An Internship Report on

BHARATH HEAVY ELECTRICALS LIMITED

HEAVY PLATES AND VESSELS PLANT

Submitted in accordance with the requirement for the degree of

Bachelor of Technology

By

Jakka Vishala
(Roll No. 20L31A0367)

Under the Faculty Guidence of

Mrs.V.Savitri
Associate Professor

Department of Mechanical Engineering

Vignan’s Institute of Information Technology(A)
(Approved by AICTE and Permanently Affiliated to JNTU, Kakinada)
Beside VSEZ, Duvvada, Visakhapatnam – 530049
2022-23
 Department of Mechanical Engineering
Vignan’s Institute of Information Technology(A)
Beside VSEZ, Duvvada, Visakhapatnam – 530049

CERTIFICATE
This is to certify that the “Summer Internship report” submitted by JAKKA VISHALA (Regd.
No.: 20L31A0367) is work done by her and submitted during 2022–2023 academic year, in partial
fulfillment of the requirements for the award of the degree of BACHELOR OF TECHNOLOGY
in Mechanical Department at Bharath Heavy Electricals Limited (Heavy plates and
vessel plant) Visakhapatnam.

Internship Mentor Head-Internships

Mrs.V.Savitri Dr. B.Prasad

Head of the Department

Dr. S. Rambabu
 Acknowledgement

I express my deep gratitude to my guide Mrs.V.Savitri, Associate Professor,

Department of Mechanical Engineering, Vignan’s Institute of Information
Technology, Visakhapatnam for rendering me guidance and valuable advice always.
He has been a perennial source of inspiration and motivation right from the inception
to the completion of this project.
I am indeed very grateful to Dr.S.Rambabu, Head, Department of Mechanical,
Vignan’s IIT, Visakhapatnam for his ever willingness to share his valuable knowledge
and constantly inspire me through suggestions.
I sincerely thank all the Staff Members of the Department forgiving me their heart full
support in all stages of the project work and completion of this project. In all humility
and reverence, I express my profound sense of gratitude to all elders and Professors
who have willingly spared time, experience and knowledge to guide me in my
Internship.

JAKKA VISHALA
20L31A0367
 ABSTRACT

During our internship training in BHEL, we worked at different departments and sections
and acquired knowledge regarding variety of machinery and their functioning pattern. We
did our internship for nearly 4 weeks and came to know that how the atmosphere of the
industry looks and it may help went we get placed in any core industry.
As there are many machines and materials we can learn a lot from those. Each machine
has its own process and principles.
Firstly, we were assigned to the production department so we went to the production
workshops and seen the different machines, materials and working of those machines. The
time management, communication and the work management followed by the workers is
very helpful for us to learn from them.
We learned the importance of coordination between the superior and sub-ordinated for
smooth functioning of the industry. We also developed our communication skills and
personal characteristics. And this all may help us during our placements and while doing
the future internships.
TABLE OF CONTENTS:

S.No CONTENTS PAGE NO

1. Introduction 6-7
History 8
Production Facility 8
Departments 8
2. Products made by BHEL 9-11

3. Quality assurance 12-13

4. Departments of BHEL 14-16

5. Non Destructive Testing 17-20

6. Lists of Machines in BHEL 21-23

7. Machines and Equipments 24-28

Light machine shops 28-30
Heavy machine shops 30
Press shops 30-34
8. Research and Development 35-36

9. Activity log for 4 weeks 37-45

10. Outcomes Description 46-48

Daily GPS photos 49-54
Internship Certificate 55

11. Conclusions and Future scope 56-57

5
 Chapter –1
Introduction

6
INTRODUCTION TO BHEL(HPVP,VISAKHAPATNAM)

Bharat Heavy Electrical Limited (BHEL) Heavy Plates & Vessels Plant, formerly Bharat Heavy Plates and
Vessels Ltd (BHPV). On 30.08.2013 Bharat Heavy Plates & Vessel (BHPV) has merged as 17 unit of BHEL
and named as BHEL- THUVE.

It is the largest fabrication industry for fabrication of process equipment's and Boiler plants in India required
for fertilizers, petroleum, chemical, petro-chemical, steel and allied industries.

BHEL HPVP is equipped to manufacture a wide variety of fabricated product lines for the process industries
like oil gas, space, defense etc., either to its own design or to the specification of customer's consultant

In BHEL research and development (R&D) was started in the year 1978 with the financial assistance from
Government of India and is recognized by department of science and technology (DST), India. Since
inception, R&D developed many critical products for aerospace applications for HAL and ADA Bangalore.

