of welding seam;
• norms of consumption.
The mass of surfacing is called the weight of the metal, which fills the joining seam. The exact
data of this parameter is given in the welding procedure sheet. Its indicator for rough
calculations is from 1 to 1.5% of the weight of the metal structure.
The dimensions of the seam are measured with a tape measure over the joint. The result is
multiplied by the total number of stitches present in the section. This is due to the fact that deep
joints are brewed in parallel or sequential application of two or three joints.
The rate of application is the weight of surfacing per one meter of the seam. It is calculated for
either a single node or part, or depending on the type of welding operation being performed.
Given these nuances, the calculation of the consumption of additive products should be carried
out both theoretically and practically.
55
CHAPTER 4
CONSUMPTION IN ACTUAL PRACTICE
4.1 Practical calculation
It involves determining the mass of the metal and conducting welded test work. When they are
completed, the cinder is measured, the voltage and current strength, the length of the completed
seam are considered. Based on these data, the number of required electrodes for welding a seam
of a certain length is determined.
Accurate calculation will be when both the external data and the position angle in the
performance of the basic work remain the same as those that were during testing. To avoid
inaccuracy in the definition, the experiment is repeated three to four times. If you comply with
this condition, the calculation will be even more accurate than using formulas.
4.2 Calculating weld volume and weight
Calculating the volume of a weld is one of the first steps to be taken when estimating the cost
of making a weld.
With this information, and knowing the deposition rate of the process, it is possible to
determine the arc time (the length of time that an arc is burning and depositing weld metal) and
the amount of welding consumables required to fill the joint. Both of these are required in order
to calculate the cost of making the weld.
Determining the volume of a weld requires some knowledge of basic geometrical calculations
to determine the area of the weld and multiply this figure by its length. The first step then is to
calculate the cross-sectional area of the joint.
There are three factors that determine the volume of the weld in a single V butt weld. These
are the angle of the bevel, b, the excess weld metal and the root gap, g, as illustrated in Fig. To
calculate the area of this weld we need to be able to add together the areas of the four
components illustrated in Fig.
56
The dimension 'c' is given by (tan b x t); the area of a single red triangle is therefore t (tan b x
t)/2. The total area of the two red regions added together can be calculated using the formula
2t (tan b x t)/2 or t (tan b x t).
The width of the weld cap, w, is given by W = 2(tan b x t) + g.
The area of the excess weld metal is approximated by the formula (W x h)/2.
The area provided by the root gap by g x t.
The bevel angles, b, most often used are 10° = (tan 0.176), 15° = (tan 0.268), 22.5° = (tan
0.414) 32.5° = (tan 0.637) and 45° = (tan 1.00). As will become obvious when the weight is
calculated, it is easier to ensure that the decimal point is in the right place if centimetres are
used in the calculations rather than millimetres.
4.3 Actual consumption in Nepal Hydro and Electric Limited
If the weld is in a plate 11mm thickness, 5mm root gap, 65° included angle (b = 32.50°; tan
32.5° = 0.637) and with a cap height of 2 mm we have: -
1. c = tan32.5 x 11
= 0.637 x 11
= 7.00 mm
2. w = 2(0.637x11) + 5mm
= 19mm
so, the area of the cap = (19x2)/2
= 19 sq. mm.
3. area of the orange area = 5mm x 11mm
= 55 sq.mm.
4. area of the two red areas = 2 x (7.00 x 11)/2
= 77 sq.mm.
Total Area of the cross section = 19 +55+77 = 151 Sq.mm
Length of the pipe = 2500 mm
Volume of the cross section = cross section area x length of the pipe
= 151 x 2500
= 377500 cu.mm
Density of the electrode = 7.86 x 10-3 gm / cu.mm
Weight of the electrode required = Volume x density of the electrode
57
= 377500 x 7.86 x10-3
= 2.97 kg ~ 3 kg
Circumference of the penstock = π* D = π * 2300
Circumferential volume = π * 2300* 151
=1.091*106mm3
Weight of the electrode required = 1.091*106mm3 * 7.86 * 10-3 gm / mm3
= 8.575 kg ~ 10 kg
Weight of the after used electrode (Ø4mm) = 0.050kg
3
No. of electrode required longitudinally = = 60
0.050
10
No. of electrode required in circumference = 0.050 = 200
Total weight of the electrode required = 6+6+10 = 22kg
Total no. of electrode required = 22/ 0.050 = 440 ~ 450
4.3 Calculation Error
No calculation method gives 100% accuracy. Purchasing consumables to ensure a full and
continuous workflow is recommended with a margin. It is necessary to consider the possibility
of the presence in the batch of electrodes of defective and low-quality products.
In order not to stop welding, you should increase the data obtained in the calculations by five
or seven percent. This is guaranteed to save you from various kinds of force majeure. It is also
taken into account that the quantity of the consumable material depends both on technological
process, and on the type of additive to be filled with additives.
58
4.4 How to reduce costs?
There are several conditions that allow you to save on consumables for welding, but do not
affect the quality:
1. The greatest economy of additives makes it possible to achieve the use of a semi-
automatic or automatic welding machine. When the work is done manually, the losses
are from five percent or more. With automatic and semi-automatic process this indicator
is twice lower. If both additives and apparatus are of high quality, the reduction in
consumables will be maximum.
2. The current and voltage indices must fully correspond to the selectable filler material.
Therefore, tuning welding machine, it is necessary to give special attention these
parameters.
3. The number of electrodes consumed under equal conditions may differ. This is due to
the position of the consumable when welding. Therefore, many welders prefer not to
limit themselves to formulas and resort to practical calculations, conducting several
tests to find the "ideal" position.
Observance of these three important conditions and a wise choice of the way to save can reduce
the amount of required filler material by almost thirty percent. This is quite an impressive
amount in money terms.
• brand electrode or wire;

