REDUCTION OF REWORK TIME IN WELDING PROCESS

-A CASE STUDY AT BHEL, TRICHY

G84 Project Work

Submitted in partial fulfillment for the requirement of B.E. degree in Mechanical Engineering of Anna University Submitted by R.VIGHNESHWARAN (06G87) and V.VIGNESH BALAJI (06G88) Guided by Dr.S.KARTHIKEYAN

Department of Mechanical Engineering THIAGARAJAR COLLEGE OF ENGINEERING

(An Autonomous Institution Affiliated To Anna University)

MADURAI 625 015

March 2010

THIAGARAJAR COLLEGE OF ENGINEERING

(An Autonomous Institution Affiliated to Anna University)

MADURAI 625 015.

CERTIFICATE
Certified that this is a bonafide record of the G84 Project Work & Viva Voce done by Mr. R. VIGHNESHWARAN (06G87) and 2010. Mr. V. VIGNESH BALAJI (06G88) of Eight Semester B.E. (Mechanical Engineering) during the year 2009 -

Signature of the Guide

Signature of H.D.M.E

Station: Madurai

Date:

Submitted for Viva-Voce examination held at Thiagarajar College of Engineering, Madurai 625 015, on __________________.

INTERNAL EXAMINER

EXTERNAL EXAMINER

H.D.M.E.

CERTIFICATE

This is to certify that the G84 Project Work Report entitled REDUCTION OF REWORK TIME IN WELDING PROCESS, being submitted by

Mr. R.VIGHNESHWARAN and Mr. V.VIGNESH BALAJI in partial fulfillment for the requirement of Bachelor of Engineering Degree in Mechanical Engineering, is a record of bonafide work. The results embodied in this report have not been submitted to any other university or institute for the award of any degree or diploma.

Mr. R. VIGHNESHWARAN Mr. V. VIGNESH BALAJI (B.E. STUDENT) Station: Madurai

Dr. S. KATHIKEYAN (GUIDE) Date:

LIST OF CONTENTS Chapter No Title Page Bonafide Certificate Certificate BHEL Certificate Acknowledgement List of contents List of symbols List of figures List of tables Abstract
1 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.4 1.5 1.6 2 2.1 2.1.1 2.1.2 2.1.3 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.4 INTRODUCTION. About BHEL About Boiler Drum Manufacturing Process of a Boiler Drum Shell Formation End Cover Processing Drum Processing Production Test Plate List of Materials Composition LITERATURE SURVEY Welding Process Shielded Metal Arc Welding (SMAW) Flux Core Arc Welding (FCAW) Submerged Arc Welding (SAW) Weld Defects Cause of Rework and Quality Related Problems in Butt Welds Slag Inclusion Porosity Cracks Incomplete Penetration Lack of Fusion Undercuts Spatters Coarse Ripples and Undulations Testing of Welds

TITLE

Page No. I Ii Iii Iv V VI VII VIII Ix

1 3

4 5 5 6 7 8 8 9 10 10 10 10 11 12 13 13 13 13 14 14 14 14 15 15

2.4.1 2.4.2 2.4.2.1 2.4.2.2 2.5 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5

Destructive Testing Non-Destructive Testing X-Ray/Radiographic Testing Ultrasonic Testing Weld Symbols PROBLEM DESCRIPTON AND DATA COLLECTION Problem Description Data Collection SOFTWARE USED AND DATA ANALYSIS Opening Screen Capturing Length, Depth and Welder Number Graph Showing the Defect Details Stratification of Values Further Analysis Form: Official Record Maintenance

15 15 16 16 18

4.6 4.7 4.8 4.9 5 5.1 5.2 5.3 5.4 5.4.1

5.4.2 5.4.3 5.4.4 5.4.5 5.5 5.6 6 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.2 7

Detailed Analysis Screen Major Causes of Delay Cause and Effect Diagram for Slag Inclusion Cause and Effect Diagram for Porosity METHODOLOGY/PROCESS APPROACH Process Approach Problem Identified Action to be Taken Proposed Study
Specimen 1 (Pipe + Plate) Specimen 2 (Pipe) Specimen 3 (Pipe) Specimen 4 (Tee) Specimen 5 (Voltage Overlay) Observed Parameters MPI and Heat Treatment RESULTS AND DISCUSSIONS Cutting Plane and Macro Examination Report Specimen 1 Specimen 2 Specimen 3 Specimen 4 Specimen 5 Inferences from the Proposed Study Conclusions

References