BHEL is experienced in the design of columns, multi-layered vessels, Heat Exchangers, Liquid Oxygen and
Nitrogen Unit. Evaporation Plants, Digesters, Mounted Vessels, Sulphur Recovery Unit, Gas Dehydration,
Crude Stabilization Unit, Storage Vessels etc.

Plant Installed Capacity : 23210MT (Licensed)

Turnover for the year 2016-17 : 108 Crores

Physical Turnover for 2016-17 : 4600 MT

Employees as on 1st May 2017:

Executives : 220

Supervisors : 79

Workers : 702

Total : 1001

Apprentices : 39

Contract Labor : 295

7
 HISTORY

BHEL was established in 1964 ushering in the indigenous heavy electrical equipment industry in India. Heavy
electricals limited was merged with BHEL in 1974. In 1991 BHEL was converted into a public limited
company.

PRODUCTION FACILITY

Factory Area : 197 Acres

Total Covered Area : 90,000 Sq. Meters
Covered area of Production Shops : 56,000 Sq. Meters
Power Requirement : 3,000 KW from APSEB
No. of Ancillary Units : 11

DEPARTMENTS
BHEL HPVP Consists of following departments which plays a crucial role to complete the job.
• Modernization & Captive Investment
• Engineering Department
• Project Management
• Material Management Dept. (M.M)
• Planning Technology Dept.
• Industrial Engineering Dept.
• Production Dept.
• Quality Control Dept.
• Welding Technology Dept.
• Electric & Instrumentation Dept.
• Works Engineering
• Erection & Commissioning Dept.
• Research & Development Dept. (R & D)
• Out sourcing Dept.
• Sub-Contracting Machine Dept.
• Finance Dept.
• Corporate Planning Dept.
• Transportation

8
 Chapter –2
Products made by BHEL

9
• TRANSPORTATIONTANKS
11 Transportation tanks of stainless steel and carbon steel, rail or truck mounted including low
temperature applications are manufactured.

Fig:1 TRANSPORATATION TANKS

• STORAGE TANKS:
Storage spheres of any size and thickness including low temperature service. BHEL also undertakes
erection and site stress relieving of these spheres.

Fig:2 STORAGE TANKS

• DEAERATOR SHEATERS:
BHEL HPVP manufactures complete feed water heater systems including deaerator, high-pressure
heaters and low-pressure heaters.
• CRYOGENIC PRODUCTS:
BHEL HPVP manufactures cryogenic products which are used to store liquids, liquid gases at low
temperature (below -150°C,-238°C or 123 K).

Fig:3 CRYOGENIC VESSELS

• PRESSURE VESSELS AND COLUMNS:

From multi-layer construction with design pressure of 280 kg/sq.cm to simple low and medium

10
 pressure columns are manufactured. Tall and Heavy Columns with lengths up to 90 meters and weights
up to 450 tons. Pressure ranges from vacuum to 55 kg/cm2 . With the backup of experienced engineers
and a host of heavy capacity cranes and other equipment, BHEL HPVP undertakes site fabrication and
erection of heavy equipment of any size and weight.

Fig:4 PRESSURE VESSELS AND COLUMNS

• PAPER & PULP:
Batch in continuous pulp digesters & multiple effect evaporation plant. Today BHEL, with its vast
manufacturing capability, can manufacture process equipment of almost any size. In addition, it has
the requisite handling facilities and being located at Visakhapatnam has excellent facilities for
transporting all size vessels. In case of extra large equipment that cannot be transported, BHEL
undertakes site fabrication & erection.
• AIRFIN COOLERS:
13 Air fin coolers of forced draft type for refineries, petro chemicals, and fertilizers. Complete units
with fans, driving systems, structural scheme, louvers and paneling.