• section of beam;
• type of welding
Depending on the type of joint (butt, angular, T-joint), the seam area of the joint is calculated
in different ways.
59
CHAPTER 5
DEVIATION ANALYSIS
General
Usually, the welding residual stress level of the weld zone is close to the yield stress of the
welded material. These high stresses are responsible for stress corrosion cracking and fatigue
crack growth in the weld zone, which shorten the service life of the welded structure.
For the practical welder it is important to be able to estimate the requirement for stick electrodes
or other filler metals quickly, easily and accurately enough. An accurate calculation is not
possible using generally applicable chart as follows.
The deviations were defined for the minimum and maximum values of each element of the
parent metal and the weld metal, which in fact consisted almost completely of the electrode
metal Subsequently, these data were used to determine the relative deviation of the actual and
practical consumption of electrode.
5.1 Stick Metal Arc Welding Consumption of Electrode
Consumption of Electrode
3
2.75
2.5 2.4
Consumption Kg/ m
2
2 1.9
1.8
1.7
1.5 1.4 1.4

1.3
1.03
1
0.5
0
16 20 22 28 32
Plate Thickness in MM
Actual Practical
Fig: - Deviation Chart
60
5.2 Submerged Arc Welding Consumption of Electrode
Consumption of Electrode
3
2.8
2.6 2.6
2.5
2.3
Consumption Kg/m
2 1.9
1.8
1.5 1.4
1.3
0.5
0
16 22 28 32
Plate Thickness in MM
Actual Practical
Fig: - Deviation Chart
61
CHAPTER 5
REASON FOR DEVIATION
How you prepare your work plate (or stationary structure) for welding may contribute
more to the outcome of the operation than anything else. Your joints, bevelled edges, grinded
root faces and surfaces should fit together in a smooth and uniform manner before you start
the weld. There shouldn’t be any burrs, gaps or evenness.
As a student, it’s easy to assume that once the metal heats up, everything’s falls together
naturally and all the little rough spots will disappear like magic. In fact, you can make things
worse if you don’t take the time to do your fit-up correctly. Needless to say, the angle of the
bevelled sides should be appropriate for the thickness of the metal and the welding process
being used. (In MIG welding, steeper angles are possible than in stick welding). You should
also tack your plates and use clamps as needed to prevent the joint from closing up in advance
of the weld, or the distortion caused by the heat.
Cleaning your weld edges in advance is also important. While some stick electrode is designed
to penetrate through rust and mill scale, those impurities can still cause problems. And while
low – Carbon steel is much easier to work with than other metals, you should still adopt the
habit of cleaning or grinding the areas you plan to weld.
The welding of high-strength steels is characterized by the high probability of formation of