Fig:5 AIRFIN COOLERS

11
 Chapter –3
Quality Assurance

12
QUALITY ASSURANCE
QA is defined as a procedure or set of procedures intended to ensure that a product or service under
development (before work is complete, as opposed to afterwards) meets specified requirements. QA is
sometimes expressed together with QC as a single expression quality assurance and control (QA/QC)
RAW MATERIAL TESTING - Chemical, mechanical and bending tests
After that rolling as shells
FIT UP EXAMINATION - weld inspection
DP TEST - for fillet welds
RADIOUGRAPHY TEST - for byt welds
PRESSURE TEST
HEAT TREATMENT TEST

1. Heat treatment
a) Fully annealed samples

i) Heat in oven to 16000f

ii) Turn off oven, leaving that sample inside until cool

b) Quenched and tempered

i) Heat in carbon rich environment to 16000F for 1 hour
ii) Remove from oven and immediately quench in oil
iii) Perform a RH c hardness test
iv) Heat to 10000F for 1 hour
v) Return to room temperature

2. Tensile testing
a) Perform a Rockwell Hardness B test on AR and O samples and Rockwell Hardness C test on QT samples
b) Measure and record sample diameter
c) Create indents for gage length 2" apart and record actual distance between marks
d) Insert into UTM and attach extensometer Heat Treatment of Steel Lab Report
e) Begin tensile test
f) Remove extensometer at 0.2 strain for O Samples, and at 0.1 strain for AR and QT samples
g) Continue testing
h) Measure and record final diameter and gage length

3. Data analysis
a) Export data to excel format
b) Plot stress Vs strain up to removal of extensometer
c) Using measured final strain and breaking stress

13
 Chapter –4
Departments in BHEL

14
Material Management Department
• Material Management is simply the process by which an organization is supplied with the good and
services that it needs to achieve its objectives of buying, storage and movement of materials
• Materials Management is related to procuring storing and providing that appropriate material of right
quality, right quantity at right place in right time so as to co-ordinate and schedule the production
activity in an integrative way for an industrial undertaking. Most industries buy materials, transport
them in to the plant, sell and transport the product to the customer.
• All these activities of purchase of materials, flow of materials, manufacture them in to the product,
supply and sell the product at the market requires various types of materials to manage and control
their storage, flow and supply at various place. It is only possible by efficient materials management.
• Functions: Efficient materials planning, buying or purchasing, procuring and receiving, storing and
inventory control, supply and distribution of materials, Quality assurance, Good supplier and customer
relationship, improved departmental efficiently

Planning Department
• In Planning department, the material from material management department and technical department
is taken and planned how to do? What to do? And where to do?
• This is the department which splits the total work of fabrication by sending the parts of the job to
different departments such as marking, rolling, shell section, water panels, pipes, headers, press section
and different machining processes. It also decide the complete plan of finishing, quality checking and
NDT tests.
• This is an important department which directly decides the rate of manufacturing.

Production Department
Production department mainly have four sections:
i) Combustion systems
ii) Heat exchangers
iii) Cryogenic products
iv) Pressure vessels
i) Combustion systems
It contains two plants
1. CSP 1 (Combustion system plant
2. CSP 2 (Combustion system plant
This plants produce boilers
ii) Heat Exchangers
This section produces heat exchangers. But now as BHPV merged in BHEL, only production of boilers
are concentrated. This shop is now called as Header shop

15
 iii) Cryogenics Plant:
This pant produces cryogenic products which are used in separation of different gases from air in many
industries. These plants are exposed to very low temperatures. Modules are produced in these plants
For example these plants are exposed to temperatures around - 180 to 200° -
iv) Pressure Vessels:
Pressure vessels are used in many chemical and refinery industries. Any industry inn course of its
function, requires to mix different types of materials. Many of material not mix up at room temperature. We
require high pressures and temperatures in this process. Pressure vessels are utilized in above situations, which
most of the industries require. These are used to sustain very high pressures.
The pressure vessel construction also depends width, thickness, headers etc. While these equipment are
being fabricated, it needs certain shapes such as bends, curves, holes etc. these requirements are fulfilled by
Feeder shops.

Logistics Department
• Logistics is the management of the flow of goods between the point of origin and the point of
consumption in order to meet some requirements, of customers or corporations. After checking all the
required NDT testing and quality assurance, the product is shipped to the consumers by Logistics
department
• This department also includes loading, unloading, transportation, alignment of the job and positioning
of center of gravity while loading.
• Very complicated tasks and high level accuracy operators are required while transporting dimensioned
consignments

Erection department
Very large consignments are transported as parts and assembled and erected, even the lifting equipment
such as cranes are also unassembled and transported to the site of working and assembled again. This process
may take around two to six months.

Finance Department
• Finance is important to an organization as the firm has to know how viable it is and balance profit with
costs.
• The role of the finance department can be summarized:
• Prepare and create financial accounts such as Trading, Profit and Loss Account and the Balance Sheet.
• Keep and maintain financial records - sales figures and records of expenditure would be held by the
Finance department and used by other departments also.
• Prepare and plan internal financial information this would mainly be performed in the case of a budget,
which is a financial plan and can help managers take corrective action.

16
 Chapter –5
Non Destructive Testing

17
Non-destructive examination (NDE) or non-destructive testing is defined as those inspection methods,
which allow materials to be examined without changing or destroying their usefulness. NDE is an
integral part of the quality assurance program. A number of NDE methods are employed to ensure that
the weld meets design specification and does not contain defects. The inspector should choose an NDE
method capable of detecting the discontinuity in the type of weld joint due to the configuration and lists
the common types and location of discontinuities and illustrates their positions within a butt weld
The five most common testing methods used for weld examinations are:
1) Visual Testing
2) Dye Penetrant Test
3) Magnetic Particle Test
4) Ultrasonic Test
5) Radiography Test
Visual Testing:
Visual testing is the most basic and common inspection method. Visual testing is a process done by
naked eye to identify the surface defects. Usually after each and every testing process, visual
examination is required. Visual examination also includes equipment’s like magnifying glasses, fiber
scope, mirror, micro scope etc.

Fig:6 VISUAL TESTING

Dye penetrant Test:
Dye Penetrate methods have been developed to detect Cracks, Porosity, Blow holes and Flaw in non-
porous material. This will not reveal defects, which are not open.
In this method, visible (or) fluorescent dye penetrate, which are surface active in nature, are
applied to cleaned surface of specimen by suitable means. After allowing sufficient time (dwell time)
for penetration of penetrant. On the surface is approximately removed. Care to be taken not to disturb
the penetration in the discontinuity. The developer which is absorptive in nature is applied to the
specimen, which aids the bleeding out of penetrant to the surface after sufficient time thereby outlining
the discontinuity. The specimen is post cleaned to remove the remaining penetrant & developer

18
materials & coating to prevent corrosion is also applied.

Fig:7 DYE PENETRANT TEST

Magnetic Particle Test:
This method uses electric current or a permanent magnet to create a magnetic field in the surface to be
checked which the magnetic particles indicated where the field is broken by a discontinuity. Fluorescent
magnetic particles are also used for enhanced identification of defects. This method is used on Ferro
magnetic metals.

Fig:8 MAGNETIC PARTICLE TEST

Ultrasonic Test:
Ultrasonic tester is a portable precise direct reading and easy to operate type of instrument, to measure
the depth of cracks& internal defects etc.
In ultrasonic testing, ultrasound waves are generated by piezo electric transducers which
converts electrical energy to mechanical vibrations and vice versa. These waves are made to fall on the
material to be tested. As the wave travels through the material, it may get reflected, refracted, scattered
(or) transmitted depending upon the structure of material. As they reach deflects they reflected back&
these waves are displayed on the monitor at verse time & inspector can visualize a cross section
specimen shaving depth of futures that are recorded.
19
 Fig:9 ULTRASONIC TEST

Radiography Test:
Radiography has grown out of engineering, and is a major element of non-destructive testing. It is a
method of inspecting materials for hidden flaws by using the ability of short X-rays and 26 Gamma rays
to penetrate various materials. The specimen to be inspected is placed between the source of radiation
and the detecting device, usually the film in a light tight holder or cassette, and the radiation is allowed
to penetrate the part for the required length of time to be adequately recorded.

Fig:10 RADIOGRAPHY TEST

20
 Chapter –6
List Of Machines in BHEL

21
CUTTING MACHINES

Designation Brief technical parameters

Plate shearing machine Maximum width - 3150 mm

Profile gas cutting machine Maximum Size 3200x1500m

Maximum thickness 300mm

Plasma cutting machine Maximum thickness of stainless

steel that can be cut 800mm

METAL FORMING MACHINES

Designation Brief technical parameters

Plate bending rolls Max thickness of plate 150mm

Max width plate 3 mts

Section bending rolls Angle 110x110x7 mm

Channel 200x75x7.5 mm
Beam 225x100x8 mm

Pipe bending machine Max diameter 315 mm

Max thickness 8mm
Max radius 200 mm

Hydraulic press Capacity 1600 tons

Maximum size of plate 500x500mm
Max thickness 100mm
Eccentric press capacity 1000 tons.

22
WELDING MACHINES

Manual welding Various capacities

Sub merged arc welding machines Various capacities 1200 amps

TIG welding machines Various capacities including pulsed

TIG and fully automatic

MIG welding machines Various capacities including TIG and

semi-automatic

Special purpose machines Orbital TIG welding machinesTube or

tube sheet welding machines, stud
welding.