cold cracks and a decrease of the mechanical properties of the welded joints because the high-
strength steels are characterized by higher susceptibility to the formation of quenched
structures in the weld metal and the heat affected zone (HAZ).
A possible reason for such a large scatter of the mechanical properties of the metal of the
welded joint may be the considerable heterogeneity of the chemical composition of the high
strength steel and electrode wire.
Reasons
1. The changes of chemical composition of industrial grades of steels and welding wires
within the range of the standardized allowances are one of the reasons for the deviation.
2. Poor joint design and fit -up.
3. Incorrect machine setting.
4. Using the wrong (or defective) rod / wire.
5. A hot or cold ambient temperature, high humidity, or other atmospheric conditions.
6. Your welding travel speed is too fast, not allowing enough time for the shielding gas or
rod flux ingredients to do their job.
7. Size: - The thickness of the base metal should factor into the decision about which
diameter electrode, rod, wire or torch tip you use to make the weld, as well as your
voltage, wire speed and/or current settings. There are plenty of other size factors to
consider, but metal thickness usually comes first.
62
CHAPTER 5
WAYS OF MITIGATION
General
Mitigation of welding residual stress and welding deformation requires an additional process
to mechanically or thermally alleviate these problems after the completion of welding in most
cases. Producing a weld bead that's the right size, shape and depth involves many variables.
Arc welding students remember most of them by reciting the acronym "CLAMS", since each
letter stands for a welding parameter. Here's the list:
Current - Amperage generally dictates the size and penetration of a weld bead when you're
moving your torch at the right speed. Welders refer to charts from welding machine and
electrode manufacturers, or a welding procedure specification (WPS) for their current
settings, or try welding on sample plates of the same thickness to see what works best.
Length of Arc - How close to the work plates the welder holds the arc of a wire or welding
electrode can affect the amount of current and heat going into the joint. Held close to the work
plates, the current and heat in the weld remains high. Held farther away, the electrode produces
less heat and more spatter. As a rule of thumb, in stick welding arc length should match the
diameter of the electrode metal. In other words, if you're using a 1/8-inch rod, hold it 1/8 inch
from the joint surface. You can increase the length of the arc to reduce heat to the puddle or to
limit the deposition of weld metal.
Angle - There are two torch angles to remember when welding. The first is the work angle,
which is the relationship between the joint and the torch (or rod). Ideally, you'll hold your torch
perpendicular, or 90 degrees, to the joint. The big exception to the rule is T-joints, where the
work angle varies between 30 to 50 degrees. The second angle used in welding is the travel
angle. This is the relationship between the torch and line of travel. In order to see the joint and
puddle, the welder may tip the rod up to 10 degrees in the direction of travel, or sometimes
against the direction of travel.
Speed - If you move too fast, the size of the weld will be small and achieve insufficient
penetration. Move too slow and you'll end up with a fat weld bead and likely too much heat
going into your work plates.
63
CHAPTER 6
CONCLUSION
After Completing my Practise School at NHE. I came to gain overview of Management system.
Mechanical Department, Quality Management System and service provided by the company.
As a final year student of Mechanical Engineering. I understood the role of engineers in design,
fabrication, installation, testing, and commissioning along with the management skills, which
will definitely help me in the future days.
The management has effectively handled the manpower of the company with so much of time
optimization without hampering the moral of the workers, rather encouraging them. I found
the machines and equipment used very much sophisticated with huge capacity I have ever
observed. The procedure followed were standard and there was no loop hole in quality
management system. The extent of the job performed is enormous, still the material handling
is quite good. The services that this company is providing are very much significant in the
context of Hydro power development in Nepal and every one should really appreciate it.
As a project work, deviation analysis is studied and way of mitigation especially for the shield
metal arc welding method mostly used the arc welding technique industry. The deviation
analysis is done on the basis of thickness of the plate and consumption of electrode on
submerged and stick metal arc welding method used by NHE. From the deviation analysis we
can see that the consumption of electrode (on weightage) in practical process more than actual
process, and studied about their reason and solution of the deviation. From the chart we can
also see that the consumption of electrode in submerged arc welding is more than the stick
metal arc welding but time required for the stick metal arc welding is more than the sub merged
arc welding. So, for the mass production company the SAW is better than the SMAW but the
cost will be high in SAW.
After done the project and observing the process, equipment and manpower need in
maintenances and fabrication of hydropower component, I can clam that it extended my
horizon of knowledge and experience for which I am very much Thankful to the company. I
believe I will get similar support in the future.
64
CHAPTER 7
REFERENCES
[1]. http://www.weldersuniverse.com/weld_defects.html
[2]. http://www.weldersuniverse.com/welding_parameters.html
[3]. https://www.millerwelds.com/resources/welding-resources/stick-
welding-resources/stick-welding-tips.
[4]. https://ilmoproducts.com/stick-welding-charts/
[5]. https://www.praxairdirect.com/Industrial-Gas-and-Welding-
Information-Center/Welding-Tips-Tricks-and-Information/Stick-
Welding.html
[6]. Welded of penstock by Technical staff of the Bureau of Reclamation
[7]. Engineering design process by Seyyed Khandani, Ph.D
[8]. Turbine Repair, Revised April 1989 by William Duncan, Jr., Facilities Instruction,
standards & techniques Volume 2-5.
65
View publication stats