MACHINES TOOLS

Light machine shop Various lathes including semi-

automatic milling, shaping, drilling &
boring. Various types of milling &
boring

Heavy machine shop Machinery both single & double

horning
Max table diameter 5000mm
Max height 1600mm
Max weight 10 tons

Material handling EOT cranes of various capacities

Max handling capacity 60 tons
Max lifting beams 120 tons

Heating & annealing Annealing furnace size

36580x5300x5300mm
Max charges 120 tons
Max temperature 1100 degree cent
grade

23
 Chapter –7
Machines And Equipment

24
MACHINES IN MATERIAL PREPARATION SHOP

Once the markings are completed the sheets/ plates are sent for cutting as per dimensions.
Depending upon the length, thickness and path to be followed during cutting the operation is
done on different machines like

1. Flame planning machine

2. Shearing machine

3. Manual gas cutting

4. Gas cutting pug machine

5. Edge planning machine

FLAME PLANNING MACHINE

The FLAME PLANER is a large scale gas cutting machine suitable for the heaviest duties
while maintaining the accuracy and fine precision movements of smaller machines. Time and
labout saving high production efficiency is the key to the low production costs available with
FLAME PLANER. Both strip and bevel cutting are simplified operation and may be performed
simultaneously, and a quick cutting tip exchange is all that is necessary to switch between
acetylene and propane capacity. A highly accurate carriage system is assembled with quality
cutting apparatus as one rugged, efficient, hard working unit.

Fig:11 FLAME PLANNING MACHINE

25
SHEARING MACHINE
A shearing machine is made of straight blades that cut stock without making a formation of
chips or making the use of burning or melting. Shearing Machines are commonly used to
produce sheet metal or plates as well as rods. The processes covered by shearing machines
include blanking, piercing, roll slitting and trimming. The machine can also be used in the
metalworking industry as well as the paper and plastic industry.
Shearing machine is of 2 types
I. 10mm shearing machine
II. 20mm shearing machine

Fig:12 SHEARING MACHINE

MANNUAL GAS CUTTING

For cutting metallic plates, the general purpose shears, flame planning machines are used
as explained above. These are useful for only straight line cuts. For thicker plates when the cut
is to be made along specified contours the two above mentioned cannot be used. To this end
oxy-fuel gas cutting is useful. It is possible to rapidly oxidize iron and steels when heated to
temperature between 800 to 1000 degc. When a high pressure oxygen het with a pressure of
the order 300kpa is directed against a heated steel plate, the oxygen burns the metal and blows
it away causing the cut (kerf). This process was invented by Thomas Fletcher in 1887 and is
extensively used for cutting steels mainly because, the equipment required is simple and can
be carried anywhere without heavy steel plates.

26
 Fig:13 MANNUAL GAS CUTTING

AUTOMATIC GAS CUTTING EQUIPMENT

Gas cutting is functional for use with low carbon and low alloy steels, with a carbon content
generally restricted to 1/10 to 3/10 of 1%. The various alloy elements found in steel affect the
ability of the oxygen to cut the metal. Elements such as manganese, silicon, phosphorus and
sulphur have very little effect in normally found levels. Other elements such as chromium,
nickel, molybdenum, and carbon generally reduce the ability of oxygen to sever the material
up to the various limits of each.Prior to attempting to flame cut a piece of material, you must
study it and consider the elements it contains as well as the combinations of these elements,
just as you would if you studies the metal for physical properties for heat treatment, flame
hardening, etc.
A cutting torch divers the oxygen and mixes part of it with the fuel gas to create the preheat
flame, forming the ring of flame around the cutting tip. This preheat flame will reach a
temperature of 400°F to 6000°F, depending on the fuel gas used as well as the ration of oxygen
to fuel gas. It is the NC cutting machine that enables high accuracy, high efficiency, and a high
safety work, and we propose to satisfy customer's requirement

Fig:14 AUTOMATIC GAS CUTTING

27
EDGE PLANNING MACHINE
In high thick carbon steel plants and stain less steel plate's edge preparation is not possible
by ordinary gas cutting. In those cases we go for machining of the plate by edge planning
machine. The length of the bed of an edge planning machine is 12 meters which can hold a
plate up to that length. Basically for holding the plate firmly during machining hydraulic and
mechanical jacks were used which are arranged alternately above the bed. Just like as in a lathe
machine here also we have carriage, cross slide, tool post with similar application. Main
advantage of this machining is that it can even be used for stain less steels.

Fig:15 EDGE PLANNING MACHINE

LIGHT MACHINE SHOP (L.M.S):

In this shop, all small components machining such as marking holes in the sheet and drilling of
small components will taken up here. Light machine shop isa finishing process of softening the metal
and the excess material is removed. Small lathe machines are used for the job to remove the excess
material. Nozzle to flange welding is done in this shop. In this feeder shop lathe works, drilling boring
and milling operations are done. Boiler items, nozzles and flanges, headers are prepared in this shop.
MACHINES ARE USED IN L.M.S:
•Small and Medium Lathes
• Auto Lathes
• Radial Drilling Machine
• Small Horizontal Boring
• Medium Horizontal Boring
• Heavy Lathe
• Plane Drilling Machine

28
• CNC Drilling Machine
• CNC Deep Hole Drilling Machine(HMT)
• Cylinder Grinding Machine
• Horizontal Surface Grinder
• CNC Lathe Machine

Fig:16 LATHE MACHINES

Fig:17 DRILLING MACHINES

29
 Fig:18 MILLING MACHINES

HEAVY MACHINE SHOP (H.M.S):

In this shop, the job was brought from the press shop, pressure vessels etc for machining. Heavy
machine shop is a finishing process of softening the metal and the excess material is removed.
Machining, drilling, surfacing of the components are done which are carrying the large capacity of job
where the light machine shop can't carry the job.
The shop is equipped with one 200 m dia, one400 m dia, and two 2500 m dia, heavy double
column, vertical and horizontal boring machines besides a number of small thickness. Horizontal
boring is capable of boring to a maximum depth of 2000 mm. The machine ability is done for heavy
jobs in heavy machine shop.
MACHINES USED IN H.M.S:
1. Drilling machines.
2. Lathe machines.

PRESS SHOP
In press shop, the dished ends required for vessels are prepared and pressing of plates are done by
using hydraulic press. In BHEL, we have 3 Hydraulic press of different capacityie.1600T,400T.
Basically hydraulic press with 1600T capacity are used for pressing of dished ends, petals of storage

30
spheres and various other parts. In press shop the equipment plates are kept in furnace and remove the
hot plates and moulded into different shapes by using hydraulic press. Pressing is done by forming
process. Stamping is also known as pressing. It is the process of placing flat sheet metal in either blank
or coil form into a stamping press where a tool and die surface forms the metal into a net shape. 43
Stamping includes a variety of sheet metal forming manufacturing process, such as punching using a
machine press or stamping press, blanking, embossing, bending, flanging and coining. It is a single stage
operation where every stroke of the press produces the desired form on the sheet metal part, or could
occurs through a series of stages. Stamping is done on cold metal sheet.
MACHINES USED IN PRESS SHOP:
1. SECTION BENDING ROLL.
2. PNEUMATIC HAMMER.
3. PIPE BENDING.
4. HYDRAULIC PRESS 250T.
5. HYDRAULIC PRESS 400T.
6. HYDRAULIC PRESS 1600T.
7. BENDING ROLL FOR TUBES.
8. FURNACE

Fig:19 SECTION BENDING ROLL

31
 Fig:20 PNEUMATIC HAMMER

Fig:21 400 TON HYDRAULIC PRESS

32
Fig:21 1600 TON HYDRAULIC PRESS

33
Fig:22 FURNACE

34
 Chapter –8
Research And Development

35
RESEARCH & DEVELOPMENT
There are three other condensers used in HVAC (Heating, Ventilation and Air conditioning) systems.
a.Water-cooled
b.Air-cooled
c.Evaporative

Water-cooled:
Although a little more pricey to install, these condensers are the more efficient type. Commonly used for
swimming pools and condensers piped for city water flow, these condensers require regular service and
maintenance. They also require a cooling tower to conserve water. To prevent corrosion and the forming of
algae, water cooled condensers require a constant supply of makeup water along with water treatment.
Depending on the application you can choose from tube in tube, shell and coil or shell and tube condensers. All
are essentially made to produce the same outcome, but each in a different way.
Air-cooled:
If the condenser is located on the outside of the unit, the air cooled condenser can provide the easiest
arrangement. These types of condensers eject heat to the outdoors and are simple to install. Most common uses
for this condenser are domestic refrigerators, upright freezers and in residential packaged air conditioning units.
A great feature of the air cooled condenser is they are very easy to clean. Since dirt can cause serious issues
with the condensers performance, it is highly recommended that these be kept clear of dirt.
Evaporative:
While these remain the least popular choice, evaporative condensers can be used inside or outside of a
building and under typical Conditions, operate at a low condensing temperature. A Condenser is a device or
unit used to condense a substance from Its gaseous to its liquid state, by cooling it. In so doing, the latent heat is
given up by the substance and transferred to the surrounding environment.