Internship Report 1

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Internship Report 1

Enviado por

Direitos autorais:

Formatos disponíveis

See discussions, stats, and author profiles for this publication at: https://www.researchgate.

Internship Report at Nepal Hydro and Electric Limited.

Technical Report · January 2018

Design and Development of Agriculture Harvesting Robot . View project

The user has requested enhancement of the downloaded file.

ELABORATES THE PRACTICAL APPROACH TO HYDRO MECHANICAL WORK

Under the esteemed guidance of

Mr. Er.Sagar Basnet & Er. Sanjit Sah

DEPARTMENT OF MECHANICAL ENGINEERING

Green Fields, Vaddeswaram, Tadepalli,

NEPAL HYDRO AND ELECTRIC LIMITED

Ram Prasad Banjade Er. Sanjit Sah

DEPARTMENT OF MECHANICAL ENGINEERING

Department Coordinator Head of the Department

University Guide External

Dated: - November Aashish Bhandari

➢ Conversation with Employees

Welding Terminology ........................................................................................................................ 44

LIST OF ABBREVIATIONS AND ACRONYMS

LIST OF THE FIGURES

Figure 1: Cavitation on Francis Runner

Figure 2: Pitting on Francis Runner

Figure 3: Reclamation of wicket gates

Figure 4: Undergoing DPT Testing Francis Runner

Figure 5: Magnetic Particle Testing

Figure 6: Dye Penetration Testing

Figure 7: Flow Detector

Figure 8: UT Testing on Penstock

Figure 9: Heavy Mechanical Workshop

Figure 10: Rolling of Mild Steel Plate

Figure 11: Substation

Figure 12: 6*50m Rapti Bridge, Axial View

Figure 13: Electrical Division Equipment

Figure 14: Project Management

Figure 15: Edge Preparation of Butt Joint

Figure 16: Welding Terminology

Figure 17: Arc Stick Welding

Figure 18: Nozzles

Figure 19: Oxy- Acetylene Gas Welding

Figure 20: Gas Cylinders

Figure 21: Sub-Merged Arc Welding

Figure 22: Deviation Charts

Figure 23: Angle Position

1.1 Background Of NHE

1.2 Company Objectives

1.2 Capabilities Of NHE

• Steel Liners, Penstock Pipes and Manifold (max. 8m Dia.),

3. High Voltage Substation construction (Turn Key Project)

1.3 Mission and Vision

1.4 Initiation of projects

1.5 Past Project Of NHE

Manufacturing and Nov

32 MW Kulekhani Supply of 37.8

Fabrication and Aug

1.6 Current Major Jobs at NHE

Rasuwagadi Manufacture, Delivery, Installation 12 December-

Switchgears and Civil Construction

GOD-2073/074 - 15, Supply,

• Current Reference List of Projects

1.7 NHE – AN OVERVIEW

TURBINE REPAIR PROCEDURE

Figure: - Cavitation on Francis Runner

Figure: - Pitting on Francis Runner

DECISION ON BEST APPROACH TO REPAIR