36
 Chapter –9
Activity log for 4 weeks

37
 ACTIVITY LOG FOR WEEK-1
Brief description of Learning Person In-Charge
Day Date
the daily activity Outcome Signature
Joined and paid the fee Learned what
are the
Interacted with the machines and
senior manager equipments
Day-1 30/05/2023 regarding the present in the
internship BHEL

Visited all the By visiting we

departments came to know
what type of
departments
Day-2 31/05/2023
present in the
BHEL

Visited the production Seen all the

workshop products that
are made in the
production
Day-3 01/06/2023
departments

Visited the production Seen all the

workshop machines
present in that
production
Day-4 02/06/2023
workshop

Visited the production Particularly

workshop seen the
boilers,
pressure
Day-5 03/06/2023
vessels

Visited the production Seen the

Day-6 workshop assemblies of
05/06/2023
the products
and how they
are assembled

38
 WEEKLY REPORT
WEEK – 1 (From Date: 30/05/2023 to Date:05/06/2023)

Objective of the Activity Done: Visited the production workshop

Detailed Report:
Understood how the industrial workshops look and how the industrial person work. As the

boilers, pressure vessels etc., are only seen in the books and photos, but seeing them in the real is the great

experience. Not only that we seen the internal looking of the boilers making etc. It was a great experience to

see the machines and materials present there and the working of those machines.

39
 ACTIVITY LOG FOR WEEK-2

Day Date Brief description of the Learning Person In-Charge

daily activity Outcome Signature
Visited the production Seen the
workshop flame cutting
machine,
shearing
Day-7 06/06/2023
machine

Visited the production Manual gas

workshop cutting, CNC
oxy - fuel
plasma
Day-8 07/06/2023
cutting and
planning
machine
Visited the production Seen all the
workshop light machine
shops
Day-9 08/06/2023

Visited the production Seen other

workshop machines in
light machine
shops
Day-10 09/06/2023

Visited the production Seen the

workshop heavy
machine
shops
Day-11 10/06/2023

Visited the production Seen the

workshop other
machines in
heavy
Day-12 12/06/2023
machine
shops

40
 WEEKLY REPORT
WEEK – 2 (From Date: 06/06/2023 to Date: 12/06/2023)
Objective of the Activity Done: Visited the production workshop
Detailed Report:
It was a great experience to see the machines and materials present there and the working of those

machines. We planned to see the machines that are present in the workshop and seen the equipments. All the

machines that are present in the BHEL are heavily designed machines and we can learn a lot from those

machines. Each machine has its own working and principle. They are vastly designed according to there

requirements. And on all machines there is a start date, due date and test date. The work that is happening

inside the workshop is pre planned and according to the daily plan, there are working.

41
 ACTIVITY LOG FOR WEEK-3
Day Date Brief Learning Person In-
description Outcome Charge
of the daily Signature
activity
Visited the Bending roll
production for tubes,
workshop furnace
Day-7 13/06/2023

Visited the Pneumatic

production hammer., pipe
workshop bending
Day-8 14/06/2023

Visited the Visited the

production press shop
workshop
Day-9 15/06/2023

Visited the Seen the

production metal
workshop forming
machines
Day-10 16/06/2023

Visited the Seen the

production Hydraulic
workshop press 250t,
hydraulic
Day-11 17/06/2023
press 400t,
hydraulic
press 1600t
Visited the Seen how the
production welding is
workshop done to the
components
Day-12 19/06/2023

42
 WEEKLY REPORT
WEEK – 3 (From Date: 13/06/2023 to Date: 19/06/2023)

Objective of the Activity Done: Visited the production and welding departments
Detailed Report:

As it is the third week of our internship we visited the production department and

seen the other machines that are present there. There are different machines with the same

name but with different thickness, size, capacity and width. As the parameters are different the

design of the machines are also different. The working is also quite different from each other,

depending upon the requirements of the product the machine is selected. And by looking at

those machines we can learn a lot about there working and usage. And it is quite interesting to

do work there.

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 ACTIVITY LOG FOR WEEK-4

Day Date Brief description of the Learning Person In-Charge

daily activity Outcome Signature
Visited the welding Seen the
workshop welding done
using
TIG,MIG, arc
Day-13 20/06/2023
welding
machines

Visited the non Seen the

destructive testing different
workshop testing
equipments
Day-14 21/06/2023
like Magnetic
particle, Dye-
penetration
Visited the non Seen the
destructive testing testing
workshop equipments
like
Day-15 22/06/2023
Radiographic,
ultrasonic,
hydraulic tests
Visited the quality control Seen the
department quality
assurance and
quality
Day-16 23/06/2023
control

Stayed in the As it is the

administrative building last day we
taken the
certificate for
Day-17 24/06/2023
our internship

44
 WEEKLY REPORT
WEEK – 4 (From Date: 20/06/2023 to Date: 24/06/2023)

Objective of the Activity Done: Visited the welding, Non-destructive testing and quality control
departments
Detailed Report:

As it is the last week of our internship so we decided to visit different departments. Firstly

we visited the welding workshops and seen all the welding equipments that are used there. Next we visited

the non destructive testing workshops and seen the equipments that are used for testing the components. There

are very interesting equipments present there, where without destructing the component we can test the

component. Later we visited the quality control department where all the products quality is checked and give

the assurance to that product by using different tests. As quality control plays a vital role in any industry so it

should be taken in an very efficient way without any mistakes and the product or the service under the

development should meet the required requirements. And on the final day we collected our internship

certificates.

45
 Chapter –10
Outcomes Description

46
 Describe the work environment you have experienced

• The work environment is quite good and interesting, as there are many machines and equipments present

in BHEL we can learn a lot from there.

• There are different job roles present in the BHEL and different work is assigned to different people.

• They follow different procedures and processes.

• The time management is highly followed in BHEL in all the aspects.

• Before starting of the work the team leader will motivate the workers and appreciate their work.

• And they all follow the rules and regulations that are approved by their authorities.

Describe the real time technical skills you have acquired

• Good communication and organizational skills.

• Ability to communicate and transfer project information with the on-site team.

• Ability to read contract drawings.

Describe the managerial skills you have acquired

• We can learn a lot about the leadership qualities and team work in BHEL.

• The team work of the workers is more appreciable as they all work according to the work they were assigned.

• They are all well behaved and punctual.

• The decisions are made according to the work and all are following the unity of work there

47
 Describe how you could improve your communication skills

• Talk face to face whenever possible.

• Use examples. For clear communication, try to be as specific as possible.
• Ask questions. If you’re not sure about something, don’t be afraid to ask questions.
• Confidently speaking whenever necessary.
• Greeting others and thanking them…etc.,

Describe how could you could enhance your abilities in group discussions,
participation in teams, contribution as a team member, leading a
team/activity.

• Know the topic and be the first to get off the blocks.
• Be a good listener and speak with confidence.
• Consider your body language and be polite.
• Lead the conversation and practice active listening.
• Should lead the team properly and motivate them to do the work efficiently

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Daily Activity GPS Photos

Day-1, Date: 31/05/2023 Day-2, Date:01/06/2023

Day-3, Date: 02/06/2023 Day-4, Date: 03/06/2023

49
Day-5, Date: 06/06/2023 Day-6, Date: 07/06/2023

Day-7, Date: 08/06/2023 Day-8, Date: 09/06/2023

50
Day-9, Date: 10/06/2023 Day-10, Date: 12/06/2023

Day-11, Date: 13/06/2023 Day-12, Date: 14/06/2023

51
Day-13, Date:15/06/2023 Day-14, Date:16/06/2023

Day-15, Date:17/06/2023 Day-16, Date:19/06/2023

52
 Day-17, Date:20`/06/2023 Day-18, Date:21/06/2023

Day-19, Day-20,
Date:22/06/2023 Date:23/06/2023

53
Day-21, Date:24/06/2023

54
Internship Completion Certificate

55
 Chapter –11
Conclusions and Future Scope

56
CONCLUSION
This has been an effective training experience in BHEL (HPVP), VSKP with a great exposure to industrial level
working. We got an experience in fabrication of cryogenic vessels, boilers, heat exchanger and observed the
working of non-destructive tests and many types of welding processes.

All our anticipated knowledge has been turned into reality during our course of training in BHEL(HPVP), VSKP.
We are extremely thankful to the human resource and development centre for giving us this opportunity. We also
thank the staff of the BHEL (HPVP) for imparting all the knowledge

57